SECTION INDEX

NAME SECTION

GENERAL 0
ENGINE - CHASSIS 1
4Y-E REPAIR 1.1
1DZ-II REPAIR 1.2
4Y-E LPG DEVICE REPAIR 1.3
TRANSMISSION (Pn1•2•3 / Cu2•3) 2
TRANSMISSION (Cu1 Ton Series) 2.1
PROPELLER SHAFT 3
DIFFERENTIAL 4
FRONT AXLE 5
REAR AXLE 6
STEERING 7
BRAKE 8
BODY 9
MATERIAL HANDLING SYSTEM 10
MAST 11
CYLINDER 12
OIL PUMP 13
OIL CONTROL VALVE 14
MINI LEVER - JOYSTICK 15
SAS / OPS 16
SSTLIST - SERVICE STANDARDS LIST 17
MULTIFUNCTION DISPLAY DX (OPTIONAL) 18
ELECTRICAL SYSTEM TROUBLESHOOTING [except Cu1] 19
ELECTRICAL SYSTEM TROUBLESHOOTING [Cu1 ton series] 19.1
WIRING DIAGRAM E
SERVICE INFORMATION BULLETINS SIB
 0-1

GENERAL
Page Page
EXTERIOR VIEWS ..................0-2 PRECOAT BOLTS................. 0-15 0
VEHICLE MODEL....................0-3 HIGH PRESSURE 1
HOSE FITTING
FRAME NUMBER....................0-4 2
TIGHTENING TORQUE....... 0-15
HOW TO USE 3
WIRE ROPE SUSPENSION
THIS MANUAL.......................0-5
ANGLE LIST........................ 0-16 4
EXPLANATION METHOD ...........0-5
SAFE LOAD FOR
TERMINOLOGY ........................0-6 EACH WIRE ROPE 5
ABBREVIATIONS ......................0-6 SUSPENSION ANGLE ........ 0-16 6
OPERATIONAL TIPS ..............0-7 COMPONENTS WEIGHT ...... 0-17 7
HOISTING THE VEHICLE .......0-8 RECOMMENDED 8
HOW TO START LUBRICANT
THE HOUR METER ...............0-8 QUANTITY & TYPES .......... 0-18 9
LUBRICATION CHART ......... 0-19 10
ATTENTIVE POINTS
ON SAS..................................0-9 PERIODIC MAINTENANCE .. 0-21 11
CIRCUIT TESTER..................0-10 INSPECTION METHOD ........... 0-21
12
STANDARD BOLT & NUT PERIODIC REPLACEMENT
TIGHTENING TORQUE .......0-12 OF PARTS AND 13
LUBRICANTS...................... 0-26 14
BOLT STRENGTH CLASS
IDENTIFICATION METHOD ....0-12
15
16
17
18
19
20
21
E
0-2a General

EXTERIOR VIEWS

Section 0
0-2 General 0-2b

EXTERIOR VIEWS

Section 0
0-3 General 0-3

VEHICLE MODEL 8FG(D)U15-32

8FGCU20-32
Pneumatic Tire Models (Pn)

Classification
Load Capacity Vehicle Model Transmission Type Engine
0
Series Model
1
8FGU15 T/C 4Y Gasoline
Pn15 3000 lbs
8FDU15 T/C 1DZ-II Diesel
2
Pn1 ton series
8FGU18 T/C 4Y Gasoline 3
Pn18 3500 lbs
8FDU18 T/C 1DZ-II Diesel 4
8FGU20 T/C 4Y Gasoline
Pn20 4000 lbs 5
8FDU20 T/C 1DZ-II Diesel
Pn2 ton series
8FGU25 T/C 4Y Gasoline
6
Pn25 5000 lbs
8FDU25 T/C 1DZ-II Diesel 7
8FGU30 T/C 4Y Gasoline 8
Pn30 6000 lbs

Pn3 ton series

8FDU30 T/C 1DZ-II Diesel
9
*8FGU32 T/C 4Y Gasoline
Pn32 6500 lbs 10
*8FDU32 T/C 1DZ-II Diesel

11
Cushion Tire Models (Cu)
12
Classification

Series Model
Load Capacity Vehicle Model Transmission Type Engine
13
Cu20 4000 lbs 8FGCU20 T/C 4Y Gasoline 14
Cu2 ton series
Cu25 5000 lbs 8FGCU25 T/C 4Y Gasoline
15
Cu30 6000 lbs 8FGCU30 T/C 4Y Gasoline
Cu3 ton series 16
Cu32 6500 lbs *8FGCU32 T/C 4Y Gasoline

*: USA and CANADA Only

17
18
19
20
21
E
Section 0
 General 0-4a
0-3

VEHICLE MODEL 8FGCU15,18,SU20

Series Load Capacity Vehicle Model Transmission Type Engine

3000 lbs 8FGCU15 T/C 4Y Gasoline 0

1Cu1
tonton series
series 3500 lbs 8FGCU18 T/C 4Y Gasoline 1
4000 lbs *8FGCSU20 T/C 4Y Gasoline
2
*: USA and CANADA Only
3
FRAME NUMBER 4
Frame No. Punching Position 5
6
7
8
9
10
11
12
13
14
Punching position
15
Series Engine Vehicle model Punching format
16
8FGCU15
17
1Cu1
ton ton series
series 4Y 8FGCU18
8FGCSU20 - 10011
*8FGCSU20 - 10011
18
8FGCSU20 19
*: EEC spec. 20
21
E
Section 0
0-4
0-4b General

FRAME NUMBER 8FG(D)U15-32

8FGCU20-32
Frame No. Punching Position

Punching position

Series Engine Vehicle model Punching format

8FGU15
4Y 8FGU18-10011
8FGU18
1 ton series
8FDU15
1DZ-II 8FDU18-10011
8FDU18
8FGU20
4Y 8FGU25-10011
8FGU25
Pneumatic tire 2 ton series
8FDU20
1DZ-II 8FDU25-10011
8FDU25
8FGU30
4Y 8FGU32-10011
8FGU32
3 ton series
8FDU30
1DZ-II 8FDU32-10011
8FDU32
8FGCU20 8FGCU25-10011
2 ton series
8FGCU25 8FGCU25 10011*
Cushion tire 4Y
8FGCU30 8FGCU32-10011
3 ton series
8FGCU32 8FGCU32 10011*
*: EEC spec

Section 0
 General 0-5

HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
0
Pattern A: Explanation of each operation step with illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by 1
explanation of cautions and notes summarized as point operations.

Example of description in pattern B

2
DISASSEMBLY·INSPECTION·REASSEMBLY 3
Tightening torque unit T = N·m (kgf·cm) [ft·lbf]
4
• Step Nos. are partially sometimes omitted in
illustrations. 5
• When a part requiring tightening torque
instruction is not indicated in the illustration, the 6
part name is described in the illustration frame.
7
8
9
T = 46.1 ~ 48.1
(470 ~ 490) 10
[34.0 ~ 35.5]

11
12
13
Disassembly Procedure 14
1 Remove the cover. [Point 1]
15
2 Remove the bushing. [Point 2] Ã Operation explained later
3 Remove the gear. 16
Point Operations 17
[Point 1] Explanation of key point for operation with an illustration
Disassembly: 18
Ã

Put a match mark when removing the pump cover.

[Point 2]
19
Inspection:
Measure the bush inside diameter.
20
Limit: 19.12 mm (0.7528 in) 21
E
Section 0
0-6 General

2. How to read components figures

(1) The components figure uses the illustration in the
(Example)
parts catalog for the vehicle model. Please refer
to the catalog for checking the part name. 3201
The number at the right shoulder of each
components figure indicates the Fig. number in FIG number in parts catalog
the parts catalog.
3. Matters omitted in this manual
(1) This manual omits description of the following jobs, but perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)

TERMINOLOGY
Caution:
Important matters of which negligence may cause hazards on human body. Be sure to observe them.
Note:
Important items of which negligence may cause breakage or breakdown, or matters in operation procedure
requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.

ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASC Auto Speed Control R/B Relay block
ATT Attachment RH Right hand
Cu Cushion tire models RR Rear
FR Front Society of Automotive
SAE
J/B Junction block Engineers (USA)

ASSY Assembly SAS System of active stability

LH Left hand SOL Solenoid
LLC Long life coolant SST Special service tool
M/T Manual transmission STD Standard
NMR No-load maximum speed T= Tightening torque
OPS Operator Presence Sensing Torque converter &
T/C
OPT Option transmission

O/S Oversize ccT Number of teeth (c c)

Pn Pneumatic tire models U/S Undersize
PS Power steering W/ With
QFV 4-stage mast (Quadruple) L/ Less

Section 0
 General 0-7a
0-7

OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
(3) Always disconnect the battery terminal before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge,
etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to
prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate
in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and O-rings with new ones each time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(Tighten to the center of the specified tightening torque range.)
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table.
3. Grasping the trouble state
When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trouble
requires disassembly or replacement for remedying.
4. Disposal of waste fluid, etc.
When draining waste fluid from the vehicle, receive it in a container.
If any oil, fuel, coolant, oil filter, battery or other harmful substance is directly discharged or scrapped without
permission, it will either adversely affect human health or destroy the environment. Always sort waste fluids, etc.
and treat them properly by requesting disposal by specialized companies.

5. Jack up points
Jack up points are provided in the front and rear portions of the
vehicle. Always apply jacks at the jack up points.
Front side:
A circular groove to accept a screw jack is provided under the
front side of the frame.
When a garage jack is used, jack up at the bottom surface of
the frame.
For screw
jack Rear side:
Pn models
A circular groove to accept a screw or garage jack is provided
at the bottom surface of the counterweight.
For screw jack Cu models (except Cu1 ton series)
(Pn models) Jack up at the under the counterweight or the bottom surface
of the frame.

For garage jack

(Pn2·3 ton series)

Section 0
0-7b General

Continued from previous page:

8FGCU15,18,SU20
5. Jack up points

Front side:
Jack up at the bottom surface of the frame.

Rear side:
Jack up at the under the counterweight or the bottom surface
of the frame.

Section 0
 General 0-8

6. Hydraulic oil level inspection procedure *

Checking the oil amount inside tank, as shown below, contact
top of cap on retainer. (Do not push it into retainer.)
*NOTE: Excludes 7FGCU15,18,SU20

HOISTING THE VEHICLE

When hoisting the vehicle, sling with wire rope(s) at the mast hook
holes and the rear side of the head guard.
Caution:
• Use wire ropes having sufficient strength.
• Never hoist the forklift by the weight hook holes.

HOW TO START THE HOUR METER

SPARE 30A BLR 1 25A 2
Be sure to start the hour meter when delivering a new vehicle to a
B SPARE 7.5A STA 1 30A 2 customer.
2 7.5A 1 RR WIP 1 20A 2 Remove the fuse (7.5 A) in position A inside the relay block and
ST 2 7.5A 1 FR WIP 1 20A 2 install it to position B (HOUR MET).
GAUGE 2 10A
1 1 2 Make sure that the engine is stopped when installing the fuse.
BACK LP 2 10A
40A AM1
1
SFT 2 7.5A 1
5 3
2
TURN 2 7.5A 1 A
2 IGN 2 *2 1
3 5 HORN 1 15A 2

Section 0
 0-9 General

ATTENTIVE POINTS ON SAS

1. Reference should be made to seperate manual “New Model Feature 8FGU/8FDU15-32 Pub. No.PU023” for the
explanations of SAS functions and operations.
2. Read Section 16 SAS/OPS “Precautions for Repair” on Page 16-11 in this repair manual in advance.
3. Whenever the repair or replacement is performed to the place where relative to SAS function, matching
procedure by which the SAS regain proper function must be performed. (See Page 16-26)
4. The warning on the SAS caution label must be confirmed when the modification or change is such as to change
the original specification.
If improper, change the label. (See Page 16-32)
5. Care should always be exercised for safety operation whenever you operate the truck.
Make distinction between the SAS featured trucks and those of none, because the control features are different.
6. The SAS oil control valves comprise many precision valves. Since dirty or contaminated hydraulic oil will
adversely affect the functions of these valves, always wash the parts clean at the time of installation after
disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodic replacement of the hydraulic oil
is very important.
7. Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause faults.
Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary equipment, optional parts,
etc.).

Section 0
 General 0-10

CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively according to the
purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the measured value should only
be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement.

1. Difference in measurement results with the digital type and analog type
* The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual.
Cautions when the polarities are different between the analog type and digital type are described below.

Forward direction Reverse direction (1) Analog circuit tester

Measurement result example
Tester range: kΩ range
Analog type
Continuity exists
Forward
11 kΩ
No continuity
Reverse
∞

(2) Digital circuit tester

Forward direction Reverse direction Measurement result example
Tester range: MΩ range
Digital type
No continuity
Forward
1
Continuity exists
Reverse
2 MΩ

Section 0
0-11 General

2. Difference in result of measurement with circuit tester

The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage. The diode
characteristics are shown in the figure below.

(mA) 6 The resistance values of the same semiconductor measured with

two types of circuit testers having different power supply voltages
5
are different.
4
Germanium This manual describes the results of measurement with a circuit
Forward current

diode
3 tester whose power supply voltage is 3.0 V.
2 Silicon diode

0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Forward voltage (V)

3. Difference in measurement result by measurement range (analog type)

In the analog type circuit tester, changing the measurement range switches over the internal circuit to vary the
circuit resistance. Even when the same diode is measured, the measurement result varies with the
measurement range.

Always use the range described in the repair manual for

measurement.
Resistor Meter

0Ω
Current flow

Variable resistor

Resistor

Range: x 10 (SW1)

Resistor

Range: x 1 (SW2)

Power source: 1.5 V

Red Black

Section 0
 General 0-12

STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. For tightening torque of hexagon head bolt, welded bolt and stud bolt with the standard bearing surface, identify
bolt class based on the below chart and then determine using the tightening torque table.
2. For tightening torque of hexagon flange bolts, identify bolt class based on the below chart and then determine
using the tightening torque table.
3. For tightening torque of nuts, check the mating bolt and use the method 1.

BOLT STRENGTH CLASS IDENTIFICATION METHOD

Identification by Bolt Shape
Shape and class Class
4 = 4T
5 = 5T
Bolt head No. 6 = 6T
7 = 7T
8 = 8T

No mark 4T

Hexagon head bolt

Two protruding lines 5T

Three protruding lines 7T

Four protruding lines 8T

Welded bolt 4T

No mark 4T

Stud bolt

Grooved 6T

Section 0
0-13 General

Identification by Part No.

Part No. Shape

Length (mm) Diameter

Hexagon head bolt
Diameter (mm)
Length
Class

Diameter
Length (mm)
Stud bolt
Diameter (mm)
Length
Class

Tightening Torque Table

Diameter Pitch Specified torque

Class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.4 55 4
8 1.25 13 130 9
10 1.25 25 260 19
4T
12 1.25 47 480 35
14 1.5 75 760 55
16 1.5 113 1150 83
6 1.0 6.5 65 5
8 1.25 16 160 12
10 1.25 32 330 24
5T
12 1.25 59 600 43
14 1.5 91 930 67
16 1.5 137 1400 101
6 1.0 7.8 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6T
12 1.25 72 730 53
14 1.5 108 1100 80
16 1.5 172 1750 127
6 1.0 11 110 8
8 1.25 25 260 19
10 1.25 52 530 38
7T
12 1.25 95 970 70
14 1.5 147 1500 108
16 1.5 226 2300 166
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8T
12 1.25 108 1100 80
14 1.5 172 1750 127
16 1.5 265 2700 195

Section 0
 General 0-14

Identification by Bolt Shape (Hexagon flange bolt)

Class 4.8T 6.8T 8.8T 10.9T 11.9T

No mark

Hexagon flange bolt

— —
No mark

Tightening Torque Table (Hexagon flange bolt)

Diameter Pitch Specified torque

Class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.5 56 4
8 1.25 13 130 9
10 1.25 27 280 20
4.8T
12 1.25 50 510 37
14 1.5 78 800 58
16 1.5 120 1220 88
6 1.0 7.5 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6.8T
12 1.25 71 720 52
14 1.5 110 1120 81
16 1.5 170 1730 125
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8.8T
12 1.25 110 1120 81
14 1.5 175 1780 129
16 1.5 270 2750 199
6 1.0 15.5 160 12
8 1.25 38 390 28
10 1.25 80 820 59
10.9T
12 1.25 145 1480 107
14 1.5 230 2350 170
16 1.5 360 3670 266
6 1.0 17.5 180 13
8 1.25 42 430 31
10 1.25 89 910 66
11.9T
12 1.25 160 1630 118
14 1.5 260 2650 192
16 1.5 400 4080 295

Section 0
0-15 General

PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the following
cases:
(1) After it is removed.
(2) When the precoat bolt is moved (loosened or tightened)
Seal lock agent
by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable
tightening torque range. If the bolt moves, retighten it
according to the steps below.
2. Method for reuse of precoat bolts
(1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded portion
of the bolt.

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth
to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before
installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter Standard tightening torque N·m (kgf·cm) [ft·lbf] Hose inside
of screw Standard Tightening range diameter mm (in)
7/16 — 20UNF 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
9/16 — 18UNF 34 (350) [25.3] 32 ~ 36 (330 ~ 370) [29.3 ~ 26.8] 9 (0.35)
3/4 — 16UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8 — 14UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8 — 14UNF 78 (800) [57.9] 74 ~ 82 (740 ~ 840) [53.5 ~ 60.8] 15 (0.59)
1·1/16 — 12UNF 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
1·5/16 — 12UNF 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
PF3/8 34 (350) [25.3] 32 ~ 36 (330 ~ 370) [23.9 ~ 26.8] 9 (0.35)
PF1/2 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)

Section 0
 General 0-16

WIRE ROPE SUSPENSION ANGLE LIST

Suspension Suspension
Lifting angle Tension Compression Lifting angle Tension Compression
method method

0° 1.00 time 0 time 90° 1.41 time 1.00 time

90°

1.0 tf

tf
41
1.
2t 2t

30°

30° 1.04 time 0.27 time 120° 2.00 time 1.73 time
tf

120°
1.04

f
2t
2t 2t

60° 1.16 time 0.58 time

60°
f
6t
1.1

2t

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (tf) [lbf]
Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load
0° 0° 30° 60° 90° 0° 30° 60° 90°
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] [2337] [1940]
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
(0.32 in)
[7078] [992.3] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(0.4 in)
[11.69] [1565.6] [3153] [3021] [2646] [2205] [6174] [5954] [5292] [4410]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5 mm
(7.84) (1.12) (2.2) (2.1) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
(0.5 in)
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379] [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[21675] [3087] [6174] [5954] [5292] [4190] [12348] [11907] [10584] [8379]

Section 0
0-17 General

8FG(D)U15-32
COMPONENTS WEIGHT 8FGCU20-32

8FGCU15,18,SU20

Section 0
 General 0-18a

RECOMMENDED LUBRICANT QUANTITY & TYPES 8FG(D)U15-32

8FGCU20-32
Description Application Quantity l (US gal) Classification Type
Motor oil
API
Gasoline 4Y 4.0 (1.06) SAE30
SH, SJ, SL, SM
SAE10W-30
Engine
Diesel engine oil
API
Diesel 1DZ-II 7.9 (2.09) SAE30
CE, CF, CF-4
SAE10W-30
T/C (1 speed) 8.0 (2.11)
Transmission ATF GM Dexron® II
T/C (2 stator T/C) 9.0 (2.38)
Pn1 ton series 5.8 (1.53)
6.1 (1.61)
Pn2 ton series
6.4 (1.69)*
API Hypoid gear oil
Differential 6.1 (1.61)
Cu2·3 ton series GL-4 SAE85W-90
6.4 (1.69)*
8.2 (2.16)
Pn3 ton series
8.4 (2.22)*
Pn1 ton series 31 (8.2)
Hydraulic oil Pn2 ton series 35 (9.2) ISO
(V mast, max. lifting height Hydraulic oil
Cu2·3 ton series 33 (8.7) VG32
3300 mm (131 in))
Pn3 ton series 38 (10.0)
Pn1 ton series 45 (11.9)
Fuel tank Cu2·3 ton series 45 (11.9) —— ————
Pn2·3 ton series 60 (15.8)
Proper quantity
SAE J-1703
Brake line All models Reservoir Tank ——
DOT-3
0.2 (0.05)
Cu2·3 ton series 7.4 (1.95)
Brake cooling oil —— Shell DONAX TD
Pn2·3 ton series 8.0 (2.11)
• MP grease
Chassis parts All models Proper quantity —— • Molybdenum
disulfide grease
• LLC 30-50% mixture
(for winter or
allseason)
Coolant
Attached Table 1 Coolant volume LLC • Coolant with
(excluding reservoir tank)
rustinhibitor
(for spring, summer
and autumn)
0.47 (0.124)
Coolant (Reservoir Tank) All models ↑ ↑
(at Full level)
*: Only wet brake models
Note:
Since the hydraulic oil volume varies with the mast specification, be sure to check finally with the level
gauge.
Attached Table 1 Coolant volume Unit: l (US gal)
Engine Pn1 ton series Pn2 ton series Pn3 ton series Cu2·3 ton series
4Y 8.1 (2.14) 9.3 (2.46) 9.3 (2.46) 8.1 (2.14)
1DZ-II 6.8 (1.80) 7.9 (2.09) 7.9 (2.09) —

Section 0
0-18b
0-16 General

RECOMMENDED LUBRICANT QUANTITY & TYPES 8FGCU15,18,SU20

Description Application Quantity l (US gal) Classification Type
Motor oil
API
Engine Gasoline 4Y 4.0 (1.06) SAE30
SH, SJ, SL, SM
SAE10W-30
Transmission T/C 9.5 ~ 10.7 (2.51 ~ 2.82) ATF GM Dexron® II
API Hypoid gear oil
Differential All models 4.8 (1.27)
GL-4 SAE85W-90
Hydraulic oil
ISO
(V mast, max. lifting height 1 ton series 30 (7.9) Hydraulic oil
VG32
3300 mm (131 in))
Fuel tank All models 27 (7.1) —— ————
Proper quantity
SAE J-1703
Brake All models Reservoir Tank ——
DOT-3
0.2 (0.05)
• MP grease
Chassis parts All models Proper quantity —— • Molybdenum
disulfide grease
• LLC 30-50% mixture
(for winter or
allseason)
Coolant
4Y LLC • Coolant with
(excluding reservoir tank)
rustinhibitor
(for spring, summer
and autumn)
0.47 (0.124)
Coolant (Reservoir Tank) All models ↑ ↑
(at Full level)

Note:
Since the hydraulic oil volume varies with the mast specification, be sure to check finally with the level
gauge.

Section 0
 General 0-19

LUBRICATION CHART
Standard Model

(14) G G (14)
(1) B B (1)
(13) G G (13)
(3) A A (3)
(4) F F C C (2)
(12) A A (15)

(10) G E E (5)
(16) G D D (8)
(7) A B B* (9)
(6) A A (7)
(17) A A (6)
(18) A A (17)
(11) G A (18)
I

II

III

IV

V
*: For the engine oil grades listed below, change oil every 500 hours.
Gasoline vehicle: API SL, SM and above
Diesel vehicle: API CF-4 and above

{ Inspection
z Replacement
I Inspect every 8 hours (daily)
A MP grease
II Inspect every 40 hours (weekly)
B Engine oil
III Inspect every 250 hours (6 weeks)
C Hypoid gear oil
IV Inspect every 1000 hours (6 monthly)
D Hydraulic oil
V Inspect every 2000 hours (annual)
E Automatic transmission fluid
F Brake fluid
G Molybdenum disulfide grease

1 Chain 10 Rear axle beam front pin

2 Differential 11 Rear axle beam rear pin
3 Front wheel bearing 12 Tilt steering locking mechanism
4 Brake master cylinder 13 Mast support bushing
5 Torque converter case 14 Tilt cylinder front pin
6 Rear wheel bearing 15 Propeller shaft
7 Steering knuckle king pin 16 Swing lock cylinder lower pin
8 Oil tank 17 Tie rod end pin
9 Engine crank case 18 Rear axle cylinder end pin

Section 0
0-20 General

Wet Brake Model

(14) G G (14)
(1) B B (1)
(13) G G (13)
(3) A A (3)
C C (2)
(12) A A (15)
(4) F F
(10) G E E (5)
(16) G D D (8)
(7) A B B* (9)
(6) A A (7)
(17) A A (6)
(18) A A (17)
(11) G A (18)
I

II

III

IV

*: For the engine oil grades listed below, change oil every 500 hours.
Gasoline vehicle: API SL, SM and above
Diesel vehicle: API CF-4 and above

{ Inspection
z Replacement
I Inspect every 8 hours (daily)
A MP grease
II Inspect every 40 hours (weekly)
B Engine oil
III Inspect every 250 hours (6 weeks)
C Hypoid gear oil
IV Inspect every 1000 hours (6 monthly)
D Hydraulic oil
V Inspect every 2000 hours (annual)
E Automatic transmission fluid
F Shell DONAX TD
G Molybdenum disulfide grease

1 Chain 10 Rear axle beam front pin

2 Differential 11 Rear axle beam rear pin
3 Front wheel bearing 12 Tilt steering locking mechanism
4 Brake cooling oil tank 13 Mast support bushing
5 Torque converter case 14 Tilt cylinder front pin
6 Rear wheel bearing 15 Propeller shaft
7 Steering knuckle king pin 16 Swing lock cylinder lower pin
8 Oil tank 17 Tie rod end pin
9 Engine crank case 18 Rear axle cylinder end pin

Section 0
 General 0-21

PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection. Repair or replacement if required.
M: Measurement. Repair or adjustment if required.
T: Retightening C: Cleaning L: Lubrication
*: For new vehicle *1: Flaw detector
Inspection Period Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
ENGINE
Proper starting and abnormal noise I ← ← ←
Rotating condition at idling M ← ← ←
Rotating condition during acceleration M ← ← ←
Exhaust gas condition I ← ← ←
Main body Air cleaner element C ← ← ←
Valve clearance (IDZ-II·2Z) M* M
Compression M
Cylinder head bolt loosening T
Muffler rubber mount I
PCV system Clogging and damage in PCV valve and piping I ← ← ←
Governor No-load maximum rpm M ← ← ←
Oil leak I ← ← ←
Lubrication
Oil level I ← ← ←
system
Clogging and dirt of oil filter I ← ← ←
Fuel leak I ← ← ←
Operation of carburetor link mechanism I ← ← ←
Dirt and clogging of fuel filter and element I ← ← ←
Fuel system
Injection timing M ←
Injection nozzle injection pressure and spray status M
Draining of sedimenter I ←
Coolant level in radiator and leak I ← ← ←
Rubber hose degradation I ← ← ←
Cooling system Radiator cap condition I ← ← ←
Fan belt tension, looseness and damage I ← ← ←
Radiator rubber mount I
Pipe and joint gas leak I ← ← ←
Pipe and joint damage I ← ← ←
LPG fuel system Regulator tar removal I ← ← ←
LPG container installation section looseness and
I ← ← ←
damage

Section 0
0-22 General

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Exhaust gas concentration measurement
M ← ← ←
(carbon monoxide and hydrocarbon)
Exhaust system piping looseness and damage I

3-Way catalytic Vacuum piping damage I ← ← ←

converter system Vacuum sensor damage I
Coolant temperature sensor damage I
Injector damage and cleaning (LPG vehicle) I
Register damage (LPG vehicle) I
Actuator damage I ← ←
Travel and load
Axle pedal sensor and switch damage I ← ←
handling control
Traveling speed sensor damage I
POWER TRANSMISSION SYSTEM
Leak I ← ← ←
Differential Oil level I ← ← ←
Bolt loosening T
Leak I ← ← ←
Fluid level I ← ← ←
Torque Operating mechanism function and looseness I ← ← ←
converter &
transmission Control valve and clutch functions I ← ← ←
Inching valve function I ← ← ←
Stall and hydraulic pressure measurement M ←
Loose joint T ← ←
Propeller shaft Looseness at spline connections I
and axle shaft Looseness of universal joint I
Twisting and cracks of axle shaft I
DRIVE SYSTEM
Tire inflation pressure M ← ← ←
Tire cuts, damage and uneven wearing l ← ← ←
Loose rim and hub nuts T ← ← ←
Wheels
Tire groove depth M ← ← ←
Metal chips, pebbles and other foreign matter
l ← ← ←
trapped in tire grooves
Rim, side bearing and disc wheel damage I ← ← ←
Abnormal sound and looseness of front wheel
I ← ← ←
Wheels bearing
Abnormal sound and looseness of rear wheel
I ← ← ←
bearing
Front axle Cracks, damage and deformation of housing I
Cracks, damage and deformation of beam I
Rear axle Looseness of axle beam in vehicle longitudinal
M
direction

Section 0
 General 0-23

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
STEERING SYSTEM
Play and looseness I ← ← ←
Steering wheel
Function I ← ← ←
Oil leak I ← ← ←
Steering valve
Looseness of mounting T ← ← ←
Oil leak I ← ← ←
Power steering Mounting and linkage looseness I ← ← ←
Damage of power steering hose I
King pin looseness I ← ← ←
Knuckle
Cracks and deformation I
BRAKING SYSTEM
Play and reserve M ← ← ←
Brake pedal
Braking effect I ← ← ←
Operating force I ← ← ←
Braking effect I ← ← ←
Parking brake
Linkage and cable looseness and damage I ← ← ←
Grease applied to parking brake pedal release pin L
Brake pipe Leak, damage and mounting condition I ← ← ←
Reservoir tank Leak and fluid level I ← ← ←
Master cylinder
Function, wear, damage, leak and mounting
and wheel I
looseness
cylinder
Clearance between drum and lining M ← ← ←
Wear of shoe sliding portion and lining I
Drum wear and damage I
Brake drum and
Shoe operating condition I
brake shoe
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Deformation, cracks and damage I
Backing plate
Loose mounting T
Oil leak I ← ← ←
Cooling oil level in tank I ← ← ←
Accumulator operation I
Wet brake
Brake valve function, damage, or looseness in the
I
installed parts
Brake disc clearance adjustment (disc wear) I

Section 0
0-24 General

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I ← ← ←
Forks Misalignment between left and right fork fingers I ← ← ←
Cracks at fork root and welded part I*1
Deformation and damage of each part and crack at
I ← ← ←
welded part
Mast and lift bracket looseness I ← ← ←
Mast and lift Wear and damage of mast support bushing I
bracket
Wear, damage and rotating condition of rollers I ← ← ←
Wear and damage of roller pins I
Wear and damage of mast trip I ← ← ←
Tension, deformation and damage of chain I ← ← ←
Chain lubrication I ← ← ←
Chain and chain
Elongation of chain I
wheel
Abnormality of chain anchor bolt I ← ← ←
Wear, damage and rotating condition of chain wheel I ← ← ←
Various
Abnormality and mounting condition of each part I ← ← ←
attachments
HYDRAULIC SYSTEM
Loosening and damage of cylinder mounting T ← ← ←
Deformation and damage of rod, rod screw and rod
I ← ← ←
end
Cylinder operation I ← ← ←
Cylinder Natural drop and natural forward tilt (hydraulic drift) M ← ← ←
Oil leak and damage I ← ← ←
Wear and damage of pin and pin support I ← ← ←
Lifting speed M ← ← ←
Uneven movement I ← ← ←
Oil pump Oil leak and abnormal sound I ← ← ←
Oil level and contamination I ← ← ←
Hydraulic oil tank Tank and oil strainer C ←
Oil leak I ← ← ←
Loose linkage I ← ← ←
Control lever
Operation I ← ← ←
Oil leak I ← ← ←
Oil control valve Relief pressure measurement M
Relief valve and tilt lock valve functions I ← ← ←
Oil leak I ← ← ←
Hydraulic piping Deformation and damage I ← ← ←
Loose joint T ← ← ←

Section 0
 General 0-25

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Cracks on distributor cap I ← ← ←
Spark plug burning and gap I ← ← ←
Distributor side terminal burning I ← ← ←
Ignition timing
Distributor cap center piece wear and damage I ← ← ←
Plug cord internal discontinuity I
Ignition timing M ←
Starting motor Pinion gear meshing status I ← ← ←
Charger Charging function I ← ← ←
Battery fluid level I ← ← ←
Battery
Battery fluid specific gravity M ←
Damage of wiring harness I ← ← ←
Electrical wiring
Fuses I ← ← ←
Open-circuit in glow plug I ←
Preheater
Open-circuit in intake heater I ←
Engine stopping
Diesel engine key stop device function I ← ← ←
system
SAFETY DEVICES, ETC.
Cracks at welded portion I ← ← ←
Head guard
Deformation and damage I ← ← ←
Loosening of mounting T ← ← ←
Back-rest
Deformation, crack and damage I ← ← ←
Lighting system Function and mounting condition I ← ← ←
Horn Function and mounting condition I ← ← ←
Direction indicator Function and mounting condition I ← ← ←
Instruments Functions I ← ← ←
Backup buzzer Function and mounting condition I ← ← ←
Dirt, damage I ← ← ←
Rear-view mirror
Rear reflection status I ← ← ←
Loosening and damage of mounting I ← ← ←
Seat Seatbelt damage and function I ← ← ←
Seat switch function I ← ← ←
OPS Functions I ← ← ←
Damage and cracks of frame, cross members, etc. I
Body
Bolt looseness T
Functions I ← ← ←
Loosening and damage at sensor mounting portion I ← ← ←
Damage, deformation, oil leakage and loosening of
SAS I ← ← ←
the mounting of functional parts
Loosening and damage of wire harnesses I ← ← ←
Lock cylinder accumulator performance I
Others Grease up L ← ← ←

Section 0
0-26 General

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

z: Replacement
Interval Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Engine oil z*2 ← ← ←
*1 ← ←
Engine oil filter z z
Engine coolant (every 2 years for LLC) z ← ←
Fuel filter z ←
Torque converter oil z ←
Torque converter oil filter z ←
Differential oil z
Hydraulic oil z ←
Hydraulic oil filter z*1 z ←
Wheel bearing grease z
Air cleaner element z
Cups and seals for brake master and wheel cylinders z
Brake fluid z ←
Spark plugs z*3
Power steering hoses z*4
Power steering rubbers parts z*4
Hydraulic hoses z*4
Brake fluid reservoir tank hose z*4
Fuel hoses z*4
Torque converter rubber hoses z*4
Chains z*5
Oil pump seal for material handling z*5
SAS Swing lock cylinder z*6
Wet brake cooling oil (OPT) z*1 z ←
Wet brake valve seal (OPT) z
Wet brake cooling hose (OPT) z*4
Wet brake piston seal (OPT) z*7
Wet brake disc and plate (OPT) z*7
Wet brake accumulator (OPT) z*8

*1: For new vehicle

*2: For the engine oil grades listed below, change oil every 500 hours.
Gasoline vehicle: API SL, SM and above
Diesel vehicle: API CF-4 and above
*3: Every 3 years or every 2500 hours
*4: Every 2 years
*5: Every 3 years
*6: Every 10000 hours
*7: Every 6 years
*8: Every 10 years

Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.

Section 0
 1-1

ENGINE
Page Page
ENGINE EXTERIOR VIEW ......1-2 MUFFLER & EXHAUST 0
PIPE ..................................... 1-21
ENGINE MAIN 1
PARAMETERS.......................1-4 COMPONENTS....................... 1-21
2
ENGINE PERFORMANCE REMOVAL·INSTALLATION ...... 1-22
CURVES.................................1-6 BATTERY .............................. 1-23 3
ENGINE ASSY.........................1-8 COMPONENTS....................... 1-23 4
REMOVAL·INSTALLATION ........1-8 SPECIFICATIONS ................... 1-24 5
AIR BLEEDING OF INSPECTION .......................... 1-25 6
THE FUEL SYSTEM ............1-11 V-BELT TENSION
7
ENGINE INSPECTION· ADJUSTMENT..................... 1-26
ADJUSTMENT.....................1-11
1-12
ACCELERATOR PEDAL....... 1-27 8
4Y ENGINE .............................1-12 9
COMPONENTS....................... 1-27
1DZ-II ENGINE VEHICLE .........1-13
INSPECTION·ADJUSTMENT.... 1-28 10
AIR CLEANER.......................1-15
EZ PEDAL (OPT) .................. 1-30 11
SPECIFICATIONS ...................1-15
COMPONENTS....................... 1-30
COMPONENTS .......................1-15
12
DISASSEMBLY·INSPECTION·
AIR CLEANER REASSEMBLY ...................... 1-31 13
CLEANING·INSPECTION .......1-16
ADJUSTMENT ........................ 1-33 14
CLOGGING WARNING SYSTEM
INSPECTION (OPT) ...............1-17 TRAVEL AND LOAD 15
HANDLING CONTROL
RADIATOR.............................1-18 DEVICE (OPT) ..................... 1-35 16
COMPONENTS .......................1-18 COMPONENTS....................... 1-35 17
SPECIFICATIONS ...................1-19 REMOVAL·INSTALLATION ...... 1-36 18
COOLANT CAPACITY AND THROTTLE OPENING
ANTIFREEZE TABLE .............1-19 DEGREE ADJUSTMENT........ 1-38 19
COOLANT INSPECTION ..........1-19 TROUBLESHOOTING ............. 1-39 20
21
E
1-2 Engine

ENGINE EXTERIOR VIEW

4Y Engine

Section 1
 Engine 1-3

1DZ-II Engine

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
Section 1
1-4a
1-4 Engine

ENGINE MAIN PARAMETERS 8FGU15-32

8FGCU20-32
Gasoline Engine
Vehicle model 8FGU15~25
8FGU30·32
Item 8FGCU20~32
Engine model 4Y ←
Engine type Gasoline · 4 cycle ←
In-line 4 cylinder,
Number and arrangement of cylinders ←
longitudinally mounted
Combustion chamber type Wedge ←
Valve mechanism OHV·chain drive ←
91.0 × 86.0
Bore x stroke mm (in) ←
(3.583 × 3.386)
Total displacement cm3 (in3) 2237 (136.51) ←
Compression ratio 8.8 ←
Maximum output Gasoline exclusive 38 (51)/2570 44 (59)/2570
kW (PS)/rpm LPG convertible/Gasoline 38 (51)/2570 43 (58)/2570
LPG convertible/LPG 38 (51)/2570 42 (57)/2570
LPG exclusive 38 (51)/2570 42 (57)/2570
Maximum torque Gasoline exclusive 160 (16.3)/2100 165 (16.8)/2570
N·m (kgf·m)/rpm LPG convertible/Gasoline 160 (16.3)/2100 162 (16.5)/2570
LPG convertible/LPG 160 (16.3)/2100 160 (16.3)/2200
LPG exclusive 160 (16.3)/2100 160 (16.3)/2200
Minimum fuel consumption Gasoline exclusive 298 (219)/2000 310 (228)/1600
g/kW·h (g/PS·h)/rpm LPG convertible/Gasoline 298 (219)/2000 310 (228)/1600
LPG convertible/LPG 233 (171)/2000 ←
LPG exclusive 233 (171)/2000 ←
Service weight kg (lb) ← ←
No-load maximum speed rpm 2570 ←

Section 1
 Engine 1-4b
1-3
0-5

ENGINE MAIN PARAMETERS

8FGCU15,18,SU20
Gasoline Engine
Engine model 4Y
Engine type Gasoline · 4 cycle 0
Number and arrangement of cylinders In-line 4 cylinder, longitudinally mounted
Combustion chamber type Wedge
1
Valve mechanism OHV·chain drive
Bore x stroke mm (in) 91.0 × 86.0 (3.583 × 3.386)
2
Total displacement cm3 (in3) 2237 (136.51)
3
Compression ratio 8.8
Maximum output Gasoline exclusive 36 (48)/2250 4
kW (PS)/rpm LPG convertible/Gasoline 36 (48)/2250
LPG convertible/LPG 36 (48)/2250 5
LPG exclusive 36 (48)/2250
Maximum torque Gasoline exclusive 160 (16.3)/2100 6
N·m (kgf·m)/rpm LPG convertible/Gasoline 160 (16.3)/2100
LPG convertible/LPG 160 (16.3)/2100 7
LPG exclusive 160 (16.3)/2100
Minimum fuel consumption Gasoline exclusive 298 (219)/2000 8
g/kW·h (g/PS·h)/rpm LPG convertible/Gasoline 298 (219)/2000
LPG convertible/LPG 233 (171)/2000
9

Service weight
LPG exclusive
kg (lb)
233 (171)/2000
134 (295)
10
No-load maximum speed rpm 2570
11
12
13
14
15
16
17
18
19
20
21
E
Section 1
1-5 Engine

Diesel Engine
Vehicle model
8FDU15·18 8FDU20~32
Item
Engine model 1DZ-II ←
Engine type Diesel · 4 cycle ← 0
In-line 4 cylinder,
Number and arrangement of cylinders ←
longitudinally mounted 1
Combustion chamber type Whirl chamber ←
Valve mechanism OHV·gear drive ← 2
86.0 × 107.0
Bore x stroke mm (in) ←
(3.386 × 4.213) 3
Total displacement cm3 (in3) 2486 (151.71) ←
Compression ratio 21.5 ← 4
Maximum output kW (PS)/rpm 39 (53)/2400 42 (57)/2500
Maximum torque N·m (kgf·m)/rpm 160 (16.3)/2300 160 (16.3)/2500 5
Minimum fuel
conspumption
g/kW·h (g/PS·h)/rpm 247 (181)/1400 ←
6
Service weight kg (lb) 162 (357) ←
No-load maximum speed rpm 2600 2800 7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
Section 1
 Engine 1-6a

ENGINE PERFORMANCE CURVES

4Y 8FGU15-25·8FGCU20-32

Gasoline (Exclusive·Convertible)
LPG (Exclusive·Convertible)

Torque

Shaft torque

Fuel consumption ratio

4Y 8FGU30-32

Gasoline (Exclusive)
Gasoline (Convertible with LPG)
LPG (Exclusive·Convertible)

Torque

Gasoline (Exclusive)
Gasoline (Convertible with LPG)
LPG (Exclusive·Convertible)

Shaft torque

Gasoline (Exclusive·Convertible)
LPG (Exclusive·Convertible)
Fuel consumption ratio

Section 1
1-6b
1-4 Engine

ENGINE PERFORMANCE CURVES

4Y 8FGCU15,18,SU20

Gasoline (Exclusive·Convertible)
LPG (Exclusive·Convertible)

Torque

Shaft torque

Fuel consumption ratio

Section 1
 Engine 1-7

1DZ-II Engine 8FDU15·18

Torque

Shaft torque

Fuel consumption ratio

1DZ-II Engine 8FDU20~32

Torque

Shaft torque

Fuel consumption ratio

Section 1
1-8 Engine

ENGINE ASSY 8FG(D)U15-32

8FGCU20-32
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]

22
27
25

8
28
18 12
26

Engine mount nut T = 53.2~98.0 (542~1000) [39.2~72.4]

End plate set bolt T = 49.0~78.4 (500~800) [36.2~57.9]
1DZ-II·2Z: T = 125~186 (1275~1897) [92.2~137.2]
Drive plate set bolt (For connecting the engine crank shaft)
4Y: T = 78~98 (795~1000) [57.5~72.4]
Drive plate set bolt (For connecting the torque converter) T = 14.7~21.6 (150~220) [10.9~15.9]
Torque converter housing set bolt T = 29.4~44.1 (300~450) [21.7~32.6]

Section 1
 Engine 1-9

Removal Procedure 8FG(D)U15-32

1 (See page
Remove the engine hood. (See Section 11)
11-XX.)
8FGCU20-32
2 Remove the lower panel and toe board.
3 Drain coolant.
4 Remove the battery.
5 Remove the sedimenter bracket set bolt to free the bracket. (1DZ-II engine vehicle)
6 Disconnect the accelerator wire.
7 Disconnect the fuel hose.
8 Remove the relay block bracket set bolt and free the relay block.
9 Remove the battery set plate.
10 Remove the air cleaner and air inlet.
11 Remove the exhaust cover plate.
12 Disconnect the exhaust pipe.
13 Disconnect the water hose.
14 Disconnect the T/C cooler hose. [Point 1]
15 Remove the radiator and fan shroud.
16 Remove the under cover.
17 Remove the wiring and wire harness clamps around the engine.
18 Remove the oil pump set bolt and free it.
19 Remove the cover plate. [Point 2]
20 Remove the 6 drive plate set bolts. [Point 3]
21 Remove the engine mount nuts.
22 Slightly hoist the engine. [Point 4]
23 Support the torque converter housing with wooden blocks.
24 Separate the torque converter housing and engine. [Point 5]
25 Remove the engine ASSY.
26 Remove the drive plate.
27 Remove the torque converter end plate.
28 Remove the starting motor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply sealant (08833-76002-71 (08833-00080)) before tightening the drive plate set bolt (for connecting
engine and crankshaft).
• Bleed air from the fuel system after installation of the engine ASSY. (1DZ-II engine vehicle)
(See page 1-18.)

Section 1
1-10 Engine

Point Operations 8FG(D)U15-32

8FGCU20-32
[Point 1]
Removal:
Put match marks on the radiator and torque converter cooler
hose.

Cover plate [Point 2]

Removal:
Remove the cover plate.

[Point 3]
Removal•Installation:
Rotate the drive plate using the crank shaft pulley set bolt, and
remove the drive plate set bolt.

SST(1) [Point 4]
Removal•Installation:
SST(2)
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)

Removal:
Temporarily hoist up until the mount bolt completely comes out
of the hole in the frame.

Section 1
 Engine 1-11a
1-11

[Point 5] 8FG(D)U15-32
8FGCU20-32
Removal:
Use a flat-head screwdriver for separation.
If the fitting is too tight, change the SST hook position and
adjust the engine angle for easier separation.

AIR BLEEDING OF THE FUEL SYSTEM

1DZ-II Engine Vehicles Only
1. Perform air bleeding by moving the priming pump knob up and
down.
2. Once the pump operation becomes heavy, air bleeding is
completed.

ENGINE INSPECTION·ADJUSTMENT
Note:
• Warm up the engine beforehand, and proceed with inspection and adjustment when the vehicle is in the
following state:
• Coolant temperature: 75°C (167°F) or above, engine oil temperature: 60°C (140°F) or above, hydraulic oil
temperature: 50°C (122°F) or above

Section 1
1-11b Engine

ENGINE ASSY
8FGCU15,18,SU20
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
0
14 7 12
1
2
3
4
5
6
7
8
9
10
11
12
13
23 13 14
5 15
16
6

17
18
Engine mounting nut T = 53.9 ~ 99.0 (550 ~ 1010) [39.8 ~ 73.1]
End plate set bolt T = 49.0 ~ 78.5 (500 ~ 800) [36.2 ~ 57.9] 19
Drive plate set bolt (for connecting engine crankshaft) T = 56.9 ~ 64.7 (580 ~ 660) [42.0 ~ 47.7]
Drive plate set bolt (for connecting torque converter) T = 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9] 20
Torque converter housing set bolt T = 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]
21
E
Section 1
 Engine 1-11c

Removal Procedure
8FGCU15,18,SU20
1 Remove the radiator cover.
2 Remove the engine hood.
3 Remove the lower panel, rear toe board and front toe board.
4 Drain coolant.
5 Remove the relay block and electrical parts plate set bolts to free them.
6 Remove the battery and battery tray.
7 Remove the air cleaner.
8 Disconnect the fuel hose.
9 Disconnect connectors and wiring harness clamps around the engine.
10 Remove the radiator reservoir tank and tank bracket.
11 Disconnect the torque converter cooler hose. [Point 1]
12 Remove the radiator.
13 Remove the oil pump.
14 Disconnect the exhaust pipe.
15 Disconnect the wiring from the starting motor.
16 Remove the cover plate (for drive plate).
17 Remove 6 drive plate set bolts.
18 Slightly hoist the engine. [Point 2]
19 Remove the engine mounting nuts.
20 Sling the torque converter housing with wire rope and support it with the head guard (or support it with wooden
blocks).
21 Separate the torque converter housing and engine. [Point 3]
22 Remove the engine ASSY with drive plate and torque converter end plate.
23 Remove the drive plate.
24 Remove the torque converter end plate.
25 Remove the starting motor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply sealant (08833-00080) before tightening the drive plate set bolt (for connecting engine crankshaft).

Section 1
1-11d Engine

Point Operations
8FGCU15,18,SU20
[Point 1]
Removal:
Put match marks on the radiator and torque converter cooler
hose.

SST(1) [Point 2]
Removal•Installation:
SST(2)
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)

Removal:
Temporarily hoist up until the mount bolt completely comes out
of the hole in the frame.

[Point 3]
Removal:
Use a flat-head screwdriver for separation.
If the fitting is too tight, change the SST hook position and
adjust the engine angle for easier separation.

Section 1
 Engine 1-12

ENGINE INSPECTION·ADJUSTMENT
Note:
• Warm up the engine beforehand, and proceed with inspection and adjustment when the vehicle is in the
following state:
• Coolant temperature: 75°C (167°F) or above, engine oil temperature: 60°C (140°F) or above, hydraulic oil
temperature: 50°C (122°F) or above

4Y ENGINE
Idle Speed Inspection·Adjustment
1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Inspect the idle speed.
Standard: 750 ± 30 rpm (For both gasoline and LPG)
CNG/LPG)

Rev terminal

3. If the standard is not met, adjust by the following procedure.

(1) Connect the plug-in analyzer.
SST 09240-26600-71
Note:
• Vehicles equipped with the multifunction display (OPT)
have the same functions as the analyzer, so the plug-in
analyzer is not necessary.
• For an explanation on using the multifunction display and
plug-in analyzer, refer to the multifunction display section.

(2) Set the idle speed to within standard values on the idle
adjustment screen.

No-load Maximum Speed Inpsection

1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator is fully pressed down.
8FGCU15,18,SU20:
Standard: 2250 ± 30 2250 ± 30 both
rpm (For rpm gasoline and LPG)
8FGU15-32, 8FGCU20-32: 2570 ± 30 rpm

Rev terminal

Section 1
1-13 Engine

3. Inspect the relief down amount.

Operate the tilt lever fully backward at the maximum engine
speed, and measure the engine speed upon full relief.
Measure the decrease (relief down) in the engine rpm.
Standard: Within 200 rpm

Ignition Timing Inspection·Adjustment

1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Inspect the idle speed.
Standard: 750 ± 30 rpm
3. Install the timing light.
4. Use the SST to short circuit terminals TC and EI of the
Diagnostic connector
diagnostic connector.
SST 09238-13130-71
Caution:
If the short circuit positions are incorrect, this will cause a
fault. Make sure to short circuit the correct terminals.

5. Inspect the ignition timing.

If the standard is not met, loosen the distributor set bolt and
rotate the distributor to adjust the ignition timing to the
standard value.
Standard: 7° (BTDC) (For both gasoline and LPG/CNG)

1DZ-II ENGINE VEHICLE

Idle Speed Inspection·Adjustment
1. Install the rev counter.

Rev counter

Section 1
 Engine 1-14

Idle adjusting screw 2. Check the return of the accelerator wire, and also check that
the injection pump idle adjusting screw is in contact with the
accelerator lever.
3. Inspect the idle speed.
Standard
1DZ-II: 750 ± 25 rpm
4. If the standard is not met, loosen the lock nut and adjust with
the idle adjusting screw.
Accelerator lever 5. Tighten the lock nut, and inspect the idle speed again.

Maximum adjusting screw No-load Maximum Speed Inspection·Adjustment

1. Install the rev counter.
2. Inspect the no-load maximum speed.
(1) While the engine is at standstill, press down the
accelerator fully, and check that the adjusting lever is
touching the maximum adjusting screw.
(2) Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator pedal is fully
Accelerator lever pressed down.
Standard
8FDU15·18: 2600 ± 50 rpm
8FDU20~32: 2800 ± 50 rpm
In the case of vehicles equipped with travel and load handling
control, the rpm tolerance is .
3. Adjust the no-load maximum speed.
Remove the sealing of the maximum adjusting screw, and
adjust by turning it.

4. Inspect the relief down amount.

(1) Operate the tilt lever to fully backward at the maximum
engine speed, and measure the engine speed upon full
relief. Measure the decrease (relief down) in the engine
rpm.
Standard: Within 200 rpm
5. Seal the set screw.

Section 1
1-15a Engine

AIR CLEANER 8FG(D)U15-32

8FGCU20-32
SPECIFICATIONS
Single (STD) Double (OPT)
Type Cyclone type ←
Size 7-inch ←
Intake type Fresh air introduction type ←
Outer 18600 (2883)
Filtering area cm2 (in2) 18600 (2883)
Inner 510 (79.1)
Others With evacuator valve ←

COMPONENTS
1703

Section 1
 Engine 1-15b

AIR CLEANER
8FGCU15,18,SU20
SPECIFICATIONS
Single (STD) Double (OPT)
Type Cyclone type ←
Size 6-inch ←
Intake type Fresh air introduction type ←
Outer 14000 (2170)
Filtering area cm2 (in2) 14000 (2170)
Inner 570 (88.4)
Others With evacuator valve ←

COMPONENTS
1703

Section 1
1-16 Engine

AIR CLEANER CLEANING·INSPECTION

1. Open the engine hood.
2. Remove the element.
Note:
In case of the double element type (OPT), do not remove the
inner element for other than replacement.

3. Clean the element.

(1) For ordinary cleaning, blow with compressed air [690 kPa
(7 kgf/cm2) [100 psi] or less] vertically along the pleats
from the inside of the element.
If heavily contaminated, washing is possible.

(2) Element washing method

Dissolve neutral detergent in tepid water (approx. 40°C
(104°F)) and immerse the element in it for about 30
minutes. Then, rinse the element well with clear water.
[Water pressure: 275 kPa (2.8 kgf/cm2) [40 psi] or less]
After washing, naturally dry the element or dry the
element with a dryer (cold air).
Note:
• Do not damage the paper filter during washing.
• Never use compressed air or hot air for drying.

4. Clean the evacuator valve (dust discharge valve).

Hold the tip end of the evacuator valve and discharge dust and
dirt from the inside of the valve.
5. Inspect the element.
After cleaning, place an electric bulb in the element to inspect
any damage in the element. If any pinhole, tear or damage is
found, replace it with a new element.
6. Element replacement
Replace the element after it is washed six times or generally at
intervals of 12 months.

Section 1
 Engine 1-17

7. Install the element.

Install the evacuator valve in the illustrated direction.

25°

CLOGGING WARNING SYSTEM

INSPECTION (OPT)
1. Warning lamp inspection
(1) Check that the air cleaner warning lamp comes on when
the ignition key switch is turned ON and goes out when
the engine starts.

2. Individual inspection
(1) Use a mity vac to apply a negative pressure to the
vacuum switch, and inspect for continuity.
Standard
4Y engine vehicle
2630~3218 Pa (270~330 mmAq) (19.9~24.3 mmHg):
continuity exists
1DZ-II engine vehicles
6904~8042 Pa (704~820 mmAq) (51.7~60.3 mmHg):
continuity exists

Section 1
1-18 Engine

RADIATOR 8FG(D)U15-32
8FGCU20-32
COMPONENTS
4Y

1603

1DZ-II

1603

Section 1
 Engine 1-19a
1-19

SPECIFICATIONS 8FG(D)U15-32
8FGCU20-32
Type Crossflow
Fin type Corrugated fin
Coolant capacity (in radiator) See the table below
Cap opening pressure kPa (kgf/cm2) [psi] 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1]
Others Built in torque converter cooler (torque converter vehicle)

COOLANT CAPACITY AND ANTIFREEZE TABLE

Unit: l (US gal)
30% Antifreeze 50% Antifreeze
Total coolant Antirust mixture
Radiator capacity mixture mixture
capacity 5%
(down to -15°C) (down to -35°C)
Pn1, Cu2·3 ton series 2.7 (0.71)
Pn2 ton series 3.7 (0.98)
Pn3 ton series 3.7 (0.98)

Note:
• The total coolant capacity does not include the capacity of the reservoir tank.
• Reservoir tank capacity: 0.47 l (0.124 US gal) (at FULL mark position)

COOLANT INSPECTION
1. Inspect the coolant level.
Check that the coolant level is between FULL and LOW in the
radiator reservoir tank.

2. Measure the coolant concentration. (LLC)

(1) Measure the temperature and specific gravity of the
coolant.
Note:
The coolant concentration must be 30% (STD: 50%) or above.

Section 1
1-19b Engine

RADIATOR
8FGCU15,18,SU20
COMPONENTS
1603

Section 1
 Engine 1-19c

SPECIFICATIONS
8FGCU15,18,SU20
Type Crossflow
Fin type Corrugated fin
Coolant capacity (in radiator) See the table below
Cap opening pressure kPa (kgf/cm2) [psi] 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1]
Others Built in torque converter cooler (torque converter vehicle)

COOLANT CAPACITY AND ANTIFREEZE TABLE

Unit: l (US gal)
30% Antifreeze mixture 50% Antifreeze mixture Antirust mixture
Radiator capacity Total coolant capacity
(down to -15°C) (down to -35°C) 5%
2.7 (0.71)

Note:
• The total coolant capacity does not include the capacity of the reservoir tank.
• Reservoir tank capacity: 0.47 l (0.124 US gal) (at FULL mark position)

COOLANT INSPECTION
1. Inspect the coolant level.
Check that the coolant level is between FULL and LOW in the
radiator reservoir tank.

2. Measure the coolant concentration. (LLC)

(1) Measure the temperature and specific gravity of the
coolant.
Note:
The coolant concentration must be 30% (STD: 50%) or above.

Section 1
1-20 Engine

(2) Find the concentration of the coolant from the table on the
50% (approximately -38°C) left.
40% (approximately -26°C)
Note:
30% (approximately -16°C)
This graph shows the relationship between coolant
temperature and specific gravity at concentrations of 30, 40
and 50%.
For example when the coolant temperature is 55°C and the
specific gravity is 1.035, the coolant concentration at this time
can be found as follows:
The intersection point of 55°C and 1.035 is between the 30%
line and 40% line, so this point is approximately 35%. In other
Specific gravity

words, the concentration is approximately 35%.

3. Check that there is no oil etc. mixed in with the coolant.

Measured temperature (°C)

Section 1
 Engine 1-21

MUFFLER & EXHAUST PIPE 8FG(D)U15-32

8FGCU20-32
COMPONENTS
4Y

1702

1DZ-II (1·K2·K3 Ton Series)

1702

Section 1
1-22a
1-22 Engine

REMOVAL·INSTALLATION 8FG(D)U15-32
8FGCU20-32
Note:
The muffler can be removed by either of the two methods shown below.
(1)Remove the muffler after removing the counterweight.
(2)Remove the muffler after removing the radiator W/ counterweight.
Here, method (1) is explained.
3

4
2

Removal Procedure
1 Remove the counterweight. (See page 11-XX.)
2 Separate the union between the exhaust pipe and muffler.
3 Remove the exhaust pipe fixation bolts.
4 Remove the muffler.
5 Disconnect the tail pipe from the muffler.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Use a new gasket.

Section 1
 Engine 1-22b

MUFFLER & EXHAUST PIPE 8FGCU15,18,SU20

COMPONENTS
STD

1702

EXPORT SPEC

1702

Section 1
1-22c Engine

REMOVAL·INSTALLATION
8FGCU15,18,SU20
Note:
The muffler can be removed by either of the two methods shown below.
(1)Remove the muffler after removing the counterweight.
(2)Remove the muffler after removing the radiator W/ counterweight.
Here, method (1) is explained.

Removal Procedure
1 Remove the counterweight. (See Section 11)
2 Separate the union between the exhaust pipe and muffler.
3 Remove the exhaust pipe fixation bolts.
4 Remove the muffler.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Use a new gasket.

Section 1
 Engine 1-23

BATTERY
COMPONENTS
4Y

1901

1DZ-II

1901

Section 1
1-24 Engine

SPECIFICATIONS
Battery type list (The battery is selected according to the equipped engine).
Engine
4Y 1DZ-II
Specifications
GR35 GR24R
STD
(JIS 55D23L) (JIS 80D26L)
Voltage V 12 ←
5 hour rated capacity Ah 48 55
Specific gravity of battery fluid in use
1.280 ←
(at 20°C (68°F))
Battery weight kg (lb) 16.2 (35.7) 19.0 (41.9)

Section 1
 Engine 1-25

INSPECTION
1. Inspect the battery fluid level.
Inspect that the battery fluid level is between the UPPER and
LOWER lines. Add distilled water if insufficient. Do not overfill
UPPER
above the upper fluid limit.
LOWER

2. Inspect the specific gravity of the battery fluid.

Use a hydrometer to measure the specific gravity of the battery
fluid.
Standard: 1.280 (at 20°C (68°F))
Calculating equation
S20 = St + 0.0007 (t-20)
S20: Specific gravity converted to 20°C (68°F)
St: Measured specific gravity at t°C
t: Fluid temperature at the time of measurement

3. Inspect the battery terminals.

If battery terminals are contaminated to white, clean then and
apply a thin coat of MP grease on terminals.
4. Inspect the battery terminals and the harness connecting
portions for loosening.
Retighten the battery terminals and the harness connecting
portions.

Battery Removal
1. Disconnect battery terminals.
Note:
Disconnect the negative terminal first.
2. Remove the battery stopper.
3. Remove the battery.

Battery Installation
The installation procedure is the reverse of the removal procedure.

Section 1
1-26 Engine

V-BELT TENSION ADJUSTMENT

1. Inspect the V-belt tension.
Standard
[amount of delfection when pressed with 98 N (10 kgf)]
4Y: 8~13 mm (0.31~0.51 in)
1DZ-II: 8~13 mm (0.31~0.51 in)

Standard
[When using a tension gauge (SST)]
SST 09216-76002-71 (09216-00021)
4Y: 294~490 N (30~50 kgf) [66~110 lbf]
1DZ-II: 324~559 N (33~57 kgf) [73~126 lbf]

Set bolt 2. V-belt deflection adjustment

4Y engine vehicle
Adjustment bolt (1) Loosen the fixing bolt.
(2) Loosen the set bolt and turn the adjustment bolt to adjust
the tension.
(3) Tighten the fixing bolt and recheck the belt tension.
Note:
Fixing bolt Be careful not to apply excessive tension to the belt.

1DZ-II engine vehicles

Adjustment bolt
(1) Loosen the fixing bolt and adjusting bolt.
(2) Stretch the V-belt using a pry bar with the length of 300 to
400 mm (11.8 to 15.7 in), and tighten the alternator
adjustment bolt.
(3) Tighten the fixing bolt then recheck the belt tension.
Note:
Adjustment of the tension using a pry bar gives rise to
Fixing bolt considerable individual differences, and tends to result in
excessive or insufficent tension. Therefore, be sure to inspect
the deflection amount.

Section 1
 Engine 1-27

ACCELERATOR PEDAL
COMPONENTS
4Y

2601

1DZ-II

2601

Section 1
1-28 Engine

INSPECTION·ADJUSTMENT
B 1. Inspect the angle of the accelerator pedal.
1DZ-II
A
A: When the accelerator is OFF 45°
Rod B: At full throttle (reference) 20°

Adjust by adjusting the length of the rod.

Stopper bolt

1DZ-II Stopper bolt 2. 1DZ-II engine vehicles

engine vehicles Adjust the height of the stopper bolt on the floor side so that
Link the link contacts the stopper bolt on the engine side when the
pedal is depressed.

3. Adjust the accelerator wire so that there is about 2° of play in

the pedal.

4Y·Diesel Vehicle with Travel and Load Handling Control (OPT)

1. Inspect the angle of the accelerator pedal.
B
A: When the accelerator is OFF Pn/Cu2·3: 45°
45° Cu1: 39°
A
m)

B: At full throttle (Reference) 16°

2m

Rod Adjust by adjusting the length of the rod.

(5

2. : mm
Temporarily set the pedal stopper bolt height to 52
(2.05 in). 52mm (2.05 in)
Pn/Cu2·3:
Stopper bolt Accelerator Cu1: 32mm (1.26 in)
sensor

3. Adjust the accelerator sensor.

(1) Connect the plug-in analyzer.
SST 09240-26600-71
For diesel vehicles with travel and load handling control
(OPT) use the multifunction display.
Note:
For an explanation on using the display, refer to the
multifunction display section.

Section 1
 Engine 1-29

(2) Adjust the sensor voltage when the accelerator is OFF.

Display the I/O ENGINE CTRL 4/10 screen on the display.
Adjust the installation position of the accelerator sensor
so that the VPA1 output (V) comes to the value below,
and fix it with a the set screw.
VPA1: 0.85 ± 0.1 V

(3) Adjust the height of the stopper bolt so that the difference
between the VPA1 output (V) in the full throttle position
and the initial VPA1 output (V) is 2.4 V or greater, and the
VPA2 output (V) in the full throttle position is less than 4.6
V.
(Note: the change in output per single turn of the stopper
bolt is 0.06 V)
(4) After adjustment, apply thread tightener (08833-76002-71
(08833-00080)) to the threaded section of the stopper bolt
lock nut and reassemble it.
(5) Clear the learned values.
For the 4Y:
Remove the battery plug for more than 10 seconds, then
reconnect it.
For diesel vehicles with drive control:
Turn the key ON with the accelerator sensor connector
disconnected. (An accelerator sensor error will be
detected.)
Then, turn the key OFF and reconnect the accelerator
sensor connector.
(6) Check that the VPA1 and VPA2 values displayed with the
accelerator OFF are within a range specified below of the
values displayed inside the brackets.
Standard: Within ± 0.1 V

Section 1
1-30 Engine

EZ PEDAL (OPT)
COMPONENTS
2601

Section 1
 Engine 1-31

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]

1
3

29 (296) [21.4]

Disassembly Procedure
1 Remove the pin and separate the pad W/switch from the pedal. [Point 1]
2 Remove the switch ASSY. [Point 2]
3 Remove the holder W/magnet. [Point 3]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Apply grease on the inner surface of each bushing.
• After reassembly, adjust the direction switch. (See page 1-27.)

Pin Point Operations

Hook [Point 1]
Disassembly:
Extract the pin by lightly tapping the pin edge (the flange-less
Pad Notched portion side).
Reassembly:
Push the pin in with its notched flange portion in the illustrated
direction until it goes beyond the pad side hook.

Section 1
1-32 Engine

[Point 2]
Inspection:
Check continuity of direction switches.
Forward side:
c Continuity between c and d when the switch is pressed.
Forward
d Reverse side:
Continuity between c and e when the switch is pressed.
e

Reverse

Reassembly:
Reassemble in the following order:
1. Install the switch on the pedal.
Set the switch while fully pressing it onto the pad.
Apply locking agent (08833-76002-71 (08833-00080)) at the
tip end of the screw before tightening the nut.

2. Fix the switch harness by means of the plate.

A Avoid overlaying of three wire harnesses in the harness tube
as illustrated.
Also push portion A of the harness so as not to be raised (to
prevent interference at the time of pin insertion).

[Point 3]
Reassembly:
Since the holder W/magnet needs height adjustment, set it
temporarily in a low position. See page 1-28 for adjustment.

Section 1
 Engine 1-33

ADJUSTMENT
Note:
• Adjust the pedal roller height and pedal stopper bolt height in the same way as for the standard pedal.
(See page 1-28.)
• Direction switch adjustment is explained here.

Direction Switch Adjustment Procedure

1. 1. Fully tilt the accelerator pedal pad to either of one side.
It shall not contact to the magnet at the time.

2. 2. Screw in the magnet holder at the tilted side.

3. 3. Where the pad starts moving slightly is the position that the
magnet come to contact with the accelerator pedal pad plate.
Then thread in by a half (1/2) turn from that point.

4. 4. Tighten the lock nut.

Secure the magnet holder so as not to turn.

5. Adjust the other side in the same manner as in 1. to 4.

Lock nut
Magnet holder

6. After adjustment, confirm that the switches are actuated before

magnets contact to the pedal pad plate by tilting the pad
slowly.

Section 1
1-34 Engine

Adjusting Accelerator Link

1. Install the accelerator link stopper bolt.
2. After installing the stopper, adjust the bolt so that the clearance
is as specified in the illustration.

8 ~ 11 mm
(0.31 ~ 0.43 in)

3. After installing the accelerator sensor, loosen the stopper bolt

and tighten the lock nut at the position where the link stops.

Lock nut
Stopper bolt

T Adjusting Limit Switch (for Diesel Vehicles)

1. Install the limit switch to the accelerator switch bracket.
2. Temporarily install the accelerator switch bracket to the
accelerator link bracket.
3. Adjust the clearance as specified in the table below while
turning the accelerator switch bracket.
Limit
switch Clearance (T) (mm) Switch Condition
0.15 ON
Accelerator switch bracket 0.65 OFF

Stopper bolt
Adjusting Pedal Height (for Diesel Vehicles)
1. Adjust the stopper bolt height so that the link contacts the
Link stopper bolt on the engine side when the pedal is depressed.
At this time, the pedal play should be adjusted to within 0.4 to
1.7°.

Reference:
B Vehicle Type 8FDU15·18 8FDU20~32
A 20 mm (0.79 in) 25 mm (0.98 in)
B 15° 14°
A
C 32°

Section 1
 Engine 1-35

TRAVEL AND LOAD HANDLING CONTROL DEVICE (OPT)

1DZ-II Engine Vehicle

COMPONENTS
2607

Section 1
1-36 Engine

REMOVAL·INSTALLATION

LBA26-006

Removal Procedure
1 Open the engine hood and disconnect the negative terminal of the battery.
2 Remove the battery.
3 Remove the relay block bracket set bolt and free the relay block.
4 Remove the sedimenter.
5 Remove the battery set plate.
6 Disconnect the injection pump side link.
7 Remove the actuator. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installation, adjust the throttle opening degree. (Refer to 1-37)
• After installation, operate the accelerator pedal and check that the links are working normally.

Section 1
 Engine 1-37

[Point 1]
Inspection:
Inspect the actuator.
1. Check that the actuator shaft can be manually turned smoothly
without sticking.
2. Check the resistance of the actuator.
Tester range: Ω × 1 range
Standard
Between (1) and (3): Approx. 2.5~3.7 Ω
Between (2) and (3): Approx. 2.5~3.7 Ω
Between (1) and (4): Approx. 5.0~7.4 Ω
Between (2) and (5): Approx. 5.0~7.4 Ω

Inspection:
Measure the insulation resistance between each actuator
terminal and body.
Tester range: Ω × 1 M range
Standard: 100 MΩ or more

[Point 2]
Inspection:
Inspect the continuity of the limit switch.
Standard
Free position: ∞ Ω
When pushed 2.3 mm (0.091 in) or more: 0 Ω

Section 1
1-38 Engine

Idle set THROTTLE OPENING DEGREE

screw Thickness ADJUSTMENT
gauge
Idle Switch (Injection Pump Lever Completely Closed)
Adjustment
LBA26-010 1. Fix the injection pump lever in completely closed state with a
thickness gauge (1.3 mm (0.051 in) thickness) placed between
the lever and the idle set screw.

2. Tighten the adjustment bolt on the idle switch side from the
state where the switch and bolt are not in contact (switch OFF)
and adjust the bolt to the point where the switch switches
(OFF→ON). (It is possible to tighten up to 1/4 turn from the
Idle switch switching point)
3. Fix the adjustment bolt with the lock nut.
Lock nut
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.
Adjustment bolt

NMR Switch (Injection Pump Lever Completely Open)

Thickness gauge Adjustment
NMR set 1. Fix the injection pump lever in completely open state with a
screw thickness gauge (0.3 mm (0.051 in) thickness) placed between
the lever and the NMR set screw.

2. Tighten the adjustment bolt on the NMR switch side from the
state where the switch and bolt are not in contact (switch OFF)
and adjust the bolt to the point where the switch switches
Adjustment (OFF→ON). (It is possible to tighten up to 1/4 turn from the
NMR switch bolt switching point)
3. Fix the adjustment bolt with the lock nut.
Lock nut 4. Unlock the injection pump lever from fully open state.
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.

Section 1
 Engine 1-39

TROUBLESHOOTING
This page contains troubleshooting advice for the mechanical system of the travel and load handling control device.
In the case of an error code being recieved, or trouble with the electrical system, refer to the troubleshooting section.
● Idle switch open error
Check the injection pump

Check that the injection pump return spring is Not broken A defect in the mechanical system of the travel and
not broken. load handling control device.
Check the components of the travel and load
Broken
handling control device.

Replace the return spring

Checking the components

of the travel and load
handling control device

There is
Move the link by hand, and check that there is interference
no interference with surrounding parts. Remove the interference.

There is no interference
There is
looseness or
Check that there is no looseness or rattling in the rattling
motor bracket. Retighten the installation bolts.

There is no looseness
or rattling
There is
Check that there is no bending in the connecting bending
rod or bracket. Replace defective components.

There is no bending

There is
Check that there is no catching on the sliding catching
portion of the ball joint. Clean and grease the joint section.

There is no catching

90°C (194°F )
Check that the temperature around the motor in or more
use is 90°C (194°F) or less. Outside the range of the motor operation warranty.

90°C (194°F) or less

Mechanically no cause can be found, therefore

refer to the travel and load handling control device
electrical system troubleshooting.

Section 1
1-40 Engine

● The idle speed deviates from the specified value

Check the injection pump

specified A defect in the mechanical system of the travel and load

Hold pump lever completely closed with your speed handling control device.
hand, then start the engine and check whether Check the components of the travel and load handling
the engine idles at the specified speed. control device (refer to 1-38).
Not-specified speed

Adjust the idle set screw

● The idle up speed does not rise

Check the injection pump

There is no A defect in the mechanical system of the travel and load

Move the pump lever with your hand to check catching handling control device.
that there is no catching in the sliding
Check the components of the travel and load handling
movement.
control device (refer to 1-38).
There is catching

Service the injection pump (apply grease, etc.)

● No NMR
Check the injection pump

Check that there is NMR when starting the A defect in the mechanical system of the travel and load
There is NMR handling control device.
engine and turning the pump lever to the fully-
open position with your hand. Check the components of the travel and load handling
control device (refer to 1-38).
There is no NMR

Adjust the maximum set screw

● The engine does not respond to operation of the accelerator pedal

Check the injection pump

A defect in the mechanical system of the travel and load

With the engine running, move the pump lever Engine revs up
handling control device.
with your hand and check the rev-up response.
Check the components of the travel and load handling
Engine doesn't rev up control device (refer to 1-38).

Service or replace the injection pump

Section 1
 4Y-E Repair
SECTION INDEX
1 NAME 1I SECTION

GENERAL0
0

TROUBLESHOOTING
ENGINE OVERHAUL (4Y-M)
ENGINE OVERHAUL (4Y-E)
FUEL SYSTEM (4Y-M)
FUEL SYSTEM (4Y-E)
PCV DEVICE
COOLING S
LUBRICATION SYSTEM
IGNITION SYSTEM (4Y-M)
IGNITION SYSTEM (4Y-E)
STARTING SYSTEM
CHARGING SYSTEM
APPENDIX
 4Y-E Repair

GENERAL

SPECIFICATIONS............................................ 0-2
ENGINE EXTERIOR VIEW ................................. 0-3
ENGINE SECTIONAL VIEW .............................. 0-5
HOW TO USE THIS MANUAL ........................... 0-7
EXPLANATION METHOD .......................................... 0-7
TERMINOLOGY .......................................................... 0-8
ABBREVIATIONS ....................................................... 0-9
OPERATING TIPS ........................................... 0-10
POINTS FOR WHICH SPECIAL CARE
MUST BE TAKEN .................................................. 0-10
GENERAL INSTRUCTIONS ..................................... 0-10
ELECTRICAL PARTS INSPECTION........................ 0-13
BOLT & NUT TIGHTENING TORQUES .......... 0-15
BOLT STRENGTH CLASS IDENTIFICATION
METHOD AND TIGHTENING TORQUE ................ 0-15
PRECOATED BOLTS (BOLTS WITH SEAL
LOCK AGENT COATING ON THREADS) .... 0-18
SI UNITS........................................................... 0-18
HANDLING FlPG (LIQUID GASKETS)............ 0-19

Section 1.1.0
 4Y-E Repair

SPECIFICATIONS

Engine model*

1 Type I Gasoline I t

Cycle 4 t

lnline 4 cylinder,
Number and arrangement of cylinders
longitudinally mounted

I Ignition order I I

Start up method Self starting type t

ICombustion chamber type Wedge type

IValve mechanism 1
I
OHV chain drive I
I

Bore x stroke mm (in.) 91.0 x 86.0 (3.58 x 3.39) t

ITotal displacement cc (cu-in) I

Compression ratio 8.8 t

Compression pressure kPa (kgf/cm2) [psi]/rpm 1226 (12.5) [ I 7811250 t

IMinimum fuel consumption when fully loaded g1PS.h (rpm)

Refer to repair manual for
each vehicle model

Refer to repair manual for

No-load maximum speed rpm t
each vehicle model

Refer to repair manual for

Idle speed rpm t
each vehicle model

I1 Engine dimensions (length x width x height)

Weight
mm (in.)

kg (Ib) /
709x525~733
(27.9 x 20.7 x 28.9)
709x 513x 733
(27.9 x 20.2 x 28.9)

Compression rings 2 t
Number of piston rings
Oil ring 1 t

Open BTDC 12" t

Intake valve open/close interval
Close ABDC 40" t

Open BBDC 54" t

Exhaust valve openlclose interval
Close ATDC 6" t
-

Intake 0 (Automatic adjusting type) t

Valve clearance mm (in.) .
Exhaust 0 (Automatic adjusting type) t

Blow-by gas reductor type Closed type t

*: In this manual the engine with mechanical fuel injection fitted is referred to as 4Y-M, while the one with electronic
fuel injection fitted is referred to as 4Y-E.

Section 1.1.0
 4Y-E Repair

ENGINE EXTERIOR VIEW

4Y-M

Section 1.1.0
 4Y-E Repair

4Y-E (OPT)

Section 1.1.0
 4Y-E Repair

ENGINE SECTIONAL VIEW

Section 1.1.0
4Y-E Repair

Section 1.1.0
 4Y-E Repair

HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operating procedure
(1) Operating procedures are described using either pattern A or pattern B.
Pattern A: Each step of the operation is explained with its own illustration.
Pattern B: The entire operation is indicated by step numbers in one illustration, followed by cautions, notes,
and "Point Operations".

Example of pattern B

Tightening torque unit -+ T = N m (kgfcm) [ft.lbfl

The numbers may partially be

omitted in the illustration.
In the case where a part for
which the tightening torque is
specified is not shown in the
illustration, the name of the
part will be listed inside the
illustration frame.

DisassemblymReassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Crank pulley WI set bolt
2 Timing gear cover
3 Idle gear No.1 [Point I]
4 Oil pump ASSY [Point 21

Point Operations Explanation of operation

point with illustration Operations that have a following explanation
[Point 11
Inspection:
Measure the backlash.
Standard: 0.05 mm (0.0020 in.)

[Point 21
Reassemblv: Install the rotor in the ~ositionshown in the illustration.
Section 1.1.0
 4Y-E Repair

2. How to read component figures

(1) The component figures use the illustration in the parts (Example)
catalog for the vehicle model. Please refer to the catalog 3201
to check the art name.
3. Matters omitted from this manual Parts catalog f
FIG number
(1) This manual omits descriptions of the following jobs, but
perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)

TERMINOLOGY
Warning:
ltems that may lead to an injury to either the operator or another person, and items and operation points
which, if not followed, may lead to an injury or accident.
Caution:
ltems that must not be performed because doing so will result in damage to the vehicle or it's components,
and items in the operation to which special attention should be paid.
Note:
Supplemental explanations for performing the operation easily.
Standard: Value showing the allowable range in inspection or adjustment.
Limit: The maximum or minimum value allowed in inspection or adjustment.

Section 1.1.0
 4Y-E Repair

ABBREVIATIONS
Reference symbol Original word Meaning
iH Right Hand Right hand side
-H Left Hand Left hand side
Front Front
Rear Rear
This refers to the part size used by the maker at the time of assembly
STD Standard
being the standard size.
For parts that do not engage well anymore due to wear from long use,
or repeated disassembly, by replacing the part that is engaged by a
Over Size part of slightly larger dimensions, it's corresponding part can be
reused. These parts that have larger dimensions than STD, and are
referred to as 01s.
As with the OIS parts, by replacing the engaging part with one that has
UIS Under Size a smaller hole, it's corresponding part can be reused. These parts that
have smaller dimensions than STD, and are referred to as UIS.
ATDC After Top Dead Center After the top dead center point of the piston in the cylinder.
BTDC Before Top Dead Center Before the top dead center point of the piston in the cylinder.
IN Intake Refers to the intake system.
EX Exhaust Refers to the exhaust system.
SST Special Service Tool Special service tool
Torque Tightening torque
A part that consists of two or more single parts or sub-assembled parts
ASSY Assembly
that have been assembled together into an intergrated whole.
A part in which two or more parts are joined together by welding,
SUBIASSY Sub Assembly
casting, riveting etc.
The following items are attached.
WI
(Example: WI washer ... With a washer attached)
LWR Lower Lower

Section 1.1.0
 4Y-E Repair

OPERATING TIPS
POINTS FOR WHICH SPECIAL CARE MUST BE TAKEN
1. Always set the engine on an engine stand for carrying out assembly and disassembly of an engine. Never
operate on a workbench or on the floor as this is dangerous.

2. When handling and moving the cylinder head ASSY or the cylinder block, always wear gloves and do not use
your bare hands.

GENERAL INSTRUCTIONS
1. For safe operation
(1) Wear the correct safety gear (cap, safety goggles, gloves, safety shoes).
(2) To prevent burns, do not touch the radiator, muffler or exhaust pipe directly after stopping the engine.
(3) Do not put your clothing or tools near to the rotating part when the engine is turning.
(4) When the engine is not on, always have the engine switch OFF, and remove the starter key.
2. Preparation for disassembly
(1) Prepare general tools, SSTs, measuring instruments, lubricant and parts that cannot be reused.
(2) When disassembling a complex part, put imprints and match marks in places that will not effect the function
of the part in order to facilitate easy reassembly.
3. Prevention of entry of foreign bodies
Foreign bodies such as dust, sand and metal pieces inside the engine cause faults to occur.
(1) Thoroughly remove sand and mud etc. sticking to the engine exterior.
(2) Protect disassembled parts from dust with a plastic cover or similar.
Section 1.1.0
 4Y-E Repair

4. Prevention of damage to parts

Damage to contact surfaces or rotating parts can cause oil leakage or burning
(1) To disassemble contact surfaces of parts, do not use a screw driver or such, but tap them lightly with a
plastic hammer to separate them.
(2) When clamping parts in a vice, do not clamp them directly in the vice, but between aluminum plates.
5. Washing parts
(1) Before reassembling each part, wash thoroughly, dry by blowing them with air and apply the specified oil.
(2) Parts that may not be washed in alkaline chemicals.
Aluminum parts, rubber parts (O-rings etc.)
(3) Parts that may not be washed in treated oil (kerosene, non-residue solvent etc.).
Rubber parts (O-rings etc.)
6. Removal and installation of fuel system parts
(1) Work area for removal and installation of fuel system parts
(a) Work in a well-ventilated area where there are no sparks from surrounding welding equipment,
grinders, drills, electric motors, or stoves.
(b) Do not work in or near a pit that could fill up with the vapor from evaporated fuel.
(2) Removal and installation of fuel system parts
(a) Prepare a fire extinguisher before beginning work.
(b) To prevent static electricity, attach an earth wire to the fuel changer, vehicle, fuel tank and so forth, and
spread as much water on the floor as can be spread without causing slipping.
(c) Do not use electric pumps or working lights as these may give off sparks or become hot.
(d) Do not use a steel hammer as there is a possibility of a spark being generated during use.
(e) Dispose of fuel-soaked waste cloths separately.
7. Position and orientation when reassembling
(1) Reassemble each part with the same position and orientation from before it was disassembled.
(2) Reassemble the correct parts in the correct order, keeping to the specified standards (tightening torque,
adjustment values etc.). (Reassemble using the middle value within the range for tightening torque and
adjustment values).
(3) Always use genuine parts for replacements.
(4) Always use new parts for oil seals, O-rings, gaskets, cotter-pins and so forth.
(5) Before reassembling, apply seal packing for gaskets depending on their place of application, apply the
specified oil or grease to the specified places for sliding parts, and apply MP grease to the lip section of oil
seals.
8. Handling hose clamps
(1) Before removing a hose, check the insertion depth of the hose, and the position of the hose clamp so that
you can definately return them to their original positions.
(2) Replace deformed or fatigued clamps with new parts.
(3) When reusing the hose, align the new clamp over the mark left on the hose by the previous clamp.
(4) Adapt leaf spring clamps by applying force in the direction of tightening after attaching them.
9. Adjustment and checking operations
Use a gauge or tester to adjust to the specified service standard.

Section 1.1.0
 4Y-E Repair

10. Disposal of waste fluids

When draining waste fluid from the vehicle, always drain it into an appropriate container.
Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substances may adversely affect human
health and the environment. Always collect and sort them well, and ask specialized companies for appropriate
disposal.
Also, be sure to collect or wipe up spilled waste fluids.
11. Protection of functional parts
Before connecting the battery terminal after vehicle inspection or maintenance, thoroughly check each
connector for any connection failure or imperfect connection.
Failure to connect, or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers.

Section 1.1.0
 4Y-E Repair

ELECTRICAL PARTS INSPECTION

1. Always disconnect the battery plug before inspecting or servicing electrical parts.
2. Pay sufficient attention when handling electronic parts.
(1) Never subject electronic parts, such as computers and
relays, to impact.
(2) Never expose electronic parts to high temperature or
humidity.
(3) Do not touch connector terminals, as they may be
deformed or damaged due to static electricity.

3. Use a circuit tester that matches the object and purpose of measurement.
Analog type: This type is convenient for observing movement during operation and the operating condition. The
measured value should be used only for reference or rough judgement.
Digital type: A fairly accurate reading is possible. However, it may be difficult to observe variation or movement.
(1) Difference between results of measurement with analog and digital types
The results of measurements using the analog type and the digital type may be different.
Use the circuit tester according to its instruction manual.
Differences between the polarities of the analog type and the digital type are described below.

(a) Analog circuit tester

Example of measurement result
Forward Reverse
Tester range: kR range
Forward direction: Continuity 11 kR
Reverse direction: No continuity a,

(b) Digital circuit tester

I Forward Reverse
Example of measurement result
Tester range: 2 MR range
Forward direction: Continuity 2 MR
Reverse direction: No continuity 1

Section 1.1.0
 4Y-E Repair

(2) Differences in results of measurement with circuit testers

The circuit tester power supply voltage depends on the
tester type: 1.5 V, 3.0 V and 6.0 V.
The resistance of a semiconductor such as a diode varies
with the circuit tester power supply voltage.
Diode characteristics are shown in the figure to the left.
The resistance values of the same diode measured with
two types of circuit testers having different power supply
voltages are different.

This manual describes the results of measurement with

an analog circuit tester with a power supply voltage of 3.0
v.
Forward voltage (vI
(3) Differences in results of measurement by measurement range.
In the analog type circuit tester, changing the
measurement range switches over the internal circuit to
vary the circuit resistance. Even when the same diode is
measured, the measurement result varies according to
the measurement range.
Variable resistor Always use the range described in the repair manual for
0
3
G measurement.

i,ay Resistor

lo
"6 Voltage: 1.5 V

Red
3
Black

Section 1.1.0
 4Y-E Repair

BOLT & NUT TIGHTENING TORQUES

Standard Bolt & Nut Tightening Torque
Tightening torques of standard bolts and nuts are not indicated throughout the manual.
Use the procedures and table below to judge the standard tightening torque.
1. Judge the tightening torque for the hexagon head bolt, welded bolt or stud bolt having the standard bearing
surface according to the tightening torque table by identifying the bolt strength class from the table below.
2. Judge the tightening torque for the hexagon flange bolt based on the threading diameter.
3. The nut tightening torque can be judged from its corresponding bolt type by using procedure 1.

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND

TIGHTENING TORQUE
Identification by Actual Part

Shape and Strength class Strength class

@ Number in relief or hallmark on head

Hexagon head bolt

0 No mark

(standard bearing
surface)
8 Bolt with two raised lines on head

0 Bolt with three raised lines on head

8 Bolt with four raised lines on head

Welded bolt

No mark

Stud bolt

About 2 mm (0.08 in.) groove@)on onelboth edge(@

Section 1.1.0
 4Y-E Repair

Identification by Part No.

TYpe I Part NO Shape

91611-40625
Nominal
Nomtnal length (mm) diameter
Hexagon bolt Nominal diameter (mm)
Strength class I Nominal length
_I
921 32-40614
Nommal length (rnm) Nominal
diameter
Stud bolt Nominal diameter (mm)
Strength class

Tightening Torque Table

Nominal diameter Pitch Standard tightening torque

Strength class
mm mm N.m kgfcm ft.lbf

Section 1.1.0
 4Y-E Repair

Identification by Bolt Shape (Hexagon flange bolt)

Class

Hexagon flange
bolt
P No mark

PNo mark

Tightening Torque Table (Hexagon flange bolt)

Nominal diameter Pitch Standard tightening torque

Strength class
mm mm

4.8T

6.8T

8.8T

Section 1.1.0
 4Y-E Repair

PRECOATED BOLTS
(BOLTS WITH SEAL LOCK AGENT COATING ON THREADS)
1. Do not use the precoat bolt as it is in either of the following
cases:
(1) After it has been removed.
(2) When it has been moved by tightness check, etc.
(loosened or tightened)
Note:
For torque check, tighten the bolt at the lower limit of the
allowable tightening torque range; if the bolt moves, retighten
Seal lock agent
it according to the steps below.
2. How to reuse precoated bolts
(1) Wash the bolt and threaded hole.
(The threaded hole must be washed even when replacing
the bolt with a new one.)
(2) Completely dry the washed parts by blowing with air.
(3) Apply the specified seal lock agent to the bolt threaded
portion.

SI UNITS
Meaning of SI
This manual uses SI units. SI represents the International System of Units, which was established to unify the various
systems of units used in the past for smoother international technical communication.

New Units Adopted in SI

I Item New unit ( Conventional unit ( Conversion rate*l (1 [conventional unit] = X [SI unit]) 1
r Force*2 I N (newton) I kgf I Ikgf = 9.80665 N I
Torque2
(Moment) I I

Pressure*2 Pa (pascal) kgflcm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa

? ? mmHg 1 mmHg = 0.133322 kPa

I I I

Revolving speed I rlmin rPm 1 rpm = Irlmin

I Spring constanV2 I N/mm I kgflmm I 1 kgflmm = 9.80665 Nlmm I
Volume L cc Icc=lmL
Power W PS 1 PS = 0.735499 kW
Heat quantity W-h cal 1 kcal = 1.16279 W.h
I

Specific fuel
gNV-h g1PS.h 1 g1PS-h = 1.3596 g1kW.h
consumption

Reference:
*I: X represents the value in SI units as converted from 1 [conventional units], which can be used as the rate for
conversion between conventional and SI units.
*2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgfl, which should be
used as the unit of force.

Section 1.1.0
 4Y-E Repair

Conversion between Conventional and SI Units

Equations for conversion
Conversion rate: Figure corresponding to X in the
Value in SI unit = Conversion rate x Value in conventional unit
conversion rate column in the table
Value in conventional unit = Value in SI unit + Conversion rate
above

Caution:
When converting, change the unit of the value in conventional or SI units to the one in the conversion rate
column in the table above before calculation. For example, when converting 100 W to the value in
conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499.

HANDLING FlPG (LIQUID GASKETS)

FIPG:
08826-7600 1-71

Example of Application Area

Points for application method and reassembling parts.
Caution:
When removing the gasket, be careful not to let broken pieces
of the gasket get inside the engine.
1. Clean the contact surfaces of every part and corresponding
part with a waste cloth so that they are free of oil, moisture,
and foreign objects.
2. Apply FlPG to the side of the part to be attached. Parts
requiring FlPG to be applied are listed in the point operations
for each section.
Always overlap the start and finish of the application so that
there is no excess application or insufficient application.
Take care not to move the parts after reassembling them.
Reassemble within 3 minutes of finishing the application.
For at least 2 hours after reassembly, do not pour in coolant or
lubrication oil, and do not start the engine.

Section 1.1.0
 4Y-E Repair

TROUBLESHOOTING
Page

TROUBLESHOOTING ....................................... 1-2

MECHANICAL TROUBLE .......................................... 1-2
ENGINE DOES NOT CRANK NORMALLY................ 1-3
ENGINE DOES NOT START EASILY.
OR DOES NOT START AT ALL .............................. 1-4
ENGINE IS ROUGH. OR STOPS.
DURING IDLING ...................................................... 1-5
CANNOT ACCELERATE SMOOTHLY
(INCLUDING HESITATION)..................................... 1-6
INSUFFICIENT POWER OUTPUT
(INCLUDING HUNTING) .......................................... 1-8
ENGINE OVERHEATS ............................................... 1-9
EXCESSIVE FUEL CONSUMPTION........................ 1-10
ABNORMAL COMBUSTION .................................... 1-11
ABNORMAL ENGINE NOISE.
OR NOISY ENGINE ............................................... 1-13
EXCESSIVE ENGINE OIL CONSUMPTION ............ 1-16

Section 1.1.1
 4Y-E Repair

TROUBLESHOOTING
This manual describes the basic 4Y-M vehicle (mechanical fuel injection system). For troubleshooting for the
electrical systems of the 4Y-E (electronic fuel injection system), refer to the troubleshooting pages for the separate
repair manual for each vehicle.

MECHANICAL TROUBLE
The causes of engine faults are divided into 3 factors of gasoline engines.

3 Factors of Gasoline Engines

I 3 factors Main functional parts I
I Good air-fuel mixture ( Fuel tank, fuel pump, fuel strainer, carburetor, air governor etc. I
I Good compression I Engine body (Intake and exhaust valves, piston rings, cylinders etc.) I
( Distributor, spark plugs, resistive cord and ignition
I Good ignition

The basics are as described above, however, since insufficient maintenance also gives rise to faults. Carry out pre-
inspections of the following items.
I Pre-inspection items I
Coolant Spark plugs
Engine oil Ignition timing
Battery and terminals Idle speed status
I Air cleaner I Air governor operating condition I
Fan belt Looseness in any engine part

List of Items
Status Fault I Page
Engine has trouble in starting or does not Engine does not crank normally See PI-3
start Engine does not start easily, or does not start at all See PI-4
Engine is rough, or stops, during idling See PI-5
Engine running rough Cannot accelerate smoothly (including hesitation) See PI-6
I Insufficient power output (including hunting) I See PI-8
Engine overheats - See PI-9
Excessive fuel consumption - See PI-10
Knocking See PI-11
Run on See PI-11
Abnormal combustion
I After fire I See PI-12
Back fire See PI-12
Noise that changes with operation of the clutch pedal See PI-13
Noise that is often heard during idling See PI-13
Abnormal engine noise, or noisy engine
Noise that is often heard at a certain engine speed See PI-14
I Noise that is often heard regardless of engine speed I See PI-15
Excessive engine oil consumption - See PI-16

Section 1.1.1
 4Y-E Repair

ENGINE DOES NOT CRANK NORMALLY

When the ignition key switch is turned ON, the starter motor does not respond, or makes an abnormal noise.
I Phenomenon I Main places for inspection and adjustment I
1. Battery
2. Battery cables
Starter does not respond [Point I] 3. Ignition key switch
4. Starter unit
5. Neutral safety switch

I 1. Battery

I Slow cranking speed or clicking sound

12.Starter motor
3. Engine body (When all the plugs are removed, the engine
should rotate easily.)
1. Starter clutch
I
"Rev and rattle" sound 2. Ring gear
3. Magnetic switch

[Point I]
To test whether the fault is with the circuit to the starter motor, or
with the starter motor itself, connect the starter motor directly to the
battery with the 30 terminal and 50 terminal leads. If the starter
motor turns, then the fault is in the circuit. If it does not turn, then
the fault is in the motor.

Section 1.1.1
 4Y-E Repair

ENGINE DOES NOT START EASILY, OR DOES NOT START AT ALL

I Classification Main places for inspection and adjustment
1. Spark plugs I
2. Plug cords
3. lgnition key switch
Ignition [Point I ]
4.Distributor
15. Igniter I
16.Ignition timing I
1. Fuel pump
2. Fuel pipe
13. Fuel strainer I
Fuel [Point 21
1 4.Air breather of the fuel tank I
5. Fuel
6. Carburetor [Point 31
7. Air governor [Point 41
1 8. Choke valve I
1. Valve
2. Piston rings
Compression
3. Piston
4. Cylinder

[Point I]
Inspect sparks using the spark plug
Remove the spark plug and position it about 6 to 8 mm (0.24 to 0.31
in.) away from earth. Normally, during cranking, a strong spark
should fly out. Check all the plugs in the same way.
If there is no spark at all, inspect the distributor and the primary lead
side.

[Point 21
Inspect the fuel flow to the carburetor
Disconnect the fuel pipe connector on the carburetor side, and run
the engine with the starter motor. Check whether the fuel is ejected
strongly from the fuel pipe.
Caution:
Do not allow open flames to come near during the
inspection.
Take measures to prevent the fuel from scattering.

Section 1.1.1
 4Y-E Repair

[Point 31
lnspect the fuel ejection status of the acceleration pump jet
Remove the intake air connector from the top of the carburetor.
Inspect the ejection of fuel from the pump jet when the throttle valve
is operated.

[Point 41
lnspect the air governor
If the ribbon spring or coil spring of the governor is broken, the
governor valve will stay fully closed and the engine will be unable
to start.
0
ENGINE IS ROUGH, OR STOPS, DURING IDLING
Phenomenon Main places for inspection and adjustment
1. Carburetor
2. PCV valve
13. Resistive cord I
Engine is rough during idling [Point I]
14. Distributor I
5. Ignition timing
6. Tappet clearance
7. Valve contact
18.Plug I
1. Idle-up actuator
Roughness during idle-up 2. VTV
3. Vacuum hose

[Point I]
lnspect non-combusting cylinders
Hold the bottom of the resistive cord and pull it off from the plug.
Work through each cylinder, disconnecting the cord end from the
spark plug terminal and stopping the spark. lnspect for the
presence of combustion by checking:
The change in engine speed
Change in combustion sound, or change in vibration

Section 1.1.1
 4Y-E Repair

CANNOT ACCELERATE SMOOTHLY (INCLUDING HESITATION)

I Classification I Main places for inspection and adjustment
I
I
I 1. Accelerator pedal and link [Point I]
Fuel 2. Governor
I 13. Accelerator pump
I 1. Spark plugs
2. Ignition timing
3, Ignition circuit
4. Vacuum advancer [Point 21
Ignition 15.Vacuum hose
1 6. Vacuum controller
7. Breaker plate
8. Governor controller [Point 31
9. Air governor [Point 41
I 1. Intake and exhaust valve contact
12. Piston rings
Compression
13. Piston

I 4. Cylinder

[Point I]
Adjust the accelerator pedal and link system
The opening of the throttle valve depends on the adjustment of the
accelerator pedal height and the link wire. Check that the throttle
valve becomes fully open when the accelerator pedal is fully
depressed.

[Point 21
Check vacuum advancer function
1. Connect a timing light with the engine running. Inspect to see
that the degree of advance is reduced when the vacuum hose
is disconnected from the distributor, and that it returns to its
original position when the vacuum hose is reconnected.
Note:
If this inspection is as it should be, omit the inspection in 2.

Section 1.1.1
 4Y-E Repair

2. When the engine is stopped, disconnect the vacuum hose

connector from the distributor and apply vacuum to a
diaphragm to check that the vacuum advancer is working
smoothly, Inspect the return condition as well.

[Point 31
Check governor controller function
1. Connect a timing light. When the engine speed is gradually
increased from idle, there should be an advance.
Note:
If this inspection is as it should be, omit the inspection in 2.

2. With the engine stopped, remove the distributor cap. When the
rotor is turned by hand about 15" in the turning direction and
released, it should return.

[Point 41
Check function of the VCV inside the air governor
Using a timing light to check the degree of advance, disconnect the
vacuum hose from the distributor with the engine running at 2000
rpm or more. Check that the degree of advance becomes smaller.

Section 1.1.1
 4Y-E Repair

INSUFFICIENT POWER OUTPUT (INCLUDING HUNTING)

1 Classification Main places for inspection and adjustment
1. Ignition timing [Point 21
2. Vacuum advancer
3. Ignition circuit
Ignition 4. Governor controller
5. Vacuum pipe
6. Vacuum controller
7. Breaker plate
1. Air governor [Point 31
Fuel 2. Carburetor
3. VCV inside air governer
1. Valve
2. Piston rings
Compression
3. Piston
14. Cylinder I
1. Slipping of the clutch
Drivetrain [Point I] 2. Slipping of the torque converter one-way clutch
(torque converter models only)

[Point I]
Inspect the relief down speed
This is a test to see whether the lack of power output is on the engine side or on the drivetrain system side. If the
relief down engine speed is within the standard values, then the engine is normal and the drivetrain system needs to
be checked.
Note:
If the ignition timing is retarded, the engine speed will become slower during a torque converter stall test.
Do not mistake this for a reduction in stall speed (only torque converter vehicles).

[Point 21
Generally if the ignition timing is retarded excessively, the vehicle after-fires, and tends to overheat easily. If the
ignition timing is advanced excessively, this tends to cause knocking and loss of power. With forklifts in particular, the
construction makes knocking unlikely to occur (the drive gear ratio is large), and therefore it becomes difficult to
recognise fault phenomena indicative of advanced timing.

[Point 31
Adjust the air governor
If the relief down engine speed is faster than standard, or if the engine starts hunting, adjust the air governor. If power
output does not improve (the relief down is large) even after adjusting the air governor, the fault is in the governor
itself, or in the fuel system, ignition system, or compression system.

Section 1.1.1
 4Y-E Repair

ENGINE OVERHEATS
Classification Main places for inspection and adjustment
1. Governor controller
I Ignition
2. Ignition timing I
1. Cylinder head gasket
Compression 2. Cylinder head
3. Cylinder block
1. Coolant
2. V-belt
3. Radiator [Point I]
4. Thermostat

[Point I]
Check for bubble formation inside radiator
When bubbles form in the radiator due to a fault in the cyclinder head, gasket, or cylinder block, the engine oil
becomes cloudy.

Section 1.1.1
 4Y-E Repair
1-10

EXCESSIVE FUEL CONSUMPTION

Before beginning troubleshooting, ask the following questions and respond as necessary.
1. When did it start? (Since the vehicle was new, recently, since it has become colder etc.)
2. High fuel consumption compared with what? (The lift used previously, a similar vehicle, other manufacture's lift
etc.)
3. What is the lift being used for? (Stacking and unloading cargo, carrying, in a small space, traveling distances etc.)
4. Others (Fuel, tyres, additional specifications, operating time, change in load, change of operator etc.)
1. Engine structure (compression ratio, improved fuel burning, cooling loss, mechanical
efficiency etc.)
II
2. Vehicle structure (vehicle weight, tyres, drivetrain system transmission efficiency, gear ratio
etc.)
Factors in high fuel
3. Conditions in the usage environment (weather, traveling environment, load environment,
consumption
operation method, altitude etc.)
4. Maintenance status of the engine and vehicle (ignition timing, air-fuel mixture, compression
pressure etc.)
5. Specification, differences in attachments (mast lift height, attachments, air conditioner)
I
Places for inspection and adjustment when fuel consumption has become greater than previously
Classification Main places for inspection and adjustment
1. Vacuum hose
Ignition 2. Vacuum advancer
3. Governor controller I
1. Carburetor
Fuel 2. Leak in the fuel system
3. Choke valve
1. Valve
2. Piston rings
Compression
3. Piston
4. Cylinder
1. Slipping of the manual clutch
Drivetrain
2. Slipping of the torque converter one-way clutch
1. Brakes dragging I
Braking 2. Brake automatic adjustment mechanism I
3. Brake shoe return mechanism
1. Thermostat
Cooling -

2. Coolant temperature [Point I] I

[Point 11
If the temperature of the engine coolant becomes too high or too low, optimal fuel combustion cannot be achieved
and fuel consumption increases. In particular, if repeated traveling and loading is carried out when the engine is cold,
the combustion timing is delayed due to slow propagation speed of the air-fuel mixture, and because the gasoline
has poor vaporization, the engine may misfire, resulting in imperfect combustion and loss of engine output.

Section 1.1.1
 4Y-E Repair
1-11

ABNORMAL COMBUSTION
The abnormal noises and other noises caused by abnormal combustion in the engine are classified as follows:
Knocking
On sudden acceleration, or when the accelerator pedal is fully depressed, a high pitched "ping ping" knocking
sound is heard. This has a bad effect on the piston and valves, and will also damage the engine.
Run on
Even after the ignition key switch has been turned OFF, combustion continues in the combustion chamber, and
the engine continues to run erratically.
After fire
When travelling for a long time under engine braking, or when the accelerator pedal is suddenly released, a loud
"bang" is heard due to an explosion in the exhaust system, with flame being visible around the muffler.
Back fire
The combustion does not complete within the explosion cycle, and continues until the intake valve opens for the
next cycle, igniting the air-fuel mixture while it is still being intaken. This causes a back fire, in which the air-fuel
mixture in the intake manifold or carburetor explode.

Knocking
Classification Main places for inspection and adjustment
1. Ignition timing
2. Vacuum advancer
Ignition 3. Governor controller
4. Spark plugs
5. Carbon build-up in the combustion chamber
i

Run on
I Phenomenon I Main places for inspection and adjustment I
1. Spark plugs
lgnition
2. Carbon build-up in the combustion chamber
1. Carburetor solenoid valve [Point I]
Fuel
2. Idle speed

[Point 11
Inspect the carburetor solenoid valve
With the engine stopped, when the ignition key switch is turned ON
and OFF, if a clicking sound is audible from the solenoid valve, then
electrically everything is normal.
For the defective valve inspection, if there is still run on when the
throttle valve is completely closed (idling), then it can be judged that
the sealing of the valve tip is defective.

Section 1.1.1
 4Y-E Repair

After fire
Inspection content
Check the operation and adjustment of parts that might make the air-fuel mixture too rich.
Air cleaner element clogging
Fuel, intake system ldle adjusting screw too loose
Float level too high?
Too much choke (Autochoke mechanism defective)
Check the initial setting of the ignition timing and that the spark advance is operating normally.
Is the timing too retarded when idling?
Ignition timing,
* Spark advance operation inspection (Do the vacuum advancer and the governer controller
spark advance
start operating a little late when the accelerator pedal is suddenly released?)
Is the stationary plate not sliding well?
Correct the cause of any occasional missing of the ignition.
Are the specified spark plugs being used?
Spark plugs, ignition device
lnspect for soiling, wear or gap defect of the spark plugs.
Inspect for soiling or poor connections in the secondary circuit of the ignition system.

Back fire
Inspection content
Check the operation and adjustment of parts that might make the air-fuel mixture too lean.
Float level too low?
Insufficient ejection from the accelerator pump
Power jet clogging
Fuel, intake system
Power piston malfunction
Choke valve malfunction (if it opens too early when cold, the mixture becomes lean)
ldle adjusting screw too tight (air-fuel mixture in the slow speed system becomes too lean)
Air being sucked in from the intake manifold
Inspect to see whether the ignition timing is too retarded.
Ignition timing, Is the timing too retarded when idling?
spark advance Timing control operation inspection (this occurs easily after engine OIH, or reinstalling of the
distributor - whenever the timing is extremely out)
Valve timing Is the valve timing out?

Section 1.1.1
 4Y-E Repair

ABNORMAL ENGINE NOISE, OR NOISY ENGINE

Further breakdown of abnormal noises, or excessive noise generation is as follows.
1. Noise that changes with operation of the clutch pedal
2. Noise that is often heard during idling
3. Noise that is often heard at a certain engine speed
4. Noise that is often heard regardless of engine speed

Noise that changes with operation of the clutch pedal

Operation Main causes

I No change in the abnormal noise even when the clutch pedal

is depressed
I Seizure of the crankshaft thrust bearing

Abnormal noise disappears when the clutch pedal is 1. Worn crankshaft thrust bearing
depressed 2. Transmission defect

Noise that is often heard during idling

Probable cause I Example of sound Notes
Put a sound scope on the water pump body to check.
Defective water pump Rasping sound
Remove the V-belt and turn the water pump by hand. If the turning feels
bearing
rough or bumpy to the hand, then the bearing is defective.
Squealing sound Apply engine oil from outside the seal, or spray an anti-squealing agent.
Oil seal squeal
Chirping sound The sound becomes quieter or stops.
Put a sound scope near the timing gear cover to check.
When the engine is warmed up, the sound can be heard clearly.
When the engine is warm, if the engine is taken from idle to high speed, the
Rattling sound
sound becomes small, or stops.
Inspect the sprocket gear runout.
Knocking sound
Put a sound scope on the camshaft bearing section to check.
Camshaft bearing wear Dull knocking
The sound becomes quieter at high speed.
sound

Defective chain tensioner

I Rattling sound
GravelY
This sound can be heard on startup and stops after a while.

Put a sound scope on the distributor body to check.

If the rotor is turned clockwise by hand and released, it should return easily to
Wear inside the distributor Whirring sound its original position.
and the gears Clattering sound
Inspect the contact point of the center piece and the rotor.
Remove the distributor and inspect the gear.
Adjust the valve clearance.
Defective contact of the
Clicking sound Put a sound scope near the cylinder head valve to check.
valve and seat
The sound becomes smaller or stops when the valve is sticking up.
Put a sound scope on the cylinder head to check.
Improper contact or
Clicking sound This sound often occurs when a pushrod is not turning.
damage to the valve lifter
Remove the lifter and inspect the contact surface.
Run out of oil on valve Grating sound The sound becomes smaller or stops if engine oil is applied, or if the valve
rocker arm Squeaking sound rocker arm position is shifted.
Check by depressing the clutch pedal.
Crankshaft Clattering sound If the sound stops, there is too much play in the thrust direction.
thrust direction play Rasping sound When the clutch pedal is depressed, the crankshaft is pushed forwards and
the thrust play is reduced to nothing, so the noise stops.

Section 1.1.1
 4Y-E Repair

Probable cause I Example of sound I Notes

Noise stops if the fuel pump is removed.
Fuel pump operation Pumping noise
noise NPmPm" noise A small noise is normal. Care should be taken as it can easily be mistaken for
another sound.
Inspect the intake manifold and air cleaner for appropriate installation.
Sucking noise
Air intake noise Try plugging the place where the air gets in with engine oil, grease or cotton
Hissing noise
waste.

Noise that is often heard at a certain engine speed

Probable cause Example of sound I Notes
The sound occurs on sudden acceleration from idle.

I Belt slipping

Contact noise of the

Squealing sound Adjust the belt to the standard tension.
Inspect the belt for wear, cracking and oil.

alternator bearing or Whirring noise Check by removing the belt and turning the alternator by hand.
Grating noise

The knocking sound is loud when the engine is cold, and grows quieter or
stops as the engine warms up.
Side knocking of the Since auminum alloy pistons expand more than the cylinder, the piston
sound clearance grows smaller and the side knock grows smaller.
piston
If the spark plug is disconnected, the sound changes and generally grows
quieter.
I This can be heard loudly from the bottom of the engine when accelerating
after warm-up or directly after acceleration.
Knocking of the
Knocking m ~ n d When the engine is at the speed when the knocking sound usually occurs
connecting rod bearing
(about 1000 rpm), if the spark plug is disconnected, the sound changes,
generally becoming quieter.
This can be heard loudly from the bottom of the engine when accelerating
after warm-up or directly after acceleration.
Crankshaft bearing
Knocking sound The sound does not change even if the spark plug is disconnected.
knocking
This is a somewhat lower, sharper sound than the connecting rod bearing
1 knocking.
The noise gets louder as the engine warms up, and is a harder sound than
the piston side knocking.
Knocking sound

+
Rattling sound When the engine is at the speed when the knocking sound usually occurs
(about 1000 rpm), if the spark plug is disconnected, the knocking sound
changes.
Humming sound The noise stops when the belt is removed and the engine is running.
Unbalanced cooling fan
Whining sound Check for bending of the fan, loose fit, or runout.
The sound becomes louder on sudden acceleration.
Loose set bolt on the Rattling ~ ~ n The
d sound becomes quieter or stops when the clutch pedal is fully
flywheel Knocking sound depressed,
he sound is similar to crankshaft bearing knocking, but it sounds harder.

I
Timing chain wear
Grating sound
Scraping sound
Put a sound scope on the timing chain cover to check.
The noise becomes louder if the engine is run at high speed.

Section 1.1.1
 4Y-E Repair

Noise that is often heard regardless of engine speed

Probable cause Example of sound Notes
Inspect for the presence of valve clearance using a thickness gauge.
Excess valve clearance or Clicking sound If there is a clearance, the sound stops. In this case, correct the oil tappet.
aulty contact Clattering sound If the sound does not stop, there is a defect in the contact of the rocker arm
and the valve.
Put a sound scope on the valve section to check.
Creaking sound
Jalve sticking sound The sound becomes quieter or stops if engine oil is applied, or an anti-
Squeaking sound
squealing agent is sprayed on.
A "raspberry" Check by holding a wet cloth to the spot on the exhaust system to plug where
fxhaust leak sound the leak is suspected to be.
A "put-put" sound The noise becomes louder when the engine speed is increased.
Disconnect the spark plug to inspect.
When disconnected, the sound becomes quieter or stops.
Apply oil to the cylinder head gasket and to the spark plug gasket attachment
Sompression leak Hissing sound section to check.
If there is a leak, the oil blows out.
If the gasket is destroyed, the combustion gas may leak into the cooling
system, causing bubbles to form in the top of the radiator

Section 1.1.1
 4Y-E Repair

EXCESSIVE ENGINE OIL CONSUMPTION

A classification of oil consumption by the main phenomena is as follows:
1. Oil loss via the piston ring
This is when the oil that lubricates the cylinder walls gets into the combustion chamber.
After the engine has warmed up, after left idling or operated at about 1000 rpm for 4 to 5 minutes, if the engine
is raced, a large amount of white-purple exhaust is output for the first 30 to 60 seconds, thereafter tending to
become less. In this case, if left idling or operated at under 1000 rpm for another4 to 5 minutes, then raced again,
the engine emits a large amount of white-purple exhaust again as before.
2. Oil loss via the valve guide
This is when the oil enters the combustion chamber from the clearance between the valve stem and the valve
guide.
After warming the engine, race it at about 2000 rpm and inspect the exhaust gas. At this time, a large amount
of white-purple exhaust gas is exhausted, and this output increases gradually if the engine speed is increased.
3. In-flow from the crankcase emission control system (PCV device)
Phenomenon Main places for inspection and adjustment 1
Leaking to the exterior of the engine
( I. PCV valve I
12.Engine body I
1. Cylinder head
2. Cylinder block
Leaking to the interior of the engine 3. Head gasket
4. Oil loss via the piston ring [Point I]
5. Oil loss via the valve guide [Point 21

[Point I]
lnspect for oil loss via the piston ring
A lot of carbon build-up will be visible around the top of the piston.

[Point 21
lnspect for oil loss via the valve guide
This can be determined from the carbon build-up on the intake
valve head and on the top of the piston, and how wet with oil the
valve head is.

Section 1.1.1
 4Y-E Repair

ENGINE OVERHAUL (4Y-M)

Page

SST TO BE USED .............................................. 2-2

ENGINE ATTACHMENTS .................................. 2-4

CYLINDER HEAD .............................................. 2-7

COMPONENTS ........................................................... 2-7
........ 2-10
DISASSEMBLY=INSPECTION=REASSEMBLY
TIMING GEAR .................................................. 2-19
COMPONENTS......................................................... 2-19
........ 2-22
DISASSEMBLY=INSPECTION.REASSEMBLY
CYLINDER BLOCK.......................................... 2-31
COMPONENTS......................................................... 2-31
DlSASSEMBLY.INSPECTlON.REASSEMBLY.:...... 2-33
ENGINE ADJUSTMENT................................... 2-42
V-BELT 1NSPECTION.ADJUSTMENT ..................... 2-42
INSPECTION-ADJUSTMENT OF
IGNITION TIMING .................................................. 2-43
INSPECTIONmADJUSTMENT OF
IDLE-UP SPEED .................................................... 2-43
INSPECTIONmADJUSTMENT OF
IDLE SPEED .......................................................... 2-44
NO LOAD MAXIMUM
SPEED INSPECTION AND
ADJUSTMENT ....................................................... 2-44
COMPRESSION INSPECTION................................. 2-44

Section 1.1.2
 4Y-E Repair

SST TO BE USED
Illustration Part No. Part name

Oil pan seal cutter

Valve guide bushing remover & replacer

Valve spring compressor

Camshafi bearing remover & replacer

Belt tension gauge

Piston pin remover & replacer

Oil filter wrench

Rocker arm support tool set

Section 1.1.2
 4Y-E Repair

I Illustration Part No. part name

Valve lifter tool

Bearing remover

Puller B set

Replacer set

Replacer B set

Handle set

Section 1.1.2
 4Y-E Repair

ENGINE ATTACHMENTS
REMOVAL-INSPECTION-INSTALLATION
T = N.m (kgf cm) [fklbfl

Removal-Installation Procedure
The installation procedure is the reverse of the removal procedure.
No. I
I
Item
I
Removal
I
Inspection
I
Installation I
1 I Fan, Pulley, V-belt See P2-42 See P2-42
2 1 Alternator 1
3 Intake pipe
4 Spark plugs
5 1 Accelerator wire 1 I I I
6 1 Carburetor 1 I I I
7 Air governor
8 Fuel pump
9 Intake.Exhaust manifolds [Point I] [Point 21
I

10 Oil level gauge

11 Oil filter [Point 31 [Point 51
12 Water pump
13 Distributor [Point 41

Section 1.1.2
 4Y-E Repair

[Point I ]
Removal:
The intake manifold and exhaust manifold are to be removed
at the same time.

[Point 21
Inspection:
Using a straight edge ruler and a thickness gauge, measure
the amount of distortion of the intake manifold.
Limit: 0.40 mm (0.0157 in.)

Inspection:
Using a straight edge ruler and a thickness gauge, measure
the amount of distortion of the exhaust manifold.
Limit: 0.40 mm (0.0157 in.)

[Point 31
Removal:
Use the SST to remove the oil filter
SST 09228-76001-71
(09228-06501)

[Point 41
Installation:
Install the distributor.
1. Align the TDC mark of the crank pully with the notch of the
timing gear cover.

Section 1.1.2
 4Y-E Repair

2. Set the position of the groove in the oil pump driveshaft at

about 30" when seen from above.

3. Align the housing groove with the drill mark of the gear, and
insert the distributor.
Note:
Do not confuse the drill mark and the straight pin.
When installing the distributor, align the screw hole for
attaching the block with the center of the groove in the
flange to install.
After installation, adjust the ignition timing. (See P2-43)

[Point 51
Installation:
After cleaning the attachment surface of the oil filter, fit an O-
ring to the oil filter and tighten the oil filter to the bracket by
hand first, and then use the SST to further tighten by 314 turn.
SST 09228-76001-71
(09228-06501)
Caution:
Apply a small amount of engine oil to the O-ring.
Clean the surface to which the O-ring will be attached.

Section 1.1.2
 4Y-E Repair

CYLINDER HEAD
COMPONENTS

40
(3-WAY CATALYTIC)

Section 1.1.2
4Y-E Repair

Section 1.1.2
4Y-E Repair

Refer to
2601-HJ

Section 1.1.2
 4Y-E Repair

Disassembly-Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
I No. I Item I Disassembly I Inspection I Reassembly
1 Remove parts in procedures 1 to 13 on page 2-4.
2 Cylinder head cover
3 Rocker shaft ASSY [Point I ] [Point 21 [Point 181
4 Valve stem cap [Point 31
5 Valve push rod [Point 41 [Point 51 [Point 171
6 Cylinder head bolt [Point 61 [Point 161
7 Cylinder head gasket [Point 71 [Point 151
1 8 1 Valve spring and valve I [Point 81 1 [Point 91 1 [Point 141
9 Valve stem oil seal [Point 131
10 Valve guide bushing [Point 101 [Point Ill [Point 121

Section 1.1.2
 4Y-E Repair

Point Operations
[Point I ]
Disassembly:
Evenly loosen the support set bolts in two or three times,
following the order shown in the illustration.

[Point 21
Inspection:
Inspect for wear or damage to the contact surface for the
rocker arm valve stem cap.
If there is a slight damage, correct it by polishing with oil stone,
and replace if there is a considerable wear or damage.

Inspection:
Move the rocker arm as shown in the illustration, and inspect
the clearance between the rocker arm and the shaft. If the
clearance is large, disassemble and inspect it.

Inspection:
lnspect the oil clearance between the rocker arm and the
rocker shaft.
1. Measure the rocker arm inside diameter with a caliper gauge.
Standard: 18.500 to 18.515 mm (0.7283 to 0.7289 in.)

Measure the rocker shaft outside diameter with a micrometer.

Standard: 18.474 to 18.487 mm (0.7273 to 0.7278 in.)
Calculate the oil clearance by the difference between the arm
i~inerdiameter and the shaft outer diameter.
Standard: 0.013 to 0.041 mm (0.0005 to 0.0016 in.)
Limit: 0.08 mm (0.0031 in.)
If it exceeds the limit, replace the rocker arm or the rocker
shaft.

Section 1.1.2
 4Y-E Repair

[Point 31
Inspection:
lnspect the valve stem cap.
1. Measure the wall thickness of the valve stem cap.
Standard: 1.31 to 1.49 mm (0.0516 to 0.0587 in.)
2. If there is a slight scratch on the contact surface with the rocker
arm, correct it by polishing with oil stone, and if there is
considerable wear or damage, replace with a new one.

[Point 41
Disassembly:
Store the removed push rods carefully so that their order will
not be mixed up during reassembly.

[Point 51
Inspection:
lnspect the push rod.
1. lnspect the runout in the push rod.
Limit: 0.30 mm (0.0118 in.)
If it exceeds the limit, replace the push rod.
2. lnspect for blockage of the push rod oil hole.
If there is a blockage, remove it with an air gun.

[Point 61
Disassembly:
Loosen the cylinder head bolts in two or three times, following
the order shown in the illustration.

[Point 71
Inspection:
Use a straight edge ruler and a thickness gauge to measure
the distortion of the lower surface of the cylinder head and the
attachment surface of the manifold.
Limit
Cylinder head lower surface: 0.15 mm (0.0059 in.)
Manifold attachment surface: 0.10 mm (0.0039 in.)
If it exceeds the limit, grind or replace.

Section 1.1.2
 4Y-E Repair

Inspection:
lnspect for cracking in the cylinder head.
With color check (dye penetrant inspection), inspect the
combustion chambers, the intake ports, the exhaust ports, and
the lower and upper faces of the heads.

[Point 81
SST
Disassembly:
Use the SST to disassemble the valve spring and valve.
SST 09202-76002-71
(09202-70020)
Disassembly:
Store the removed parts by sorting them out for each cylinder.

[Point 91
Inspection:
lnspect the oil clearance between the valve guide bushing and
the valve stem.
1. Measure the valve guide bushing inside diameter with a caliper
gauge.
Standard
IN: 8.010 to 8.030 mm (0.3154 to 0.3161 in.)
2. Measure the outside diameter of the valve stem
Standard
IN: 7.970 to 7.985 mm (0.3138 to 0.3144 in.)
EX: 7.965 to 7.980 mm (0.3136 to 0.3142 in.)
3. Calculate the oil clearance.
Standard
IN: 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
EX: 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Limit
IN: 0.10 mm (0.0039 in.)
EX: 0.12 mm (0.0047 in.)
If it exceeds the limit, replace the valve stem or the valve guide
bushing. Also, if necessary, grind the inside surface by using a
reamer to correct the oil clearance between the valve guide
bushing and the valve stem within the standard range.

Section 1.1.2
 4Y-E Repair

Inspection:
Inspect the valves.
1. Measure the wall thickness of the valve head.
Standard
IN: I.0 to 1.4 mm (0.039 to 0.055 in.)
EX: 1.3 to 1.7 mm (0.051 to 0.067 in.)
Limit
IN: 0.5 mm (0.020 in.)
EX: 0.8 mm (0.031 in.)

2. Measure the total length of the valves.

Standard
IN: 108.2 mm (4.260 in.)
EX: 108.5 mm (4.272 in.)
Limit
IN: 107.7 mm (4.240 in.)
EX: 108.0 mm (4.252 in.)

Inspection:
lnspect the valve seat
1. Apply red lead primer thinly to the valve face.
2. Insert the valve into the valve guide bushing, and press the
valve onto the valve seat. Do not rotate the valve while it is
pressed onto the valve seat.
3. lnspect the width of the contact surface to see whether it is
within the standard along the entire circumference.
Standard
Contact width: 1.2 to 1.6 mm (0.047 to 0.063 in.)
If the width is not within the standard, replace the valve or
correct the valve seat.
4. Correct the valve seat.
Caution:
Use a carbide tip cutter for the EX side.
Cutting should be performed while constantly checking
the contact point and contact width of the valve.
In order not to create steps, gradually reduce the force
towards the end of cutting.
Make corrections after inspecting the valve guide
bushing.

Section 1.1.2
 4Y-E Repair

(1) Grind the valve seat with a 45" valve seat cutter.
(2) If the contact position is on the outward side, grind using
a 30" cutter.

Contact sukace

(3) If the contact position is on the inward side, grind using a

IN side: 60" 60" cutter on the IN side, and a 65" cutter on the EX side.
I-,

I /
Contact surface
Inspection:
7~
2.0 rnrn (0.079 in.)
I 1.
Inspect the valve spring.
Measure the squareness at the top end of the spring.
Limit IN-EX: 2.0 mm (0.079 in.)

2. Measure the free length.

Standard
IN-EX: 46.0 mm (1.81 in.)
Limit
INmEX: 45.5 mm (1.79 in.)

[Point 101
Disassembly:
Remove the valve guide bushing.
1. Use a bar and hammer to break off the valve guide bushing.
Snap ring 2. Remove the snap ring.

Section 1.1.2
 4Y-E Repair

3. Gradually warm the cylinder head to between 80 and 100°C

(176 to 212°F).

4. Use the SST and a hammer to tap out the valve guide bushing.
SST 09201-76006-71
(09201-60011)

[Point 111
Inspection:
Use a caliper gauge to measure the inside diameter of the
bushing bottom hole, then select the bushing to be used.
I Bushing inside diameter (rnm) [in.] ] Bushing size 1
13.000 to 13.027 (0.5118 to 0.5129) STD bushing
13.027 (0.5129) or more O/S 0.05 bushing

If the bushing bottom hole inside diameter is 13.027 mm

(0.5129 in.) or more, correct the inside of the bushing bottom
hole with a reamer.
Bushing bottom hole inside diameter:
13.050 to 13.077 mm (0.5138 to 0.5148 in.)
If the bushing bottom hole inside diameter is 13.077 mm
(0.5148 in.) or more, replace the cylinder head.
[Point 121

@-
Lw SST
Reassembly:
Install the valve guide bushing.
1. Gradually warm the cylinder head to between 80 and 100°C
\\ Snap ring
(176 to 212°F).
2. Use the SST and a hammer to tap the bushing in until the snap
ring makes contact with the head.
SST 09201-76006-71
(09201-60011)

Section 1.1.2
 4Y-E Repair

[Point 131
Reassembly:
Apply engine oil to the valve stem oil seal lip portion and to the
valve stem, and reassemble them.
Reassemble according to the dimensions shown in the
illustration on the left.
SST 09201-76005-71
(09201-58010)

[Point 141
SST
Reassembly:
Use the SST to reassemble the valve spring and valve.
SST 09202-76002-71
(09202-70020)

[Point IS]
Front side Gasket Reassembly:
/ Check the direction of the gasket and install the gasket.

[Point 161
Reassembly:
Tighten the cylinder head bolts in two or three times, following
the order shown in the illustration.

Front 1 I 1
10 4 2 5

[Point 171
SST Reassembly:
Use the SST to position and install the push rod.
SST 09270-76001-71
(09270-71010)

Section 1.1.2
 4Y-E Repair

I I Reassembly:
~ v e n ltighten
~- the support set bolts in two or three times,
following the order shown in the illustration.

Reassembly:
Check the direction of the rocker arm shaft, then use the SST
to position the rocker arm and install the rocker arm ASSY.
SST 09270-76001-71
(09270-71010)

Section 1.1.2
 4Y-E Repair

TIMING GEAR
COMPONENTS

Section 1.1.2
4Y-E Repair

Section 1.1.2
4Y-E Repair

Section 1.1.2
 4Y-E Repair

DISASSEMBLY-INSPECTION-REASSEMBLY
T = N.m (kgf.cm) [fblbf]

DisassemblymReassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Fan pulley, V-belt, alternator See P2-42 t t

2 Cylinder head ASSY* See P2-10 t t

3 Crankshaft ~ u l l e v
4 Crank position sensor
5 Timing gear cover and gasket
6 Crankshaft bearing [Point I ] [Point I91
7 Pump drive sprocket and drive chain, crankshaft sprocket [Point 21 [Point 181
8 Chain tensioner [Point 31
9 Timing chain, crankshaft sprocket, camshafi sprocket [Point 41 [Point 171

Section 1.1.2
 4Y-E Repair

No. Item Disassembly Inspection Reassembly

10 Chain vibration damper [Point 51
11 Valve lifter [Point 61 [Point 71
12 Oil pan [Point 81 [Point 161
1 13 1 Thrust plate and camshaft I [Point 91 1 [Point 101 1 [Point IS]
14 Timing gear case
15 Front oil seal [Point Ill [Point 141
16 Camshaft bearing [Point 121 [Point 131

* If you remove the parts other than the camshaft, you do not need to remove the cylinder head.
Point Operations
[Point I ]
Disassembly:
Use the SST to remove the crankshaft bearing.
SST 09950-76014-7 1 ..................(1
(09950-40011)
09950-76018-71 ..................(2)
(09950-60010)

[Point 21
Disassembly:
Use the SST to remove the bearing (case side).
SST 09320-23000-71

Disassembly:
Use the SST to remove the bearing (gear side).
SST 09950-76014-71 .................. (1)
(09950-40011)
09950-76018-7 1 ..................(2)
(09950-60010)

[Point 31
Inspection:
Use a vernier caliper to measure the tensioner.
Standard: 15.0 rnrn (0.591 in.)
Limit: 12.5 rnrn (0.492 in.)

Section 1.1.2
 4Y-E Repair

[Point 41
Inspection:
Chain Inspect the timing chain.
Tension the chain to 49 N (5 kgf) [11.0 Ibfl, then measure the
chain length in at least 3 places at random to inspect the
stretch of the chain.
Limit: 291.4 mm (11.472 in.)

Inspection:
Inspect the timing gear.
Measure the outside diameter of the sprocket with the chain
on.
Limit
Crankshaft: 59 mm (2.32 in.)
Camshaft: 114 mm (4.49 in.)

[Point 51
Inspection:
Use a vernier caliper to measure the thickness of the damper.
Standard: 6.6 mm (0.260 in.)
Limit: 5.0 mm (0.197 in.)

[Point 61
Disassembly:
Use a wire with the end bent into an L shape to remove the
valve lifter.
Note:
Bend the end of the wire about 1 mm (0.04 in.), and insert
the wire into the center hole of the valve lifter to hook the
valve lifter.
Clean the wire thoroughly first.

Line the removed valve lifters up in number order. Always

store them with standing up with the hole facing upwards.
Do not disassemble the valve lifters.

Section 1.1.2
 4Y-E Repair

[Point 71
Inspection:
Inspect the oil clearance of the valve lifter.
Measure the outside diameter of the valve lifter.
Standard: 21.387 t o 21A04 m m (0.8420 to 0.8427 in.)

Measure the inside diameter of the cylinder block bottom hole.

Standard: 21A17 to 21.443 m m (0.8432 t o 0.8442 in.)
Calculate the oil clearance of the valve lifter.
Standard: 0.012 to 0.056 mm (0.0005 to 0.0022 in.)
Limit: 0.10 m m (0.0039 in.)
If it exceeds the limit, replace the valve lifter.

Inspection:
Valve lifter leak down test
1. Bleed the air from the valve lifter.
Immerse the valve lifter in a container full of diesel oil, and use
the SST to move the plunger up and down several times.
SST 09276-76001-71
(09276-710 10)
Caution:
The diesel oil i s used only for the test. When installing the
valve lifter, perform bleeding again i n engine oil.
2. Use a tester and apply 196 N (20 kgf) [44.1 Ibfl of force to the
Plunger I
plunger of the air-bled lifter. After the plunger has dropped
Tester about 2 mm (0.08 in.), measure the time taken for the plunger
/ dropping a further 1 mm (0.04 in.).

- Lifter body
3. Measure 3 times, shifting the position of the plunger 120" each
time, and find the average value.
Standard: 7 to 28 sec.11 mm (0.04 in.)
(oil temperature 20°C [68"F])

[Point 81
Disassembly:
Do not deform the flange section of the oil pan during the
operation.
SST 09032-76001-71
(09032-00100)
Caution:
Do not use the SST on the timing gear case side.
Do not pry with a screwdriver.

Section 1.1.2
 4Y-E Repair

[Point 91
Disassembly:
Remove the camshaft.
Caution:
When pulling out the camshaft, pull it out straight t o avoid
damaging the camshaft bearing.

[Point 101
Inspection:
Measure the thrust clearance of the camshaft.
Standard: 0.07 t o 0.22 mm (0.0028 to 0.0087 in.)
Limit: 0.3 mm (0.012 in.)

Inspection:
Measure the height of the cam.
Standard
IN: 38.620 t o 38.720 mm (1S2OS t o 1S244 in.)
EX: 38.629 t o 38.729 mm (1.5208 t o 1.5248 in.)
Limit
IN: 38.26 mm (1.5063 in.)
EX: 38.27 mm (1.5067 in.)

Inspection:
Inspect the bending of the camshaft.
Bending = runout of the dial gauge12
Limit: 0.06 mm (0.0024 in.)

Inspection:
Inspect the oil clearance of the camshaft bearing.
1. Measure the outside diameter of the camshaft journal
Standard
No.?: 46.459 t o 46.475 mm (1.8291 to 1.8297 in.)
No.2: 46.209 t o 46.225 mm (1.8192 to 1.8199 in.)
No.3: 45.959 to 45.975 mm (1.8094 to 1.8100 in.)
No.4: 45.709 to 45.725 mm (1.7996 t o 1.8002 in.)
N0.5: 45.459 t o 45.475 mm (1.7897 t o 1.7904 in.)

Section 1.1.2
 4Y-E Repair

2. Measure the inside diameter of the camshaft bearing.

Standard
No.1: 46.500 to 46.540 mm (1.8307 to 1.8323 in.)
No.2: 46.250 to 46.290 mm (1.8209 to 1.8224 in.)
No.3: 46.000 to 46.040 mm (1.8110 to 1.8126 in.)
No.4: 45.750 to 45.790 mm (1.8012 to 1.8028 in.)
NOS: 45.500 to 45.540 mm (1.7913 to 1.7929 in.)
3. Calculate the oil clearance.
Standard: 0.025 to 0.081 mm (0.0010 to 0.0032 in.)
Limit: 0.1 mm (0.0039 in.)
If it exceeds the limit, replace the bearing.
[Point 111
Disassembly:
Use the SST to tap out the oil seal.
SST 09950-76018-71..................(1)
(09950-60010)
09950-76020-71..................(2)
(09950-70010)

Disassembly:
Remove the camshaft bearing.
1. Remove the oil pump w/ strainer. (See P8-6)
2. Use the SST to remove the rear tight plug.
SST 09215-76004-71
(09215-00101)

3. Use the SST to remove the camshaft bearing.

SST 0921 5-76004-71
(09215-00101)

Section 1.1.2
 4Y-E Repair

Note:
Each bearing has a different outside diameter, so take care
when removing and reinstalling them.

[Point 131
Disassembly:
Install the camshaft bearing.
1. Align the oil holes of the cylinder block and the bearing.

c Front 2. Use the SST to install the bearing.

SST 092 15-76004-71

i.I # 3.
(09215-00101)
Use a new tight plug to apply ThreeBond 1386 to the outer
circumference, and drive the tight plug into the cylinder block
until the surface is even.
SST 09215-76004-71
(09215-00101)

[Point 141
Reassembly:
Using the SST, drive the oil seal into the timing gear cover until
the surface is even.
SST 09950-76018-71 .....................(1
(09950-60010)
09950-76020-71 .....................(2)
(09950-70010)

[Point 151
Reassembly:
Take care as the thrust plate has a direction

Front

Section 1.1.2
 4Y-E Repair

[Point 161
Reassembly:
Apply FIPG to the seal section of the oil pan.
FIPG: 08826-76001-71
(For handling of FIPG, See PO-19)

FIPG

I [Point 171
I Mark
Reassembly:
Install the timing chain, camghaft sprocket, and crankshaft
sprocket.
1. Position the crankshaft key exactly at the top.
2. Align the camshaft key with the upper mark on the thrust plate.

3. Assemble the timing chain, camshaft sprocket, and crankshaft

sprocket at the same time.
Caution:
Be sure to align the marks of each sprocket with the marks on
the timing chain.

Section 1.1.2
 4Y-E Repair

[Point 181
Gear side SST(1) Case side
Reassembly:
Use the SST to install the bearing.
SST 09950-76018-71 .....................(1)
(09950-60010)
09950-76020-71 .....................(2)
(09950-70010)

[Point 191
Reassembly:
Tap the bearing inner race evenly around with a bar to fit it.

Section 1.1.2
 4Y-E Repair

CYLINDER BLOCK
COMPONENTS

Refer to
Refer to FIG.1301 AH
FIG.1302
I I

Section 1.1.2
 4Y-E Repair

I I
Llll lllJ

I
I s20c ;
Llll 1114

Section 1.1.2
 4Y-E Repair

T = N.m (kgf cm) [ft.lbfl

Disassembly-Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure
No. Item Disassembly Inspection Reassembly
1 Cylinder head ASSY See P2-10 t t

2 Timing gear-related See P2-22 t t

3 Oil pump ASSY WI oil strainer

4 1 Rear oil seal retainer Wl oil seal I [Point I ] I I [Point 141
5 Rear oil seal
6 Measuring the thrust clearance of the connecting rod [Point 21
7 Connecting rod cap W1 bearing [Point 31 [Point I31
8 Piston W l connecting rod [Point 41 [Point 121
9 Piston disassembly [Point 51 [Point 61 [Point 111
10 Measuring the thrust clearance of the crankshaft [Point 71
11 Crankshaft cap, bearing, thrust washer [Point 81 [Point 101
12 Crankshaft [Point 91

Caution:
Be sure that the parts for each cylinder are assembled in their correct combinations.

Section 1.1.2
 4Y-E Repair

Point Operations
[Point I ]
Disassembly:
Use a screwdriver and a hammer to tap out the oil seal.

[Point 21
Inspection:
Move the connecting rod back and forth to measure the thrust
clearance.
Standard: 0.016 to 0.312 mm (0.0063 to 0.00123 in.)
Limit: 0.35 mm (0.0138 in.)

[Point 31
Inspection:
Measure the oil clearance of the connecting rod bearing.
Perform the measurement with a Plastigage, and tighten the
connecting rod cap set nut to the specified torque.
Do not turn the crankshaft during the measurement.
Standard: 0.020 to 0.051 mm (0.0008 to 0.0020 in.)
Limit: 0.10 mm (0.0039 in.)

Caution:
When using STD bearings, use a bearing with the same
reference number (6, 7, 8) as that punched into the
connecting rod cap.
Remove the Plastigage completely after measuring.

[Point 41
Disassembly:
Attach a vinyl hose or similar to the connecting rod bolt to
protect the cylinder inner wall and the crankshaft.

Section 1.1.2
 4Y-E Repair

Note:
Sort the removed pistons, connecting rod caps, and bearings
into the order of the cylinders.

[Point 51
Disassembly:
Disassemble the piston and the connecting rod.
1. Remove the piston ring and the oil ring.

2. Use the SST and a press to push out and remove the piston
pin.
SST 09221-76002-71
(09221-25018)
Note:
The removal should be performed at room temperature.

Sort out the removed parts for each cylinder, and be sure
not to mix them up during reassembly.

[Point 61
Inspection:
lnspect the cylinder block.
1. lnspect for any distortions on the upper face of the cylinder
block.
Limit: 0.05 mm (0.0020 in.)
Check that there are no considerable scratches on the cylinder
wall surface. If there are scratches, rebore the cylinder.

Section 1.1.2
 4Y-E Repair

2. Measure the six points shown in the left illustration, and find
the difference between the maximum and minimum values.
Crank axle
direction Limit: 0.05 mm (0.0020 in.)

c Thrust

10 rnrn
(0.39 in.)

3. Measure the piston clearance.

,24 rnm Measure the outside diameter of the piston.
Measurement position:
Measure the diameter at the place in a position 24 mm
(0.94 in.) from the top of the piston and orthogonal to
the piston pin.
Standard
STD: 90.925 to 90.955 mm (3.5797 to 3.5809 in.)
OIS 0.5: 91.425 to 91.455 mm (3.599 to 3.601 in.)

Measure the cylinder bore and calculate the piston

clearance.
Crank axle
Front direction Standard: 0.065 to 0.085 mm (0.0026 to 0.0033 in.)
If the value exceeds the limit, replace the piston or rebore
c Thrust
the cylinder and install an 01s piston.

Boring dimension = P + C - H
P: Outside diameter of the piston C: Piston clearance
H: Honing margin (0.02 mm [0.0008 in.] or less)

Inspection:
Inspect the piston and the connecting rod.
1. Measure the gap between the piston ring and the ring groove
along the entire circumference.
Standard: 0.03 to 0.07 mm (0.0012 to 0.0028 in.)

2. Press the piston ring into the sliding section of the piston, and
measure the piston ring gap.
Standard
No.1: 0.23 to 0.48 mm (0.0091 to 0.0189 in.)
No.2: 0.16 to 0.44 mm (0.0063 to 0.0173 in.)
Oil ring: 0.13 to 0.47 mm (0.0051 to 0.0185 in.)

Section 1.1.2
 4Y-E Repair

Reassemblv:
Install the piston ring.
lnstall the oil ring expander.
Install the oil ring side rail using the piston ring tool.
There is no difference between the top and bottom sides of the
~ u k mark
h oil ring side rail.
Install each compression ring with the punch mark at the top
using the piston ring tool.
Punch mark
Top ring: 1T
Second ring: 2 T
Align the ring gaps as shown in the illustration.
Compression Upper side
ring No.2 rail

Front

Lower side Compression

rail ring No.1 and
Expander

[Point 71
Inspection:
Measure the thrust clearance of the crankshaft.
Standard: 0.020 to 0.220 mm (0.0008 to 0.0087 in.)
Limit: 0.30 mm (0.0118 in.)
If it exceeds the limit, replace the thrust washer.

[Point 81
Disassembly:
Evenly loosen the cap set bolts in several times, following the
order shown in the left illustration.

Section 1.1.2
 4Y-E Repair

Note:
Upper (on cylinder block side)
Store the caps, bearings and washers in correct order in order
to reinstall them in the same position as when they were
removed.

Front

Lower (on bearing cap side)

[Point 91
Inspection:
Measure the oil clearance of the crankshaft.
Do not turn the crankshaft during the measurement.
Standard: 0.02 to 0.051 mm (0.0008 to 0.0020 in.)
Limit: 0.10 mm (0.0039 in.)
If it exceeds the limit, replace the bearing. Or, if necessary,
replace the crankshaft.

Note:
When using STD bearings, replace with a bearing with the
same reference number (1 to 3) as that punched into the
cylinder block.

Inspection:
Inspect the bending of the crankshaft.
Inspect the bending when turning the crankshaft once.
Bending = runout of the dial gauge12
Limit: 0.06 mm (0.0024 in.)

Section 1.1.2
 4Y-E Repair

Inspection:
Inspect for crankshaft wear.
1. Measure the outside diameters of all of the crankshaft journals
and pins.
Standard
Journal outside diameter: 57.985 to 58.000 mm
(2.2829 to 2.2835 in.)
Crank pin outside diameter: 47.985 to 48.000 mm
(1.8892 to 1.8898 in.)
2. Calculate the ellipticity and taper degree.
Limit Ellipticity: 0.02 mm (0.0008 in.)
Taper degree: 0.02 mm (0.0008 in.)
If it exceeds the limit, replace the crankshaft.
[Point 101
Reassembly:
Install the bearing cap.
1. Install with the oil groove of the thrust washer facing the
crankshaft.
2. Check the front mark, and install in the same place as before
it was disassembled.

Disassembly:
Evenly tighten the bearing cap bolts in several times, following
the order shown in the illustration.

[Point 111
Front mark
(Depression) Reassembly:
Reassemble the piston and connecting rod.
1. Align the front marks of the piston and the connecting rod.

Section 1.1.2
 4Y-E Repair

2. Apply engine oil to the piston pin and piston pin hole.
Piston pin 3. Use the SST and a press to press fit the piston pin.
SST 09221-76002-71
(09221-25018)
Note:
The assembly should be performed at room temperature.

[Point 121
Reassembly:
Install the bearing.
Ensure that no foreign matter, oil, etc., becomes attached to
the contact surface between the bearing and the connecting
rod.
Apply engine oil to the inner surface of the bearing.
Assemble the upper bearing to the locking groove of the
connecting rod.
Install the lower bearing to the locking groove of the bearing
cap.
Reassembly:
Attach a vinyl hose or similar to the connecting rod bolt to
protect the cylinder inner wall and the crankshaft.

Front mark Reassembly:

-
(Depression) When reinstalling the piston to the cylinder, be sure to install it
\ in the same cylinder from which it was removed.
Apply engine oil to the sliding sections of the connecting rod
and the piston.
Use a piston ring compressor to assemble with the front mark
Front facing front.

Section 1.1.2
 4Y-E Repair

1 1 [Point 131
Reassembly:
Install the connecting rod cap.
1. Install with the front mark of the bearing cap facing the front of
the engine.
2. Align the punch marks of the connecting rod.
Note:
There are several kinds of alphabet punch marks.
Each of the rotation angles of the punched alphabet
marks differs. Be sure to align them when installing.
3. Make sure that no foreign matter or oil, etc., becomes attached
to the back surface of the bearing.
4. Apply engine oil to the inner surface of the bearing.
5. Tighten the left and right bolts alternately in two or three times.

[Point 141
Reassembly:
Use the SST to knock in the oil seal.
SST 09950-76019-71 ........ .. ..... . .. (1)
(09950-60020)
09950-76020-71 ........ .. ...... .. (2)
(09950-70010)

Section 1.1.2
 4Y-E Repair

Pushing force 98 N (10 kgf) [22 lbfj

ENGINE ADJUSTMENT
V-BELT INSPECTION-ADJUSTMENT
V-belt Inspection
1. Check the belt for correct installation.
2. Apply a pushing force of 98 N (10 kgf) [22 Ibfl between the
alternator and the water pump and measure the amount of
deflection.
When installing a new part: 7 to 9 mm (0.28 to 0.35 in.)
When inspecting: 8 to 13 mm (0.31 to 0.51 in.)
Caution:
Measurement of the belt deflection amount must be
performed between the specified pulleys.
When replacing with a new belt, adjust the deflection to
the middle value of the standard "When installing a new
part".
Apply the standard of "When inspecting" for the
inspection of the belt if it is used for five minutes or more.
When reassembling the belt that is used for 5 minutes or
more, adjust to the mean value of the standard in "When
inspecting".
Tension standard when using SST
SST 092 16-76001-71
(09216-00020)
When installing a new part: 392 to 588 N (38 to 62 kgf)
[84 to 137 Ibfl
When inspecting: 294 to 490 N (30 to 50 kgf)
[66 to 110 Ibfl

V-belt Deflection Adjustment

1. Loosen the fixing bolt.
2. Loosen the set bolt, then turn the adjustment bolt to adjust the
tension.
3. Tighten the set bolt then re-check the belt tension.
4. Tighten the fixing bolt.
Caution:
Be careful not to apply too much tension to the belt.

Section 1.1.2
 4Y-E Repair

1NSPECTION.ADJUSTMENT OF IGNITION
TIMING
Warm-up the engine.
Standard
Coolant temperature: 75°C (167°F) or above
Hydraulic oil temperature: 50°C (122°F) or above
Engine oil temperature: 60°C (140°F) or above
Install the rev counter and timing light.
Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
lnspect the idle speed.
Standard: Refer t o repair manual for each vehicle model.
Inspect and adjust the ignition timing
(1) Disconnect the distributor vacuum hose.
(2) Use the timing light to inspect the ignition timing.
Standard: BTDC 7'1750 rpm
(3) If the value is outside of the standard, loosen the
distributor set bolt and rotate the distributor to adjust to
the standard value.
(4) Tighten the set bolt and inspect the ignition timing again.
T = 17.5 N-m (178 kgf-cm) [12.9 ft-lbfl
(5) If the ignition timing has been adjusted, seal the
distributor set bolt with sealing tape.
Idle up INSPECTIONlADJUSTMENT OF IDLE-UP
actuator
SPEED
Warm-up the engine.
Standard
Coolant temperature: 75°C (167°F) or above
Hydraulic oil temperature: 50°C (122°F) or above
Engine oil temperature: 60°C (140°F) or above
Install the rev counter. (Refer to above)
Start the engine, and measure the engine speed with the
vacuum hose removed from the idle-up actuator.
Standard
MIT 1100 A 30 rpm
TIC: 1000 A 30 rpm
If the value is outside of the standard, adjust it by turning the
Adjusti~ adjusting screw.
screw
Caution:
If the adjusting screw is turned clockwise, the engine speed
increases.
4. After adjustment, connect the vacuum hose

Section 1.1.2
 4Y-E Repair

INSPECTION-ADJUSTMENTOF IDLE
SPEED
Warm-up the engine
Standard
Coolant temperature: 75°C (167°F) or above
Hydraulic oil temperature: 50°C (122°F) or above
Engine oil temperature: 60°C (140°F) or above
Install the rev counter and vacuum gauge.
Vacuum ho6e
(1) Install the rev counter.
(2) Disconnect the vacuum hose from the vacuum advancer,
and connect the vacuum gauge.
Inspect and adjust the idle speed.
(1) Start the engine and alternately adjust the throttle
adjusting screw "A" and the idle adjusting screw "B", to
adjust so that the vacuum is at a stable maximum at the
regulation idle speed.
(2) If the idle up adjusting screw is connected to the idle up
actuator rod and the idle speed does not reduce, loosen
the idle up adjusting screw. (See P2-43)
Standard
Idle speed: Refer to repair manual for each vehicle
model.
Vacuum: 400 mmHg or more
NO LOAD MAXIMUM SPEED INSPECTION
AND ADJUSTMENT
(See P4-24)

COMPRESSION INSPECTION
Note:
When there is a drop in power output or excessive oil
consumption, or if the fuel consumption is extremely high,
measure the compression pressure in the cylinders.
1. Warm-up the engine.
Standard
Coolant temperature: 75°C (167°F) or more
Hydraulic oil temperature: 50°C (122°F) or more
2. Remove all the spark plugs.
3. Disconnect the distributor connector.
4. Measure the compression pressure.
Caution:
Operate the starter before inspecting the compression in
order to expel foreign bodies from inside the cylinder.

Section 1.1.2
 4Y-E Repair

(1) Insert a compression gauge into the spark plug hole.

(2) Open the throttle up fully.
(3) Crank the engine with the starter to measure the
compression pressure.
Standard: 1225 kPa (12.5 kgflcm2) 1178 psi]
Limit: 883 kPa (9.0 kgflcm2) 1128 psi]
Caution:
In order to maintain the engine speed to more than 250 rpm,
use a fully charged battery.
(4) Carry out the above operations (1) to (3) on every
cylinder, and inspect the pressure difference.
Limit
Pressure difference between cylinders:
98 kPa (1.O kgflcm2) 114 psi]
(5) If some cylinders have a compression pressure less than
the limit, or if their pressure differences are more than the
limit, add a small amount of engine oil from the spark plug
hole, and repeat the above operations (1) to (3).
(a) If the pressure goes up by adding oil, there may be
wear or damage to the piston ring and the cylinder
wall.
(b) If the pressure remains low even if oil is added, there
may be a burnout of the valve, defect in valve
contact, or pressure leak from the gasket.
5. Connect the distributor connector.
6. Install the spark plugs.

Section 1.1.2
 4Y-E Repair

ENGINE OVERHAUL (4Y-E)

Page

SST TO BE USED .............................................. 3-2

ENGINE ATTACHMENTS .................................. 3-4
................ 3-4
REMOVAL-INSPECTION~INSTALLATION
CYLINDER HEAD .............................................. 3
COMPONENTS........................................................... 3-8
DISASSEMBLY4NSPECTION.REASSEMBLY........ 3-11
TIMING GEAR .................................................. 3-20
COMPONENTS......................................................... 3-20
DISASSEMBLY1INSPECTION.REASSEMBLY........ 3-23
CYLINDER BLOCK.......................................... 3-32
COMPONENTS......................................................... 3-32
........ 3-34
DISASSEMBLY-INSPECTION-REASSEMBLY
ENGINE ADJUSTMENT................................... 3-43
V-BELT INSPECTION-ADJUSTMENT..................... 3-43
IDLE SPEED INSPECTION ...................................... 3-44
INSPECTIONlADJUSTMENT OF
IGNITION TIMING .................................................. 3-44
NO-LOAD MAXIMUM SPEED MEASUREMENT..... 3-45
COMPRESSION INSPECTION................................. 3-45

Section 1.1.3
 4Y-E Repair

SST TO BE USED
Illustration Part No. Part name

Oil pan seal cutter

Valve guide bushing remover & replacer

Valve spring compressor

Camshaft bearing remover & replacer

Belt tension gauge

Piston pin remover & replacer

Oil filter wrench

Sub-harness

Section 1.1.3
 4Y-E Repair

I Illustration Part No. Part name

Rocker arm support tool set

Valve lifter tool

Bearing remover

Puller B set

Replacer set

qeplacer B set

iandle set

Section 1.1.3
 4Y-E Repair

ENGINE ATTACHMENTS
REMOVAL-INSPECTION-INSTALLATION
T = N.m (kgf cm) [ftlbfl

Removal.lnstallation Procedure
The installation procedure is the reverse of the removal procedure.
I No. I Item Removal Inspection Installation I
I 1
I
I Fan. pulley, V-belt
I
See P3-43
I
t
I
t I
2
I

1 Alternator
I I I

I
3
I

1 Spark plugs
I I I

1
4 Throttle body and adapter
5 Fuel filter and hose [Point I]
6 Delivery pipe, injector [Point 21
7 Intake.exhaust manifolds [Point 31
8 Oil level gauge
9 Oil filter [Point 41 [Point 61
10 Water pump
11 Distributor [Point 51

Section 1.1.3
 4Y-E Repair

Point Operations
[Point I]
Removal:
Depressurization of the fuel system is performed with the
following procedure.
1. Prepare a waste cloth and a fuel receptacle tray under the
delivery pipe.
2. Wrap the union part in waste cloth, loosen the union bolt
slightly and release the fuel pressure.
3. With the union bolt loosened, drain all the fuel into the
receptacle tray.
Caution:
Do not allow any fire to come close during the operation.
Take measures to prevent the fuel from scattering.

[Point 21
Removal:
Remove the delivery pipe and the injectors (4 pieces) at the
same time.
Note:
Draw the delivery pipe out perfectly straight with respect
to the injectors.
Take good care that the injectors do not fall.

[Point 31
Inspection:
Using a straight edge ruler and a thickness gauge, measure
the amount of distortion of the intake manifold.
Limit: 0.40 mm (0.0157 in.)

Section 1.1.3
 4Y-E Repair

Inspection:
Using a straight edge ruler and a thickness gauge, measure
the amount of distortion of the exhaust manifold.
Limit: 0.40 mm (0.0157 in.)

[Point 41
Removal:
Use the SST and remove the oil filter
SST 09228-76001-71
(09228-0650 1)

[Point 51
Installation:
Install the distributor.
Align the TDC mark of the crank pully with the notch of the
timing gear cover.

Set the position of the groove in the oil pump driveshaft at

about 30" when seen from above.

Align the housing groove with the drill mark of the gear, and
insert the distributor.
Note:
Do not confuse the drill mark and the straight pin.
When installing the distributor, align the screw hole for
attaching the block with the center of the groove in the
flange to install.
After installation, adjust the ignition timing. (See P3-44)

Section 1.1.3
 4Y-E Repair

[Point 61
Installation:
After cleaning the attachment surface of the oil filter, fit an O-
ring and tighten the oil filter to the bracket by hand first, and
then use the SST to further tighten by 314 turn.
SST 09228-76001-71
(09228-06501)
Caution:
Apply a small amount of engine oil to the O-ring.
Clean the surface to which the O-ring will be attached.

Section 1.1.3
 4Y-E Repair

CYLINDER HEAD
COMPONENTS

Section 1.1.3
4Y-E Repair

Section 1.1.3
 4Y-E Repair

Section 1.1.3
 4Y-E Repair

DisassemblymReassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Remove parts in procedures 1 to 11 on page P3-4.
2 Cylinder head cover
3 Rocker shaft ASSY [Point I ] [Point 21 [Point 181
4 Valve stem cap [Point 31
5 Valve push rod [Point 41 [Point 51 [Point 171
1 1 Cylinder head bolt I 1 I I
-

6 [Point 61 [Point 161

7 Cylinder head gasket [Point 71 [Point 151
8 Valve spring and valve [Point 81 [Point 91 [Point 141
9 Valve stem oil seal [Point 131
10 Valve guide bushing [Point 101 [Point 111 [Point 121

Section 1.1.3
 4Y-E Repair

Point Operations
[Point I ]
Disassembly:
Evenly loosen the support set bolts in two or three times,
following the order shown in the illustration.

[Point 21
Inspection:
Inspect for wear or damage to the contact surface for the
rocker arm valve stem cap.
If there is a slight damage, correct it by polishing with oil stone,
and replace if there is a considerable wear or damage.

Inspection:
Move the rocker arm as shown in the illustration, and inspect
the clearance between the rocker arm and the shaft. If the
clearance is large, disassemble and inspect it.

Inspection:
Inspect the oil clearance between the rocker arm and the
rocker shaft.
1. Measure the rocker arm inside diameter with a caliper gauge.
Standard: 18.500 to 18.515 mm (0.7283 to 0.7289 in.)

Measure the rocker shaft outside diameter with a micrometer.

Standard: 18.474 to 18.487 mm (0.7273 to 0.7278 in.)
Calculate the oil clearance by the difference between the arm
inner diameter and the shaft outer diameter.
Standard: 0.013 to 0.041 mm (0.0005 to 0.0016 in.)
Limit: 0.08 mm (0.0031 in.)
If it exceeds the limit, replace the rocker arm or the rocker
shaft.

Section 1.1.3
 4Y-E Repair

[Point 31
Inspection:
Inspect the valve stem cap.
1. Measure the wall thickness of the valve stem cap.
Standard: 1.31 to 1.49 mm (0.0516 to 0.0587 in.)
2. If there is a slight scratch on the contact surface with the rocker
arm, correct it by polishing with oil stone, and if there is
considerable wear or damage, replace with a new one.

[Point 41
Disassembly:
Store the removed push rods carefully so that their order will
not be mixed up during reassembly.

[Point 51
Inspection:
lnspect the push rod.
1. lnspect the runout in the push rod.
Limit: 0.30 mm (0.0118 in.)
If it exceeds the limit, replace the push rod.
2. lnspect for blockage of the push rod oil hole.
If there is a blockage, remove it with an air gun.

[Point 61
Disassembly:
Loosen the cylinder head bolts in two or three times, following
the order shown in the illustration.

[Point 71
Inspection:
Use a straight edge ruler and a thickness gauge to measure
the distortion of the lower surface of the cylinder head and the
attachment surface of the manifold.
Limit
Cylinder head lower surface: 0.15 mm (0.0059 in.)
Manifold attachment surface: 0.10 mm (0.0039 in.)
If it exceeds the limit, grind or replace.

Section 1.1.3
 4Y-E Repair

Inspection:
Inspection for cracking in the cylinder head.
With color check (dye penetrant inspection), inspect the
combustion chambers, the intake ports, the exhaust ports, and
the lower and upper faces of the heads.

[Point 81
SST I Disassembly:
Use the SST to disassemble the valve spring and valve.
SST 09202-76001-71
(09202-43013)
Store the removed parts by sorting them out for each cylinder.

[Point 91
Inspection:
Inspect the oil clearance between the valve guide bushing and
the valve stem.
1. Measure the valve guide bushing inside diameter with a caliper
gauge.
Standard
IN: 8.010 to 8.030 mm (0.3154 to 0.3161 in.)
2. Measure the outside diameter of the valve stem.
Standard
IN: 7.970 to 7.985 mm (0.3138 to 0.3144 in.)
EX: 7.965 to 7.980 mm (0.3136 to 0.3142 in.)
3. Calculate the oil clearance
Standard
IN: 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
EX: 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Limit
IN: 0.10 mm (0.0039 in.)
EX: 0.12 mm (0.0047 in.)
If it exceeds the limit, replace the valve stem or the valve guide
bushing. Also, if necessary, grind the inside diameter by using
a reamer to correct the oil clearance between the valve guide
bushing and the valve stem within the standard range.

Section 1.1.3
 4Y-E Repair

Inspection:
lnspect the valves.
1. Measure the wall thickness of the valve head.
Standard
IN: 1.0 to 1.4 mm (0.039 to 0.055 in.)
EX: 1.3 to 1.7 mm (0.051 to 0.067 in.)
Limit
IN: 0.5 mm (0.020 in.)
EX: 0.8 mm (0.031 in.)

2. Measure the total length of the valves.

Standard
IN: 108.2 mm (4.260 in.)
EX: 108.5 mm (4.272 in.)
Limit
IN: 107.7 mm (4.240 in.)
EX: 108.0 mm (4.252 in.)

Inspection:
lnspect the valve seat.
1. Apply red lead primer thinly to the valve face.
2. Insert the valve into the valve guide bushing, and press the
valve onto the valve seat. Do not rotate the valve while it is
pressed onto the valve seat.
3. lnspect the width of the contact surface to see whether it is
within the standard along the entire circumference.
Standard
Contact width: 1.2 to 1.6 mm (0.047 to 0.063 in.)
If the width is not within the standard, replace the valve or
correct the valve seat.
4. Correct the valve seat.
Caution:
Use a carbide tip cutter for the EX side.
Cutting should be performed while constantly checking
the contact point and contact width of the valve.
In order not to create steps, gradually reduce the force
towards the end of cutting.
Make corrections after inspecting the valve guide
bushing.

Section 1.1.3
 4Y-E Repair

(1) Grind the valve seat with a 45" valve seat cutter.
(2) If the contact position is on the outward side, grind using
a 30" cutter.

Contact surface

(3) If the contact position is on the inward side, grind using a

IN side: 60" 60" cutter on the IN side, and a 65" cutter on the EX side.
-L

I /
Contact surface
Inspection:
2.0 rnrn (0.079in.) Inspect the valve spring.
+IF
Measure the squareness at the top end of the spring.
Limit
IN-EX: 2.0 mm (0.079 in.)

Measure the free length.

Standard
IN-EX: 46.0 mm (1.81 in.)
Limit
IN-EX: 45.5 mm (1.79 in.)

[Point 101
Disassembly:
Remove the valve guide bushing.
Valve guide
bushing 1. Use a bar and hammer to break off the valve guide bushing
Snap 2. Remove the snap ring.
ring

Section 1.1.3
 4Y-E Repair

3. Gradually warm the cylinder head to between 80 and 100°C

(176 to 212°F).

4. Use the SST and a hammer to tap out the valve guide bushing.
SST 09201-76006-71
(09201-60011)

[Point 111
Inspection:
Use a caliper gauge to measure the inside diameter of the
bushing bottom hole, then select the bushing to be used.
Bushing inside diameter (mm) [in.] Bushing size
13.000 to 13.027 (0.5118 to 0.5129) STD bushing
1 13.027 (0.5129) or more I OIS 0.05 bushing I
If the bushing bottom hole inside diameter is 13.027 mm
(0.5129 in.) or more, correct the inside diameter of the bushing
bottom hole with a reamer.
Bushing bottom hole inside diameter:
13.050 to 13.077 mm (0.5138 to 0.5148 in.)
If the bushing bottom hole inside diameter is 13.077 mm
(0.5148 in.) or more, replace the cylinder head.
[Point 121
Reassembly:
Install the valve guide bushing.
1. Gradually warm the cylinder head to between 80 and 100°C
(176 to 212°F).
2. Use the SST and a hammer to tap the bushing in until the snap
ring makes contact with the head.
SST 09201-76006-71
(09201-60011)

Section 1.1.3
 4Y-E Repair

[Point 131
Reassembly:
Apply engine oil to the valve stem oil seal lip portion and to the
valve stem, and reassemble them.
Reassemble according to the dimensions shown in the
illustration on the left.

[Point 141
SST
Reassembly:
Use the SST to reassemble the valve spring and valve.
SST 09202-76002-71
(09202-70020)

[Point 151
Gasket
Front side Reassembly:
/ Check the direction of the gasket and install the gasket.

[Point 161
Reassembly:
Tighten the cylinder head bolts in two or three times, following
the order shown in the illustration.

Front
ib 4
4 Q i
[Point 171
Reassembly:
Use the SST to position and install the push rod.
SST 09270-76001-71
(09270-710 10)

Section 1.1.3
 4Y-E Repair

[Point 181
Reassembly:
Evenly tighten the support set bolts in two or three times,
following the order shown in the illustration.

Reassembly:
Check the direction of the rocker arm shaft, then use the SST
to position the rocker arm and install the rocker arm ASSY.
SST 09270-76001-71
(09270-71010)

- Projecting butward I

Section 1.1.3
 4Y-E Repair

TIMING GEAR
COMPONENTS

Section 1.1.3
4Y-E Repair

Section 1.1.3
4Y-E Repair

Section 1.1.3
 4Y-E Repair

Disassembly.Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Fan pulley, V-belt, alternator See P3-43 t t

2 Cylinder head ASSY* See P3-11 t t

3 Crankshaft pulley
1 4 1 Crank position sensor I I I [Point 201 1
5 Timing gear cover and gasket
6 Crankshaft bearing [Point I ] [Point 191
7 Pump drive sprocket and drive chain, crankshaft sprocket [Point 21 [Point 181
8 Chain tensioner [Point 31

Section 1.1.3
 4Y-E Repair

No. Item Disassembly Inspection Reassembly

9 Timing chain, crankshaft sprocket, camshaft sprocket [Point 41 [Point 171
10 Chain vibration damper [Point 51
11 Valve lifter [Point 61 [Point 71
-

12 Oil pan [Point 81 [Point 161

13 Thrust plate and camshaft [Point 91 [Point 101 [Point 151
14 Timing gear case
15 Front oil seal [Point 111 [Point 141
16 Camshaft bearing [Point 121 [Point 131

*If you remove the parts other than the camshaft, you do not need to remove the cylinder head.
Point Operations
[Point I]
Disassembly:
Use the SST to remove the crankshaft bearing.
SST 09950-76014-71 ..................(1)
(09950-40011)
09950-76018-71 ..................(2)
(09950-60010)

[Point 21
Disassembly:
Use the SST to remove the bearing (case side).
SST 09320-23000-71

Disassembly:
Use the SST to remove the bearing (gear side).
SST 09950-76014-71 ..................(1)
(09950-40011)
09950-76018-71 ..................(2)
(09950-60010)

Section 1.1.3
 4Y-E Repair

[Point 31
Inspection:
Use a vernier caliper to measure the tensioner.
Standard: 15.0 mm (0.591 in.)
Limit: 12.5 mm (0.492 in.)

[Point 41
Inspection:
Chain Timing chain inspection
Tension the chain to 49 N (5 kgf) [11.0 Ibfl, then measure the
chain length in at least 3 places at random to inspect the
stretch of the chain.
Limit: 291.4 mm (11.472 in.)

Inspection:
Timing gear inspection
Measure the outside diameter of the sprocket with the chain
on.
Limit
Crankshaft: 59 mm (2.32 in.)
Camshaft: 114 mm (4.49 in.)

[Point 51
Inspection:
Use a vernier caliper to measure the thickness of the damper.
Standard: 6.6 mm (0.260 in.)
Limit: 5.0 mm (0.197 in.)

[Point 61
Disassembly:
Use a wire with the end bent into an L shape to remove the
valve lifter.
Note:
Bend the end of the wire about 1 mm (0.04 in.), and insert
the wire into the center hole of the valve lifter to hook the
valve lifter.
Clean the wire thoroughly first.

Section 1.1.3
 4Y-E Repair

Line the removed valve lifters up in number order. Always

store them with standing up with the hole facing upwards.
Do not disassemble the valve lifters.

[Point 71
Inspection:
Inspect the oil clearance of the valve lifter.
1. Measure the outside diameter of the valve lifter.
Standard: 21.387 to 21.404 mm (0.8420 to 0.8427 in.)

2. Measure the inside diameter of the cylinder block bottom hole.

Standard: 21.417 to 21.443 mm (0.8432 to 0.8442 in.)
3. Calculate the oil clearance of the valve lifter.
Standard: 0.012 to 0.056 mm (0.0005 to 0.0022 in.)
Limit: 0.10 mm (0.0039 in.)
If it exceeds the limit, replace the valve lifter.

Inspection:
Valve lifter leak down test
1. Bleed the air from the valve lifter.
Immerse the valve lifter in a container full of diesel oil, and use
the SST to move the plunger up and down several times.
SST 09276-76001-71
(09276-710 10)
Caution:
The diesel oil is used only for the test. When installing the
valve lifter, perform bleeding again in engine oil.
2. Use a tester and apply 196 N (20 kgf) [44.1 Ibfl of force to the
Plunger I
plunger of the air-bled lifter. After the plunger has dropped
about 2 mm (0.08 in.), measure the time taken for the plunger
dropping a further 1 mm (0.04 in.).
-\
3. Measure 3 times, shifting the position of the plunger 120" each
time, and find the average value.
Lifter body Standard: 7 to 28 sec.11 mm (0.04 in.)
(oil temperature 20°C [68"F])

Section 1.1.3
 4Y-E Repair

[Point 81
Disassembly:
Do not deform the flange section of the oil pan during the
operation.
SST 09032-76001-71
(09032-00100)
Caution:
Do not use the SST on the timing gear case side.
Do not pry with a screwdriver.

[Point 91
Disassembly:
Remove the camshaft.
Caution:
When pulling out the camshaft, pull it out straight to avoid
damaging the camshaft bearing.

[Point 101
Inspection:
Measure the thrust clearance of the camshaft.
Standard: 0.07 to 0.22 mm (0.0028 to 0.0087 in.)
Limit: 0.3 mm (0.012 in.)

Inspection:
Measure the height of the cam.
Standard
IN: 38.620 to 38.720 rnm (1.5205 to 1.5244 in.)
EX: 38.629 to 38.729 mm (1.5208 to 1.5248 in.)
Limit
IN: 38.26 mm (1.5'063 in.)
EX: 38.27 mm (1.5067 in.)

Inspection:
Inspect the bending of the camshaft.
Bending = runout of the dial gauge12
Limit: 0.06 mm (0.0024 in.)

Section 1.1.3
 4Y-E Repair

Inspection:
Inspect the oil clearance of the camshaft bearing.
Measure the outside diameter of the camshaft journal.
Standard
No.1: 46.459 to 46.475 mm (1.8291 to 1.8297 in.)
No.2: 46.209 to 46.225 mm (1.8192 to 1.8199 in.)
No.3: 45.959 to 45.975 mm (1.8094 to 1.8100 in.)
No.4: 45.709 to 45.725 mm (1.7996 to 1.8002 in.)
NOS: 45.459 to 45.475 mm (1.7897 to 1.7904 in.)

Measure the inside diameter of the camshaft bearing.

Standard
No.1: 46.500 to 46.540 mm (1.8307 to 1.8323 in.)
No.2: 46.250 to 46.290 mm (1.8209 to 1.8224 in.)
No.3: 46.000 to 46.040 mm (1.8110 to 1.8126 in.)
No.4: 45.750 to 45.790 mm (1.8012 to 1.8028 in.)
NOS: 45.500 to 45.540 mm (1.7913 to 1.7929 in.)
Calculate the oil clearance.
Standard: 0.025 to 0.081 mm (0.0010 to 0.0032 in.)
Limit: 0.1 mm (0.0039 in.)
If it exceeds the limit, replace the bearing.
[Point 111
Disassembly:
Use the SST to tap out the oil seal.
SST 09950-76018-71 ..................(1
(09950-60010)
09950-76020-71 ..................(2)
(09950-70010)

[Point 121
Disassembly:
Remove the camshaft bearing.
1. Remove the oil pump wl strainer. (See P8-6)
2. Use the SST to remove the rear tight plug.
SST 09215-76004-71
(09215-00101)

Section 1.1.3
 4Y-E Repair

3. Use the SST to remove the camshaft bearing.

SST 09215-76004-71
(09215-00101)

Note:
Each bearing has a different outside diameter, so take care
when removing and reinstalling them.

[Point 131
Disassembly:
Install the camshaft bearing.
Align the oil holes of the cylinder block and the bearing.

c Front Use the SST and install the bearing.

SST 092 15-76004-7 1
(09215-00101)
Use a nevj'tight plug to apply ThreeBond 1386 to the outer
circumference, and drive the tight plug into the cylinder block
until the surface becomes even.
SST 09215-76004-71
(09215-00101)

[Point 141
Reassembly:
Using the SST, drive the oil seal into the timing gear cover until
the surface becomes even.
SST 09950-76018-71 ..................(1)
(09950-60010)
09950-76020-7 1 ..................(2)
(09950-70010)

Section 1.1.3
 4Y-E Repair

[Point 151
Reassembly:
Take care as the thrust plate has a direction

[Point 161
Reassembly:
Apply FlPG to the seal section of the oil pan
FIPG: 08826-76001-71
(For handling of FIPG, See PO-19)

I FlPG

[Point 171
I Mark Reassembly:
Camshaft key / Install the timing chain, camshaft sprocket, and crankshaft
sprocket.
1. Position the crankshaft key exactly at the top.
2. Align the camshaft key with the upper mark on the thrust plate.

Section 1.1.3
 4Y-E Repair

3. Assemble the timing chain, camshaft sprocket, and crankshaft

sprocket at the same time.
Caution:
Be sure to align the marks of each sprocket with the marks on
the timing chain.

1 Gear side / SST(1)

\
Case side
I
[Point 181
Reassembly:
Use the SST to install the bearing.
SST 09950-76018-71 ..................(I)
(09950-60010)
09950-76020-71 ..................(2)
(09950-70010)

[Point 191
Reassembly:
Tap the bearing inner race evenly around with a bar to fit it.

[Point 201
Reassembly:
Apply engine oil to the entire circumference of the O-ring then
assemble.

Section 1.1.3
 4Y-E Repair

CYLINDER BLOCK
COMPONENTS

Refer to
Refer to FlG.1301 AH 43A
FIG.1302 I I I

Refer to
FIG.1302

Section 1.1.3
4Y-E Repair

I I
Llll lll .
I

I I
Llll IIlJ
T

Section 1.1.3
 4Y-E Repair

T = N.m (kgf cm) [ft.lbfj

DisassemblymReassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Cylinder head ASSY See P3-11 t t

2 Timing gear-related See P3-23 t t

3 Oil pump ASSY WI oil strainer

4 Rear oil seal retainer WI oil seal [Point I ] [Point 141
5 Rear oil seal
6 Measuring the thrust clearance of the connecting rod [Point 21
7 Connecting rod cap WI bearing [Point 31 [Point I31
8 Piston W1 connecting rod [Point 41 [Point 121
9 Piston disassembly [Point 51 [Point 61 [Point 111
10 Measuring the thrust clearance of the crankshaft [Point 71
11 Crankshaft cap, bearing, thrust washer [Point 81 [Point 101
12 Cranksha# [Point 91

Caution:
Be sure that the parts for each cylinder are assembled in their correct combinations.

Section 1.1.3
 4Y-E Repair

Point Operations
[Point I ]
Disassembly:
Use a screwdriver and a hammer to tap out the oil seal.

[Point 21
Inspection:
Move the connecting rod back and forth to measure the thrust
clearance.
Standard: 0.016 to 0.312 mm (0.0063 to 0.00123 in.)
Limit: 0.35 mm (0.0138 in.)

[Point 31
Inspection:
Measure the oil clearance of the connecting rod bearing.
Perform the measurement with a plastigage, and tighten the
connecting rod cap set nut to the specified torque.
Do not turn the crankshaft during the measurement.
Standard: 0.020 to 0.051 mm (0.0008 to 0.0020 in.)
Limit: 0.10 mm (0.0039 in.)

Caution:
When using STD bearings, use a bearing with the same
reference number (6, 7, 8) as that punched into the
connecting rod cap.
Remove the plastigage completely after measuring.

[Point 41
Disassembly:
Attach a vinyl hose or similar to the connecting rod bolt to
protect the cylinder inner wall and the crankshaft.

Section 1.1.3
 4Y-E Repair

Note:
Sort the removed pistons, connecting rod caps, and bearings
into the order of the cylinders.

[Point 51
Disassembly:
Disassemble the piston and the connecting rod
1. Remove the piston ring and the oil ring

2. Use the SST and a press to push out and remove the piston
pin.
pin
SST 09221-76002-71
(09221-2501 8)
Note:
The removal should be performed at room temperature.

Sort out the removed parts for each cylinder, and be sure
not to mix them up during reassembly.

[Point 61
Inspection:
Inspect the cylinder block.
1. Inspect for any distortions on the upper face of the cylinder
block.
Limit: 0.05 mm (0.0020 in.)
Check that there are no considerable scratches on the cylinder
wall surface. If there are scratches, rebore the cylinder.

Section 1.1.3
 4Y-E Repair

2. Measure the six points shown in the left illustration, and find
the difference between the maximum and minimum values.
Crank axle
:rant /direction Limit: 0.05 mm (0.0020 in.)

Thrust
direction

3. Measure the piston clearance.

(1) Measure the outside diameter of the piston.
Measurement position:
Measure the diameter at the place in a position 24 mm
(0.94 in.) from the top of the piston and orthogonal to
the piston pin.
Standard
STD: 90.925 to 90.955 mm (3.5797 to 3.5809 in.)
OIS 0.5: 91.425 to 91.455 mm (3.599 to 3.601 in.)

(2) Measure the cylinder bore and calculate the piston

clearance.
Crank axle
direction Standard: 0.065 to 0.085 mm (0.0026 to 0.0033 in.)
If the value exceeds the limit, replace the piston or rebore
c Thrust
direction the cylinder and install an 01s piston.
Note:
Boring dimension = P + C H -
P: Outside diameter of the piston C: Piston clearance
H: Honing margin (0.02 mm [0.0008 in.] or less)
(0.39 in.) I

Inspection:
Inspect the piston and the connecting rod
Measure the gap between the piston ring and the ring groove
along the entire circumference.
Standard: 0.03 to 0.07 mm (0.0012 to 0.0028 in.)

Press the piston ring into the sliding section of the piston, and
measure the piston ring gap.
Standard
No.1: 0.23 to 0.48 mm (0.0091 to 0.0189 in.)
No.2: 0.16 to 0.44 mm (0.0063 to 0.0173 in.)
Oil ring: 0.13 to 0.47 mm (0.0051 to 0.0185 in.)

Section 1.1.3
 4Y-E Repair

Reassembly:
Install the piston ring.
Install the oil ring expander.
Install the oil ring side rail using the piston ring tool.
There is no difference between the top and bottom sides of the
~u\nchmark oil ring side rail.
Install each compression ring with the punch mark at the top
using the piston ring tool.
Punch mark
Top ring: 1T
Second ring: 2 T
Align the ring gaps as shown in the illustration.
Compression
Upper side rail
ring No.2

Front

Lower side Compression

rail ring No.1 and

[Point 71
Inspection:
Measure the thrust clearance of the crankshaft.
Standard: 0.020 to 0.220 mm (0.0008 to 0.0087 in.)
Limit: 0.30 mm (0.0118 in.)
If it exceeds the limit, replace the thrust washer.

[Point 81
Disassembly:
Evenly loosen the cap set bolts in several times, following the
order shown in the left illustration.

Section 1.1.3
 4Y-E Repair

Note:
Upper (on cylinder block side)
Store the caps, bearings and washers in correct order in order
to reinstall them in the same position as when they were
removed.

1
Front

Lower (on bearing cap side)

[Point 91
Inspection:
Measure the oil clearance of the crankshaft by using a
plastigage.
Do not turn the crankshaft during the measurement.
Standard: 0.02 to 0.051 mm (0.0008 to 0.0020 in.)
Limit: 0.10 mm (0.0039 in.)
If it exceeds the limit, replace the bearing. Or, if necessary,
replace the crankshaft.

Note:
When using STD bearings, replace with a bearing with the
same reference number (1 to 3) as that punched into the
cylinder block.

Inspection:
lnspect the bending of the crankshaft.
lnspect the bending when turning the crankshaft once
Bending = runout of the dial gauge12
Limit: 0.06 mm (0.0024 in.)

Section 1.1.3
 4Y-E Repair

Inspection:
Inspect for crankshaft wear.
1. Measure the outside diameters of all of the crankshaft journals
and pins.
Standard
Journal outside diameter: 57.985 to 58.000 mm
(2.2829 to 2.2835 in.)
Crank pin outside diameter: 47.985 to 48.000 mm
(1.8892 to 1.8898 in.)
2. Calculate the ellipticity and taper degree.
Limit
Ellipticity: 0.02 mm (0.0008 in.)
Taper degree: 0.02 mm (0.0008 in.)
If it exceeds the limit, replace the crankshaft.
[Point 101
Reassembly:
Install the bearing cap.
1. Install with the oil groove of the thrust washer facing the
crankshaft.
2. Check the front mark, and install in the same place as before
it was disassembled.

Disassembly:
Evenly tighten the bearing cap bolts in several times, following
the order shown in the illustration.

[Point 111
Front mark
(Depression) Reassembly:
Reassemble the piston and connecting rod
1. Align the front marks of the piston and the connecting rod.

Section 1.1.3
 4Y-E Repair

2. Apply engine oil to the piston pin and piston pin hole.
Pin 3. Use the SST and a press to press fit the piston pin.
SST 09221-76002-71
(09221-25018)
Note:
The assembly should be performed at room temperature.

[Point 121
Reassembly:
Install the bearing.
Ensure that no foreign matter, oil, etc., becomes attached to
the contact surface between the bearing and the connecting
rod.
Apply engine oil to the inner surface of the bearing.
Assemble the upper bearing to the locking groove of the
connecting rod.
Install the lower bearing to the locking groove of the bearing
cap.
Reassembly:
Attach a vinyl hose or similar to the connecting rod bolt to
protect the cylinder inner wall and the crankshaft.

Reassembly:
Front mark When reinstalling the piston to the cylinder, be sure to install it
(Depression)
in the same cylinder from which it was removed.
Apply engine oil to the sliding sections of the connecting rod
and piston.
*
Front
Use a piston ring compressor to assemble with the front mark
facing front.

Section 1.1.3
 4Y-E Repair

1 [Point 131
Reassembly:
Install the connecting rod cap
1. Install with the front mark of the bearing cap facing the front of
the engine.
2. Align the punch marks of the connecting rod.
Note:
There are several kinds of alphabet punch marks.
Each of the rotation angles of the punched alphabet
marks differs. Be sure to align them when installing.
3. Make sure that no foreign matter or oil, etc., becomes attached
to the back surface of the bearing.
4. Apply engine oil to the inner surface of the bearing.
5. Tighten the left and right bolts alternately in two or three times.

[Point 141
Reassembly:
Use the SST to knock in the oil seal.
SST 09950-76019-71 ... .. .. . ..........(1)
(09950-60020)
09950-76020-71 .. . .... . .......... (2)
(09950-70010)

Section 1.1.3
 4Y-E Repair

Pushing force 98 N (10 kgf) [22 Ibfl

ENGINE ADJUSTMENT
V-BELT INSPECTION-ADJUSTMENT
V-belt Inspection
1. Check the belt for correct installation.
2. Apply a pushing force of 98 N (10 kgf) [22 lbfj between the
alternator and the water pump and measure the amount of
deflection.
When installing a new part: 7 to 9 mm (0.28 to 0.35 in.)
When inspecting: 8 to 13 mm (0.31 to 0.51 in.)
Caution:
Measure the belt deflection between specified pulleys.
When replacing with a new belt, adjust the deflection to
the middle value of the standard "When installing a new
part".
Apply the standard of "When inspecting" for the
inspection of the belt if it is used for five minutes or more.
When reassembling the belt that is used for 5 minutes or
more, adjust to the mean value of the standard in "When
inspecting".

Tension standard when using SST

SST 09216-76001-71
(092 16-00020)
When installing a new part: 392 to 588 N (38 to 62 kgf)
[84 to 137 Ibfl
When inspecting: 294 to 490 N (30 to 50 kgf)
[66 to 110 Ibfl

V-belt Deflection Adjustment

1. Loosen the fixing bolt.
2. Loosen the set bolt, then turn the adjustment bolt to adjust the
tension.
3. Tighten the set bolt then re-check the belt tension.
4. Tighten the fixing bolt.
Caution:
Be careful not to apply too much tension to the belt.

Section 1.1.3
 4Y-E Repair

IDLE SPEED INSPECTION

1. Warm-up the engine.
Standard
Coolant temperature: 75 to 80°C (167 to 176°F) or more
2. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
3. lnspect the idle speed.
Standard: Refer to repair manual for each vehicle model.
Note:
If the idle speed is outside the standard value, refer to the
section on "ldle speed adjustment" in the repair manual for
each vehicle model.
INSPECTIONlADJUSTMENT OF IGNITION
TIMING
1. Warm-up the engine.
Standard
Coolant temperature: 75 to 80°C (167 to 176°F) or more
2. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).

3. lnspect the idle speed.

Standard: Refer to repair manual for each vehicle model.
Note:
If the idle speed is outside the standard value, refer to the
section on "ldle speed adjustment" in the repair manual for
each vehicle model.
4. Install the timing light.

~ i h ~ n o s tconnector
ic
5. Use the SST to connect terminals 10 and 16 of the diagnostic
connector.
SST 09238-13130-71
Caution:
If the wrong terminals are connected, a malfunction will occur.
Be sure to connect the correct terminals.

Diagnostic connector

Section 1.1.3
 4Y-E Repair

6. Inspect the ignition timing.

Standard: 7" (BTDC)
7. If the ignition timing is outside the standard, loosen the
distributor set bolt and rotate the distributor to adjust the
ignition timing to the standard value.

NO-LOAD MAXIMUM SPEED

MEASUREMENT
1. Warm-up the engine.
Standard
Coolant temperature: 75 to 80°C (167 to 176°F) or more
2. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
3. Fully depress the accelerator pedal and measure the
maximum speed.
Standard: Refer to the repair manual for each vehicle
model.
EFI fuse COMPRESSION INSPECTION
1. Warm-up the engine.
Standard
Coolant temperature: 75 to 80°C (167 to 176°F) or more
2. Disconnect the battery negative terminal.
3. Remove the spark plug
4. Remove the IGN fuse and EFI fuse.
IGN fuse
5. Remove the throttle body set nut and insert a wooden block
etc. between the throttle body and the surge tank to maintain
a clearance of 3 to 5 mm (0.12 to 0.20 in.).
Note:
Secure the intake air.

Section 1.1.3
 4Y-E Repair

6. Connect the negative terminal of the battery and measure the

compression pressure.
Note:
In order to ensure a cranking speed of more than 250 rpm,
use a fully charged battery.
Turn the starter before measuring the compression
pressure in order to eliminate the foreign matter inside the
cylinder.
Insert a compression gauge into the spark plug hole.
Crank the engine with the starter and measure the
compression pressure.
Standard: 1225 kPa (12.5 kgflcm2) [I78 psi]
Limit: 883 kPa (9.0 kgflcm2) [I28 psi]
Measure the compression pressure of all four cylinders
and inspect the difference.
Limit of pressure difference between cylinders:
98 kPa (1.0 kgflcm2) [ I 4 psi]
If some cylinders have a compression pressure less than
the limit, or if their pressure differences are more than the
limit, add a small amount of engine oil from the spark plug
hole, and repeat the operations (1) to (3) above.
(a) If the pressure goes up by adding oil, there may be
wear or damage on the piston ring or the cylinder
wall.
(b) If the pressure remains low even after oil is added,
there may be a burnout of the valve, defect in valve
contact, or pressure leak from the gasket.
Install the spark plugs.
T = 18 N-m(183 kgf-cm)113.2 ft-lbfl

Section 1.1.3
 4Y-E Repair

FUEL SYSTEM (4Y-M)

Page

SST TO BE USED .............................................. 4-2

FUEL PUMP ....................................................... 4-3
COMPONENTS........................................................... 4-3
REMOVAL................................................................... 4-4
AIRTIGHTNESS INSPECTION ...................................
INSTALLATION .......................................................... 4-5
CARBURETOR .................................................. 4-6
SCHEMATIC DIAGRAM ............................................. 4-6
COMPONENTS........................................................... 4-7
ON-VEHICLE INSPECTION ....................................... 4-8
REMOVAL-INSTALLATION....................................... 4-9
DISASSEMBLY........................................................... 4-9
INSPECTION............................................................. 4-13
REASSEMBLY.......................................................... 4-15
CARBURETOR ADJUSTMENT ............................... 4-17
FAST IDLE CAM ADJUSTMENT ............................. 4-19
CHOKE VALVE ADJUSTMENT ............................... 4-19
AIR GOVERNOR .............................................. 4-20
COMPONENTS......................................................... 4-20
REMOVALlINSTALLATION ..................................... 4-21
DISASSEMBLY......................................................... 4-21
INSPECTION............................................................. 4-22
REASSEMBLY.......................................................... 4-23
ADJUSTMENT .......................................................... 4-24

Section 1.1.4
 4Y-E Repair

SST TO BE USED
r Illustration Part No. I Part name

09860-76001-71
Carburetor screwdriver set
(09860-11011)

Section 1.1.4
 4Y-E Repair

FUEL PUMP
COMPONENTS

Section 1.1.4
 4Y-E Repair

REMOVAL
1. Disconnect the fuel pump outlet and inlet pipes.

2. Fuel pump ASSY removal

(1) Remove the fuel pump ASSY.
(2) Remove the insulator.

AIRTIGHTNESS INSPECTION
1. Preparation for inspection
Outlet
(1) Supply a small volume of gasoline to the fuel pump to
keep the airtightness of the check valve.
(2) Operate the arm without blocking the pipe, and check the
Arm
arm travel and play.
Note:
The arm travel and play checked in the preparation shall be
used as the basis for later inspections.
2. Diaphragm inspection
(1) Block the inlet pipe and outlet union with fingers, and
operate the arm to check that the arm movement
becomes heavy.
Caution:
Do not operate the arm forcibly.

3. Inlet valve inspection

Block the outlet union with a finger and operate the arm to
check that it moves freely without reaction force and that the
play of the arm increases.

Section 1.1.4
 4Y-E Repair

4. Outlet valve inspection

Block the inlet pipe with a finger and operate the arm to check
that the operating force becomes heavy.
Caution:
Do not operate the arm forcibly.

5. Oil seal inspection

Block the vent hole with a finger and operate the arm to check
that the operating force becomes heavy.
Caution:
Do not operate the arm forcibly.

I
Vent hole position

INSTALLATION
1. Fuel pump ASSY installation
Install the fuel pump ASSY and insulator to the cylinder block
by using two set nuts.
T = 21 N.m (214 kgfcm) [15.5 ftdbfl
Caution:
Surely bring the rocker arm into contact with the camshaft.
2. Fuel pump piping connection

Section 1.1.4
 4Y-E Repair

CARBURETOR
SCHEMATIC DIAGRAM

1 Accelerator pump diaphragm 12 Slow jet

2 Accelerator pump nozzle 13 Float
3 1 Small venturi tube 11 1
14 Power valve
4 Choke valve 15 Solenoid valve
5 Main nozzle 16 Economizer jet
6 Choke breaker 17 Idle adjusting screw
7 Main air bleed 18 Throttle valve
8 Slow air bleed No.2 19 Idle-up actuator
9 Power piston 20 Slow air bleed No.1
10 Strainer 21 Main jet
11 Needle valve

Section 1.1.4
 4Y-E Repair

COMPONENTS

Section 1.1.4
 4Y-E Repair

ON-VEHICLE INSPECTION
1. Remove the air cleaner connector.
2. Inspect the carburetor and the link.
(1) Check the tightening of the set screw, plug, and union
(2) Inspect for the link wear and missing of the snap ring.
(3) Check that the throttle valve fully opens when pressing the accelerator pedal fully.
(4) Clean each part.
Warning:
Before handling the fuel system, disconnect the negative terminal of the battery.
Do not put open flames nearby.
Caution:
Separate between each component in order not to mix up with similar parts.
Make sure to avoid gasoline to attach on rubbers.
lnspection in Cold State
Choke breaker system inspection
1. Start the engine.
2. Check that the rod returns when the choke breaker vacuum
hose is disconnected.

Accelerator pump nozzle

lnspection in Hot State
Choke valve full opening inspection
Check that the choke valve is fully opened.
Accelerator pump inspection
Operate the accelerator pump and check that the fuel is
injected from the accelerator pump nozzle.
Air cleaner connector installation

\
Idle-up speed ins~ection(See P2-43)
Accelerator pump lever
Idle speed inspection (See P2-44)
No-load maximum speed and loaded maximum speed
inspection (See P4-25)

Section 1.1.4
 4Y-E Repair

Choke valve
set screws Refer to P2-4

DISASSEMBLY
Caution:
Throttle arm Since there are many similar components, arrange the
Throttle valve disassembled components orderly.
Use the SST.
SST 09860-76001-71
(09860-11011)
Do not disassemble the following parts:
Choke valve set screws
Throttle valve set screws
Throttle arm
Automatic choke mechanism
Small venturi tube
Power valve

Automatic choke mechanism

Air t Air Horn Disassembly

Caution:
Do not separate the wax body from the air horn.
Air horn ASSY removal
(1) Set screw
(2) Air horn
(3) Gasket

Choke breaker disassembly

(1) Set screw
(2) Cover
(3) Spring
(4) Diaphragm with lever
(5) Gasket

1 I--, ,Float
Float removal
Remove the float lever pin, and remove the float.

Section 1.1.4
 4Y-E Repair

Needle valve removal

(1) Needle valve push pin
(2) Spring
(3) Needle valve

Power piston Power piston removal

(1) Power piston stopper screw
(2) Power piston stopper
(3) Power piston
(4) Spring

Needle valve seat removal

(1) Needle valve seat
(2) O-ring

Carburetor Body Disassembly

1. Carburetor body removal
(1) Remove two screws, and disconnect the carburetor body
and the flange.
(2) Remove the gasket and insulator.

I Hot idle 2. Hot idle compensator removal

(1) Hot idle compensator
(2) O-ring

Section 1.1.4
 4Y-E Repair

Accelerator Accelerator pump nozzle and outlet check valve removal

pump nozzle
(1) Accelerator pump nozzle
(2) O-ring
(3) Spring
(4) Steel ball

Slow jet removal

Idle-up actuator removal

(1) Remove set screws and the idle-up actuator.

Main passage plug 1 Main jet removal

(1) Remove the main passage plug and gasket.
(2) Remove the main jet and gasket from the main passage
plug hole.

Accelerator pump diaphragm removal

(1) Remove set screws, and remove the accelerator pump
cover.
(2) Remove the diaphragm and spring.
Throttle adjusting screw removal
(1) Throttle adjusting screw
(2) Spring

Section 1.1.4
 4Y-E Repair

9. Solenoid valve removal

solenoid valve

Flange Disassembly
1. Remove the lever and arm.
Remove the throttle lever set nut, and then remove the throttle
lever ASSY, throttle arm ASSY, bushing and spring.

Wrench Caution:
When removing the throttle lever set nut, put the rotation
stopper at the accelerator pump cam side in order not to add
force on the throttle valve.

2. Remove the idle adjusting screw.

(1) Idle adjusting screw
(2) Spring

Idle adjusting screw

Section 1.1.4
 4Y-E Repair

INSPECTION
Clean disassembled components before inspection.
(1) Use a soft brush to wash and clean casted components.
(2) Clean the carbon around the throttle valve.
(3) Wash other components.
(4) Blow off all dirt and foreign matters from the jets, fuel
passage and body sliding contact surface.
Caution:
Do not clean the jets with a wire since the holes may be
deformed.
1. Choke valve and choke shaft inspection
Push the choke valve with a finger and check that it is fully
opened smoothly.

2. Needle valve inspection

(1) Check the sliding motion of the needle valve.
(2) Install the float, reverse the air horn, and check if air is
leaking when sucked from the fuel inlet pipe side.

3. Power piston sliding status inspection

(1) Install the spring and power piston to the carburetor body.
Check that the piston slides smoothly without looseness
when pushed with a finger.

Section 1.1.4
 4Y-E Repair

Hot idle compensator inspection

Use fingers to move the valve of the hot idle compensator, and
check that it moves lightly.

Solenoid valve function inspection

(1) Connect the solenoid valve to the battery and set it to ON
and OFF. Check that a clicking sound is heard.
(2) Replace the valve if it does not function correctly.

Accelerator pump diaphragm inspection

(1) Check the diaphragm for any damage.
(2) Push the plunger rod with a finger. Check that it moves
smoothly.

Power valve sliding inspection

Push the power valve rod lightly with a finger, and check that it
slides smoothly.

ower valve rod

Idle adjusting screw inspection

Check that the tapered portion of the idle adjusting screw is not
Good stepped and that the threaded portion is not damaged.
Throttle valve and shaft inspection
Operate the throttle lever, and check that the throttle shaft
slides smoothly.

No good

Section 1.1.4
 4Y-E Repair

10. Idle-up actuator inspection

(1) Check that the rod moves when negative pressure is
applied to the diaphragm chamber.
(2) Check that the rod quickly returns to the original position
when the negative pressure is set from the state in (1) to
zero.

REASSEMBLY
The reassembly procedure is the reverse of the disassembly procedure.
Caution:
Use new ones for all the gaskets and O-rings.
Adjust the float with the following procedure before reassembling it.
1. Install to the valve seat in the following order of the needle
valve, spring and needle valve bushing pin.
2, Install the float and float lever pin.

pin
3. Turn the air horn upside down, and measure the gap between
the tip of the float and the air horn using SST when the float
goes down by its own weight.
SST 09240-76002-7 1
(09240-00014)
Standard: 5.5 mm (0.217 in.)

Clearance between
the float and the air horn

4. Lift the float, and measure the gap between the float lip section
and the needle valve bushing pin using SST.
SST 09240-76003-71
(09240-00020)
Standard: I. I to 1.3 mm (0.043 to 0.051 in.)

I I( I clearance

Section 1.1.4
 4Y-E Repair

If the value is outside the standard in procedure 3, adjust by

bending the float lever section A.
If the value is outside the standard in procedure 4, adjust by
bending the float lever section B.

Section 1.1.4
 4Y-E Repair

CARBURETOR ADJUSTMENT
1. ldle adjusting screw adjustment
Fully tighten the idle adjusting screw, and then loosen it by
about three turns.
Caution:
Do not tighten the screw too tightly.
ldle adjusting

dle-up actuator rod 2. Throttle valve adjustment

a/ Forcibly turn the fast idle cam clockwise to bring the cam
into released state.
Retract the idle-up actuator rod.

Fast idle cam

Measure throttle valve idle opening angle.

SST 09240-76002-71
(09240-00014)
Standard (from horizontal level): 13.5"

For adjustment, turn the throttle adjusting screw "A"

Inspection and adjustment of fast idle

With the condition of an ambient temperature 25 & 2°C (77 +
35.6"F), adjust the fast idle cam (See P4-19), then align the I
mark on the fast idle cam to the center of the roller, and
measure the opening angle of the throttle valve.
SST 09240-76002-71
(09240-00014)
Standard (from horizontal level): 23 to 25"

Section 1.1.4
 4Y-E Repair

For adjustment, turn the fast idle adjusting screw "A"

Caution:
Inspection and adjustment must be carried out by the
carburetor as a unit, and with an ambient temperature of
25 f 2°C (77 f 356°F).
Do not adjust unless it is necessary.

Choke breaker inspection and adjustment

Apply a pressure of 400 mmHg or more to the choke
breaker diaphragm chamber, and measure the choke
valve opening angle.
SST 09240-76002-71
(09240-000 14)
Standard (from horizontal level): 39 to 41"

For adjustment, bend the choke breaker rod end.

Check if the choke valve opens and the reading does not
drop when a negative pressure is applied.

3'9 to 41 " Choke breaker rod

38 to 42"

Supporting
Kick
point
3 \[
i$.g.gun'Oader
/ I
.'
U nt l o a d e r link
I
lever
Unloader inspection and adjustment
Measure the choke valve angle when the throttle valve is fully
open.
Standard (from horizontal level): 38 to 42"
For adjustment, bend the kick lever.

lever

I ,. I

Section 1.1.4
 4Y-E Repair

6. Idle-up actuator inspection and adjustment

Adjusting
screw (1) Forcibly turn the fast idle cam clockwise to release the
cam.
17.5"
(2) Measure the throttle valve angle (touch angle) when the
idle-up actuator rod is in contact with the adjusting rod.
Standard (from horizontal level): 17.5"
For adjustment, turn the adjusting screw.

FAST IDLE CAM ADJUSTMENT

Caution:
Adjustment must be carried out with an ambient
temperature of 25 t 2°C (77 f 35.6"F).
Do not adjust unless it is necessary.
Adjust with the adjust screw so I mark of the fast idle cam will
come to the center of the roller pin of the fast adjust lever, and
fix with the lock nut.
After completing the above I mark adjustment, adjust the fast
idle opening angle. (See P4-18)

~ a sadjust
t
lever

CHOKE VALVE ADIJUSTME

Spring hook section
Caution:
/ Pinion Do not adjust unless it is necessary.
1. After completing the adjustment of the I mark of the fast idle
cam, adjust the positions of the rack and pinion at an ambient
+ +
temperature of 25 2°C (77 356°F).
2. For the position adjustment, turn the pinion so that the left end
bump of the rack fits to the cog directly opposite the match
mark of the pinion.
3. Turn the pinion lever clockwise, tighten the set screw "A" and
"B" when the choke valve opens 16 to 21" from the horizontal
position.

/
Set sdrew B
Fast idle cam

Section 1.1.4
 4Y-E Repair

AIR GOVERNOR
COMPONENTS

Section 1.1.4
 4Y-E Repair

REMOVAL-INSTALLATION
Refer to P2-4

DISASSEMBLY
1. Governor cover removal
(1) Untie the lock wire.
(2) Remove three set screws. Remove the governor cover.

2. Bush w l adjusting screw removal

(1) Remove the lock bolt.
(2) Turn the adjusting screw counterclockwise. Remove the
bush w l adjusting screw.
Note:
Note the screwed in depths of the screw and bush.

Adjusting screw W

3. Spring SUB-ASSY removal

Remove the snap ring. Remove the spring SUB-ASSY.

Snap rin

4. Throttle valve and valve shaft removal

Throttle valve
\ (1) Remove valve set screws. Remove the throttle valve.

(2) Remove the throttle valve shaft.

I ~ h r o t t l evalve shaft

Section 1.1.4
 4Y-E Repair

INSPECTION
1. Governor body inspection
(1) lnspect the governor body for any corrosion. If corroded,
remove rust with fine grained sandpaper.
(2) Manually move the stabilizer piston. Check smooth
sliding without sticking.
(3) Inspect the body for distortion. Replace the body if
distorted.

2. Governor spring and ribbon inspection

(1) Replace the governor spring if any fatigue, deformation or
other abnormality is found.
(2) Replace the governor ribbon if any bending, deformation,
crack, or other abnormality is found.

3. Throttle valve and the valve shaft inspection

(1) Check for damage and deformation of the throttle valve.
(2) Assemble the throttle valve shaft to the governor body.
Turn the cam manually and check for any sticking or
looseness caused by wear.
(3) Check for wear (looseness when the shaft is inserted) or
rusting of the governor body needle bearing.

4. Adjusting screw and bush inspection

(1) Check for bending of the adjusting screw and damage of
the thread.
(2) Check for damage of the bush thread.

Section 1.1.4
 4Y-E Repair

REASSEMBLY
The reassembly procedure is the reverse of the disassembly procedure
Caution:
Clean the governor body with compressed air prior to reassembling.
When reassembling the throttle valve shaft, apply MP grease thinly to the governor body needle bearing.
After completing the throttle valve shaft and valve reassembly, check for smooth operation.
Temporarily install the air governor spring to the following dimension.
1 ton vehicle 2 to 3 ton vehicle
Adjusting screw protrusion A 16.8 mm (0.661 in.) 21.9 mm (0.862 in.)
I Effective spring turns B I 11 turns 1 13 turns I

Section 1.1.4
 4Y-E Repair

ADJUSTMENT

Lock bolt

Tips for Adjusting Each Part

About the lock bolt
Counterclockwise turn ...........unlocks the bushing.
Clockwise turn .......................locks the bushing.
About bushing
Counterclockwise turn ...........decreases no-load maximum speed.
Clockwise turn .......................increases no-load maximum speed.
Caution:
When turning the bushing, make sure to fix the adjusting screw with a flat-blade screwdriver.
About adjusting screw
Counterclockwise turn ...........reduces the relief down when the tilt lever of the oil control valve is operated. From
the condition where the relief down is within the specified value, 1/10 clockwise
turn will correct kinks in the spring.
Clockwise turn ....................... reduces hunting during no-load or load maximum speed. Turning the adjusting
screw clockwise, 114 counterclockwise turn from the position where there is no
hunting, and then 1/10 clockwise turn will correct kinks in the spring.

Air governor adjustment standard

Standard:
Refer to repair manual for each vehicle model.

Section 1.1.4
 4Y-E Repair

Air Governor Adjustment Procedures

Caution:
Be sure to complete the carburetor adjustment before
adjusting the air governor.
1. Engine warming up
Standard
Coolant temperature: 75°C (167°F) or more
Hydraulic oil temperature: 50°C (122°F) or more
Engine oil temperature: 60°C (140°F) or more
2. Tachometer installation
3. No-load maximum speed
(1) Remove the sealing.
(2) Loosen the bushing lock bolt.
(3) Fully depress the accelerator pedal to open the throttle
valve fully. Measure the engine speed.
If the engine speed is more than the standard, turn the
bushing counterclockwise. (A)
If the engine speed is less than the standard, turn the
bushing clockwise. (B)
Note:
Refer to adjustment procedures of each section.
4. Loaded maximum speed adjustment
(1) Fully depress the accelerator pedal and maintain the
speed at the no-load maximum speed.
(2) Operate the tilt lever backward and measure the relief
down.
- less
Relief down: 300 rpm or
(3) If the relief down exceeds 250 rpm, turn the adjusting
screw counterclockwise for adjustment.
Note:
Refer to adjustment procedures of each section.
5. Hunting adjustment
(1) If hunting occurs at either the no-load or loaded maximum
speed after completing the adjustments in steps 3 and 4,
adjust hunting by the bushing and adjusting screw.
Adjusting screw ......... Hunting adjustment

b
smaller

Note:
Bushing .....................Maximum speed adjustment

If hunting disappears after several times, it should be

judged no hunting.
Repeat above steps 3 to 5 for setting to the standard
values.

Section 1.1.4
 4Y-E Repair

FUEL SYSTEM (4Y-E)

Page

SST TO BE USED .............................................. 5-2

THROTTLE BODY ............................................. 5-3
COMPONENTS ........................................................... 5-3
REMOVAL.INSPECTION~INSTALLATlON................ 5-4
INJECTOR .......................................................... 5-6
COMPONENTS ...........................................................
REMOVAL-INSPECTION-INSTALLATION................ '5-7
FUEL PRESSURE REGULATOR............................. 5-10
FUEL PUMP ..................................................... 5-11
COMPONENTS......................................................... 5-11
REMOVAL.INSPECTION.INSTALLATlON.............. 5-12
INTAKE TEMPERATURE SENSOR ................ 5-15
REMOVAL................................................................. 5-15
INSPECTION............................................................. 5-15
INSTALLATION ........................................................ 5-15

Section 1.1.5
 4Y-E Repair

SST TO BE USED
Illustration Part No. Part name
- - -- -

Injection measuring tool set

EFI inspection wire

Section 1.1.5
 4Y-E Repair

THROTTLE BODY
COMPONENTS

Section 1.1.5
 4Y-E Repair

Removal~lnstallationProcedure
The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Battery negative terminal
2 Air cleaner hose
3 Intake pipe
4 Air intake connector
5 Throttle body [Point I]
6 I Vacuum sensor
Point Operations
*I
[Point I]
Inspection:
lnspection of the throttle body
1. Make sure that the throttle shaft is not loose
2. Firmly press the throttle valve with your finger to open and
close.
Air horn 6" 3. When the throttle valve is in a free condition, there must be an
appropriate angle and clearance between the air horn and the
throttle valve.
[Reference] Throttle angle is approx. 6".
Section 1.1.5
 4Y-E Repair

Inspection:
Inspection of the throttle motor
Measure the resistance value between the terminals.
Standard
Between M(+) and M(-): 0.3 to 100 R

Section 1.1.5
 4Y-E Repair

INJECTOR
COMPONENTS

Section 1.1.5
 4Y-E Repair

REMOVAL-INSPECTION-INSTALLATION

Rem~val.lnstallationProcedure
The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Battery negative terminal
2 Throttle body See P3-4 t t
3 Elimination of fuel pressure in fuel system See P3-5 t t
4 Pressure regulator [Point I] [Point 51
5 Delivery pipe, spacer, and injector See P3-5 [Point 21 [Point 41
6 Injector spacer [Point 31

Note:
During the reassembly, use new gaskets and O-rings.
Point Operations
[Point I]
Removal:
Place a fuel tray under the pressure regulator.
Wrap a small piece of waste cloth around the union section,
and eliminate the fuel pressure by slowly loosening the union
bolt.
Caution:
Put waste cloth in order to prevent the fuel from
splashing.
DO not allow any fire to come close during the operation.

Section 1.1.5
 4Y-E Repair

O-ring 1 [Point 21
Inspection:
lnspection of the injector injection amount and leakage
1. Install SST as shown in the left illustration to the injector with
the O-ring and grommet installed, and install the injector with
the fuel filter on the vehicle side and the single item of the
pressure regulator.
SST 09268-76007-71
(09268-41047)
Caution:
Put waste cloth in order to prevent the fuel from
splashing.
Do not allow any fire to come close during the operation.
2. Disconnect the connector of the fuel pump relay inside the
f Terminal 2 I 3.
relay box.
Short circuit the terminal 1 and terminal 2 in the disconnected
relay block.

4. Connect SST to the injector.

SST 09842-76001-71
(09842-30070)
5. Turn the ignition key switch on to activate the fuel pump.
6. Connect SST to the battery, and measure the injection amount
of the injector.
Standard: 41 to 42 cc115 seconds
\ Caution:
Battery
Fuel will be splashed when injecting, so put a vinyl hose with
the inside diameter of 9 to 10+ to the tip of the injector nozzle
and receive fuel in the measuring cylinder.
7. Maintain the condition in which the fuel pressure is applied,
and inspect the leakage from the nozzle section.
Standard: 1 drop or less13 minutes
Inspection:
lnspection of the injector resistance
Standard: 13.8 + 0.4 SZ (20°C) [68OF]

Section 1.1.5
 4Y-E Repair

[Point 31
Installation:
Firmly install the O-ring and the insulator to the injector spacer,
and then install the spacer to the intake manifold.

O-ring

s
-\/ Intake manifold
Spacer Note:
Apply EIG oil or grease to the O-ring portion of the spacer
when inserting it.
Insert the spacer straight and check that the spacer is
firmly attached.

[Point 41
Installation:
Apply gasoline to the O-ring, and firmly insert the injector to the
delivery pipe as far as it will go.
Note:
While turning the injector to left and right, firmly insert the
injector to the delivery pipe.
Align all the four connector sections of the injector to face
upward.
After the reassembly, check that the injector rotates
smoothly.
[Point 51
O-ring
Installation:
Install the pressure regulator to the delivery pipe.
Note:
Apply gasoline to the O-ring before insertion.

Section 1.1.5
 4Y-E Repair

FUEL PRESSURE REGULATOR

Inspection
Caution:
Put waste cloth in order' to prevent the fuel from
splashing.
Do not allow any fire to come close during the operation.
1. Remove the negative terminal of the battery.
I
Delivery pipe 2. Eliminate the fuel pressure. (See P5-7)
3. Install the fuel pressure indicator between the fuel filter and the
delivery pipe via SST.
SST 09268-76007-71
(09268-41047)
4. Turn the ignition key switch on to activate the fuel pump, and
measure the fuel pressure at that moment.
Standard: 284 5 kPa (2.9 f 0.1 kgflcm2) [41.2 & 1.4 psi]
Note:
The above standard is applied when the vacuum port of the
pressure regulator is an atmospheric discharge.

Section 1.1.5
 4Y-E Repair

FUEL PUMP
COMPONENTS

(COOLER) (FUEL CAP WIKEY)

I I I

Section 1.1.5
 4Y-E Repair

Removal.lnstallation Procedure
The installation procedure is the reverse of the removal procedure.
I No. I Item Removal Inspection Installation
( 1 I Relay box I I 1 I
1 2 1 Battery I I I I
3 Battery set plate
4 Fuel hose [Point I ]
1 5 1 Fuel tank cover I [Point 21 1 I [Point 61 1
1 6 1 Fuel pump I [Point31 ( [Point41 1 [Point51 1
Point Operations
[Point I]
Removal:
Place waste cloth and a fuel tray under the fuel filter, and then
disconnect the fuel hose.
Caution:
Take measures to prevent the fuel from splashing.
Do not allow any fire to come close during the operation.
Drain the fuel from the filter and the hose side thoroughly.

Section 1.1.5
 4Y-E Repair

[Point 21
Removal:
Disconnect the fuel tank cover pipe and the fuel hose.
Note:
Make sure to use two wrenches when loosening.

[Point 31
Removal:
Loosen the hose clamps, and remove the fuel pump ASSY.
Hose
clamps

Fuel pump

[Point 41
Inspection:
Apply the battery voltage between the terminals, and check
that the motor runs.
Caution:
Inspection should be performed in a short period of time
(within 5 seconds).
Bring the pump away from the battery as far as possible.
Carry out the switching operation at the negative side of
the battery.
Inspection:
Using the tester, measure the resistance between the
terminals.
Standard: 0.2 to 3.0 R

[Point 51
Pipe
Installation:
Install the fuel pump to the tank cover.
Caution:
Hose The hose connecting the main unit of the pump and the pipe
should be inserted thoroughly so that it will not lean to the one
side.

Section 1.1.5
 4Y-E Repair

Caution:
In order to prevent a gap at the bottom of the tank cover when
There should fixing the pump, adjust with the dimensions of the inserted
pipe and the hose at the top of the pump.

[Point 61
Installation:
Install the fuel hose to the fuel pipe of the tank cover.
Caution:
Make sure to tighten using two wrenches.
There should be no interference with other parts by a
kinked hose.

/ Tank =over

Section 1.1.5
 4Y-E Repair

Intake temperature INTAKE TEMPERATURE SENSOR

% < REMOVAL
, Grommet
1. Hold the connector lock, and disconnect the connector.
2. Remove the intake temperature sensor.

// Air cleaner
inlet hose

INSPECTION
Measure the resistance value between the terminals.
Temperature (OC) [OF] -20 [-41 20 [68] 80 [ I 761
Resistance (kQ) 16.2 2.45 0.32

INSTALLATION
Firmly press the intake temperature sensor into the grommet
section of the air cleaner inlet hose.
Note:
After the installation, check its condition.
Make sure that it is firmly inserted and not installed at an
angle.

Section 1.1.5
 4Y-E Repair

PCV DEVICE
Page

VENTILATION VALVE ....................................... 6-2

COMPONENTS ........................................................... 6-2
REMOVAL................................................................... 6-3
INSPECTION............................................................... 6-3
INSTALLATION .......................................................... 6 -3

Section 1.1.6
 4Y-E Repair

VENTILATION VALVE
COMPONENTS

Section 1.1.6
 4Y-E Repair

REMOVAL
I Hose
\ Ventilation
1. Remove the hose between the ventilation valve and the
throttle body.
2. Remove the ventilation valve from the cylinder head cover.

I Ventilation valve INSPECTION

1. lnspection of the ventilation valve
Shake the ventilation valve with your hand, and inspect
whether the rattling sound can be heard.
If you can hear the rattling sound, then it is normal.
2. lnspection of the PCV device rubber hose
Inspect for any damages, cracks or deterioration on the PCV
device rubber hose. lf there are any abnormalities, replace
with a new one.

INSTALLATION
The installation procedure is the reverse of the removal procedure.

Section 1.1.6
 4Y-E Repair

COOLING SYSTEM
Page

WATER PUMP .................................................. 7-2

COMPONENTS .................................................... 7-2
REMOVAL~INSPECTION~INSTALLATION ............... 7-3
DISASSEMBLY4NSPECTION-REASSEMBLY......... 7-4
WATER TEMPERATURE SENSOR .................. 7-6
REMOVAL........................................................... 7-6
INSTALLATION ................................................... 7-6
INSPECTION ...................................................... 7-6

Section 1.1.7
 4Y-E Repair

WATER PUMP
COMPONENTS

Section 1.1.7
 4Y-E Repair

T = N.m (kgf cm) [fklbfl

Removal.lnstallation Procedure
The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Drain coolant.
2 V-belt See P3-4 t t
3 Fan
4 Fan pulley
1 5 / Radiator outlet hose I 1 I I
6 1 Water pump

Section 1.1.7
 4Y-E Repair

Disassembly.Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
I No. I Item I Disassembly I Inspection I Reassembly I
1 Water inlet
2 Thermostat [Point I] [Point 31
3 Water pump cover [Point 21

Point Operations
[Point I]
Inspection:
Inspect the temperature when the valve starts to open, and the
temperature when it is fully open.
1. Insert the thermostat into water and raise the temperature of
water while stirring.

Section 1.1.7
 4Y-E Repair

2. Measure the temperature at which the valve starts to open,

8 mm
and the temperature at which it is fully open.
(0.31 in.)
or more Standard
Starts to open: 74.5 to 78.5"C (116 to 173°F)
Fully open: 95°C (203°F)
Lift amount when fully open: 8 mm (0.31 in.) or more
Note:
Replace the valve if it is open at room temperature, or if it does
not seal well.

[Point 21
Inspection:
lnspect the water pump.
Inspect the water pump rotor section for cracks, damage, and
obvious rust.

Manually rotate the water pump rotor to inspect for abnormal

bearing noise, and to see that it turns smoothly.
0

[Point 31
Reassembly:
Install the gasket to the thermostat, and then install it to the
water inlet.
Caution:
Make sure that the jiggle valve faces upward when installing
the thermostat.

Section 1.1.7
 4Y-E Repair

WATER TEMPERATURE ENSOR

REMOVAL
1. Disconnect the connector.
2. Remove the water temperature sensor.
Note:
Set the offset wrenches on both the extension and the
water temperature sensor, and remove the water
temperature sensor without turning the extension.
If the extension is loose, wrap the seal tape and install it
tape
to the cylinder head.
T = 29.10 f 5.0 N-m (296 f 50 kgfmcm) [21.4 + 3.6 ft-lbfj
INSTALLATION
~asket \ The installation procedure is the reverse of the removal procedure.

Water temperature sensor

INSPECTION
Using the circuit tester, measure the resistance value between the
terminals according to temperature changes.
Note:
By disconnecting the harness connector from the water
temperature sensor, you can also measure the resistance
while the engine is mounted.

( ) reference value
( Temperature ("C) ["F] I -20 [-41 0 [321 20 [68] 80 [ I 761 110 [230] 1
Resistance (kn) I 16.2 * 1.6 (5.88) 2.45 * 0.24
I

0.32 * 0.03 (0.14) I

Section 1.1.7
 4Y-E Repair

LUBRICATION SYSTEM
Page

SST TO BE USED .............................................. 8-2

OIL PRESSURE INSPECTION .......................... 8-3
ENGINE OILmOILFILTER REPLACEMENT ...... 8-4
....................................... 8-5
OIL PUMPmSTRAINER
COMPONENTS ........................................................... 8-5
REMOVAL.INSPECTION.INSTALLATlON................ 8-6
DISASSEMBLYmINSPECTION.REASSEMBLY.......... 8-8

Section 1.1.8
 4Y-E Repair

SST TO BE USED
Illustration Part No. Part name
I I

Section 1.1.8
 4Y-E Repair

OIL PRESSURE INSPECTION

1. Inspect the oil.
Standard:
The level should read between F and L on the level gauge.
The oil should not be markedly dirty and be of appropriate
viscosity.
There should be no contamination of coolant or gasoline.

2. Measure the oil pressure.

(1) Remove the pressure switch, and install the oil pressure
gauge.

(2) Warm up the engine and measure the oil pressure.

Standard
Coolant temperature: 75 to 85°C (167 to 185°F)
Operating oil temperature: 50°C or more (122°F)
Standard
Idle speed: 29.42 kPa (0.3 kgflcm2) [4.3 psi] or more
2000 rpm: 196 to 441 kPa (2.0 to 4.5 kgflcmz)
[28.4 to 64.0 psi] or more
3. Install the pressure switch.

Section 1.1.8
 4Y-E Repair

ENGINE OILmOILFILTER
REPLACEMENT
1. Drain the engine oil.
(1) Remove the oil filler cap.
(2) Remove the oil drain plug and drain the oil.

2. Use the SST and remove the oil filter.

SST 09228-76001-71
(09228-06501)
3. Install the oil filter.
Hand tighten the oil filter with an O-ring fitted. Use the SST to
tighten an additional 314 turn from the hand-tight position.
SST 09228-76001-71
(09228-06501)
Caution:
Apply a small amount of engine oil to the O-ring.
Clean the surface to which the O-ring will be attached.
4. Pour in engine oil.
(1) Install the oil drain plug with a new gasket.
Caution:
Befolre attaching the plug, remove the old gasket stuck on the
oil pan and clean the surface to which the new gasket will be
attached.
(2) Pour in engine oil.
Oil pan capacity: 4.0 1 (1.1 US gal)
(3) Attach the oil filler cap.
5. lnspect the oil level.
Check using the oil level gauge.
6. lnspect for oil leaks.
Start the engine, and check that no oil is leaking.
7. Check the oil level.
After inspecting for oil leaks, check the oil level again.
Note:
Wait 3 minutes after stopping the engine before checking the
oil level.

Section 1.1.8
 4Y-E Repair

OIL PUMPmSTRAINER
COMPONENTS

Section 1.1.8
 4Y-E Repair

Removal.lnstallation Procedure
The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Engine oil See P8-4 t t
2 Oil pan See P2-22 t t
3 Oil pump w/ strainer [Point I] [Point 21

Point Operations
[Point I]
Inspection:
Oil pump function inspection
1. As shown in the left illustration, soak the intake side (strainer
side) of the oil pump in oil, and turn the pump shaft clockwise
with a flat-blade screwdriver. Check that oil is discharged from
the oil discharge hole.

Section 1.1.8
 4Y-E Repair

2. Block the discharge hole with your finger, and turn the oil pump
shaft clockwise. Check that the shaft does not rotate.

I Distributor shaft [Point 21

Installation:
Install the oil pump w/ strainer to the cylinder block.
Align
the pa Caution:
Turn the pump shaft to align the position of the protruding
portion at the tip of the distributor shaft and the slit at the tip
of the oil pump shaft.
Oil pump 5 \
shaft
\

Section 1.1.8
 4Y-E Repair

DISASSEMBLY-INSPECTION-REASSEMBLY

Disassembly.Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
I No. I Item ( Disassembly I Inspection I Reassembly 1
1 Oil strainer
2 Drive and driven rotors [Point I] [Point 21
3 Relief valve

Point Operations
[Point I]
Inspection:
lnspection of drive and driven rotors
1. Using the thickness gauge, measure the clearance (body
clearance) between the driven rotor and the pump body.
Standard: 0.10 to 0.16 mm (0.0039 to 0.0063 in.)
Limit: 0.20 mm (0.008 in.)

Section 1.1.8
 4Y-E Repair

2. Measure the side clearance of the rotor using a straight edge

ruler and the thickness gauge.
Standard: 0.03 to 0.09 mm (0.0012 to 0.0035 in.)
Limit: 0.15 mm (0.0059 in.)

3. Using a thickness gauge, measure the tip clearance of the

drive rotor and the driven rotor.
Standard: 0.06 to 0.15 mm (0.0024 to 0.0059 in.)
Limit: 0.2 mm (0.008 in.)

[Point 21
Reassembly:
Install the drive and driven rotors with the punch marks on the
drive rotor and the driven rotor facing the pump body.

Section 1.1.8
 4Y-E Repair

IGNITION SYSTEM (4Y-M)

Page

CIRCUIT DIAGRAM ........................................... 9-2

SPARK PLUGS .................................................. 9-3
INSPECTION............................................................... 9-3
DISTRIBUTOR ................................................... 9-4
COMPONENTS ........................................................... 9-4
ON-VEHICLE INSPECTION ....................................... 9-5
REMOVAL~INSPECTION~INSTALLATION ................ 9-7
DISASSEMBLYllNSPECTlON-REASSEMBLY.......... 9 -8

Section 1.1.9
 4Y-E Repair

CIRCUIT DIAGRAM

Black with two orange stripes

Ignition key
Switch

Section 1.1.9
 4Y-E Repair

SPARK PLUGS
INSPECTION
1. Clean the spark plugs using the spark plug cleaner.
2. Inspect the spark plugs, and replace any that are abnormal.

3. Inspection of the plug gap

Standard: 0.7 to 0.8 mm (0.028 to 0.031 in.)

Section 1.1.9
 4Y-E Repair

DISTRIBUTOR
COMPONENTS

I I
Refer to Refer to
FIG. 1901 FIG.,1901

Section 1.1.9
 4Y-E Repair

ON-VEHICLE INSPECTION
Caution:
Do not confuse the positive and negative terminals of the battery.
Do not remove the battery cable while the engine is running.
Do not perform any operations that generate destructive pulse.
Make sure the firm connection without any wrong wiring.
When pulling out the resistive cord, do not pull the cord section.
1. lnspection of the resistive cord
(1) Remove the distributor cap.
(2) Using the circuit tester, measure the resistance of the
resistive cord.
Limit: less than 25 kwone cord

2. lnspection of the ignition coil

Secondary (1) Measurement of the primary coil resistance
resistance
Standard: 1.2 to 1.5 R
(2) Measurement of the secondary coil resistance
Standard: 7.7 to 10.4 kR

Primary coil resistance

3. lnspection of the igniter

Remove the distributor cap, the rotor, and the dust cover.
(1) lnspection of the input voltage
(a) Turn the ignition key switch on.
(b) Measure the voltage between the positive terminal of
the ignition coil and the earth.
Standard: approx. 12 V

(2) lnspection of the transistor OFF

(a) Turn the ignition key switch on.
(b) Disconnect the inspection connector.
(c) Measure the voltage between the black wire side of
the inspection connector and the earth.
Standard: approx. 12 V

Section 1.1.9
 4Y-E Repair

I Neaative side I (3) lnspection of the transistor ON

(a) Turn the ignition key switch on.
(b) Measure the voltage between the inspection
connector and the earth.
Standard: approx. 0 to 3 V
Caution:
Make sure that the polarity is correct.
Perform the inspection within 10 seconds.

4. lnspection of the distributor

Signal rotor
) lnspection of the air gap
Using the thickness gauge, measure the gap between the
signal rotor and the pickup coil.
Standard: 0.2 to 0.4 mm (0.008 to 0.016 in.)
If it is outside the standard, replace the signal generator.

pickup coil

(2) lnspection of the governor process

Turn the rotor to the right, and inspect whether the rotor
returns smoothly.

(3) lnspection of the vacuum advancer

Disconnect the vacuum hose, and apply approx. 400
mmHg negative pressure to the diaphragm, and check
that the vacuum advancer moves. If the vacuum
advancer does not move, replace the vacuum advancer.

(4) lnspection of the pickup coil

(a) Turn the ignition key switch off.
(b) Using the circuit tester, measure the resistance of
the pickup coil.
Standard: 140 to 180 R
If it is outside the standard, replace the signal
generator.

Section 1.1.9
 4Y-E Repair

T = N.m (kgf cm) [ft.lbfl

Removal.lnstallation Procedure
The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Battery negative terminal
2 Resistive cord
1 3 1 Connector I I I I
4 Vacuum advancer hose
5 Distributor See P2-4

Section 1.1.9
 4Y-E Repair

T = N.m (kgf cm) [ft.lbfl

DisassemblymReassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
I No. I Item I Disassembly I Inspection I Reassembly I
( 1 I Distributor cap I I I I
1 2 1 Distributor rotor 1
3 Dust cover
4 Ignition coil [Point 151
5 Igniter [Point 141
6 Vacuum advancer [Point I ] [Point 131
7 Distributor wire
8 Signal rotor [Point 21 [Point I21
9 Signal generator ASSY [Point 31
10 Governor spring
11 Signal rotor shaft [Point 41 [Point 51 [Point 111
12 Governor weight [Point 61 [Point 101
13 Governor shaft [Point 71 [Point 81 [Point 91

Section 1.1.9
 4Y-E Repair

Point Operations
[Point I]
Disassembly:
Disconnect the advancer link from the plate pin of the signal
generator ASSY, and remove the advancer.

[Point 21
Disassembly:
Remove the signal rotor.
1. Using the screwdriver, pull out the rotor set spring.
2. Remove the signal rotor.

[Point 31
Inspection:
lnspection of the breaker plate
Rotate the breaker plate, and check that there are no drags or
jamming.
If there are any drags or jamming, replace the signal generator
ASSY.

[Point 41
Disassembly:
Remove the signal rotor shaft.
1. Remove the cam cap.
2. Remove the screw, and remove the signal rotor shaft.

[Point 51
Inspection:
lnspection of the signal rotor shaft
Install the signal rotor shaft to the governor shaft, and check for
looseness.
If it is loose, replace the signal rotor or the governor shaft.

Section 1.1.9
 4Y-E Repair

[Point 61
Disassembly:
Remove the governor weight.
Using the screwdriver, remove the snap ring and two governor
weights.

[Point 71
Disassembly:
Remove the governor shaft.
1. Remove the spiral gear.
(1) Using the grinder, shave off the caulking portion of the pin.

(2) Using the pin punch, knock out the straight pin.
(3) Remove the spiral gear and the thrust washer.
2. Remove the governor shaft and the thrust washer.

[Point 81
Inspection:
Inspection of the governor shaft
1. Rotate the governor shaft, and check the condition of the
governor shaft rotation.

2. Using the thickness gauge, measure the governor shaft thrust

clearance.
Standard: 0.15 to 0.50 mm (0.0059 to 0.0197 in.)
If it is outside the standard, adjust with the thrust washer.

Section 1.1.9
 4Y-E Repair

Plate [Point 91
washer Reassembly:
lnstall the governor shaft.
Thrust
washer 1. Apply grease thinly to the governor shaft.
2. lnstall the thrust washer on the governor shaft.
3. Reassemble the governor shaft to the housing.

4. lnstall the plate washer and the spiral gear on the governor
shaft.
5. Align the drill mark of the spiral gear and the housing groove.
Caution:
Check that the stopper pin is at the position shown in the
illustration.
pin
lnstall the straight pin.

Using the thickness gauge, measure the governor shaft thrust

clearance.
Standard: 0.15 to 0.50 mm (0.0059 to 0.0197 in.)
If it is outside the standard, adjust with the thrust washer.
Thrust washer thickness: 0.3 mm (0.012 in.)
0.4 mm (0.016 in.)
0.5 mm (0.020 in.)
0.6 mm (0.024 in.)

Pinch the both ends of the straight pin with the vise and caulk
the pin.

[Point 101
Reassembly:
lnstall the governor weight.
1. Apply grease thinly to the governor shaft.
2. lnstall the governor weight.
3. lnstall the snap ring.

Section 1.1.9
 4Y-E Repair

[Point 111
Reassembly:
Install the signal rotor shaft.
/ Adjust the direction of the stopper pin and the notch on the
shaft, and install the signal rotor shaft.

pin

Install the screw.

Fill grease inside the shaft.
Install the cam cap.

[Point 121
Reassembly:
lnstall the signal rotor.
1. Insert the signal rotor into the rotor shaft, and adjust the
notches.

2. Inspection of the air gap

Signal rotor
(1) Measure the air gap.
Standard: 0.2 to 0.4 m m (0.008 to 0.016 in.)
If it is outside the standard as a result of the inspection,
replace the signal generator ASSY.
(2) During the replacement, wash the new magnet holding
screw and the threaded portion of the coil with non-
residue solvent, and then apply ThreeBond 1324
Pickup coil between 3 and 5 mm (0.12 to 0.20 in.) from the tip of the
threaded portion.

Section 1.1.9
 4Y-E Repair

(3) Temporarily fasten to the coil SUB-ASSY threaded hole

through the breaker plate and magnet mounting holes.
(4) Adjust the air gap between 0.2 and 0.4 mm (0.008 to
0.016 in.) with the thickness gauge, and fully tighten the
screw.
Caution:
When replacing the signal generator ASSY, make sure to
replace the rotor set spring with a new one.
Make sure that oil or grease does not attach to the screw
and the threaded portion of the coil.
Make sure to remove any residue of ThreeBond 1324.
Do not start the engine until ThreeBond 1324 is hardened.
[Point 131
Reassembly:
lnstall the vacuum advancer.
1, Insert the breaker plate pin to the advancer link hole.
2. Install the advancer and the wire clamp.

[Point 141
Reassembly:
lnstall the igniter.
1. lnstall the igniter and tighten two screws.
2. lnstall three wires to the terminal of the igniter.

Correct Incorrect 3. As shown in the left illustration, sufficiently slacken the pickup
coil wire, and fix it to the clip.

Section 1.1.9
 4Y-E Repair

[Point 151
Reassembly:
Install the ignition coil.
1. Install the ignition coil and the gasket.
2. Install the wire to the ignition coil terminal.

Section 1.1.9
 4Y-E Repair

IGNITION SYSTEM (4Y-E)

Page

SPARK PLUGS ................................................ 10-2

INSPECTION............................................................. 10-2
DISTRIBUTOR ................................................. 10-3
COMPONENTS ......................................................... 10-3
ON-VEHICLE INSPECTION ..................................... 10-4
REMOVAL................................................................. 10-4
INSTALLATION ........................................................ 10-5
IGNITER ........................................................... 10-6
GENERAL ................................................................. 10-6
REMOVAL.INSPECTION~INSTALLATlON.............. 10-7

Section 1.1.10
 4Y-E Repair

SPARK PLUGS
INSPECTION
1. Clean the spark plugs using the spark plug cleaner.
2. Inspect the spark plugs, and replace any that are abnormal.

3. Inspection of the plug gap

Standard: 0.7 to 0.8 mm (0.028 to 0.031 in.)

Section 1.1.10
 4Y-E Repair

DISTRIBUTOR
COMPONENTS

Refer to Refer to

Section 1.1.10
 4Y-E Repair

' ON-VEHICLE INSPECTION

Caution:
Do not confuse the positive and negative terminals of the battery.
Do not remove the battery cable while the engine is running.
Do not perform any operations that generate destructive pulse.
Make sure the firm connection without any wrong wiring.
When pulling out the resistive cord, do not pull the cord section.
1. lnspection of the resistive cord
(1) Remove the distributor cap.
(2) Using the circuit tester, measure the resistance of the
resistive cord.
Limit: 25 kR or less cord

2. lnspection of the ignition coil

Secondary
(1) Measurement of the primary coil resistance
resistance
Standard: 1.2 to 1.5 R
(2) Measurement of the secondary coil resistance
Standard: 7.7 to 10.4 kR

I Primary coil resistance

'I
3. Measurement of the pickup coil resistance
ligap
r \ Pickup coil I Standard: 460 k 50 fl
Note:
Pickup coil is measured by the total resistance value of the
two serially connected coils, measured at the connector
section.
4. lnspection of the air gap between the signal rotor and the
pickup coil
Standard: 0.2 to 0.4 mm (0.008 to 0.016 in.)

REMOVAL
1. Disconnect the negative terminal of the battery.
2. Disconnect the resistive cords from the spark plugs.
3. Disconnect the two connectors to the distributor.
4. Remove the distributor cap.

connectors

Section 1.1.10
 4Y-E Repair

Mark the target I 5. Check the direction of the distributor rotor.

Note:
When installing the distributor main unit to the engine, prevent
a displacement resulting from a shaft gear fitting defect due to
the direction of this rotor.
6. Remove the set bolt, and then remove the distributor.

INSTALLATION
1. Align the TDC mark of the crank pulley with the notch of the
timing gear cover.

2. Set the position of the groove in the oil pump driveshaft at

about 30" when viewed from the upper side.

3. Align the housing groove with the drill mark of the gear, and
insert the distributor.
m
Note:
Do not confuse the drill mark and the straight pin.
When installing the distributor, align the screw hole for
attaching the block with the center of the flange groove to
install.
When the distributor is completely set, the direction of the
rotor must be correct.
Install the distributor cap.
Connect the two connectors to the distributor.
Connect the resistive cord.
Connect the negative terminal of the battery.
Adjust the ignition timing. (See P3-44)

Section 1.1.10
 4Y-E Repair

IGNITER
GENERAL
Caution:
Since the igniter contains several IC parts, inspection of the power transistor ONlOFF using the single unit
of the ignitor is so difficult. Therefore, judge the quality by the inspection according to the troubleshooting
in the repair manual for each vehicle model.
Note:
For the judgment of the igniter quality, the following items will be the observation points.
The ignition coil is normal, and the wiring to the igniter and the connecter are also normal.
There is a normal output of IGt signal from the ECU to the igniter as well as IGt signal from the igniter to
the ECU, and the wiring and connector are normal.

ECU

-
Igniter

Section 1.1.10
 4Y-E Repair

T = N.m (kgfcm) [ft.lbfl

Removal.lnstallation Procedure
The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Relay box
1 2 1 Battery I I I I
1 3 1 Battery set plate I I I I
4 1 Igniter I

Section 1.1.10
 4Y-E Repair

STARTING SYSTEM
Page

SST TO BE USED ............................................ 11-2

STARTER MOTOR........................................... 11-3
COMPONENTS ......................................................... 11-3
.............. 11-4
REMOVAL~INSPECTION.INSTALLATlON
DISASSEMBLY-INSPECTION-REASSEMBLY........ 11-5
STARTER MOTOR ASSY UNIT INSPECTION ...... 11-10

Section 1.1.11
 4Y-E Repair

SST TO BE USED
I Illustration Part No. Part name

Injection pump spline shaft puller

Section 1.1.11
 4Y-E Repair

STARTER MOTOR
COMPONENTS

Section 1.1.11
 4Y-E Repair

T = N.m (kgf cm) [ftdbfj

Removal.lnstallation Procedure
The installation procedure is the reverse of the removal procedure.
I No ( Item Removal Inspection Installation
1 Battery
2 Battery set plate
3 Disconnect the connectors and the terminals.
4 Starter ASSY

Section 1.1.11
 4Y-E Repair

DISASSEMBLY-INSPECTION-REASSEMBLY
T = N.m (kgf cm) [ft.lbfl

Disassembly-Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Lead wire
1 2 /Yoke ASSY I I [Point I ] I [Point 111
3 End frame [Point 101
4 Brush [Point 21 [Point 31 [Point 91
5 Armature ASSY [Point 41
6 Bearing [Point 51 [Point 81
7 Housing ASSY [Point 61
8 Clutch ASSY [Point 71
9 Steel ball
10 Idler gear
I 11 I Retainer, roller I I I
1 12 1 Return spring I I I
Caution:
Apply grease to the steel ball, idler, gear starter clutch and return spring on reassembly.
Section 1.1.11
 4Y-E Repair

Point Operations
[Point I ]
Inspection:
lnspect for continuity between the field coil brush and C
terminal.
Standard: Continuity exists.

Inspection:
lnspect the insulation between the field coil brush and the field.
Standard: 0.1 MR or more

[Point 21
I Brush holder 1 I
Disassembly:
Lift up the brush spring on the plus side with long-nose pliers.
Take care not to damage the brush or the commutator.

I spring I
[Point 31
Inspection:
lnspect the brush.
1. lnspect for roughness of the contact surface and the length of
the brush.
Measure the brush length in the center section (concave part).
Standard: 20.5 mm (0.807 in.)
Limit: 13.0 mm (0.512 in.)
2. When correcting the contact surface and replacing the brush,
wrap sand paper around the commutator to correct the contact
surface.

Section 1.1.11
 4Y-E Repair

Inspection:
Check that the brush spring movement is smooth, then
measure the applied load of the spring.

k
Standard: 31.4 to 39.2 N (3.2 to 4.0 kgf) [7.1 to 8.8 Ibfl
Limit: 21.6 N (2.2 kgf) [4.9 Ibfl

Brush spring

Inspection:
lnspect the insulation between the brush holder on the plus
side and the brush holder on the minus side.
Standard: 0.1 M a or more

[Point 41
Inspection:
Inspect the insulation between the commutator and the
armature coil.
Standard: 1 M a or more

Inspection:
Perform a short circuit test on the armature coil.
1. Remove completely any deposits on the surface of the
armature.
2. Using an armature tester, place an iron piece in parallel
contact to the armature and turn the armature.
Standard: The iron piece should not be attracted or
vibrate.

Inspection:
lnspect for continuity between each segment of the armature
coil.
Standard: There should be continuity between all
segments of the armature.

Section 1.1.11
 4Y-E Repair

Inspection:
lnspect the commutator.
1. Measure the runout of the periphery.
Limit: 0.05 mm (0.0020 in.) or less

2. Measure the outside diameter.

Standard: 30 mm (1.18 in.)
Limit: 29 mm (1.14 in.)

3. Measure the undercut depth between the segments.

Standard: 0.5 to 0.8 mm (0.020 to 0.031 in.)
Limit: 0.2 mm (0.008 in.)

[Point 51
Disassembly:
Use the SST to remove the bearing.
SST 09286-76001-71
(09286-46011)

[Point 61
Inspection:
lnspect the magnetic switch.
1. lnspect for continuity between the 50 terminal and the C
terminal.
Standard: Continuity exists.

Section 1.1.11
 4Y-E Repair

2. lnspect for continuity between the 50 terminal and the

magnetic switch body.
Standard: Continuity exists.

[Point 71
Inspection:
lnspect the clutch and the gear.
1. lnspect for wear and damage to the gear.
2. Check that the gear locks when rotated in the drive direction
(left) and rotates smoothly when rotated in the opposite
direction (right).

[Point 81
Reassembly:
Use a press to press fit the bearing.

[Point 91
Reassembly:
Reassemble the brushes.
1. Lift the brush spring up with a screwdriver etc, and reassemble
the brush holder into the starter yoke.
2. Pull the brush spring up and reassemble the brush into the
brush holder.

[Point 101
Reassembly:
Align the notch (a) in the end frame and the lead wire grommet
(b).

Section 1.1.11
 4Y-E Repair

[Point 111
Reassembly:
Align the notch in the yoke with the protruding section of the
magnetic switch.

STARTER MOTOR ASSY UNIT INSPECTION

Note:
Perform each test for a short time (3 to 5 seconds).
1. Pull-in test
Check that the pinion gear pops out when the ASSY is
connected as shown in the illustration.

2. Holding coil holding test

From the pull-in test status, check that the pinion gear remains
popped out even after the C terminal wire is disconnected.

3. Plunge'r return test

check that the pinion gear returns from the holding test status
of the holding coil when the terminal is disconnected as shown
in the illustration on the left.

4. No-load test
(1) Secure the starter motor with a vice.
( 2 ) During a no-load test, a large current will flow through the
lead wire, so use a thick lead wire.
(3) Read the ammeter once the display has settled.
Standard: 90 A or less

Section 1.1.11
 4Y-E Repair

CHARGING SYSTEM
Page

SST TO BE USED ............................................ 12-2

ON-VEHICLE INSPECTION ............................. 12-3
ALTERNATOR ................................................. 12-4
ELECTRICAL CIRCUIT DIAGRAM .......................... 12-4
COMPONENTS ......................................................... 12-4
DISASSEMBLY.INSPECTION.REASSEMBLY........ 12-5

Section 1.1.12
 4Y-E Repair

SST TO BE USED

F Illustration Part No. Part name

HST pump bearing replacer

Alternator rear bearing puller

Alternator rear bearing replacer

Replacer set

qandle set

Section 1.1.12
 4Y-E Repair

ON-VEHICLE INSPECTION
1. lnspect the specific gravity of the battery.
Standard: 1.25 to 1.28 (20°C) [68"F]
2. lnspect the battery terminal
3. lnspect the V-belt.
4. lnspect the fuse.
5. lnspect the wiring status.
6. lnspect for abnormal noise.
(1) Check that there is no abnormal noise from the alternator
when the engine is running.
7. Perform a no-load test.
(Adjustment voltageadjustment current inspection)
(1) Connect an ammeter and voltmeter as shown in the
illustration on the left.
(2) Gradually increase the engine speed to 1500 rpm and
measure the voltage.
Standard: 12 V
13.5 to 14.3 V (when warm)
/
Fusible link (3) Measure the current with the engine speed at 1500 rpm.
Standard: 10 A or less
Note:
Directly after the engine starts, the current may briefly become
10 A or more, but this is not abnormal.

Section 1.1.12
 4Y-E Repair

ALTERNATOR
ELECTRICAL CIRCUIT DIAGRAM

COMPONENTS

Section 1.1.12
 4Y-E Repair

Disassembly-ReassemblyProcedure
The reassembly procedure is the reverse of the disassembly procedure.
[ No. ( Item I Disassembly ( Inspection I Reassembly I
I

1 Terminal insulators
2 Rear end cover
3 Brush holder WI brush [Point I] [Point 151
4 IC regulator [Point21
5 Rectifier holder [Point 31 [Point 141
6 Alternator pulley [Point41 [Point 131
7 Rear end frame [Point 51
8 Rotor ASSY [Point 61 [Point 71 [Point 121
9 Rear bearing, spring washer [Point 81 [Point Ill
10 Bearing cover, front bearing [Point 91 [Point 101

Section 1.1.12
 4Y-E Repair

Point Operations
[Point I ]
Inspection:
lnspect the brush.
1. Measure length A of the protrusion of the brush.
Standard: 10.5 mm (0.413 in.)
Limit: 1.5 mm (0.059 in.)
2. If the length of the brush is below the limit, melt the solder part
of the brush holder and remove the brush.
3. Attach the spring to the brush holder, and solder in place so
that the brush length is 10.5 mm (0.413 in.).
4. Cut off the excess lead wire.
5. Apply insulation paint to the soldered section.
Caution:
Brush replacement should be carried out for both sides at the
same time.
.5rnrn
,413 in.)

[Point 21
Inspection:
lnspect the diode of the IC regulator.
Perform a continuity test on the diode between the B terminal
and F terminal, with the tester set in the kR range.
Standard: When the polarity is changed between F and B,
there should be continuity on one side and no
continuity on the other.

[Point 31
Inspection:
lnspect the rectifier holder.
1. Perform a continuity test with the tester in the kR range.
Standard: When the polarity is changed, there should be
continuity on one side and no continuity on the
other.

Section 1.1.12
 4Y-E Repair

2. Refer to the illustration on the left for a circuit diagram of the

rectifier.
Whether the rectifier is working or not cannot be determined
from the resistance in the forward direction. This is because
the forward direction current varies greatly depending on the
power supply voltage because of the diode characteristic, with
the result that the tester indication differs with the type of tester
and differences in the resistance range. Therefore, if the
difference between the forward and reverse current resistance
is large, the rectifier is judged to be functioning.
Caution:
A 500 V mega tester should never be used as this will destroy
the rectifier.
[Point 41
Disassembly:
Set the alternator pulley in a vice and remove the set nut.
Caution:
Always use aluminum pads in the vice.

[Point 51
Disassembly:
After removing the set nut and bolt, hold the rear end frame,
and apply a shock to the tip of the rotor shaft to separate it.
Caution:
When applying a shock, do so over a wooden block etc.

[Point 61

11
Disassembly:
Drive Use blocks as shown in the illustration to set the drive end
end frame frame horizontally, then use a press to remove the rotor.
Caution:
Take care that the rotor does not drop and damage the slip
rings or the fan.

Section 1.1.12
 4Y-E Repair

[Point 71
Inspection:
Measure the resistance between the 2 slip rings.
Standard: 3.0 R or less

Inspection:
Measure the insulation resistance between the slip rings and
the rotor core.
Standard: oo R

Inspection:
Inspect the slip rings.
1. If the slip rings are damaged, correct them with sand paper
(MOO).
2. Measure the outside diameter of the slip rings.
Standard: 14.4 rnrn (0.567 in.)
Limit: 14.0 rnrn (0.551 in.)

Inspection:
Inspect the stator coil of the drive end frame.
Measure the resistance between the phases.
Standard: Approx. 1.0 R

[Point 81
Disassembly:
Remove the rear bearing and spring washer.
SST 09820-76002-71
(09820-00021 )

Section 1.1.12
 4Y-E Repair

[Point 91
Disassembly:
Drive
Use blocks as shown in the illustration to set the drive end
end frame
frame horizontally, then use a press to remove the bearings.
Round bar
Caution:
The bearings (2 pieces) used are for high speed use, therefore
be sure to use the specified bearings when replacing them
(DENS0 part number is written clearly on them) and do not
apply shock to the bearings.
Block

[Point 101
Reassembly:
Install the front bearing.
SST 09950-7601 8-71 .............(1)
(09950-6001 0)
09950-76020-71 .............(2)
(09950-7001 0)

[Point 111
Reassembly:
Reassemble the rear bearing and spring washer.
SST 09820-76003-71
(09820-00030)

[Point 121
Reassembly:
Insert a plate washer or similar into the clearance between the
SST and the rear end frame, so that pressure is applied
uniformly to the rear end frame.
SST 09381-41 950-71

[Point 131
Reassembly:
Set the alternator pulley in a vice and tighten the set nut.
Caution:
Always use aluminum pads in the vice.

Section 1.1.12
 4Y-E Repair

[Point 141
Reassembly:
Reassemble the rectifier holder.
1. Check that the four terminal tips of the stator coil have been
securely inserted into the end frame terminal holder.
2. Temporarily tighten all the terminal attachment bolts before
fully tightening them.
3. Tighten the rectifier attachment bolt.

I Brush holder boot [Point 151

Reassembly:
Check that the brush holder boot is correctly fitted.

Section 1.1.12
 4Y-E Repair

APPENDIX
Page

SST LIST ..........................................................

SERVICE STANDARDS ................................... 13-5
ENGINE BODY ......................................................... 13-5
FUEL SYSTEM ......................................................... 13-8
COOLING SYSTEM .................................................. 13-8
LUBRICATION SYSTEM .......................................... 13-8
IGNITION SYSTEM ................................................... 13-9
STARTING SYSTEM ................................................ 13-9
CHARGING SYSTEM ............................................ 13-1O
TIGHTENING TORQUE FOR
EACH PART ................................................ 13-11

Section 1.1.13
 4Y-E Repair

SST LIST

I
Section
Illustration Part No. Part name

Oil pan seal cutter

Valve guide bushing remover &

replacer

Valve spring compressor

Camshaft bearing remover & replacer

Belt tension gauge

Piston pin remover & replacer

Oil filter wrench

Zarburetor adjusting gauge set

Section 1.1.13
 4Y-E Repair

Section
Illustration Part No. Part name

Wire gauge set

Rocker arm support tool set

Valve lifter tool

Injection pump spline shaft puller

Bearing remover

HST pump bearing replacer

Alternator rear bearing puller

Alternator rear bearing replacer

Section 1.1.13
 4Y-E Repair

Section
Illustration Part No. Part name

Carburetor screwdriver set

Puller B set

Replacer set

Replacer B set

Handle set

Injection measuring tool set

EFI inspection wire

Section 1.1.13
 4Y-E Repair

SERVICE STANDARDS
ENGINE BODY
Cylinder head
Lower surface distortion limit mm (in.) 0.15 (0.0059)
Distortion limit for mounting surface of the manifold mm (in.) 0.10 (0.0039)
IN 30" 45" 60"
Correction angle .
EX 30" 45" 65"
Valve seat
Contact angle 45"
Contact width standard mm (in.) 1.2 to 1.6 (0.047 to 0.063)

Valve guide bushing

Bore mm (in.) I Standard 1 8.010 to 8.030 (0.3154 to 0.3161)

Valve
IN 108.2 (4.260)
Standard
EX 108.5 (4.272)
Total length mm (in.)
IN 107.7 (4.240)
Limit
EX 108.0 (4.252)
IN 7.970 to 7.985 (0.3138 to 0.3144)
Stem section outside diameter mm (in.) Standard
EX 7.965 to 7.980 (0.3136 to 0.3142)
IN 0.025 to 0.060 (0.0010 to 0.0024)
Standard
Oil clearance with the valve guide bushing EX 0.030 to 0.065 (0.0012 to 0.0026)
mm (in.) IN 0.10 (0.0039)
Limit
EX 0.12 (0.0047)
IN 1.0 to 1.4 (0.039 to 0.055)
Standard
EX 1.3 to 1.7 (0.051 to 0.067)
Wall thickness of the valve head mm (in.)
IN 0.5 (0.020)
Limit
EX 0.8 (0.031)

Valve stem cap

ICap thickness mm (in.) I Standard 1.31 to 1.49 (0.0516 to 0.0587) I
Valve spring
Standard 46.0 (1.81)
Free length mrn (in.)
Limit 45.5 (1.79)
1 Squareness I

mm (in.) I
I

2.0(0.079) *

Rocker arm & shaft

Rocker arm inside diameter mm (in.) Standard 18.500 to 18.515 (0.7283 to 0.7289)
Rocker shaft outside diameter mm (in.) Standard 18.474 to 18.487 (0.7273 to 0.7278)
Oil clearance between the rocker shaft Standard 0.013 to 0.041 (0.0005 to 0.0016)
and rocker arm mm (in.) Limit 0.08 (0.0031)

Push rod
Face runout limit mm (in.) I 0.30 (0.0118)

Intake & exhaust manifold

( Distortion limit for the mounting surface of the cylinder head IN & EX I mm (in.) I 0.4 (0.0157) I

Section 1.1.13
 4Y-E Repair

Camshaft
I Face runout limit mm (in.) I 0.06 (0.0024) I
IN 38.620 to 38.720 (1.5205 to 1.5244)
Standard
EX 38.629 to 38.729 (1.5208 to 1.5248)
Cam height mm (in.)
IN 38.26 (15.063)
Limit
EX 38.27 (15.067)
. No.1 46.459 to 46.475 (1.8291 to 1.8297)
No.2 46.209 to 46.225 (1.8292 to 1.8199)
Cam journal outside diameter mm (in.) Standard No.3 45.959 to 45.975 (1.8094 to 1.8100)
No.4 45.709 to 45.725 (1.7996 to 1.8002)
No.5 45.459 to 45.475 (1.7897 to 1.7904)
No.1 46.500 to 46.540 (1.8307 to 1.8323)
No.2 46.250 to 46.290 (1.8209 to 1.8224)
Camshaft bearing inside diameter mm (in.) Standard No.3 46.000 to 46.040 (1.8110 to 1.8126)
No.4 45.750 to 45.790 (1.8012 to 1.8028)
No.5 45.500 to 45.540 (1.7913 to 1.7929)
Standard 0.025 to 0.081 (0.0010 to 0.0032)
Camshaft journal oil clearance mm (in.)
Limit 0.10 (0.0039)
Standard 0.07 to 0.22 (0.0028 to 0.0087)
Thrust clearance mm (in.)
Limit 0.3 (0.012)

Timing chain, timing gear

Timing chain stretch limit (tension 5 kg) mm (in.) 291.4 (11.472)
Crankshaft timing gear outside diameter limit (with the chain) mm (in.) 59 (2.32)
Cam shaft timing gear outside diameter limit (with the chain) mm (in.) 114 (4.49)

Tension, damper
Wall thickness of the tensioner head section Standard 15 (0.591)
mm (in.) Limit 12.5 (0.492)
Standard 6.6 (0.260)
Damper wall thickness mm (in.)
Limit 5.0 (0.197)

Valve lifter
Lifter outside diameter mm (in.) Standard 21.387 to 21.404 (0.8420 to 0.8427)
Cylinder block lifter hole diameter mm (in.) Standard 21.417 to 21.443 (0.8432 to 0.8442)
Standard 0.012 to 0.056 (0.0005 to 0.0022)
Oil clearance of the valve lifter mm (in.)
Limit 0.10 (0.0039)
Leak down test (oil temperature 20°C with 20 kg) I Standard 7 to 28 seconds/l mm (0.04 in.)
I
Cylinder block
Upper surface distortion limit mm (in.) 0.05 (0.0020)
Standard 91.000 to 91.030 (3.5827 to 3.5839)
Cylinder bore mm (in.) Wear amount limit 0.20 (0.008)
Honing allowance 0.02 (0.0008) or less

Section 1.1.13
 4Y-E Repair

Piston, piston ring

Piston outside diameter mm (in.)
STD size 1 90.925 to 90.955 (3.5797 to 3.5809)
01s 0.50 1 91.425 to 91.455 (3.599 to 3.601)
Clearance with the cylinder mm (in.) 0.065 to 0.085 (0.0026 to 0.0033)
Clearance between the piston ring and ring groove mm (in.) 0.03 to 0.07 (0.0012 to 0.0028)
No.I 0.23 to 0.48 (0.0091 to 0.0189)
Piston ring gap mm (in.) I Standard No.2 0.16 to 0.44 (0.0063 to 0.0173) I
Oil 0.13 to 0.47 (0.0051 to 0.0185)

Connecting rod
Thrust clearance rnm (in.)
Standard 1 0.160 to 0.312 (0.0063 to 0.00123)
Limit 0.35 (0.0138)

Crankshaft
Standard 0.020 to 0.220 (0.0008 to 0.0087)
Thrust clearance mm (in.)
Limit 0.30 (0.0118)
Journal outside diameter mm (in.) Standard 57.985 to 58.000 (2.2829 to 2.2835)
Standard 0.020 to 0.051 (0.0008 to 0.0020)
Journal oil clearance mm (in.)
Limit 0.10 (0.0039)
Crank pin outside diameter mm (in.) Standard 47.985 to 48.00 (1.8892 to 1.8898)
Standard 0.020 to 0.051 (0.0008 to 0.0020)
Oil clearance of the crank pin mm (in.)
I
Limit 0.10 (0.0039)
Face runout limit mm (in.) 0.06 (0.0024)
Taper and ellipticity of the journal and crank pin I Limit 0.02 (0.0008)

Engine adjustment
Refer to repair manual
Coolant capacity
for each vehicle model.
Lubricating oil capacity L (US gal) I Oil pan capacity 4.0 ( I . I )
Specific gravity of the electrolyte (electrolyte temperature 20°C) 1.28
V-belt deflection standard When installing a new one 7 to 9 (0.28 to 0.35)
mm (in.)
(pressing force 10 kgf) [22 Ibfl When inspecting 8 to 13 (0.31 to 0.51)
V-belt tension standard When installing a new one 38 to 62 (84 to 137)
(using a tension gauge) kgf (Ibf)
When inspecting 30to50(66to 110)
Spark plug gap mm (in.) Standard 0.7 to 0.8 (0.028 to 0.031)
4Y-M BTDC 7"/650
Ignition timing
I
4Y-E . I
BTDC 7OI750
Refer to repair manual
Idle speed rPm
for each vehicle model.
Refer to repair manual
No-load maximum speed
for each vehicle model.
Ignition order 1-3-4-2
Intake manifold vacuum (during idling) mmHg 400 or more
Standard 12.5 (178)
Compression kgflcm2 (psi) Limit 9.0 (128)
Cylinder difference 1.O (14)

Section 1.1.13
 4Y-E Repair

FUEL SYSTEM
Carburetor (4Y-M only)
Float elevation position 5.5 (0.217)
Float level mm (in.)
I
Float declining
- .position 1. I to 1.3 (0.043 to 0.051)
Throttle valve fully closing angle 7" (from horizontal position)
Throttle valve idle opening angle 13.5" (from horizontal position)
Throttle valve fully opening angle 90" (from horizontal position)
Fast idle opening angle (with 25°C) 23 to 25" (from horizontal position)
Choke valve fully closing angle 15" (from horizontal position)
Unloader opening angle (with fully opened throttle) 38 to 42" (from horizontal position)
Choke breaker pulling angle (with -400 mmHg) 39 to 41" (from horizontal position)
Idle-up setting opening angle 19.5" (from horizontal position)

Injector (4Y-E only)

I Injection amount cd15 seconds 1 41 to 42 I
Leakage from the nozzle 1 drop or less/3 minutes

Fuel pressure regulator (4Y-E only)

F u e l pressure kPa (kgf/cm2) [psi] 1 284 * 5 (2.9 * 0.1) i41.2 * 1.41 1
COOLING SYSTEM
Thermostat
'Temperature when starting to open "C ( O F ) 74.5 to 78.5 (166 to 173)
Temperature when fully open "C (OF) 95 (203)
Lift amount when fully open mm (in.) 8 (0.31) or more

LUBRICATION SYSTEM
Oil pump
Standard 0.03 to 0.09 (0.0012 to 0.0035)
Rotor side clearance mm (in.)
Limit 0.15 (0.0059)
Clearance between the driven rotor Standard 0.10 to 0.16 (0.0039 to 0.0063)
and pump body mm (in.) Limit 0.2 (0.008)
Standard 0.06 to 0.15 (0.0024 to 0.0059)
Rotor tip clearance mm (in.)
Limit 0.2 (0.008)

Section 1.1.13
 4Y-E Repair

IGNITION SYSTEM
Distributor (4Y-M)
Air gap mm (in.) Standard 0.2 to 0.4 (0.008 to 0.016)
Pickup coil resistance Standard 140 to 1 8 0 ~
Governor shaft thrust clearance mrn (in.) Standard 0.15 to 0.50 (0.0059 to 0.0197)
0.3 (0.012)
0.4 (0.016)
Governor shaft thrust washer thickness mm (in.)
0.5 (0.020)
0.6 (0.024)
Resistive cord resistance Limit 25 kWcord
Ignition coil primary coil resistance Standard 1.2 to 1.5 n
Ignition coil secondary coil resistance Standard 7.7 to 10.4 kR
650 to 1250 0"
Governor advance angle Engine speed 1500 2"
(on the crank axle) rPm 2000 76"
2500 13.5"
-100 0"
Vacuum advance angle Negative pressure -120 0.4 to 5"
(on the crank axle) mmHg -240 14 to 18"
-320 or more 18 to 22"

Distributor (4Y-E)
IAir gap mrn (in.) I Standard 0.2 to 0.4 (0.008 to 0.016) I
Pickup coil resistance Standard *
460 50 R
Resistive cord resistance Limit 25 kmcord
Ignition
- coil primary coil resistance Standard 1.2 to 1.5 C2
1 lgnition coil secondary coil resistance
I

Standard
I
7.7 to 10.4 kC2 I
STARTING SYSTEM
Starter motor
Motor model DC series-wound reduction model I
Nominal voltage VI
I

12 I
Nominal output kW 2.5
1 Voltage
- V 11
No-load characteristic Current A 90 or less
Revolving speed rpm 3500 or more
Ellipticity mm (in.) Limit 0.05 (0.0020)
Standard 30 (1.18) -
Outside diameter mm (in.)
Commutator Limit 29 (1.14)
Standard 0.5 to 0.8 (0.020 to 0.031)
Mica depth rnm (in.)
Limit 0.2 (0.008)
Standard 20.5 (0.807)
Length rnm (in.)
Limit 13 (0.512)
Brush
Spring mount load Standard 31.4 to 39.2 (3.2 to 4.0) [7.1 to 8.811
N (kg9 [Ibfl Limit 21.6 (2.2) [4.91]

Section 1.1.13
 4Y-E Repair

CHARGING SYSTEM
Alternator
Nominal voltage V 12
Maximum output A 60
I
Output revolution speed rPm
I

1500 1
Standard 10.5 (0.413)
Brush length mm (in.)
Limit 1.5 (0.059)
Standard 14.4 (0.567)
Slip ring outside diameter mm (in.)
Limit 14.0 (0.551)

Section 1.1.13
 4Y-E Repair

TIGHTENING TORQUE FOR EACH PART

Tightening place Tightening torque N m (kgf-cm) [ft.lbfl
Cylinder block Cylinder head :MI2 88 (900) [65.1]

Cylinder block Timing gear case

Cylinder block Chain vibration damper

Cylinder block Chain tensioner
Cylinder block Camshaft thrust plate
Cylinder block Distributor
Cylinder block Oil filter
Cylinder block Fuel pump (4Y-M)
Cylinder block Fuel filter (4Y-E)
Cylinder block Drain plug
Cylinder block Oil pan
Cylinder block Oil pump
Cylinder block Crankshaft bearing cap
Cylinder head x Cylinder head cover 5 (51) [3.7]
Cylinder head
Cylinder head
x

x
Rocker shaft
Spark plug
II 24 (244) [ I 7.71
18 (183) [13.2]
Cylinder head
Cylinder head
x

x
Manifold
Water pump
I 49 (500) [36.2]
21 (214) [15.5]
Crankshaft x Crankshaft pulley 140 (1427) [ I 03.21
Timing gear case x Timing gear cover 21 (214) [15.5]
Camshaft x Camshaft timing gear 90 (917) [66.3]
Connecting rod x Connecting rod cap I 49 (500) [36.2]
Oil strainer x Oil pump 8 (82) [5.9]
Water inlet x Water pump 21 (214) [I551
Water pump x Fan, Fan pulley 18 (183) [13.2]
Carburetor x Manifold (4Y-M) 20 (204) [14.8]
Alternator x Timing gear case I 25 (255) [ I 8.41
Alternator x Adjusting bar 19 (194) [14.0]

Section 1.1.13
…..This Page Intentionally Left Blank…..
 1DZ-II Repair
SECTION INDEX
NAME I SECTION

GENERAL

ENGINE OVERHAUL
I FUEL SYSTEM
COOLING SYSTEM
LUBRICATION SYSTEM
STARTING SYSTEM
1 1
APPENDIX
…..This Page Intentionally Left Blank…..
 1DZ-II Repair

GENERAL

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
ENGINE EXTERIOR VIEWS . . . . . . . . . . . . . . . . . . . . 0-3
ENGINE SECTIONAL VIEWS .................. 0-4
HOW TO READ THIS MANUAL ................ 0-6
EXPLANATION METHOD . . . . . . . . . . . . . . . . . . . . . . . 0-6
TERMINOLOGY ............................... 0-7
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
OPERATION PRECAUTIONS . . . . . . . . . . . . . . . . . . 0-9
SPECIAL PRECAUTIONS ....................... 0-9
GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . 0-9
INSPECTION OF ELECTRIC PARTS. . . . . . . . . . . . . . . 0-12
BOLT AND NUT TIGHTENING TORQUE . . . . . . . . 0-14
BOLT STRENGTH TYPE IDENTIFICATION
METHOD AND TIGHTENING TORQUE . . . . . . . . . . . 0-14
TIGHTENING TORQUE OF HEXAGON HEAD BOLTS
WITH FLANGE SEATS . . . . . . . . . . . . . . . . . . . . . . . . 0-16
PRECOAT BOLTS (BOLTS WlTH SEAL LOCK
AGENT COATING ON THREADS) . . . . . . . . . . . . 0-16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-17
SI UNITS
HANDLING THE FlPG (LIQUID GASKET) . . . . . . . 0-18

Section 1.2.0
 1DZ-II Repair

SPECIFICATIONS
Engine model
Diesel
1 Cycle
I Number of cylinder and arrangement In-line 4 cylinders, vertical
I Injection order
Starting method Pinion shift
Combustion chamber type Vortex type
Valve mechanism Gear drive, OHV
I Bore x stroke mm (in.)
I Piston displacement cc ( w i n )
I Compression ratio I 21.5
I Compression pressure kPa (kgf/cm2)[psillrpm 1 2850(29)[412]/260
See the repair manual for
Rated output PS/rpm
each model
See the repair manual for
Max. torque N.m (kgf.cm) [ft-lbfllrpm
each model
See the repair manual for
No-load static maximum speed
each model
I Idling speed rPm
Compression ring 2
Number of piston rings
Oil ring 1
I Cylinder liner type
Open BTDC 14"
Intake valve opening & closing timing
Close ABDC 44"

Exhaust valve opening & closing Open BBDC 52"

timing Close ATDC 14"
Ignition system Compression ignition
Injection timing 0" static (BTDC)
Oil pump type Trochoid pump
Oil filter type Paper filter
Oil pan capacity 7.0 (1.85)
Engine oil amount e (Usgal)
Total capacity 7.5 (1.98)

Section 1.2.0
 1DZ-II Repair

ENGINE EXTERIOR VIEWS

Section 1.2.0
 1DZ-II Repair

ENGINE SECTIONAL VIEWS

Section 1.2.0
1DZ-II Repair

Section 1.2.0
 1DZ-II Repair

HOW TO READ THIS MANUAL

EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with an illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration,
followed by explanation of cautions and notes summarized as "key point operations".
Example of description in pattern B
DISASSEMBLY, INSPECTION AND REASSEMBLY
Tightening torque unit -+T = N.m (kgfzm) [ftdbfl

Step numbers are

sometimes partially omitted
in illustrations.
When a part requiring
tightening torque instruction
is not indicated in the
1 illustration, the part name is
described in the illustration
frame.

Disassembly and reassembly procedure

Reassembly procedure is the reverse of the disassembly procedure.
Number Item Disassembly Inspection Reassembly
1 Crank pulley with set bolt
1 2 1 Timing gear cover I I I I
1 3 11dle~ear~o.l
I
I
I
I
I
[point I] I
I
I
4 [Point 21
Oil pump assembly A
Point operation Explanation of key point for
operation with an illustration operation covered on
the following page
[Point I]
Inspection: Measure the
Standard: 0.05 mm (0.0020 in.)
Reassembly:lnstall the rotor as an illustration.

Section 1.2.0
 1DZ-II Repair

2 . How to read components figures (Example)

The components figure uses the illustration in the parts
catalog for the vehicle model. Please see the catalog for 320 1
checking the part name.
3. Matters omitted in this manual
This manual omits descriptions of the following jobs, but FIG number in
perform them in actual operation: parts catalog
(1) Cleaning and washing of. removed parts as required
(2) Visual inspection (partially described)

TERMINOLOGY
Warning Important information and operation procedures, failure to observe which may
cause accidents.
Caution Important information, failure to observe which may cause accidents, or
information on operation procedures that requires special attention
[Note] Supplementary explanations to make operations easier
Standard The permissible range in inspection or adjustment
Limit The maximum or minimum value of the criterion in inspection or adjustment

ABBREVIATIONS
Abbreviation Original term Meaning
RH Right hand Right side
LH Left hand Left side

I FR 1 Front 1 Front side I

I RR 1 Rear 1 Rear side I
1 STD / Standard
lndicates that the standard size is the size of the parts that
were used for assembly at the manufacturer.
For items that have worn over a long time, or where the fit-
ting has loosened due to repeated removal and
1 Over size reassembly, by replacing the one side (fitting side) with an
item that has a larger size, the other side can be reused .
Sizes larger than this standard are indicated with 01s.
In the same way as OIS, by replacing the one side (fitted
side) with an item that has a smaller hole, the other side
Under size
can be reused. Sizes smaller than this standard are
indicated with UIS.

I ATDC Afier top dead center

After the top dead center position of the piston in the
cylinder.

I BTDC Before top dead center

Before the top dead center position of the piston in the cyl-
inder.

I IN ( Intake I Indicates the intake system. I

EX Exhaust Indicates the exhaust system.
SST Special service tool Indicates special tools.

Section 1.2.0
 1DZ-II Repair

I Abbreviation / Original term Meaning

1 Torque I Tightening torque
1 ASSY Assembly
An assembly is composed of two or more individual parts
or subassembly parts that are put together.

I SUBIASSY Sub assembly

Two or more individual parts that are welded, cast or
caulked together.
The item following is attached.
(Example: wlwasher = with an attached washer)
1 MIT I Manual transmission 1 lndicates a manual transmission.
I Torque converter I lndicates a automatic transmission.
1 LWR / Lower / Lower side

Section 1.2.0
 1DZ-II Repair

OPERATION PRECAUTIONS
SPECIAL PRECAUTIONS
1. Disassembly and reassembly operations for the engine assembly must be carried out while the engine
is set on the engine stand. Never perform the operations on a work bench or the floor, since doing so is
very dangerous.

2. Always wear gloves when holding or moving the cylinder head assembly or cylinder block: never use
bare hands.

GENERAL PRECAUTIONS
1. Safe operation
(1) Correctly wear protection tools. (Cap, safety glasses, gloves, safety shoes, etc.)
(2) Do not touch the radiator, muffler, exhaust pipe and other engine related parts immediately after
stopping the engine to prevent scalding.
(3) Do not bring clothes, tools and others close to rotating parts during engine operation.
(4) Turn the ignition switch OFF and remove the ignition key unless engine operation is necessary.
2. Preparation before disassembly
(1) Prepare general tools, SST, measuring tools, greases, and non-reusable parts.
(2) When disassembling a complicated assembly, put punch or matching marks at places not affecting
the function to facilitate reassembly operations.
3. Keeping out foreign matter
If foreign matter such as dust, sand or metal pieces enter the engine it could cause a malfunction.
(1) Fully clean off any sand or mud from the outside of the engine.
(2) Use plastic covers to protect the disassembled parts from dust.

Section 1.2.0
 1DZ-II Repair

4. Prevention of part damage

If there is damage to rotating parts or the connection surface of parts, it could cause oil leaks or
seizures.
(1) Do not use a screwdriver when disassembling the connection surface of parts. Disassemble by
striking the parts gently with a plastic hammer.
(2) When securing parts in a vise, do not secure the parts directly. Use aluminum plates between the
parts and the vise.
5. Washing the parts
(1) Wash the parts thoroughly before reassembly, dry with compressed air, and coat with the specified
oil.
(2) Parts that must not be washed with alkaline solutions:
Aluminum parts, rubber parts ( 0 rings, etc.)
(3) Parts that must not be washed with cleaning oil (kerosene, white gasoline, etc.):
Rubber parts ( 0 rings, etc.)
6. Removal and reassembly of fuel system parts
(1) Work area for removing and reassembling fuel system parts
(a) Perform the work in an area with good ventilation where there is no machinery that cause
sparks, such as welders, grinders, drills, electric motors or stoves.
(b) Do not work in or around a work pit where there is a danger of ignited fuel flowing in.
(2) Removal and reassembly of fuel system parts
(a) Prepare a fire extinguisher before starting to work.
(b) To prevent static electricity, attach a ground wire to areas such as the fuel changer, vehicle
and fuel tank, and pour water over the parts, but not so much that it will cause you to slip.
(c) Do not use electric equipment such as power pumps and working lamps, because they could
cause sparks or high temperatures.
(d) Do not use tools such as iron hammers, because they could cause sparks during work.
(e) Dispose separately cloths that are saturated with fuel.
7. Reassembly position and direction
(1) Reassemble the parts in the position and direction they were in before disassembly.
(2) Install correct parts according to the correct procedure and observing the determined standards
(tightening torques, adjustment values, etc.). (Reassemble at the median of the ranges for
tightening torques and adjustment values.)
(3) Always use genuine parts for replacement of existing parts.
(4) Always use new oil seals, 0 rings, gaskets, cotter pins, etc.
(5) Coat the seal packing on the gaskets depending on where they will be used, coat the specified oil
or the grease on the specified places on the sliding parts, and coat the MP grease on the oil seal
lips before reassembly.
8. Handling the hose clamps
(1) Before removing the hose, check the insertion depth of the hose and the clamp positions to make
sure that reassembly is performed correctly.
(2) Replace deformed or dented clamps with new ones.
(3) When reusing the hose, install by aligning the clamps to the clamp marks on the hose.
(4) With plate spring clamps, after installation apply pressure in the direction it is to be tightened.
9. Adjustment and checking work
Adjust to the service standard values by using gauges and testers.

Section 1.2.0
 1DZ-II Repair

10. Disposal of waste fluid, etc.

When draining waste fluid from the vehicle, receive it in a container.
If oil, fuel, coolant, oil filters, batteries or other harmful substances are directly discharged or scrapped
without permission, it will either adversely affect human health or destroy the environment. Always
sort waste fluids etc. and treat them properly by requesting disposal by specialized companies.
Further, always recover or wipe up any waste fluid that is spilt.
11. Protection of function parts
After completing inspection and maintenance work for the vehicle, before reconnecting the battery
terminal fully check each connector to make sure that no connections have been forgotten and that no
connections are incomplete.
Be especially careful of connectors related to the controller, because if these connections are forgotten
or are incomplete, it could damage the internal elements of the controller.

Section 1.2.0
 1DZ-II Repair

INSPECTION OF ELECTRIC PARTS

1. Always disconnect the battery plug before performing electric part inspections or maintenance.
2. Be very careful when handling electric parts.
(1) Do not subject electric parts such as computers or
relays to impacts.
(2) Do not subject electric parts to high temperatures or
humidity.
(3) Do not touch the connector terminals, because
deformation or static electricity could cause a
malfunction.

I
I. Use a circuit tester that suits the measurement object and obiective.
Analog system:Useful when viewing movements during operations and when viewing the operation
status. The measured values are used as a reference or as a guideline.
Digital system: Relatively accurate values can be obtained from the measurements. However,
sometimes difficult to understand when viewing operations or movements.
(1) Differences between the measurement results of the analog and digital systems
Sometimes there are differences between the measurement results of the analog and digital
systems.
See the instruction manual when using a circuit tester.
The information below describes the precautions required when there are polarity differences
between analog and digital circuit testers.

Forward direction Reverse direction (a) Analog circuit tester

Measurement results example
Tester range: kR range
Forward direction: Continuity 11 k R
Reverse direction: No continuity oo

(b) Digital circuit tester

Forward direction Reverse direction Measurement results example
Tester range: 2 MR range
Forward direction: Continuity 2 MR
Reverse direction: No continuity 1

Section 1.2.0
 1DZ-II Repair
0-13

(2) Differences between circuit tester measurement results

The circuit tester has a source voltage, which can vary
between 1.5 V, 3.0 V and 6.0 V depending on the
tester.
The tester source voltage affects the resistance
measurements of semiconductors such as diodes.
The characteristics of the diodes as shown to the left.
As can be seen, when using two circuit tester types
with different source voltages, even when the
resistance of the same diodes is measured, the
measurement results are different.

This manual mainly uses the measurement results

obtained using an analog circuit tester with a source
Forward voltage (V) voltage of 3.0 V.

(3) Differences in measurement results due to measurement ranges

When the measurement range in an analog circuit
Resistance Meter tester is changed, the internal circuit changes and the
internal resistance changes. As a result, even when the
same diode is measured, the measurement results
0 R Variable vary according to the measurement range.
resistance Therefore, use the measurement range described in
the repair manual when performing measurements.

Resistance

1"
@bVoltage: 1.5 V

Red
2
Black

Section 1.2.0
 1DZ-II Repair

BOLT AND NUT TIGHTENING TORQUE

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

Bolt head No.

No mark

Two embossed lines

Three embossed lines

Four embossed lines

No mark

Grooved

Section 1.2.0
 1DZ-II Repair

Identification by part number

1 TYpe I Example of part number Shape

91611-40625
=Length (mm)
Hexagon head bolt
Diameter (mm)
Strength type

92132-40614
L L e n g t h (mm) iameter
Stud bolt

L
Diameter (mm)
Strength type Lengt

Tightening torque table

Diameter Standard tightening torque
Strength type
N.m (kgf.cm) [ftdbfl

Section 1.2.0
 1DZ-II Repair

Identification by bolt shape (Hexagon flange bolt)

Hexagon flange bolt

0No mark

0No mark

TIGHTENING TORQUE TABLE (Hexagon flange bolt)

Strength type I Diameter

mm
Pitch
mm
Specified torque
N-m(kgfcm) [ftdbfl

Section 1.2.0
 1DZ-II Repair

PRECOAT BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON

THREADS)
1. Do not use precoat bolts in any of the following cases:
(1) When a precoat bolt is removed.
(2) When a precoat bolt is removed as a result of
tightening torque check, etc. (Loosened or tightened.)
NOTE:
Check the torque with the lower limit of the tightening
torque. If it moves, retighten it according to the
following procedure:
Seal lock agent
2. Reusing of precoat bolts
(1) Clean off the old adhesive from the bolt, nut or threads.
(Also clean the threads when replacing the bolt.)
(2) Dry with compressed air.
(3) Coat the specified seal lock agent to the bolt thread.
SI UNITS
WHAT ARE SI UNITS?
The SI unit system has been introduced for this manual. SI units unify the various unit systems that were
previously used in different countries. It is an international unit system established to ensure the smooth
exchange of technology.
NEW UNITS ARISING FROM SI UNIT INTRODUCTION

Item 1 New unit Previous unit

Conversion value * I
(1 [previous unit] = [SI unit])
Force '2 1 N (Newton) I kgf I 1 kgf = 9.80665 N
Torque *2
(Moment)
1 N.m kgfxm

Pressure *2 1 Pa (Pascal) 1 kgf/cm2 I 1 kgflcm2 = 98.0665 kPa = 0.0980665 MPa

Rotation speed rlmin rPm 1 rpm = 1 rlmin

Spring
constant *2
Nlmm 1 kgflmm 1 kgflmm = 9.80665 Nlmm

volume I L I CC
I Icc=lmL
power I w I PS I 1 PS = 0.735499 kW
Heat quantity I W.h
I cal
I 1 kcal = 1.16279 W.h

:onsumption ratio
1 gMi.h 1 g1PS.h

* I : X is the value of 1 unit of the previous unit converted into the SI unit. This value can be used as the
conversion factor for the previous unit and SI unit.
*2: The [kg] kilogram unit expressing mass is used instead of the [kgf] kilogram force unit expressing
"force" that was previously used.

Section 1.2.0
 1DZ-II Repair

CONVERSION BETWEEN PREVIOUS UNITS AND SI UNITS

Conversion formula

Conversion factor: The figure corresponding

SI unit value =conversion factor x previous unit value to X in the conversion
Previous unit value = conversion factor 1 SI unit value value field in the table
above

<Caution>
Make sure that the unit of the previous or SI unit value used in the calculation is the same as the unit in the
conversion value field in the table above. For example, when converting 100 W into the previous PS unit,
convert it into 0.1 kW before dividing it with the conversion factor of 0.735499.

HANDLING THE FIPG (LIQUID GASKET)

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

Section 1.2.0
 1DZ-II Repair

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
TECHNICALTROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
ENGINE DOES NOT CRANK NORMALLY . . . . . . . . . . 1-3
ENGINE DOES NOT START EASILY OR
DOES NOT START AT ALL . . . . . . . . . . . . . . . . . . . . 1-4
ENGINE MALFUNCTIONS OR STOPS
WHILE IDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
CANNOT ACCELERATE SMOOTHLY.............. 1-5
INSUFFICIENT OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . 1-6
ENGINE OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . 1-6
HIGH FUEL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . 1-7
FREQUENT DIESEL KNOCKING . . . . . . . . . . . . . . . . . 1-8
LARGE AMOUNT OF EXHAUST SMOKE
WHILE DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
UNUSUAL ENGINE SOUNDS AND NOISES ........ 1-9
HIGH ENGINE OIL CONSUMPTION . . . . . . . . . . . . . . . 1-12

Section 1.2.1
 1DZ-II Repair

TROUBLESHOOTING
TECHNICAL TROUBLE
The causes of engine malfunctions are classified by three elements of the diesel engine.
Three diesel engine elements
Three
Main function parts
elements

I fue(?Gttion
I Fuel tank, fuel feed pump, fuel strainer, injection pump, injection nozzle, etc.

Good
Engine unit (INIEX valves, piston ring, cylinder, etc.)
compression

I Good
preheating
/ Glow plug, preheating timer, etc.

The basic elements are described above, but malfunctions can also occur due to insufficient maintenance.
Be sure to check the following items as a pre-inspection.
Pre-inspection items
Coolant Injection nozzle
Engine oil Glow plug
Battery and terminal Injection timing
Air cleaner Idling speed condition
I Fan belt I Looseness in engine parts I
List of described items
Condition Malfunction description Page

Engine start difficult or I Engine does not crank normally I P.l-3

impossible I Engine does not start easily or does not start at all I P.l-4
1 P.l-5
I

1 Engine malfunctions or stops while idling

I

I Engine malfunction Cannot accelerate smoothly (including breathing) I P.l-5

I

I Insufficient output (including hunting) I P.l-6

Engine overheating
I

- 1 P.l-6
I High fuel consumption I - I P.l-7
I Frequent diesel knocking I - I P.l-8
Large amount of exhaust Large amount of black smoke is generated P.l-8
smoke while driving Large amount of white smoke is generated P.l-8
Sound that changes when the clutch pedal is operated P.l-9

Unusual engine sound

I Sound that is often heard while idling
I Sound that is often heard only at a certain engine speed I P.1-10
Sound that is often heard in all engine speed ranges P.1-I1
High engine oil consumption - P.l-12

Section 1.2.1
 1DZ-II Repair
1-3

ENGINE DOES NOT CRANK NORMALLY

In this symptom, there is no reaction at all when the starter is activated with the engine switch, or the
starter makes an unusual sound.
Symptom Main inspection or adjustment areas
1. Battery
2. Battery wiring
Starter does not respond [Po i n t 11 3. Engine switch
4. Starter unit
5. Neutral safety switch
1. Battery
Cranking operation is delayed, or there is a
clattering sound

1. Starter clutch
Rasping sound 2. Ring gear
3. Magnet switch

[Point I]
To judge whether the defect is in the circuit to the starter or in
the starter motor itself, directly connect terminal 30 and
terminal 50 of the starter to the battery with a lead wire. If the
starter operates the defect is in the circuit, and if it does not
operate the defect is in the motor.

Section 1.2.1
 1DZ-II Repair

ENGINE DOES NOT START EASILY OR DOES NOT START AT ALL

I Classification
I Main inspection or adjustment areas
I
1. Glow indicator lamp [Point 21
Preheating 2. Glow plug
3. Preheating timer [Point 31
1. lnjection pump injection timing [Point 41
2. lnjection pump solenoid [Point 51
Injection [Point I ] 3. Fuel line air bleeding
4. Fuel filter
5. lnjection nozzle [Point 61
1 1.Valve contact I
/ 2. Piston ring I
Compression
/ 3.Piston I
I 4. Cylinder

[Point I ]
Check the fuel supply to the injection pump
While the return hose is disconnected from the injection pump in the fuel tank, operate the priming pump
on the top of the fuel filter.lf fuel is not discharged from the return hose, next disconnect the hose in the
injection pump inlet and perform the same check.
[Point 21
Check the operation of the glow indicator lamp
Turn the engine switch to the ON position and check the operation of the glow indicator lamp in the
combination meter.
[Point 31
Check the operation of the preheating timer
The power supply time for the glow plugs is determined in accordance with the engine coolant
temperature. If the power supply time is extremely short it can cause a starting defect.
[Point 41
Check the injection timing of the injection pump
When trying to detect the probable cause, it is unlikely that a malfunction in only one of the cylinders would
cause a starting defect. For this reason, perform an injection timing inspection before performing an
individual nozzle inspection or compression inspection.
[Point 51
Check the operation of the injection pump solenoid
Put your hand on the solenoid body and check whether or not the internal plunger moves in parallel with
turning the engine switch ON and OFF.

Section 1.2.1
 1DZ-II Repair

[Point 61
Check the fuel supply to the injection nozzle
Loosen the nut of the high pressure pipe that is connected to
the injection nozzle, and check that the fuel is injected with
sufficient force during cranking.

ENGINE MALFUNCTIONS OR STOPS WHILE IDLING

Classification Main inspection or adjustment areas
I I 1. Injection pump injection timing I
2. lnjection pump
lnjection [Point I ]
3. Fuel line air bleeding
4. lnjection nozzle
Compression 1.Valve mechanism
1. Clogging of the intake and exhaust systems
Others
2. Unusual load on the engine due to the loading pump, etc.

[Point I ]
Engine speed condition inspection
Check the idling speed and adjust if necessary.Further, if the engine seems as though it will stop, operate
the accelerator lever and perform the following inspection while the engine speed is high.
While the engine is idling, loosen the high pressure nuts on the nozzle side for each cylinder in turn, and
check whether or not there are changes in the engine speed condition.When there no changes in the
engine speed while the nuts are loosened, it means that there is an abnormality in the cylinder.
CANNOT ACCELERATE SMOOTHLY
Classification Main inspection or adjustment areas I
1. Accelerator pedal link [Point I ]
Fuel
2. lnjection timing
1. INIEX valve contact
2. Piston ring
Compression
3. Piston
4. Cylinder

[Point I ]
Accelerator pedal link system adjustment
The position of the accelerator lever is determined by the
accelerator pedal height adjustment and the link wire
adjustment. Check that the accelerator lever makes contact
with the maximum adjusting screw when the accelerator
pedal is fully open.

Section 1.2.1
 1DZ-II Repair

INSUFFICIENT OUTPUT
Classification Main inspection or adjustment areas
I

/ 1. lnjection timing
Fuel 2. lnjection pump
3. lnjection nozzle
/ 1. Valve
Compression
1 2. Piston ring
/ 3. Piston
I 4. Cylinder
1. Clutch slip
Drive [Point I]
2. Torque converter one-way clutch slip

[Point I]
Relief down engine speed inspection
Inspection for determining whether the insufficient output is in the engine unit or in the drive system. If the
relief down is within the standard, the engine output is normal. Perform an inspection of the drive unit.

ENGINE OVERHEATING
Classification Main inspection or adjustment areas
1. lnjection timing
-- ---

Fuel 2. Injection pump

3. lnjection nozzle
1. Cylinder head gasket
Compression 2. Cylinder head
3. Cylinder block
1. Coolant
2. V belt
Cooling
3. Radiator [Point I]
4. Thermostat

[Point I]
Radiator internal bubble inspection
If the cylinder head, gasket or cylinder block is defective and bubbles are being generated inside the
radiator, the engine oil will become cloudy.

Section 1.2.1
 1DZ-II Repair

HIGH FUEL CONSUMPTION

Perform the following diagnosis before troubleshooting, and take action if required.
1. When did it start? (When a new vehicle was purchased, recently, since it became cold, etc.)
2. Compared to what? (Previously used forklifts, other vehicle of the same type, other forklifts, etc.)
3. What is it being used for? (Loading and unloading cargo, transportation, in confined spaces, driving
distance, etc.)
4. Others. (Fuel, tires, specification additions, work time ranges, changes in cargo, operator
replacements, etc.)
1. Engine structure (compression ratio, combustion improvement, cooling loss,
mechanical efficiency, etc.)
2. Vehicle structure (vehicle weight, tires, drive system transmission efficiency, gear
ratio, etc.)
Causes of
3. Use environment conditions (weather, driving environment, loading environment,
high fuel
driving method, altitude, etc.)
consumption
4. Engine and vehicle maintenance conditions (injection timing, compression pres-
sure, etc.)
5. Differences in specifications, supplied equipment (mast height, attachments, air
conditioning)

Areas for inspection or adjustment when the fuel consumption increases

Classification Main inspection or adjustment areas
1 1. lnjection pump I
Fuel 1 2. Fuel system leak I
1 3. lnjection timing I
/ I. Valve I
2. Piston ring
Compression

Drive
/ 1.Manual clutch slip
1 2. Torque converter one-way clutch slip I
I 1. Braking drag I
Brakes 1 2. Brake automatic adjustment mechanism I
1 3. Brake shoe return mechanism I
1. Thermostat
Cooling
2. Coolant temperature [Po i n t 11

[Point I ]
When the engine coolant temperature is too high or too low, the optimum combustion cannot be attained
and the fuel consumption increases.ln particular, repeated driving and loading operations while the engine
is cold leads to incomplete combustion and results in lower engine output.

Section 1.2.1
 1DZ-II Repair

FREQUENT DIESEL KNOCKING

I Classification I Main inspection or adjustment areas I

Fuel

I I. Valve
Compression
1 2. Piston ring
1 3.Piston I
4. Cylinder
Others 1. Clogging of the air cleaner

[Point I]
While the engine is idling, loosen the high pressure pipe nuts on the nozzle side for each cylinder in turn,
and check whether or not there are changes in unusual sounds from the engine.
If the unusual sounds from the engine stop when the nuts are loosened, it means that the injection nozzle
of that cylinder is not injecting or operating properly.

LARGE AMOUNT OF EXHAUST SMOKE WHILE DRIVING

Large amount of black smoke is generated
Symptom Main inspection or adjustment areas
Constantly generated 1. Clogging of the air cleaner
At low speeds only [Po i n t 11 1. Injection pump
1. lnjection timing (early)
Also generated at speeds other than low speeds 2. lnjection pump
3. lnjection nozzle

[Point I]
Black smoke generation condition check
Check whether black smoke is only generated at low engine speeds while the accelerator is fully open or
nearly fully open.
Large amount of white smoke is generated
Symptom Main inspection or adjustment areas
1 1. Defective fuel
1 2. Valve
Constantly generated

1 6. lnjection timing (late)

1 7. lnjection pump

Section 1.2.1
 1DZ-II Repair

UNUSUAL ENGINE SOUNDS AND NOISES

Unusual engine sounds and noises are classified according to how they are generated as described
below.
1. Sound that changes when the clutch pedal is operated
2. Sound that is often heard while idling
3. Sound that is often heard only at a certain engine speed
4. Sound that is often heard in all engine speed ranges
Sound that changes when the clutch pedal is operated

I Operation I Main causes I

No change in the unusual sound when the
clutch pedal is depressed
I Crankshaft thrust bearing seizure

Unusual sound stops when the clutch pedal is Crankshaft thrust bearing,wear
depressed 2. Transmission defect

Sound that is often heard while idling

I Probable cause Example of sound Notes
Check by placing a sound scope on the water pump body.
Water pump bearing
Remove the V belt and try to rotate by hand. If it feels gritty
defect
to your hand there is a bearing defect
Pour in engine oil from the outside of the oil seal or apply a
Oil seal noise noise damper solution with compressed air
The sound gets smaller or stops
Check by placing a sound scope in the area of the timing
gear cover
Sound is heard clearly when the engine warms up
Camshaft thrust
After the engine has warmed up and the engine speed
direction play
changes from idling to a high speed, the sound gets smaller
or stops
Check the sprocket gear deflection
Check by placing a sound scope on the camshaft bearing
Camshaft bearing
When the engine reaches a high speed the sound gets
smaller
Adjust the valve clearance
Valve and seat Check by placing a sound scope in the area of the cylinder
contact defect head valve
The sound gets smaller or stops when the valve is raised
Check by placing a sound scope on the cylinder head
Valve lifter piece * The sound is generated more easily when the push rod is
contact or damage not turning
* Remove the lifter and check the contact surface
The sound gets smaller or stops when engine oil is filled or
valve rocker arm the position of the valve rocker arm is changed

Crankshaft thrust
direction play
Koto-koto
Go-go
-Depress the clutch pedal and check
If the sound stops the play is large in the thrust direction
The play is eliminated when the clutch pedal is depressed
and the crankshaft is pushed to the front, so the sound stops

Section 1.2.1
 1DZ-II Repair

I Probable cause I
I
Example of sound I
I
Notes I
1 Check the installation condition of the intake manifold, air1
cleaner, etc.
Check by blocking the intake area with engine oil, grease
or a cloth

Sound that is often heard only at a certain engine speed

Probable cause Example of sound Notes
Sound is generated after suddenly accelerating from idle
Belt slippage Set the belt tension to the standard
Check the belt for wear. cracks and adhered oil
Contact sound from
the alternator bearing Remove the belt, turn by hand and check the sound
or brush
The knocking sound is loud when the engine is cold, anc
when the temperature gets higher the knocking sound gets
smaller or stops
The aluminum alloy piston expands more than the cylinder:
Piston side knock
so the piston clearance gets smaller and the side knock
gets smaller
When nozzle injection is stopped, the sound changes and
generally gets smaller
Heard clearly from the bottom of the engine during or
immediately following acceleration after the engine has
Connecting rod warmed up
bearing knocking
sound If nozzle injection is stopped at the engine speed where the
knocking sound is generated (about 1000 rpm), the sound
changes and generally gets smaller
Heard clearly from the bottom of the engine during or
immediately following acceleration after the engine has
warmed up
Crankshaft bearing
knocking sound Sound does not change much even when nozzle injection
is stopped
Compared to the connecting rod bearing, this knocking
sound is a little lower and sharper
The sound gets louder when the engine warms up, and itis a
harder sound than the piston side knock
Piston pin knocking
sound If nozzle injection is stopped at the engine speed where the
knocking sound is generated (about 1000 rpm), the knocking
soundchanges
When the belt is removed and the engine started, the sound
Cooling fan Bun stops
imbalance Uwan Check the fan for bend, installation looseness and
deflection
Gets louder during sudden acceleration
Flywheel installation The sound gets smaller or stops when the clutch pedal is
bolt looseness fully depressed
* Very similar to the knocking sound of the crankshaft
bearing, .but is harder

Section 1.2.1
 1DZ-II Repair

Sound that is often heard in all engine speed ranges

Example of
Probable cause Notes
sound
While the engine is running, check the valve clearance by
Large valve inserting a thickness gauge of the standard clearance
clearance and If the clearance is larger than the standard, adjust to the
contact defect standard by tightening the adjusting screw on the top of the
rocker arm
Check by placing a sound scope on the valve
Valve sticking sound The sound gets smaller or stops when engine oil or a noise
damper solution is applied with compressed air
Check by blocking with a wet cloth the likely location of the leak
Exhaust leak in the exhaust system
When the engine speed is increased, the sound gets louder
Stop the nozzle injection and check
After it is stopped, the sound gets smaller or stops
Check by coating with oil the installation areas of the cylinder
Compression leak
head gasket and the injection nozzle glow plug gasket
The oil will bubble out if there is a leak
If a gasket is damaged the combustion gas could leak into the
cooling system, generating bubbles at the top of the radiator

Section 1.2.1
 1DZ-II Repair

HIGH ENGINE OIL CONSUMPTION

The main symptoms of oil consumption are classified as shown below.
1. Oil increase
Symptom where the oil that lubricates the cylinder wall enters the combustion chamber.
After the engine warms up and is left to idle for 4 to 5 minutes or runs at 1000 rpm, when the engine is
raced there is a tendency for whitish purple exhaust gas to be emitted for the initial 30 to 60 seconds,
and then for the gas emission to drop. If this happens, after the engine is again left to idle for 4 to 5
minutes or runs at 1000 rpm, when the engine is raced whitish purple exhaust gas will be emitted in
the same way.
2. Oil decrease
Symptom where the oil enters the combustion chamber from the clearance between the valve stem
and valve guide
Check the exhaust gas condition when the engine is raced at about 2000 rpm after warming up. If a
large amount of whitish purple exhaust gas is emitted, as the engine speed is increased the emission
will get steadily larger.
Symptom Main inspection or adjustment areas
Leak to outside the engine 1. Engine unit
I

1. Cylinder head

I 2. Cylinder block
1 3. Head gasket
Leak to inside the engine I
1 4. Oil increase [Point I ] I
I 1 5. Oil decrease [Point I ] I
[Point I]
Oil increase inspection
A large amount of carbon can be seen adhered to the outer
circumference at the top of the piston.

[Point 21
Oil decrease inspection
Determined by the condition of the carbon adhered to the
intake valve cap and the top of the piston, and by the
wetness of the valve cap caused by oil.

Section 1.2.1
 1DZ-II Repair

ENGINE OVERHAUL

USED SSTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

ENGINE ACCESSORIES ...................... 2-4
REMOVAL. INSPECTION AND INSTALLATION . . . . . . 2-4
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
DISASSEMBLY. INSPECTION AND REASSEMBLY. . . 2-11
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
DISASSEMBLY. INSPECTION AND REASSEMBLY. . . 2-22
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
DISASSEMBLY. INSPECTION AND REASSEMBLY . . . 2-35
CYLINDER BLOCK BORE DIMENSIONS . . . . . . . . . . . 2-47
ENGINE TUNE-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
V BELT TENSION INSPECTION AND ADJUSTMENT . 2-48
VALVE CLEARANCE INSPECTION AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
IDLING SPEED INSPECTION AND ADJUSTMENT ... 2-49
MAXIMUM ENGINE SPEED INSPECTION AND
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
INJECTION TIMING INSPECTION AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
COMPRESSION INSPECTION . . . . . . . . . . . . . . . . . . . 2-52

Section 1.2.2
 1DZ-II Repair

USED SSTs
I Illustration Part number Part name

Oil pan seal cutter

Valve guide bush remover & replacer

Valve stem oil seal replacer

Valve spring compressor

Camshaft bearing remover & replacer

Belt tension gauge

Oil filter wrench

Plunger stroke measuring tool

Section 1.2.2
 1DZ-II Repair

Illustration Part number Part name

Bearing remover

Drive pinion bearing replacer

Puller C set

Puller B set

Replacer set

Replacer B set

Handle set

Variable pin wrench set

Section 1.2.2
 1DZ-II Repair
2-4

ENGINE ACCESSORIES
REMOVAL, INSPECTION AND INSTALLATION

Removal and installation procedure

The installation procedure is the reverse of the removal procedure.
I Procedure 1 1 Removal 1 Inspection Installation
1 1 1 Fan, pulley, V belt 1 See P.2-48 1 t

1 2 1 Alternator, adjusting bar

3 Water pump
4 Intake pipe
5 Glow plug
6 Fuel hose
1 7 1 Injection pipe
Section 1.2.2
 1DZ-II Repair

Procedure Item Removal Inspection Installation

1 8 I Nozzle leakage pipe
9 Injection nozzle [Point I ] [Point 71
10 Injection pump [Point 21 [Point 61
11 Oil filter [Point 31 [Point 51
12 Intake and exhaust manifold [Point 41

Point operation
[Point I ]
Removal: Protect the injection side of nozzles and keep
them in order to ensure there are no cylinder
number errors during installation.

Protection cap

[Point 21
Removal: Remove the injection pump.
1. Remove the injection pipe hose.
2. Remove the service cover located on the front of the
timing gear cover.
(1) Set bolt
(2) Cover

- Cover &d gasket

(3) Gasket

3. While the rotation of the crankshaft is stopped, remove

the injection pump drive gear set nut.

Section 1.2.2
 1DZ-II Repair

4. Align the TDC mark on the crank pulley with the notch of
the timing gear cover.

TDC mark
Note:
When the TDC mark and the notch of the timing gear
cover are aligned, a service tap hole for removing the
pump drive gear can be seen in the service opening.

Service tap
5. Disconnect the injection pump drive gear from the pump
using the SST.
SST 09950-76003-71
(09950-50012)

6. Remove the injection pump assembly.

(1) Pump stay bolt
(2) Pump nut set
(3) Injection pump assembly
(4) 0 ring

Caution:
Do not turn the crankshaft after removing the injection
Pump.
Be sure the pump shaft key position after removing
the injection pump.

Section 1.2.2
1DZ-II Repair

[Point 31
Removal: Remove the oil filter.
SST 09228-76004-71
(09228-07501)

[Point 41
Inspection: Check the intake manifold for distortion.

Limit: 0.4 mm (0.016 in.)

Inspection: Check the exhaust manifold for distortion.

Limit: 0.4 mm (0.016 in.)

[Point 51
Installation: Fit an 0 ring to the oil filter, and attach the oil
filter to the bracket by turning it by hand. Using
the SST, retighten the oil filter by 314 of a turn.
SST 09228-76004-71
(09228-07501)

Caution:
Coat a small amount of the engine oil on the 0 ring.
Clean the fitting surface.

Section 1.2.2
 1DZ-II Repair

[Point 61
Installation: Install the injection pump.

Note:
When installing the injection pump, install it in the
same position as when the position of the pump shaft
key was removed.
Coat a small amount of the MP grease on the 0 ring.
Use a new gasket for the service cover located on the
front of the timing gear cover.
Check and adjust the injection timing after installation.
(See P.2-45)
[Point 71
Installation: The nozzle gasket must be replaced with a new
one.
If it is not defective, reuse the nozzle seat after
fully removing the carbon.

Nozzle gasket
Nozzle seat

Section 1.2.2
 1DZ-II Repair

CYLINDER HEAD
COMPONENTS

Section 1.2.2
1DZ-II Repair

Section 1.2.2
 1DZ-II Repair
2-11
DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

The reassembly procedure is the reverse of the disassembly procedure.
Procedure Item Disassembly Inspection Reassembly
Remove items 1 to 9 and 12 shown under
Ip.2-4.
/ See P.2-4 1 t

2 Cylinder head cover

3 Rocker shaft assembly [Point I ] [Point 21 [Point 151
4 Valve stem cap [Point 31
5 Valve push rod [Point 41 [Point 51
6 Cylinder head bolt [Point 61 [Point 141
1 7 1 Cylinder head assembly I I [Point 71 1 I
Section 1.2.2
 1DZ-II Repair

Procedure Item Disassembly Inspection Reassembly

I I I I

8 Cylinder head gasket [Point 131

r -

9
-

1 valve spring, valve I [Point 81 / [Point 91 / [Point 121

r 10 I valve stem oil seal I I / [point 111
I 11 I valve guide bushing / [point 101 1 t 1 t

Point operation
[Point I ]
Disassembly: Loosen the support set bolts evenly in several
steps in the order shown to the left.

[Point 21
Inspection: Check the rocker arm for wear and damage on
the contact area with the valve stem cap.
If light damage is found, reface with an oil stone.
If there is significant wear or damage, replace it.
Inspection: Move the rocker arm as shown and check the
clearance between the rocker arm and the shaft.
If the clearance is too large, disassemble and
check the parts.

Inspection: Check the oil clearance between the rocker arm

and the rocker shaft.
Measure the inside diameter of the rocker arm.

Standard: 18.500 to 18.520 mm

(0.72835 to 0.72913 in.)
Limit: 18.60 mm (0.7273 in.)

Measure the outside diameter of the rocker shaft.

Standard: 18.470 to 18.490 mm

(0.72717 to 0.72795 in.)
Limit: 18.44 mm (0.7260 in.)

Section 1.2.2
 1DZ-II Repair

3. Calculate the oil clearance.

Standard: 0.007 to 0.049 mm

(0.00028 to 0.00193 in.)
Limit: 0.16 mm (0.0063 in.)

If the limit is exceeded, replace the rocker arm or the

rocker shaft.

[Point 31
Inspection: Check the valve stem cap.
1. Measure the thickness of the valve stem cap.

Standard: 1.31 to 1.49 mm (0.0516 to 0.00587 in.)

2. If light damage is found in the contact areas with the

rocker arm, reface with an oil stone. If there is significant
wear or damage, replace the valve stem cap.

[Point 41
Disassembly: Sort the removed push rods carefully so they

Il!!!!I!
can be reassembled in the correct order.

[Point 51
Inspection: Check the push rods for bend.
Measure the amount of bend per full turn of the
push rod.
Bend = Dial gauge deflection I 2

Limit: 0.25 mm (0.010 in.)

Section 1.2.2
 1DZ-II Repair

[Point 61
Disassembly: Loosen the cylinder head bolts evenly in
several steps in the order shown to the left.

[Point 71
Inspection: Measure the cylinder head distortion using the
straightedge and thickness gauge.
1. Check the distortion along the four edges and along the
diagonal lines at the bottom of the cylinder head.

Limit: 0.15 mm (0.0059 in.)

2. Check the distortion in the manifold fitting surface.

Limit: INlEX 0.20 mm (0.008 in.)

If the limit is exceeded, reface or replace it.

Inspection: Check the cylinder head for cracks.

Using the color check method (dye detection
method), look for cracks in the combustion
chamber, intake port, exhaust port, and the lower
and upper cylinder head surfaces.

Section 1.2.2
1DZ-II Repair

[Point 81
Disassembly: Keep the removed parts in cylinder groups.
SST 09202-76002-71
(09202-70020)

[Point 91
Inspection: Check the valve.
1. Measure the thickness of the valve head.

Limit: IN: 0.9 mm (0.035 in.)

EX: 1.0 mm (0.039 in.)

2. Measure the overall length of the valve.

Standard: IN: 108.54 mm (4.2732 in.)

EX: 108.24 mm (4.2614 in.)
Limit: IN: 107.90 mm (4.2480 in.)
EX: 107.60 mm (4.2362 in.)

Section 1.2.2
 1DZ-II Repair

Inspection: Check the valve seat.

1. Coat a small amount of red lead on the valve face.
2. Insert the valve into the valve guide bushing, and push
the valve against the valve seat.
Do not turn the valve while it is being pushed.
3. Check that the standard contact is met along the entire
circumference.

Standard: IN: 1.2 to 1.6 mm (0.0472 to 0.0630 in.)

EX: 1.6 to 2.0 mm (0.0630 to 0.0787 in.)

If the standard is not satisfied, replace the valve or

correct the valve seat.
4. Correct the valve seat.
(1) Use a 45" valve seat cutter for refacing.
( 2 ) If the contact position is deviated outside, use a 20"
cutter and if the contact position is deviated inside,
use a 75" cutter for refacing.
Use a cutter with a cemented carbide tip on the EX
side.
Cut while constantly checking the valve contact
position and contact width.
Cut the face evenly without undulation by gradually
reducing the pressure toward the end of refacing.
Correct after checking the valve guide bushing.
(3) Perform valve lapping.
Use a compound for lapping. Use red lead for
checking uniform contact with the valve along the
entire circumference.
After checking, completely remove the compound.

Inspection: Check the compression spring.

2.0 mm 1. Measure squareness at the upper end of the spring.
(0.08 in.)
Limit: INlEX 2.0 mm (0.08 in.)

Section 1.2.2
1DZ-II Repair

2. Measure the free length.

Standard: INIEX 46.0 mm (1.811 in.)

Limit: INlEX 45.5 mm (1.791 in.)

[Point 101
Inspection: Check the oil clearance between the valve guide
bushing and the valve stem.
1. Measure the inside diameter of the valve guide bushing.

Standard: IN: 8.01 to 8.03 mm (0.3154 to 0.3161 in.)

EX: 8.01 to 8.03 mm (0.3154 to 0.3161 in.)

2. Measure the outside diameter of the valve stem.

Standard: IN: 7.97 to 7.99 mm (0.3138 to 0.3146)

EX: 7.96 to 7.97 mm (0.3134 to 0.3138)
3. Calculate the oil clearance.

Standard: IN: 0.02 to 0.06 mm (0.0008 to 0.0024 in.)

EX: 0.04 to 0.07 mm (0.0016 to 0.0028 in.)
Limit: IN: 0.10 mm (0.0039 in.)
EX: 0.12 mm (0.0047 in.)

If the limit is exceeded, replace the valve or the valve

guide bushing. Further, reface the inside diameter using
the reamer as required, to bring the oil clearance
between the bushing and the valve stem within the
standard. Perform valve lapping when replacing the
valve. (See P.2-14)
Disassembly and reassembly: Replace the valve guide
bushing.
SST 09201-76002-71
(09201-10000)

Section 1.2.2
 1DZ-II Repair

Inspection: Measure the amount of protrusion of the valve

guide bushing.

Standard: 16.6 f 0.4 mm (0.654 f 0.016 in.)

[Point 111
Reassembly: Coat the engine oil on the lips of the new valve
stem oil seal and the valve stem, and
reassemble them.
SST 09201-76004-71
(09201-56010)

[Point 121
Reassembly: Reassemble the valve spring and valve.
SST 09202-76002-71
(09202-70020)

[Point 131
I @
Engine front direction
Reassembly: Check that the direction is correct when
installing the gasket.

Section 1.2.2
1DZ-II Repair

[Point 141
Reassembly: Tighten the cylinder head bolts evenly in
several steps in the order shown to the left.

[Point 151
keassembly: Tighten the support set bolts evenly in several
steps in the order shown to the left.

Section 1.2.2
 1DZ-II Repair

TIMING GEAR
COMPONENTS

Section 1.2.2
1DZ-II Repair

Section 1.2.2
 1DZ-II Repair
2-22

DISASSEMBLY, INSPECTION AND REASSEMBLY

Section 1.2.2
 1DZ-II Repair

Disassembly and reassembly procedure

Point operation
[Point I]
Disassembly: Remove the crankshaft pulley.
SST 09950-76003-71
(09950-500 12)

[Point 21
Disassembly: If cover ishard to remove, apply a screwdriver
to the slit in the cover and pry off the cover.
At this time, be careful not to damage areas
around the slit.

Section 1.2.2
 1DZ-II Repair

[Point 31
Inspection: Measure the backlash in positions A to F before
removing and after installing the gear.

Standard: 0.05 mm (0.0020 in.)

Limit: 0.3 mm (0.0118 in.)

Inspection: Measure the thrust clearance of idle gear No.1

and No.2.

Standard: ldle gear No.1: 0.03 to 0.11 mm

(0.0012 to 0.0043 in.)
ldle gear No.2: 0.10 to 0.26 mm
(0.0039 to 0.0102 in.)
Limit: ldle gear No.1: 0.3 mm (0.012 in.)
ldle gear No.2: 0.5 mm (0.020 in.)

If the limit is exceeded, replace each idle gear or thrust

washer.
[Point 41
Inspection: Check the idle gear oil clearance.
1. Measure the inside diameter of the idle gear.

Standard: No.1: 45.000 to 45.025 mm

(1.77165 to 1.77264 in.)
No.2: 50.000 to 50.025 mm
(1.96850 to 1.96948 in.)

2. Measure the outside diameter of the idle gear shaft.

Standard: No.1: 44.950 to 44.975 mm

(1.76969 to 1.77067 in.)
No.2: 49.930 to 49.945 mm
(1.96575 to 1.96634 in.)
3. Calculate the oil clearance.
Standard: No.1: 0.025 to 0.075 mm
(0.00098 to 0.00295 in.)
No.2: 0.055 to 0.095 mm
(0.00217 to 0.00374 in.)
Limit: 0.3 mm (0.012 in.)

Section 1.2.2
1DZ-II Repair

Inspection: Measure the thrust washer thickness.

Standard: 2.45 to 2.50 mm (0.0965 to 0.0984 in.)

[Point 51
Disassembly: Remove the injection pump drive gear.
SST 09950-76003-7 1
(09950-50012)

[Point 61
Disassembly: Remove the bearing.
Case side
SST 09320-23000-71

Gear side
SST 09950-76014-71
(09950-40011) .... ........ ........... (1)
SST 09950-7601 8-71
(09950-60010) .......... . . .... ....... (2)

Section 1.2.2
 1DZ-II Repair

[Point 71
Disassembly: Sort the removed valve lifters carefully so they
can be installed in the correct order.

[Point 81
Inspection: Check the valve lifter oil clearance.
1. Measure the outside diameter of the valve lifter

Standard: STD: 22.170 to 22.190 mm

(0.8728 to 0.8736 in.)
01s (0.05): 22.220 to 22.240 mm
(0.8748 to 0.8756 in.)

2. Measure the inside diameter of the cylinder block bore.

Standard: 22.200 to 22.221 mm

(0.87402 to 0.87484 in.)

3. Calculate the valve lifter oil clearance.

Standard: 0.010 to 0.051 mm

(0.00039 to 0.00201 in.)
Limit: 0.1 mm (0.004 in.)

If the limit is exceeded, replace the valve lifter.

If an 01s valve lifter is to be used, correct the inside
diameter of the bore to standard.
OIS valve lifter bore inside diameter standard:
22.245 to 22.271 mm (0.87579 to 0.87681 in.)
[Point 91
Disassembly: Do not deform the oil pan flange while
working.
SST 09032-76001-71
(09032-00100)

Caution:
Do not use the SST on the timing gear case side.
Do not pry with a screwdriver, etc.

Section 1.2.2
1DZ-II Repair

[Point 101
Inspection: Measure the thrust clearance of the camshaft.

Standard: 0.06 to 0.13 mm (0.0024 to 0.0051 in.)

Limit: 0.3 mm (0.012 in.)

Inspection: Measure the cam height.

Standard: IN: 39.928 to 40.028 mm

(1,57197 to 1.57591 in.)
EX: 40.312 to 40.412 mm
(1.58709 to 1.59102 in.)
Limit: IN: 39.47 mm (1.5539 in.)
EX: 39.85 mm (1.5689 in.)

Inspection: Check the camshaft for bend.

Bend = Dial gauge deflection I 2

Limit: 0.04 mm (0.0016 in.)

Inspection: Check the camshaft bearing oil clearance.

1. Measure the outside diameter of the camshaft journal.

Standard: No.1 (front): 47.159 to 47.175 mm

(1.85665 to 1.85728 in.)
No.2 (center): 46.959 to 46.975 mm
(1.84878 to 1.84941 in.)
No.3 (rear): 46.759 to 46.775 mm
(1.84091 to 1.84154 in.)

Section 1.2.2
 1DZ-II Repair

2. Measure the inside diameter of the camshaft bearing

Standard: No.1 (front): 47.200 to 47.225 mm

(1.85827 to 1.85925 in.)
No.2 (center): 47.000 to 47.025 mm
(1.85039 to 1.85138 in.)
No.3 (rear): 46.800 to 46.825 mm
(1.84252 to 1.84350 in.)

3. Calculate the oil clearance.

Standard: 0.025 to 0.066 mm (0.00098 to 0.00260 in.)

Limit: 0.1 mm (0.0039 in.)

If the limit is exceeded, replace the bearing. If a serious

streak or damage is found on the camshaft journal,
reface the camshaft journal and replace the bearing with
a UIS bearing.
[Point 111
Disassembly: Remove the camshaft timing gear set bolt.
SST 09960-76001-71
(09960-10010)

Disassembly: Remove the timing gear from the camshaft

. . Socket using a press.

[Point 121
Disassembly: Remove the key for crankshaft pulley and
remove the crankshaft timing gear using the
SST.
SST 09950-76014-77
(09950-40011)

Section 1.2.2
1DZ-II Repair

[Point 131
Disassembly: Remove the camshaft bearing.
1. Remove the oil strainer.
2. Remove the tight plug from the rear of the block.
SST 09215-76004-71
(09215-00101)
3. Remove the camshaft bearing No.1 and No.3.
SST 092 15-76004-71
(09215-00101)
4. Remove the camshaft bearing No.2.
SST 09215-76004-71
(09215-00101)
[Point 141
Reassembly: Install the camshaft bearing.
Align the oil holes of the bearing and of the
cylinder block.
1. Install the camshaft bearing No.2.
SST 09215-76004-71
(09215-00101)
2. Install the camshaft bearing No.1 and No.3.
SST 09215-76004-71
(092 15-00101)
3. Coat THREEBOND 1386 to the outer periphery using a
new tight plug and drive the bearings until they are flush
with the cylinder block.
SST 092 15-76004-71
(09215-00101)

Section 1.2.2
 1DZ-II Repair

Camshaft bearing size

I Standard outside diameter of camshaft journals mm (in.)

. ,
Bearing type
No.1 No.2 No.3

Standard
1 47.159to47.175
(1.85665 to 1.85728)
1 46.959 to 46.975
(1.84878 to 1.84941)
1 46.759 to 46.775
(1.84091 to 1.84154)

1 UIS 0.250
1 46.909 to 46.925
(1.84681 to 1.84744)
1 46.709 to 46.725
(1.83893 to 1.83957)
1 46.509 to 46.525
(1.83106 to 1.83169)

[Point 151
Reassembly: Drive in the oil seal using the SST until it
becomes flush with the timing gear cover
surface.
SST 09950-76019-71
(09950-60020) .......................(1
SST 09950-76020-71
(09950-70010) .......................(2)

Note:
Coat MP grease on the oil seal lips.

[Point 161
Reassembly: Coat the FlPG on the timing gear case seal.
FIPG: 08826-76001-71
(For handling the FIPG, see P.0-18)

[Point 171
Reassembly: Reassemble the crankshaft timing gear using
the SST and install the key for the crankshaft
pulley.
SST 09370-20270-71

Section 1.2.2
 1DZ-II Repair

[Point 181
Reassembly: Install the camshaft timing gear.
1. Reassemble the thrust plate with the oil groove facing
Oil groove

&
the gear side.

2. Install the camshaft timing gear set bolt.

SST 09960-76001-71
(09960-10010)

[Point 191
Reassembly: Coat the FIPG on the oil pan seal.
FIPG: 08826-76001-71
(For handling the FIPG, see P.0-18

I FIPG
/

Gear side SST ( I ) Case side I [Point 201

Reassembly: Install the bearing.
SST (2) Case side, gear side
SST 09950-76018-71
(09950-60010) ........... ... ......... (1)
SST 09950-76020-71
(09950-70010) . ......... ...... ... .... (2)

Section 1.2.2
 1DZ-II Repair

[Point 211
Reassembly: Check that the No.1 cylinder is in the TDC.
Reassemble the idle gears by aligning the
, punched marks with the marks on the other
gears.

[Point 221
Reassembly: Coat the FIPG on the timing gear cover seal.
FIPG: 08826-76001-71
(For handling the FIPG, see P.0-18)

[Point 231
Reassembly: Reassemble the crankshaft pulley.
SST 09950-76018-71
(09950-600 10) ..... .... .. ..... .... ... (1)
SST 09950-76020-7 1
(09950-70010) . ......... ....... ...... (2)

Section 1.2.2
 1DZ-II Repair

CYLINDER BLOCK
COMPONENTS

Section 1.2.2
1DZ-II Repair

Section 1.2.2
 1DZ-II Repair
2-35

DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

The reassembly procedure is the reverse of the disassembly procedure.
Procedure I Item I Disassembly I Inspection / Reassembly
1 I Cylinder head assembly I see p.2-10 I t I t

2 1 Timing gear parts I see p.2-20 I t I t

3 1 Oil strainer I I I
4 1 Rear oil seal retainer with oil seal I I I
5 / Rear oil seal I I / [point 121
6 1 Measure the thrust clearance of the connecting rod. 1
7 1 Connecting rod cup with bearing I I [Point 21 1 [Point 111
8 Piston with connecting rod [Point 101
9 Piston disassembly [Point 31 [Point 41 [Point 91
10 1 Measure the thrust clearance of the crankshaft. / ( [point 51 1
11 Crankshaft cap, bearing, thrust washer [Point 61 [Point 81
12 Crankshaft [Point 71
13 1 oil regulator I I I
Section 1.2.2
 1DZ-II Repair

CAUTION:
Do not confuse the parts of different cylinders during installation.
Point operation
[Point I ]
Inspection: Measure the thrust clearance of the connecting
rod.

Standard: 0.08 to 0.30 mm (0.0031 to 0.0118 in.)

Limit: 0.40 mm (0.0157 in.)

[Point 21
Inspection: Measure the oil clearance of the connecting rod
bearing. Measure using the plastigage, and
tighten the connecting rod cap set nut to
specified torque.
Do not turn the crankshaft during measurement.

Standard: 0.044 to 0.080 mm (0.00173 to 0.00315 in.)

Limit: 0.110 mm (0.043 in.)

If the limit is exceeded, replace the bearing. If a

serious streak or damage is found on the
bearing, reface the crankshaft and replace the
bearing with a UIS bearing.

Standard crankpin outside

Bearing cap fitting Bearing
Fittina code ?f code fitting code
diameter
mm (in.)

Section 1.2.2
1DZ-II Repair

[Point 31
Disassembly: Disassemble the piston and connecting rod.
1. Remove the piston ring and the oil ring.

2. Remove the snap ring, warm the piston to about 60 "C,

and remove the piston pin from piston using the brass
bar.
Keep the piston, the piston pins and the connecting rods
sorted by cylinder groups.

[Point 41
Inspection: Check the cylinder block.
1. Check the cylinder block for distortion in the upper
surface.

Limit: 0.1 mm (0.004 in.)

Make sure that the cylinder wall is free of serious

scratches.

2. Measure the six dimensions as shown to the left, and

determine the difference between the maximum and
minimum dimensions.

Limit: 0.2 mm (0.008 in.)

Section 1.2.2
 1DZ-II Repair

3. Check ellipticity and taper.

Ellipticity: A-B or a-b

Taper: A-a or B-b
Limit: Ellipticity: 0.02 mm (0.0008 in.)
Taper: 0.02 mm (0.0008 in.)

4. Measure the piston clearance.

(1) Measure the outside diameter of the piston.

Measuring position: Measure at location vertical

to the piston pin and 12.0
mm (0.472 in.) away from the
piston bottom (skirt).
12.0 mm
(0.472 in.) Standar'd: 85.950 to 85.980 mm
(3.3839 to 3.3850 in.)

(2) Calculate the piston clearance from the cylinder inside

diameter measured in inspection 2.

Standard: 0.040 to 0.060 mm

(0.00157 to 0.00236 in.)
Limit: 0.15 mm (0.0059 in.)

5. If the limit is exceeded in inspection 2, 3, or 4, bore the

cylinder and install an O/S piston.
Front mark If there is a wear larger than the limit for O/S piston, use
a repair liner (exclusive part).

r
(1) When replacing the piston or boring the cylinder
Cylinder inside Piston outside
Piston type diameter diameter
Piston size fitting code 1 to 3 mm (in.) mm (in.)

Section 1.2.2
 1DZ-II Repair

When boring the cylinder, select an appropriate 01s

Cylinder inside diameter fitting piston on the basis of the maximum inside diameter
code 1 to 3 among all cylinders.
Bored dimension = (01s piston outside diameter) +
(oil clearance) - (boring margin)

Oil clearance: 0.040 to 0.060 mm

(0.001 57 to 0.00236 in.)
Boring margin: 0.02 mm (0.0008 in.)

After boring the cylinder, measure again the ellipticity,

taper, difference in inside diameter, and piston
clearance.
(2) When using the repair liner.
Liner fitting Cylinder bore Cylinder liner
code diameter outside diameter
mm (in.) mm (in.)

B
L

(a) Bore the cylinder for press fitting the liner.

After boring, wash the area thoroughly and
clean it using compressed air. (For the bored
dimensions, see P.2-47)
(b) Coat the engine oil on the liner surface.
(c) Install the liner using the SST and a press.
SST 09950-76019-71
(09950-60020)

(d) When replacing the cylinder liner, remove the

liner using the SST and a press and follow
steps (a) to (c).
SST 09950-76019-71
(09950-60020)
SST

Section 1.2.2
 1DZ-II Repair

1nspection:Check the piston and connecting rod.

1. Measure the gap between the piston ring and the ring
groove along the entire circumference of the piston.

Standard: No.1: 0.06 to 0.09 mm

(0.0024 to 0.0035 in.)
No.2: 0.04 to 0.08 mm
(0.0016 to 0.0031 in.)
Oil ring: 0.03 to 0.07 mm
(0.0012 to 0.0028 in.)

2. Press down the piston ring with the piston until it

reaches the sliding parts of the ring, and measure the
piston ring end gap.

Standard: No.1: 0.27 to 0.39 mm

(0.0106 to 0.0154 in.)
No.2: 0.45 to 0.60 mm
(0.0177 to 0.0236 in.)
Oil ring: 0.20 to 0.40 mm
(0.0079 to 0.0157 in.)

3. Measure the oil clearance of the connecting rod

bushing.
(1) Measure the inside diameter of the bushing.

Standard: 27.011 to 27.023 mm

(1.06343 to 1.06390 in.)

(2) Measure the outside diameter of the piston pin.

Standard: 27.000 to 27.012 mm

(1.06299 to 1.O6346 in.)

(3) Calculate the oil clearance.

Standard: 0.007 to 0.015 mm

(0.00028 to 0.00059 in.)
Limit: 0.05 mm (0.0020 in.)

If the limit is exceeded, replace the connecting rod

assembly.

Section 1.2.2
 1DZ-II Repair

[Point 51
Inspection: Measure the thrust clearance of the crankshaft.

Standard: 0.04 to 0.24 mm (0.0016 to 0.0094 in.)

Limit: 0.3 mm (0.012 in.)

If the limit is exceeded, replace the thrust washer

or the crankshaft.

Thrust washer thickness (reference)

Standard: 1.93 to 1.98 mm (0.0760 to 0.0780 in.)
01s: 0.125, 0.250 mm (0.00492, 0.00984 in.)
[Point 61
Disassembly: Loosen the cap set bolts evenly in several
steps in the order shown to the left.
Sort the removed cap, bearing and washer
carefully so they can be installed in the correct
positions.

[Point 71
Inspection: Check the crankshaft.
1. Measure the oil clearance of the crankshaft using the
plastigage.
Do not turn the crankshaft during measurement.

Standard: 0.028 to 0.048 mm (0.00110 to 0.00189 in.)

Limit: 0.1 mm (0.004 in.)

If the limit is exceeded, replace the bearing. If a serious

streak or damage is found on the bearing, reface the
crankshaft and replace the bearing with a UIS bearing.

, Fitting code B is journal Selecting the bearing

,
Based on the appropriate fitting code given in the table
1 I No.1 to No.5 from below, select the bearing to be used.
C (code of bearing to be selected) = A (bearing bore
code) + B (journal outside diameter code)
mm (in.

~ i t t i n gcode Upper bearing has

oil groove all around
Lower bearing does
not have oil groove
f
0
1 Bearing bore 1 z1
a, Journal
diameter 1ga, Bearing
thickness

Section 1.2.2
 1DZ-II Repair

S1
Bearing
% Bearing bore
thickness

U/S bearing
mm (in.

UIS 0.25 (2.54843 to (0.08283 to

2.54921) 0.08307)

2. Check the crankshaft for bend

Measure the amount of bend per full turn of the
crankshaft.

Bend = Dial gauge deflection / 2

Limit: 0.05 mm (0.0020 in.)

Section 1.2.2
1DZ-II Repair

3. Check the crankshaft for wear.

(1) Measure the dimensions of the crankshaft journal as
shown.

Standard: 64.98 to 65.00 mm (2.5583 to 2.5591 in.)

(2) Calculate ellipticity and taper.

Limit: Ellipticity: 0.02 mm (0.0008 in.)

Taper: 0.05 mm (0.0020 in.)

If the standard is not met or if the limit is exceeded, or if a

serious streak or damage is found, reface the crankshaft and
replace the bearing with a UIS bearing.

(3) Measure the dimensions of the crankshaft pin as

shown.

Standard: 50.48 to 50.50 mm (1.9874 to 1.9882 in.)

(4) Calculate ellipticity and taper.

Limit: Ellipticity: 0.02 mm (0.0008 in.)

Taper: 0.05 mm (0.0020 in.)

If the standard is not met or if the limit is exceeded, or

if a serious streak or damage is found, reface the
crankshaft and replace the bearing with a UIS
bearing.

Finished outside diameter of the

Bearing type crankshaft pin
mm (in.)

/ UIS 1.00 1 49.49 to 49.50

(1.9484 to 1.9488)

Section 1.2.2
 1DZ-II Repair

[Point 81
Front mark
Reassembly: Reassemble the bearing cap.
1. Install the thrust washer with the oil groove facing the
crankshaft side.
2. Install in same place as before disassembly with
reference to the front mark.

Oil

3. Tighten evenly in several steps in the order as shown.

[Point 91
Reassembly: Reassemble the connecting rod.
1. Install the snap ring on one side.
2. Warm the piston to about 60°C (140°F).

3. Align the front marks on the piston and the connecting

rod.
4. lnstall the piston pin.
5. Install the snap ring.

Section 1.2.2
 1DZ-II Repair

Reassembly: Reassemble the piston ring.

1. lnstall the oil ring expander.
2. lnstall the oil ring side rail using a piston ring tool.
Oil rings may be installed with either side facing upward.
3. lnstall the piston rings using a piston ring tool with the
punched marks facing upward.
Punched mark Punched mark:Top ring: T I
Second ring: T2
Oil ring: None

4. Position the ring joints as shown.

Second ring Oil ring

I
Front
mark

B
-
Oil ring
expander
Top ring

Reassembly: Reassemble the bearing.

Prevent foreign matter, oil, etc., from adhering
to the bearing surface and coming into contact
with the connecting rod.
Coat the engine oil on the bearing bore.
lnstall the upper bearing by matching the
connecting rod lock groove.
lnstall the lower bearing by matching the
bearing cap lock groove.

[Point 101
Reassembly: Reassemble the piston in the same cylinder
from which it was disassembled.
Coat the piston and connecting rod sliding
parts with engine oil.
Install the piston with the front mark facing the
front side.
Do not damage the cylinder inner surface or
the crankshaft with the connecting rod bolt.

Section 1.2.2
 1DZ-II Repair

[Point 111
Reassembly: Reassemble the connecting rod cap.
1. Install the bearing cap with the front mark facing the
front side of the engine.
2. Prevent foreign matter, oil, etc., from adhering to the
bearing back surface.
3. Coat the engine oil on the bearing bore.
4. Tighten left and right bolts alternately in several steps.

[Point 121
Reassembly: Reassemble the rear oil seal.
SST 09950-76019-71
(09950-60020) ....... ... .......... ... (1
SST (2)
SST 09950-76020-71
(09950-700 10) ........... ..... ....... (2)

SST (1)

Section 1.2.2
 1DZ-II Repair

CYLINDER BLOCK BORE DIMENSIONS

( @86)
(Bore inside diameter

Note:
Upon press fitting the cylinder liner, reface the cylinder liner so that the liner will be flush with the
upper surface of the cylinder block. At the time, the maximum limit for the cylinder block must be
less than 0.1 mm (0.0039 in.).
Section 1.2.2
 1DZ-II Repair

Pressure 98 N ENGINE TUNE-UP

V BELT TENSION INSPECTION AND
ADJUSTMENT
1. Check the V belt tension.
(1) Make sure that the belt is fitted correctly.
(2) Press the belt between water pump and the alternator
with a force of about 98 N (10 kgf) [22.1 Ibfl and check
the amount of deflection.

New belts: 7 to 9 mm (0.28 to 0.35 in.)

Belts in use: 8 to 13 mm (0.31 to 0.51 in.)
Caution:
Measure the amount of deflection between the
specified pulleys.
When a new belt is fitted, adjust tension to the median
of the standard for "new belts".
When checking a belt that has been used for 5
minutes or longer, check that the tension is the
median of the standard for "belts in use".
When reassembling a belt that has been used for 5
minutes or longer, adjust the tension to the median of
the standard for "belts in use".
Standard tension when using the SST

SST 092 16-76004-71

(09216-00020)

New belts: 520 to 755 N (53 to 77 kg) [116.9 to 169.8 Ibfl

Belts in use: 324 to 559 N (33 to 57 kg) [72.8 to 125.7 Ibfl

Note:
Fit the belt tension gauge hooks to the belt crests to
measure tension.
Alternator adjusting bolt 1 2. Adjust the V belt tension.
(1) Loosen the alternator set bolt and the adjusting bolt.
(2) Tension the V belt using a 300 to 400 mm (12 to 16
in.) long lever, and tighten the alternator adjusting
bolt.
(3) Tighten the alternator set bolt and recheck the belt
tension.

Caution:
Tension adjustment using a lever tends to cause
variation from one mechanic to another. It must be
followed by measurement of the deflection.

Section 1.2.2
 1DZ-II Repair

VALVE CLEARANCE INSPECTION AND

ADJUSTMENT
1. Warm up the engine.

Standard: coolant temperature 75 to 85 OC

(167 to 185 OF)
2. Check the valve clearance.
(1) Set cylinder No.1 to the TDC.
Align the TDC notch mark on the crank pulley with the
timing pointer.
Note:
Position so that the following marks abc are i n alignment
when viewed from the top of the protrusion for position
alignment on the timing gear cover side
(a) TDC mark on the crank pulley
(b) Timing pointer
(c) End groove of the protrusion for position
alignment on the timing gear cover side
(2) Measure the valve clearance as shown.
I Cylinder No.1 at compression TDC I Standard: IN: 0.18 to 0.22 m m (0.0071 to 0.0087 in.)

-
(hot engine)
EX: 0.33 to 0.37 mm (0.0.130 to 0.0146 in.)
(hot engine)

(3) Turn the crankshaft in the forward direction to set

cylinder No.4 to the TDC.

I Cylinder No.4 at compression TDC

3.
(4) Measure the valve clearance of the remaining valves.

Adjust the valve clearance.

(1) Loosen the lock nut and turn the adjusting screw for
adjustment.
Standard: IN: 0.18 to 0.22 mm (0.0071 to 0.0087 in.)
(hot engine)
EX: 0.33 to 0.37 mm (0.0130 to 0.0146 in.)
(hot engine)

(2) Tighten the lock nut and recheck the valve clearance.

IDLING SPEED INSPECTION AND

ADJUSTMENT
1. Warm up the engine.
Standard: coolant temperature 75 to 85 OC (167 to
I 8 5 OF)
2. Attach the tachometer.
3. Check the idling speed.
(1) Check that the accelerator wire returns and make
sure that the adjusting screw of the injection pump is
touching the accelerator lever.

Section 1.2.2
 1DZ-II Repair

Idle adjusting screw I (2) Check the idling speed.

Standard: See the repair manual for each model
4. Adjust the idling speed.
(1) Loosen the lock nut and turn the adjusting screw for
adjustment.
(2) Tighten the lock nut and recheck the idling speed.

/
Accelerator lever

MAXIMUM ENGINE SPEED INSPECTION AND

ADJUSTMENT
1. Warm up the engine.
Standard: coolant temperature 75 to 85 O C
(167 to 185 O F )

2. Attach the tachometer.

3. Check the no-load static maximum speed.
(1) With the engine stationary, depress the accelerator
pedal fully and make sure that the adjusting lever is
touching the maximum adjusting screw.

Maximum adjusting screw I (2) Start the engine, depress the accelerator pedal fully
and check the engine speed (no-load static maximum
speed).
Standard: See the repair manual for each model
4. Adjust the no-load static maximum speed.
Unseal the maximum adjusting screw and turn it for
adjustment.
5. Check the maximum speed while there is a load.
(1) With the engine running at the maximum speed,
operate the loading levers and measure the engine
speed at full relief. Measure the engine speed drop
(relief down).
Engine speed drop at full relief:200 rpm

(2) Seal the set screw.

Fuel pipe No.1 I INJECTION TIMING INSPECTION AND

ADJUSTMENT
1. Set cylinder No.1 to the TDC. (See P.2-44)
2. Disconnect the fuel pipe No.1 at the pump side.
3. Remove the bolt at the rear end of the injection pump.

Section 1.2.2
1DZ-II Repair

4. Set the SST and the dial gauge in the bolt bore.
SST 09240-32880-71

Caution:
Place the end of the dial gauge on a flat surface. Also,
prevent foreign matter or dust from entering during
work.
5. While observing the dial gauge reading, turn the
crankshaft in the reverse direction by a crank angle of
over 25" from TDC of cylinder No.1. When the dial
gauge pointer deflection stops, set the dial gauge to 0.
6. Slowly turn the crankshaft in the forward direction to set
cylinder No.1 to the TDC again.
7. Read the dial gauge.
Standard: 0.90 f 0.03 mm (0.0354 f 0.0012 in.)
8. Adjust the injection timing.
Make sure that the marks on the timing gear case B
and the injection pump body A are aligned with each
other. If they are not aligned, check the amount of
offset.
Loosen the injection pump connections of the
following pipes.
Fuel inlet pipe
Injection pipe
Overflow pipe

Loosen the injection pump mounting nut and lower

bracket.
Move the pump body for adjusting.
(a) Move the pump body in direction A when the
measured value in step 7 was smaller than
0.87 mm (0.034 in.).
(b) Move the pump body in direction B when the
measured value in step 7 was larger than
0.93 mm (0.037 in.).
Tighten the injection pump mounting nut and the
lower bracket and recheck the injection timing.
Tighten the loosened pipe joints.
9. After the injection timing inspection and adjustment,
remove the SST and the dial gauge, and mount the bolt
at the rear end of the pump.

Caution:
Always use a new copper washer.
Keep out dust and foreign matter.

Section 1.2.2
 1DZ-II Repair

COMPRESSION INSPECTION
1. Warm up the engine.
Standard: coolant temperature 75 to 85 O
C
(167 to 185 OF)
2. Remove the intake pipe.
3. Disconnect the glow plug wiring and remove the glow
plug.
4. Disconnect the fuel cut solenoid connector.
5. Measure the compression.

Note:
Run the starter to empty the cylinder before measuring
the compression.
(1) Fit the compression gauge attachment to the glow
plug hole, and connect the compression gauge to the
attachment.
(2) Crank the engine and measure the compression
pressure. (at 260 rpm)
Standard: 2850 kPa (29.0 kgf/cm2) [412 psi]
Limit: 2000 kPa (20.0 kgf/cm2)[284 psi]

Note:
Use the same number of compression strokes for
each cylinder. For example, if ten compression
strokes are necessary to obtain the maximum
pressure for No.1 cylinder, also use ten strokes for the
other cylinders.
Use a fully charged battery to maintain the specified
engine speed.
(3) Measure the compression pressure for each cylinder.
Limit of difference between cylinders:
200 kPa (2 kgf/cm2) [28 psi]

(4) If the compression pressure in any cylinder is below

the limit, or if the differential pressure between any
two cylinders is larger than the limit, add a small
amount of the engine oil from the nozzle case and
repeat steps ( I ) to (3).
(a) If the pressure increases after adding the oil,
the piston ring andlor the cylinder wall may be
worn.
(b) If the pressure remains low after adding the
oil, there may be a valve seizure, poor valve
contact or pressure leakage from the gasket.

Section 1.2.2
 1DZ-II Repair

FUEL SYSTEM

USED SSTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . 3-4
DISASSEMBLY, INSPECTION AND REASSEMBLY. . . 3-6
INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . 3-9
INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . 3-15
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
AIRTIGHTNESS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Section 1.2.3
 1DZ-II Repair

USED SSTs
Part number Part name

Fuel filter wrench

Injection pump arm

njection pump tool set

Vozzle holder retaining nut wrench

Steering warm bearing puller

Section 1.2.3
1DZ-II Repair

Section 1.2.3
 1DZ-II Repair

REMOVAL AND INSTALLATION

Removal and installation procedure

The installation procedure is the reverse of the removal procedure.
Number Item Removal Inspection Installation
1 Disconnect the wiring.
2 Fuel hose
3 Fuel filter set bolt
4 Fuel filter

Caution:
Bleed air from the fuel system after installing the fuel pump.

Section 1.2.3
1DZ-II Repair

Bleeding air from the fuel system

Operate the priming pump knob up and down to bleed air.
Air bleeding has finished when the knob operations feel
heavy.

Section 1.2.3
 1DZ-II Repair
3-6

DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

The reassembly procedure is the reverse of the disassembly procedure.
Number Item Disassembly Inspection Reassembly
1- bolt, 0 ring
1 2 1 Sedimenter, 0 ring
3 Fuel filter element [Point I] [Point I]

[Point I]
Disassembly and reassembly: Replace the fuel filter.
SST 09228-76010-71
(09228-640 10)

Section 1.2.3
1DZ-II Repair

Reassembly: Coat a small amount of light oil on the 0 ring of

the fuel filter element.

Section 1.2.3
 1DZ-II Repair
3-8

INJECTION NOZZLE
COMPONENTS

Section 1.2.3
 1DZ-II Repair
3-9

REMOVAL AND INSTALLATION

Removal and installation procedure

The installation procedure is the reverse of the removal procedure.
Number Item Removal Inspection Installation
1 Intake pipe
2 Injection pipe
3 Fuel hose
4 Nozzle leakage pipe
5 / lnjection nozzle assembly I I [Point I] /
Caution:
The nozzle gasket must be replaced with a new one.

Section 1.2.3
 1DZ-II Repair

Point operation
[Point I ]
Inspection: Check the injection nozzle assembly.
1. Check the injection nozzle injection pressure.
Attach the injection nozzle to the tester.
Quickly operate the tester lever to cause a few
injections and remove the carbon deposit at the
nozzle outlet.
Slowly push the tester lever to raise the pressure.

Read the pressure gauge immediately when the rising

pressure drops suddenly.
Standard: 11.77 f 0.49 Mpa (120 f 5 kgf/cm2)
[ I 706 f 71 psi]
If standard is not met, disassemble the nozzle and
adjust by replacing the washer.
If it is below the standard, use a thicker washer, and if
it is above the standard, use a thinner washer.
43 types of washers are provided in 0.025 mm
(0.00098 in.) steps in a range of 0.900 to 1.950 mm
(0.0354 to 0.0768 in.). The injection pressure
changes by about 0.49 MPa (5 kgf/cm2) [71 psi] as
the washer thickness changes by 0.05 mm (0.00197
in.).
2. Check the oil seal at the valve seat.
(1) Slowly push the tester lever until the pressure rises to
approximately 9.8 to 10.8 MPa (100 to 110 kgf/cm2)
[I400 to 1500 psi]. Maintain the pressure for about 10
seconds, and confirm that the fuel is not leaking from
the nozzle outlet or the retaining nut.
(2) If leaking, disassemble and clean the nozzle or
0 X
replace it. Recheck after replacement.
Good No good

3. Check the spray pattern.

0 X X X
Good No good No good No good

Section 1.2.3
 1DZ-II Repair

Inspection: Disassemble, clean, and check the injection

nozzle assembly.
1. Secure the nozzle holder by way of a cushioning metal
in a vise and remove the retaining nut.
Be careful at this time that the spring inside is active.

SST 4 Note also that the removal of the retaining nut will allow
all other parts to be taken apart.
SST 09268-76003-71
(09268-64010)

2. Clean the nozzle.

(1) Use a small piece of hard wood and a brass brush.
Clean the nozzle with clean light oil.
Piece of wood ( 2 ) Clean the carbon deposit at the nozzle needle tip

fl
using a small piece of hard wood.
(3) Clean the carbon deposit on the outside of the nozzle
body using a brass brush.

3. Check the nozzle appearance.

(1) Check the nozzle body for cracks and corrosion.
(2) Check the nozzle needle for damage and corrosion. If
necessary, replace the nozzle assembly.

4. Perform a sinking test.

(1) Wash the nozzle needle with clean light oil.
(2) Incline the nozzle body by about 60°, and expose
about 113 of the needle.

Section 1.2.3
 1DZ-II Repair

(3) Release the needle, and make sure that it sinks

smoothly into the body by its own weight.
(4) Repeat the test while turning the needle a little at a
time. If the needle does not sink at any point in the
test, replace the body and needle as a set.

5. Perform reassembly with the same procedures as

disassembly and using the SST.
SST 09268-76003-71
(09268-64010)
Retaining nut tightening torque
T = 58.8 to 78.5 N-m (600 to 800 kgf-cm)
[43.4 to 57.9 ft-lbfl

Section 1.2.3
 1DZ-II Repair

INJECTION PUMP
SPECIFICATIONS
Direction of rotation Clockwise as viewed from the drive side
Injection order I A-B-C-D
Injection interval
Plunger diameter mm (in.)
Cam lift mm (in.) 2.2 (0.087)
Governor type Centrifugal (all speed)
Timer Hydraulic
Feed pump Vane type (built-in type)
Lubrication method Fuel lubrication
Fuel cut Fuel cut by a solenoid

COMPONENTS

Section 1.2.3
1DZ-II Repair

Section 1.2.3
 1DZ-II Repair
3-15

REMOVAL AND INSTALLATION

Removal and installation procedure

The installation procedure is the reverse of the removal procedure.
1 Removal I Inspection 1 Installation
1 I Intake pipe I I I
2 lnjection pipe, hose
3 Injection pump assembly See P.2-4 t t

Section 1.2.3
 1DZ-II Repair

DISASSEMBLY
Caution:
Wash the outside of the injection pump. Clean the work bench and workshop before operation.
Always measure and record the pump injection volume characteristics before disassembly. This
information gives a clue as to the cause of any adjustment error or defective parts.
While disassembling parts, check how they were installed and check them for any sign of
deformation, damage, roughening and scratches.
Arrange the removed parts in an orderly manner and distinguish parts to be replaced from those
to the reused.
1. Remove the overflow screw and drain the fuel.
n 1
Overflow screw

2. Attach the pump to the pump mounting bench using the

SST.
SST 09245-76001-7 1
(09245-54010)

3. Remove the governor cover.

(1) Socket bolt
(2) Lift the governor cover, and disconnect the control
spring from the governor spring seat.
(3) Damper spring
(4) Governor spring seat
(5) Control spring
(6) Governor cover

Section 1.2.3
1DZ-II Repair

4. Remove the fuel inlet union.

5. Remove the governor shaft parts.
(1) Loosen the governor shaft lock nut.
SST 09260-76003-71
(09260-54012)
(2) Loosen the governor shaft using a hexagon wrench.
Caution:
Note that the lock nut and the governor shaft have left-
handed threads.

(3) While extracting the governor shaft, remove the

following parts as an assembly:
(a) Flyweight holder
(b) Flyweight
(c) Flyweight washer
(d) Governor sleeve
(4) Washer
(5) Adjusting washer

6. Remove the solenoid.

(1) Boot
(2) Solenoid assembly
(3) 0 ring

7. Remove the distributor head plug.

(1) Head plug
SST 09260-76003-71
(09260-54012)
(2) 0 ring

Section 1.2.3
 1DZ-II Repair
- --

8. Remove the delivery valve.

(1) Delivery valve holder
SST 09260-76003-71
(09260-54012)
(2) Valve spring seat
(3) Valve spring
(4) Delivery valve, valve seat
(5) Valve gasket

Caution:
Keep removed valves and valve seats in pairs per
cylinder.
Keep delivery valves, delivery holders and other parts
in groups for reinstallation in the same cylinders.

Note:
Cylinder marks (A, 6, C, D) are punched on the
distributor heads.

9. Remove the distributor head.

(1) Distributor head
(2) Lever support spring

Note:
When removing the distributor head, do so carefully
while holding the plunger end with a pair of tweezers or
similar tool.

10. Remove the plunger.

(1) Plunger spring guide
(2) Plunger spring shim
(3) Plunger spring upper seat
(4) Plunger spring
(5) Spill ring
(6) Plunger spring lower seat
(7) Plunger upper plate
(8) Plunger lower plate
(9) Plunger

Section 1.2.3
1DZ-II Repair

Caution:
Do not lose adjusting shims under the plunger.
11. Remove the governor lever.
(1) Support bolt

(2) Governor lever

12. Remove the cam plate and the coupling.

(1) Plunger adjusting shim
(2) Cam plate
(3) Coupling spring
(4) Coupling

13. Remove the timer spring.

(1) T'lmer cover
(2) Timer spring
(3) Adjusting washer (2 pieces)
(4) 0 ring

Section 1.2.3
 1DZ-II Repair

14. Remove the roller ring and the timer piston.

(1) Timer clip
(2) Stopper pin

(3) Push the timer slide pin to the center of the roller ring.

Note:
Offset the drive shaft pawl by 90" from the timer slide
pin.

(4) Roller ring

Caution:
Do not drop the roller ring as the four rollers are installed
in special heights. Reinstall them in the same
combination and position.

(5) Timer piston

(6) Timer sub-piston

Caution:
Do not drop the timer sub-piston.

Section 1.2.3
1DZ-II Repair

15. Remove the drive shaft.

(1) Extract the drive shaft upward.
Caution:
Do not lose the feed pump drive key.
(2) Disassemble the drive shaft (with gear).
(a) Drive shaft
(b) Drive gear
(c) Rubber joint (2 pieces)
(d) Drive shaft washer
(e), Drive shaft
16. Remove the feed pump parts.
(1) Feed pump cover set screw
(2) Feed pump cover
(3) Liner

Caution:
Make sure that the rotor and the blade remain inside at
this time. Do not slant or pry.

(4) Rotor, blade

Caution:
Do not alter the relative positions of the four blades
and the rotor.
When replacement is necessary, replace the rotor,
blades and liner as a group.

17. Remove the regulating valve.

(1) Regulating valve
SST 09260-70003-71
(09260-54012)
(2) 0 ring

Section 1.2.3
 1DZ-II Repair

18. Remove the oil seal.

SST 09612-76006-71
(096 12-65014)

Note:
Set the SST as shown, and drive out the oil seal with a
driving bar or other appropriate tool.

19. Remove the governor cover parts.

(1) Align the lever shaft with the lever, and draw matching
marks.
(2) Nut
(3) Adjusting lever
(4) Return spring
( 5 ) Extract the lever shaft to the inside.

ÿ at chi"^ mark
w INSPECTION
1. Check the plunger.
(1) When wear, scratches, discoloration or other defects
are found at the plunger lead, replace the plunger,
spill ring and distributor head as a group.
(2) Check the plunger sliding contact surfaces as follows:
Slide the plunger several times in clean light
oil.
Incline the distributor head 60°, and pull out
the plunger by about 15 mm (0.59 in.).
When the plunger is released gently, it must
drop at least 3 mm (0.12 in.) by its own
weight.
Secure the spill ring and distributor head, and
repeat steps (b) and (c) several times, each
time changing the plunger position.
If the plunger does not drop more than 3 mm
by its own weight, replace the plunger, spill
ring and distributor head as a group.

Section 1.2.3
1DZ-II Repair

2. Check the delivery valve and holder.

(1) Check the valve seat surface and piston for
scratches, dents and wear.
(2) Check the delivery valve and holder for scratches on
the contact surfaces with the injection pipe.
(3) Check the suck-back action.
(a) Thoroughly wash the parts in light oil and do
not wipe off the oil film. Close the lower part of
the valve seat with a finger and lift the valve.
(b) The parts are in good condition if the valve
stops at the relief valve when released.
(c) Replace the valve if it falls to the seat.
3. Check the roller ring.
(1) If flaking, local wear or other flaws that prevent reuse
are found on the roller and roller pin, replace the roller
ring assembly.

(2) Measure the height of four rollers using a dial gauge

and calculate the dispersion.
Limit: 0.02 mm (0.0008 in.)
If the limit is exceeded, change the roller positions
with one another and check the height dispersion
again.

4. Check the drive shaft.

(1) Play exists between the key and the key groove.
Replace the drive shaft if the taper is damaged.
(2) Measure the amount of wear in the oil seal contact
surface.
Limit: 0.08 mm (0.0031 in.)

Section 1.2.3
 1DZ-II Repair

5. Check the cam plate.

(1) Check the cam surface for flaking, local wear or
damage.

(2) Measure the amount of wear on the cam plate that

comes into contact with the plunger.
(Measure dimension L using a vernier caliper.)
Limit: L = 4.2 mm (0.165 in.)

6. Check the flyweight.

Measure the amount of stepped wear on the flyweight
surface that comes into contact with the washer.
Limit: A = 0.2 mm (0.008 in.)
If the limit is exceeded, replace all four parts as a group.

7. Check the feed pump.

Check the sliding surface for excessive wear or damage.
If necessary, replace the feed pump assembly.

Section 1.2.3
 1DZ-II Repair

8. Check the governor lever and spill ring.

Insert the governor lever ball pin into the hole in the spill
ring. Check that the parts slide on each other smoothly.

9. Check the plunger springs.

(1) Replace those that have damaged surfaces.
Caution:
Replace both springs at the same time.
(2) Squareness of the spring
Limit: A = 2.0 mm (0.08 in.)

10. Check the pump housing.

(1) Check the feed pump for wear or scratches on the
sliding surface.
(2) Check the threads for damage.
(3) Wear on the housing bushing
(a) Fit the nut on the drive shaft as shown to the
Drive shaft left. Lightly shake the drive shaft in the
direction of the wear (lightly pushing by hand)
Nut and measure the amount of wear.

-
Shake lightly
i3ia-uge
(Force less than 20 N (2 kgf) [4.416 fl)
Bushing wear limit: 0.1 mm (0.0039 in.)
If the limit is exceeded, replace the pump housing.
(Not possible to replace the bushing only)

Wear amount
measurement

Section 1.2.3
 1DZ-II Repair

REASSEMBLY
Caution:
Keep the work bench and work area clean to prevent dust and foreign matter from entering the
pump during reassembly.
Thoroughly wash parts in clean light oil before reassembly.
Coat light oil on all sliding surfaces, 0 rings and oil seals before assembly.
0 rings, nipple washers, gaskets and joint rubbers must be replaced with new ones.
1. Reassemble the adjusting lever parts.
(1) Reassemble 0 rings and washers to the lever shaft.
(2) Reassemble parts in the lever shaft cover first.
(3) Return spring

(4) Adjusting lever

Note:
Align the matching marks on the adjusting lever and
the lever shaft.
One serration of the adjusting lever corresponds to a
lever angle of 7.5".
When replacing the adjusting lever, select a new one
that has the same punched number.

(5) Spring guide

(6) Nut
T = 4.90 to 9.81 N-m (50 to 100 kgf-cm)
[3.62 to 7.24 ft-lbfl

Matching
mark

2. Install the pump housing to the pump mounting bench.

SST 09245-76001-71
(09245-54010)
3. Reassemble the oil seal.

Note:
Use a 22 mm (0.866 in.) box and drive in the oil seal to
the end surface of the pump body.

Section 1.2.3
 1DZ-II Repair

4. Reassemble the regulating valve.

(1) Reassemble the 0 ring on the regulating valve.
(2) Regulating valve
SST 09260-76003-71
(09260-540 12 )
T = 7.85 to 9.81 N-m (80 to 100 kgfmcm)
t5.79 to 7.24 ft-lbfl

5. Reassemble the feed pump parts.

(1) Liner

Caution:
Reassemble the liner in the direction as shown to the
left. If installed incorrectly (right and left, front and back),
it will block fuel passage. (The step at the side must be
positioned at the top as shown in the illustration.)

Pay attention to (2) Rotor, blade

attention the blade
to the hole direction Caution:
position (Reversed Reassemble the rotor and the blades with the grooved
assembly is no1
possible) side facing inward as shown to the left. Check that the
rotor and the blades slide smoothly.
When feed pump replacement is required, replace the
entire assembly (rotor, blades and liner).
Liner Rotor

(3) Feed pump cover

Caution:
Check the position of the fuel discharge hole on the
feed pump cover. Never assemble the part in the
reversed position.
After the cover is reassembled, make sure that the
rotor slides smoothly in all directions (vertical and
horizontal directions).
Screw
' W J

Section 1.2.3
 1DZ-II Repair

6. Reassemble the drive shaft.

(1) Reassemble the governor drive gear to the drive
shaft. Then insert a rubber joint into the gap between
the drive shaft and the driver gear.

Caution:
Install the governor drive gear with the stepped
surface facing the pawl of the drive shaft.
Always use a new rubber joint.

(2) Drive shaft washer, drive shaft assembly, key

Caution:
Position the rotor with the key groove facing upward.
Position the rotor drive key and thrust washer to the
shaft, and reassemble them along the rotor key
groove.
Check that the parts rotate smoothly after
reassembling.

7. Reassemble the roller ring.

(1) Insert the timer slide pin into the roller ring assembly.
Caution:
Make sure that the curved surface of the washer at the
roller of the roller ring is facing the periphery.
Make sure that the slide pin is inserted to the center as
shown.

( 2 ) Hold the pump vertically and reassemble the roller

ring assembly as shown to the left.

Caution:
Do not drop the roller.
Reassemble the roller ring with the notch facing the
top of the pump housing.

Section 1.2.3
 1DZ-II Repair

8. Reassemble the timer.

(1) Assemble the sub-piston to the timer piston. Coat
grease (Denso grease No.50 or timer grease), and
insert the parts into the pump housing.

Caution:
The low pressure side (timer spring side) must be at
the right side of the pump as viewed from the drive
side. Make sure that the fuel inlet hole of the pump
housing is on the low pressure side.

Reassemble the parts with the hole in the sub-piston

facing the timer slide piston.
(2) Insert the timer slide pin into the timer sub-piston.
Reassemble the stopper pin, and fit the clip.

p;P,
Timer cover Caution:
Make sure that the timer piston slides smoothly.

(3) Reassemble the following parts:

(a) 0 ring
(b) Washers
(c) Timer spring
(d) Timer cover

Caution:
Install washers at both ends of the spring to a thickness
of 0.5 mm (0.020 in.) or more.

9. Reassemble the coupling and cam plate.

(1) Coupling
(2) Reassemble the cam plate with the pin in the same
direction as the key groove in the drive shaft.

Caution:
Reassemble the coupling so that the end with a larger
center hole diameter is on the upper side.
The cam plate pin and the drive shaft key groove must
be aligned. Otherwise, the proper sequence of
injection will be affected. -
Do not reassemble the coupling spring at this point.

Section 1.2.3
 1DZ-II Repair

10. Adjust the plunger spring shim (measuring dimension

KF)
(1) Dimension KF is the distance from the end surface of
the distributor cylinder to the end surface of the
plunger head. The set length of the plunger spring
can be altered by selective use of the plunder spring
shim.

(2) Reassemble the following parts to the cylinder head:

(9) (f) (a) Plunger spring guide
/ /Je) (b) Upper spring seat
(c) Plunger spring
(d) Lower spring sheet
(e) Plunger upper plate
(f) Plunger lower plate
(g) Plunger

Caution:
Do not reassemble the plunger spring shim at this
point.
Leave the spill ring removed.
(3) Selecting the plunger spring shim
Measure dimension KF when the plunger spring is
released, and calculate the necessary plunger spring
shim thickness from the following equation:
Shim thickness = 5.9 mm (0.232 in.) - dimension
KF

Section 1.2.3
 1DZ-II Repair
-

Size variation of plunger spring shims Caution:

Use plunger spring shims of the same thickness on
I Thickness mm (in.)
I both sides (use two identical shims per pump).
When shims of the appropriate thickness are not
available, use shims of the next larger thickness.
When a plunger spring shim replacement is required,
replace both as a pair.

11. Adjust the plunger shim (measuring dimension K)

(1) Dimension K is the distance from the end surface of
the distributor cylinder as assembled to the end
surface of the plunger head at the BDC of the plunger.
Dimension K can be altered by selective use of the
plunger adjusting shim.

Distributor
cylinder

(2) Insert a plunger shim of an appropriate thickness, and

reassemble the plunger with the cam plate drive pin
fitted along the plunger groove.

Caution:
Do not coat grease on the plunger shim.

Section 1.2.3
 1DZ-II Repair

(3) Insert the distributor head carefully, and bolt it in

place.

Note:
Turn the drive shaft and check if the plunger rotates.
The plunger will not rotate if the cam plate pin is not in
the plunger groove. If this is the case, reassemble
them correctly.

(4) Bring the plunger to the BDC and measure dimension

K.
Standard: K = 3.3 f 0.1 mm (0.130 f 0.004 in.)

Caution:
Make sure that the plunger is not raised during
measurement.

Size variation of plunger shims

(5) Selecting the plunger shim
I Thickness mm (in.) I Compare the measured value with the standard, and
select the appropriate plunger shim thickness
accordingly.
Shim thickness (mm) = tl + (t2 - 3.3)
(in.) = tl + (t2- 0.13)
t,: Shim thickness during measurement
t2: Measured dimension
(6) Remove the distributor head and plunger cam plate
again.
12. Reassemble the coupling spring.

Section 1.2.3
 1DZ-II Repair

13. Reassemble the cam plate.

Caution:
Reassemble the cam plate so that its drive pin is aligned
with the drive shaft key groove. Carefully prevent
misalignment because it will cause an incorrect injection
order.

14. Reassemble the plunger parts.

(1) Reassemble the following parts to the plunger:
(a) Plunger lower plate
(b) Plunger upper plate (with an oil groove)
(c) Plunger spring lower seat
(d) Spill ring

Plunger
R Caution:
Install the spill ring in such a way as the end surface with
a hole faces the cam plate.

(2) Reassemble the following parts to the plunger spring

lower seat:
(a) Plunger spring
(b) Spring upper seat
(c) Plunger spring shim (selective use)
(d) Plunger spring guide
(3) Plunger shim (selective use)

Caution:
Do not coat grease on the plunger shim.
(4) Reassemble the plunger parts as shown.
Note:
Reassemble the cam plate so that its drive pin fits in the
groove at the plunger leg.

Section 1.2.3
 1DZ-II Repair

15. Reassemble the governor lever.

(1) Governor lever

Note:
The ball pin of the governor lever must fit in the spill
ring.
(2) Support bolt
SST 09260-76003-71
(09260-54012)
T = 9.81 to 12.75 N.m (100 to 130 kgf-cm)
[7.2 to 9.4 ft-lbfl

16. Reassemble the distributor head.

(1) Reassemble the following parts to the distributor
head:
(a) 0 ring
(b) Lever support spring

Note:
Coat grease (Denso grease No.50 or timer grease) on the
spring to adhere it to the distributor head.

(2) Reassemble the distributor head.

Note:
The lever support spring must face the governor lever.
Push the distributor head by hand until it touches the
0 ring.

(3) Distributor head set bolts

T = 10.79 to 12.75 N-m (110 to 130 kgf-cm)
[8.0 to 9.4 ft-lbfl

Note:
Tighten the four bolts evenly and alternately.
Operate the governor lever and make sure that the
spill ring follows smoothly after tightening.

Section 1.2.3
1DZ-II Repair

17. Reassemble the head plug.

(1) Reassemble the 0 ring to the head plug.
(2) Head plug
SST 09260-76003-71
(09260-54012)
T = 58.84 to 78.45 N-m (600 to 800 kgf-cm)
[43.4 to 57.9 flmlbfl

Caution:
Always use new head plugs.

18. Reassemble the delivery valve.

(1) Gasket
(2) Delivery valve
(3) Valve spring
(4) Spring seat
(5) Valve holder
SST 09260-76003-71
(09260-54012)
T = 53.94 to 63.74 N-m (550 to 650 kgf-cm)
[39.8 to 47.0 ft-lbfl

Caution:
Always use new gaskets.
When replacement is required, always replace the
delivery valve and the valve seat as a group.

19. Reassemble the solenoid.

(1) Reassemble the 0 ring to.the solenoid.
(2) Solenoid
T = 19.61 to 24.52 N-m (200 to 250 kgf-cm)
[14.5 to 18.1 ftlbfl

Caution:
When assembling the solenoid, also assemble the
piston and spring.
(3) Boot

Section 1.2.3
 1DZ-II Repair

20. Reassemble the governor shaft parts.

(1) Reassemble the following parts to the governor
sleeve:
(a) Stop ring
(b) Sleeve plug

(2) Reassemble the following parts to the weight holder:

(a) Flyweight
(b) Flyweight washer
(c) Governor sleeve

Caution:
When flyweight replacement is required, replace all four
flyweights (per engine).

(3) Reassemble the 0 ring to the governor shaft.

(4) Reassemble the following parts:
(a) Governor shaft
(b) Adjusting washer
(c) Washer
(d) Governor flyweight assembly

Caution:
Note that the governor shaft has left-hand threads.

( 5 ) Measure the thrust clearance of the weight holder

using a thickness gauge.
Thrust clearance: 0.15 to 0.35 mm
(0.0059 to 0.0138 in.)
(over the entire circumference)
If the standard is not met, change the thickness of the
adjusting washer as necessary.
pin

~eiiht --/ k~ h r u s t
holder clearance

Section 1.2.3
 1DZ-II Repair

Size variation of adjusting washers

I Thickness mm (in.)

L (6) Adjust dimension L from the governor shaft tip to the

Governor shaft end surface of the pump housing.
Standard: L = 1.5 to 2.5 mm (0.059 to 0.098 in.)

Caution:
Note that the governor shaft has left-hand threads.

2uTphousing

(7) Governor shaft lock nut

SST 09260-76003-71
(09260-54012)
T = 24.51 to 29.42 N-m (250 to 300 kgf-cm)
[ I 8.1 to 21.7 ft-lbfl

Caution:
Note that the lock nut has left-hand threads.

Section 1.2.3
 1DZ-II Repair

21. Reassemble the governor cover.

(1) Hook the control spring to the governor cover.
Note:
The open end of the control spring hook must be
directed as shown.

(2) Reassemble the governor spring seat and damper

spring to the tension lever, and hook the control spring
in the hole in the spring seat.

Caution:
Reassemble the governor spring seat in the correct
position.
Always use a new governor cover gasket.
(3) Socket bolt

AIRTIGHTNESS TEST
After reassembly is completed, carry out an airtightness test with the following steps:
1. Install a blind plug to the overflow screw opening. Apply air pressure of about 147 kPa (1.5 kgflcm2)
[21.33 psi] from the fuel inlet hole. Insert the pump into the oil until the overflow screw is in the oil, and
check that air does not leak from any part of the pump.
2. Then, apply higher air pressure of about 490 kPa (5 kgflcm2) [71.1 psi] and check for air leaks from
any part of pump in the same condition.

Section 1.2.3
 1DZ-II Repair

ADJUSTMENT
Sequence of adjustment
1. Pre-test inspection and preparation
2. Run-in operation
3. Temporary adjustment
4. Pump internal pressure adjustment
5. Overflow rate inspection
6. Timer adjustment
7. Full load injection rate adjustment
8. Starting injection rate adjustment
9. Full load injection rate check
10. High speed lever setting
11. Load sensing timer adjustment
12. Low speed lever setting

Nozzle valve
0 to 590 kPa 0 to 980 kPa opening pressure: 14.71 k 0.49 MPa
(0 to 6 kgf/cm2) (0 to 10 kgf/cm2) (150 k 5 kgf/cm2)
[0 to 90 psi] [0 to 140 psi] [2130 k 70 psi]

(a) Feed pump (f) Nozzle and nozzle holder

(b) Fuel filter (g) Measuring cylinder
(c) Adjusting valve (h) Oil tank
(d) Pressure gauge (i) Overflow screw
(for feed pressure measurement)
(e) Pressure gauge
(for internal pressure measurement)

Section 1.2.3
 1DZ-II Repair

Pre-test inspection and preparation

1. Measure the valve opening pressure of the test nozzle
holder.
Valve opening pressure
14.71 f 0.49 MPa (150 2 5 kgf/cm2) [2133 to 2204 psi]
2. Attach the pump to the tester.

Note:
Make sure that the pump rotates smoothly when it is
turned by hand.

3. Connect the high pressure pipe and the pressure gauge

(for internal pressure measurement).
(1) Inlet hose
(2) Overflow hose

Note:
Do not confuse the overflow screw with the inlet screw.
The overflow screw has "OUT" stamped on it.

(3) Pressure gauge

Note:
The pressure gauge used is one that is integrated with a
timer measuring device. Pipes may be taken from the
overflow hose connection.

(4) High pressure pipe

Use a high pressure pipe of the following
specifications.
2.0 mm x 6.0 mm x 840mm
(0.079 in. x 0.236 in. x 33.071 in.)
(Inside diameter) (Outside diameter) (Length)

Section 1.2.3
 1DZ-II Repair

(5) Attach the angle gradation plate.

Denso part number 95895-10360

(6) Apply voltage (6 V) to the fuel cut solenoid.

Run-in operation
1. Maintain oil temperature at 40 to 45 "C (104 to 113 O F ) .
2. Adjust the feed pressure of the pump tester to 20 kPa (0.2 kgf/cm2) [2.8 psi].
3. Operate the pump at low speed (300 rpm) and make sure that air inside the pump chamber is bled
from the overflow pipe.
4. Pull and secure the adjusting lever at the full position using a spring or other appropriate tool.
Raise the pump speed gradually and make sure that injection occurs at 1200 rpm. Wipe oil off the
pump surface so that oil leakage can be detected easily.
5. Carry out a run-in operation of the pump in this condition at 1200 rpm for 5 minutes.
Caution:
Turn the switch off immediately and check the pump if oil leakage, injection failure, unusual
sounds or other problems are found during operation.

Set the key groove of the drive shaft at the angle shown.
Remove the delivery valve from cylinder C, apply a feed
pressure of 20 kPa (0.2 kgf/cm2) [2.8 psi], and make sure
that fuel starts coming out.

Note:
If fuel will not come out from cylinder C, the cam plate is
assembled incorrectly (offset by 180). When this is the
case, reassemble the cam plate correctly.

Section 1.2.3
 1DZ-II Repair

Temporary adjustment (Lever at full position)

1. Temporary adjustment of the full load standard injection
rate
Measure the injection rate at pump speed 900 rpm
(Other than 2TD 20.25: 900 rpm, for 2TD 20.25 only:
800 rpm). If the standard is not met, turn the full load set
screw as necessary.

Section 1.2.3
 1DZ-II Repair

Standard
2. Temporary adjustment of the high speed lever setting
Measure the injection rate at pump speed 1310 rpm. If
the standard is not met, turn the maximum speed set
screw as necessary.

Pump Injection rate

Model Reference point speed cm3/200st.I cyl Remarks

1 1
rpm (cu~in./200st.lcyl)
8.34 to 8.74 Adjust with the full load set
Full load reference point
(0.509 to 0.533) screw
High speed lever set
point 1 1310 1 0.80 to 2.40
(0.049100.146)
Adjust with the maximum
speed adjusting screw

Full load reference point

1 1 7.94 to 8.34
(0.485 to 0.509)
Adjust with the full load set
screw
High speed lever set
point 1 1
1.06 to 2.66
l4lo(0.065to0.162)
Adjust with the maximum

1 1
speed adjusting screw
7.74 to 8.14 A d j u s t z h the full load set
8FDlO to 15 Full load reference point

1 1
(0.472 to 0.497) screw
8FDK20 to 30
for DPF High speed lever set ,310 0.80to2.40 Adjust with the maximum
point (0.049 to 0.146) speed adjusting screw

Full load reference point

/ 8oo / 7.7 to 8.1
(0.470 to 0.494)
Adjust with the full load set
screw
High speed lever set
point 1 l3lo 1
2.2 to 4.0
(0.134to0.244)
Adjust with the maximum
speed adjusting screw

Pump internal pressure adjustment (Lever at

full position)
Measure the pressure at specified pump speeds.
Standard
Pump speed Pump internal pressure
rPm kPa kgf/cm2 psi
400 392 to 490 4.0 to 5.0 56.9 to 71.1

Section 1.2.3
 1DZ-II Repair

Pump speed Pump internal pressure

kPa kgf/cm2 psi

When the pressure is lower than the standard

Put a round rod 3 to 4 mm (0.12 to 0.16 in.) in diameter
against the regulating valve piston, and drive it in carefully as
necessary while reading the pressure gauge.

Caution:
Do not overdrive.
If the pressure is higher than the standard, replace the
regulating valve.
Overflow rate inspection (Lever at full position)
Measure the overflow rate at pump speed 1200 rpm.
Standard: 283 to 533 cm3/min. (17.27 to 32.53 cu-in./min.)

Caution:
Always use the overflow screw attached to the pump.

Timer adjustment (Lever at full position)

1. Remove the cover from the high pressure side (without
a timer spring) of the timer. Attach the timer measuring
device (Denso part number 95905-10110) and set the
zero point.

2. Measure the timer piston stroke at specified pump

speeds.
Standard
Pump speed Piston stroke
rPm mm (in.)

v
Change the washer thickness

(Hysteresis to be 0.3 mm (0.012 in.) or less)

Section 1.2.3
 1DZ-II Repair

Size variation of timer adjusting washers If the standard is not met, remove the timer cover (spring
side), and alter the adjusting washer thickness as
Thickness mm (in.) necessary at both ends of the timer spring.
0.2 (0.008) Note:
Install washers at both ends of the timer spring.
0.5 (0.020)
A larger washer thickness reduces the stroke, a
0.6 (0.024) smaller thickness increases the stroke.

Full load injection rate adjustment (Lever at full

position)
Measure the injection rate at pump speed 900 rpm (Except
for 2TD 20.25: 900 rpm, only for 2TD 20.25: 800 rpm). If the
standard is not met, adjust the rate by turning the full load set
screw as necessary.
Standard:
In'ection rate
Model Pump 'peed B
cm 1200 st. 1c y ~
rpm (cu.in.1200 st.1cyl)

8FDlO to 15
7.74 to 8.14
8FDK20 to 30 900
(0.472 to 0.497)
for DPF

[Deviation 0.6 cm3 (0.037 cub.) or less]

Starting injection rate adjustment (Lever at full

position)
i. ~ e a s u r ethe injection rate at pump speed 100 rpm.
Standard:
In'ection rate
Model Pump 'peed 4
cm 1200 s t . 1 ~ ~ 1
rpm (cu.in.1200 st.1cyl)

\
Governor sleeve over nor sleeve
plug
1 Except for 2TD
20.25 1 loo 1 9.70 to 12.9
(0.529 to 0.787)

[Deviation 1.2 cm3 (0.073 c u h . ) or less]

Section 1.2.3
 1DZ-II Repair

2. If the standard is not met, adjust the rate by replacing

the governor sleeve plug.
An increase of dimension L of the governor sleeve by
0.2 mm (0.008 in.) results in a decrease of the injection
rate by 1.6 cm3 (0.098 cu.in.)/200 st.
Size variation of governor sleeve plugs
Dimension L mm (in.) ,Dimension L mm (in.)
2.5 (0.098) 3.7 (0.146)
2.7 (0.106) 3.9 (0.154)
2.9 (0.114) 4.1 (0.161)
3.1 (0.122) 4.3 (0.169)
3.3 (0.130) 4.5 (0.177)
3.5 (0.138) 4.7 (0.185)
3.6 (0.142)
If the deviation limit is not satisfied, replace the delivery valve, delivery valve spring, etc.

Section 1.2.3
 1DZ-II Repair

Full load injection rate check

1. Make sure that the full load standard injection rate
complies with the standard shown below. If the standard
is not met, adjust the rate by turning the full load set

Standard
In'ection rate
Model Lever angle
Pump speed B
cm 1200 st. Icyl
Deviation
rPm (cu+-~/200 st.1cyl) cm3 ( w i n . )

+
18" 5"
(at Full position) 1 1 8.34 to 8.74
(0.509 to 0.533)
1 0.6 (0.037) or less

+
14" 5"
(at Full position) 1 1 7.94 to 8.34
(0.485 to 0.509)
0.6 (0.037) or less

8FDlO to 15
8FDK20 to 30
for DPF
+
18" 5"
(at Full position) 1 1 7.74 to 8.14
(0.472 to 0.497)
/ 0.6 (0.037) or less

8FD20 to 30
for DPF
+
15" 5"
(at Full position)
1 . 900
1 7.94 to 8.34
(0.485 to 0.509)
1 0.6 (0.037) or less

20" k 5"
(at Full position) 1 500 1 6.74 to 8.26
(0.411to0.504)
/ 0.5 (0.031) or less

1 I2O0 ( 8.64 to 10.16

(0.527 to 0.620)
1 0.5 (0.031) or less

Section 1.2.3
 1DZ-II Repair

1 2. If the deviation limit is not satisfied, replace the delivery

valve and delivery valve spring, or check if the delivery
valve gasket is fitted correctly.

€3
Full Idle

High speed lever setting

Turn the maximum speed set screw as necessary so that the standard injection rate is met at the
conditions shown below.
Standard
In ection rate
Pump speed
Model Lever angle cm3! 1200 st. Icyl Remarks
rpm (cu.in.1200 st.1cyl)
0.80 to 2.40
1310 High speed lever setting
(0.049 to 0.146)
18" k 5"
5.22 to 8.02
(at Full position) 1275 Confirmation
(0.319 to 0.489)
I I

1400 0.90 (0.055) or less Confirmation

I4l0 1 1.06 to 2.66

(0.065 to 0.162)
( High speed lever setting
14" k 5"
(at Full position)
375 1 3.34 to 6.14
(0.204 to 0.375)
1 Confirmation

1500 1 0.90 (0.055) or less I Confirmation

0.80 to 2.40
1310 High speed lever setting
8FDlO to 15 (0.049 to 0.146)
8FDK20 to 30
+
18" 5"
5.22 to 8.02
(at Full position) 1275 Confirmation
for DPF (0.319 to 0.489)
I I

1400
I
0.90 (0.055) or less I Confirmation
1.06 to 2.66
1410 High speed lever setting
(0.065 to 0.162)
8FD20 to 30 15" k 5"
for DPF 3.34 to 6.14
(at Full position) 1375 Confirmation
(0.204 to 0.375)
I I

1500 0.90 (0.055) or less 1 Confirmation

20" k 5"
1 2.2 to 4.0
(0.134to0.244)
High speed lever setting

:at Full position)

1275
1400
1 4.6 to 7.4
(0.281 to 0.452)
0.90 (0.055) or less
Confirmation

Confirmation

Section 1.2.3
 1DZ-II Repair

Note:
Tightening the screw decreases the injection rate.

Constant pump rotation speed Load sensing timer adjustment

1. Setting the start of effect
(1) Operate the pump at a specified speed. Slowly switch
sensing the adjusting lever from full to idle position, and
effect maintain the lever at position A where the pump
effect
internal pressure begins to drop as shown to the left.
Check if the standard injection rate is obtained at that
position.

Idle Full
Lever pos~t~on

(2) If the standard is not met, adjust the rate by turning

the governor shaft. Set the lever again as in step (1)
above, and check the standard injection rate.
Method of adjustment
When the injection rate is low
Turn the governor shaft clockwise.
When the injection rate is high
Turn the governor shaft counterclockwise.

Governor shaft installation angle

Section 1.2.3
 1DZ-II Repair

-Standard injection rate

In'ection rate
Lever angle
Pump speed $
cm I200 st. Icyl
Piston stroke
Remarks
rPm mm (in.)
(cu.in.1200 st.1cyl)
2.35 to 3.15
Full 1200 q Full
(0.143 to 0.192)
(q full - 0.8) k 0.4 1 2'35 3'1
By governor shaft

1
effect ((qfull-0.049)+0.024) (0.143t00.192)
(q full - 2.4) 2 0.4 I3 2
Confirmation
effect ((q full - 0.146) k 0.024) (0.081 to 0.129)
q Full: Injection rate (measured value) at pump speed 1200 rpm with the lever at full position
(Reference value) 9 to 10 cm3 (0.55 to 0.61 c u h . )
2. Setting the end of effect
Operate the pump at a specified speed. Slowly switch
the adjusting lever from idle to full position, and maintain
the adjusting lever at position B where the pump internal
pressure begins to rise (see the relative positions of the
lever position and pump internal pressure). Check if the
standard injection rate is obtained at that position.

Section 1.2.3
 1DZ-II Repair

Low speed lever setting

1. Free the adjusting lever.
2. Turn the idle set screw as necessary so that the standard injection rate is met at the conditions shown
below.
Standard
In'ection rate
Pump speed Deviation
Model -ever angle cmi/500 st.1cyl Remarks
rpm cm3 (win.)
(cu.in.1500 s t . 1 ~ ~ 1 )

Except for 2.5 to 5.5 '5 (0'092) Low speed lever setting
390
8FD 20 to 30 (-) 18" k 5" (0.153 to 0.336) or less
for DPF 490 0.75 (0.046) or less - Confirmation

8FD 2.5 to 5.5 '5 (0'092)

390 Low speed lever setting
20 to 30 (-) 14" k 5" (0.153 to 0.336) or less
for DPF 490 0.75 (0.046) or less - Confirmation

Note:
Tightening the screw increases the injection rate.

Confirmation after adjustment

1. After completion of adjustment, reduce the fuel cut solenoid voltage to 0 V and confirm that the
injection rate is zero at that voltage. (At pump speed 100 rpm)
*
2. Check that the lever angle is 38" 5" (2TD 20.25), 36" k 5" (8FD10 to 15.8FDK20 to 30 included DPF
vehicle model), 32" k 5" (8FD20 to 30), 29" k 5" (8FD20 to 30 for DPF) between the idle and full
positions.
3. Seal the full load set screw and the maximum speed set screw.

Section 1.2.3
1DZ-II Repair

Section 1.2.3
 1DZ-II Repair

COOLING SYSTEM

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . 4-3
DISASSEMBLY. INSPECTION AND REASSEMBLY ... 4-4

Section 1.2.4
 1DZ-II Repair

WATER PUMP
COMPONENTS

Refer to
5701-30

Section 1.2.4
 1DZ-II Repair

REMOVAL AND INSTALLATION

Removal and installation procedure

The installation procedure is the reverse of the removal procedure.
Number Item Removal Inspection Installation
1 Drain the coolant.
2 V belt See P.2-43 t t

3 Fan
4 Fan pulley
5 / ~lternatoradjusting bar
6 1 Water pump I I
7 1 Water pump inlet I I

Section 1.2.4
 1DZ-II Repair

DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

The reassembly- procedure
. is the reverse of the disassembly procedure
umber 1
I
Item
I
Disassembly
I
Inspection
I
Reassembly
1 Water outlet
I I I I

2 Thermostat [Point I]
1 3 1 Water pump rotor
1 4 / Water pump cover
Point operation
[Point I]
Check the valve opening temperature and the fully opened
temperature.
1. Put the thermostat in water and increase the water
temperature while agitating.

Section 1.2.4
 1DZ-II Repair

2. Measure the temperature at which the valve begins to

open and at which it is fully opened.
Standard opening temperature 80 to 84 "C
(176 to 183 OF)
Fully opened temperature 95 OC (203 OF)
Fully opened lift 10 mm (0.39 in.)
or more

Note:
10 mm If the valve is open at normal temperatures or if the valve
(0.39 in.)
tightness is impaired, replace the valve.
or more

[Point 21
Check the water pump.
1. Check the water pump rotors for cracks, damage and
excessive rust.
2. Check the bearing for unusual sound and resistance
when the water pump rotor is rotated by hand.

Section 1.2.4
1DZ-II Repair

Section 1.2.4
 1DZ-II Repair

LUBRICATION SYSTEM

USED SSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . 5-3
ENGINE OIL AND OIL FILTER
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Section 1.2.5
 1DZ-II Repair

USED SSTs
I Illustration Part number I Part name

09032-76001-71
Oil pan seal cutter
(09032-00100)

09228-76004-71
Oil filter wrench
(09228-07501)

Section 1.2.5
1DZ-II Repair

OIL PRESSURE INSPECTION

1. Check the oil.
Standard
The oil level must be somewhere between the F and L
marks on the level gauge.
It must be free of excessive contamination, and have
appropriate viscosity.
It must not contain coolant, light oil or other foreign
matter.

2. Measure the oil pressure.

(1) Remove the bolt and attach the oil pressure gauge.
Measuring tool DPG-100 (Banzai)
(2) Warm up the engine and measure the oil pressure.
Standard:coolant temperature
75 to 85 OC (167 to 185 OF)
Standard:At idle speed
78 kPa (0.8 kgflcm2) [11.4 psi] or more
At 1600 rpm
343 kPa (3.5 kgflcm2) [49.8 psi] or more
(3) Mount the bolt.
ENGINE OIL AND OIL FILTER
REPLACEMENT
1. Drain the engine oil.
(1) Remove the oil filler cap.
(2) Remove the oil drain plug and drain the oil.

2. Remove the oil filter.

SST 09228-76004-71
(09228-07501)
3. Install the oil filter.
Fit an 0 ring to the oil filter, and attach the oil filter by
turning it by hand. Using the SST, retighten the oil filter
by 314 of a turn.
SST 09228-76004-71
(O9228-O75OI )
Caution:
Coat a small amount of the engine oil on the 0 ring.
Clean the fitting surface.

Section 1.2.5
 1DZ-II Repair

4. Fill the engine oil.

(1) Install the oil drain plug using a new gasket.
Caution:
Before installing, dispose of the old gasket that is
adhered to the oil pan and clean the installation surface.
(2) Fill the oil.
Total capacity (F level) 7.5 e (1.98 US gal)
Oil pan capacity 7.0 8 ( I .85 US gal)
(3) Fit the oil filler cap.
5. Check the oil amount.
Check the amount with the oil level gauge.
6. Check the oil leakage.
Start the engine and check the system for oil leakage.
7. Check the oil amount.
Recheck the oil amount after the oil leakage check.

Note:
Stop the engine and wait for 3 minutes before
performing the inspection.
OIL STRAINER
REMOVAL AND INSTALLATION
1. Remove the oil pan. (See P.2-21)
SST 09032-76001-71
(09032-00100)
2. Remove the oil strainer.
3. Install the oil strainer.
T = 14.51 to 21.77 N-m
(148 to 222 kgf-cm) [10.7 to 16.1 ft-lbfl
T = 10.8 to 15.7 N-m
(110 to 160 kgf-cm) [8.0 to 11.6 ft-lbfl
4. Install the oil pan. (See P.2-21)
T = 10.8 to 15.7 N-m
(110 to 160 kgf-cm) [8.0 to 11.6 ft-lbfl

Section 1.2.5
 1DZ-II Repair

OIL PUMP
COMPONENTS

Section 1.2.5
 1DZ-II Repair
5-6

DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

The reassembly procedure is the reverse of the disassembly procedure.
Number Item Disassembly Inspection Reassembly
1 I Fan, V belt 1 See P.2-43 1
2 I Crank pulley I see p.2-21 I t

3 Timing gear cover See P.2-21 t t

4 Measure the oil pump gear backlash [Point 11

5 1 Idle gear No.1 I [Point 21 I
6 Oil pump assembly [Point 31 t

Section 1.2.5
1DZ-II Repair

Point operation
[Point I ]
Inspection: Measure the backlash between the idle gear
No.1 and oil pump gear.
Standard: 0.050 mm (0.00197 in.)
Limit: 0.3 mm (0.0118 in.)
If the limit is exceeded, replace the idle gear No.1 and
the oil pump gear as a set.

[Point 21
Disassembly: Position the matching marks at the point of
engagement between the idle gear and each
gear.

[Point 31
Inspection: Check the body clearance.
Measurement position: Clearance between the rotor
and the body
Standard: 0.10 to 0.17 mm (0.0039 to 0.0067 in.)
Limit: 0.20 mm (0.0079 in.)

1nspection:Check the tip clearance.

Measurement position: Clearance between the rotor
and the gear
Standard: 0.05 to 0.15 mm (0.0020 to 0.0059 in.)
Limit: 0.20 mm (0.0079 in.)

Section 1.2.5
 1DZ-II Repair

Inspection: Check the rotor protrusion.

Measure the driven rotor protrusion from the oil pump
body using the straightedge and dial gage.
Reference value: 3.91 to 3.97 mm
(0.1539 to 0.1563 in.)
Reassembly: The rotor is symmetric and may be installed on
either side.

Caution:
Do not drop the rotor.

Section 1.2.5
 1DZ-II Repair

STARTING SYSTEM

USED SSTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

PREHEATING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 6-3
ELECTRIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . 6-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
INSPECTION OF GLOW PLUG . . . . . . . . . . . . . . . . . . . 6-4
INSPECTION OF PREHEATING TIMER . . . . . . . . . . . . 6-4
INSPECTION OF WATER TEMPERATURE SENSOR . 6-5
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
REMOVAL, INSPECTION AND INSTALLATION . . . . . . 6-7
DISASSEMBLY. INSPECTION AND REASSEMBLY. . . 6-8
STARTER ASSEMBLY INDIVIDUAL INSPECTION.... 6-14

Section 1.2.6
 1DZ-II Repair

USED SSTs
Illustration Part number Part name

09286-76001-71
Injection pump spline shaft puller
(09286-46011)

Section 1.2.6
 1DZ-II Repair

PREHEATING SYSTEM
ELECTRIC CIRCUIT DIAGRAM

COMPONENTS

Section 1.2.6
 1DZ-II Repair

INSPECTION OF GLOW PLUG

1. Remove the glow plug.
2. Make sure that the circuit across the glow plug terminal
and body has continuity.

INSPECTION OF PREHEATING TIMER

lo 1 tl' mkdian'chiracteristici adcoidi~iafo the 1. Measure the period of time during which the glow
I water temmrature sensor median i a l u e indicator lamp remains lit when the ignition switch is
turned to the ON position.
Standard: See the chart on the left

ited
O
I -/o-Jo-1; A
h e n sensor is open-circuited
/o o: o: i o Jo 64 o! '
Water temperature ('C

2. Measure the voltage of the preheating timer when the

ignition switch is turned to the ON position.
Measurement terminals: REL(+) to E01(-)
Standard: The battery voltage (approx.12 V) should
be indicated immediately after the switch
is turned ON and go off soon after.
3. Start the engine while the battery voltage is being
applied across REL(+) and E01(-) during step 2 and
read the voltage at that time.
Standard: The voltage should read 0 V immediately
after the engine has been started.
Note:
Make this check with the timer connector connected.

Section 1.2.6
1DZ-II Repair

INSPECTION OF WATER TEMPERATURE

SENSOR
Measure the resistance across both terminals of the water
temperature sensor.
Standard: -15 "C (5 OF) : 11. I 6 to 13.62 kR
20 "C (68 OF) : 2.21 to 2.69 kR
50 "C (122 OF) : Approx. 0.43 kR

Section 1.2.6
 1DZ-II Repair

STARTER MOTOR
COMPONENTS

Section 1.2.6
 1DZ-II Repair

REMOVAL, INSPECTION AND INSTALLATION

Removal and installation procedure

The installation procedure is the reverse of the removal procedure.
\lumber Item Removal Inspection Installation
1 I Battery
2 / Battery set plate
3 1 Oil catcher
4 Disconnect the connector and terminal.
5 Starter assembly

Section 1.2.6
 1DZ-II Repair

DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

The reassembly procedure is the reverse of the disassembly procedure.
Disassembly 1 Inspection I Reassembly
1 1 Lead wire
2 ( Yoke assembly 1 [Point I ] / [Point 111
3 1 End frame 1 [Point 101
4 Brush [Point 21 [Point 31 [Point 91
5 Armature assembly [Point 41
6 Bearing [Point 51 [Point 81
7 Housing assembly [Point 61
8 Clutch assembly [Point 71
9 Steel ball
10 1 Snap retainer
11 Idle gear
12 Retainer, roller
13 Return spring
Section 1.2.6
 1DZ-II Repair

CAUTION: During reassembly, coat the grease on the steel ball, idle gear, starter clutch, and return
spring.
Point operation
[Point I ]
Inspection: Check the continuity between the field coil brush
and terminal C.
Standard: Continuity

Inspection: Check the insulation between the field coil brush

and the field.
Standard: 0.1 MQ or more

[Point 21
Brush holder I
Disassembly: Lift the (+) side brush spring using radio pliers.
Do not damage the brush and commutator.

spring
[Point 31
Inspection: Check the brush.
1. Check the brush for roughened contact surfaces, and
measure the brush length.
Measure the brush length at the center (recess).<,
Standard: 20.5 mm (0.807 in.)
Limit: 13.0 mm (0.512 in.)
2. When the contact surface is roughened or when
replacing the brush, wrap sand paper around the
commutator and correct the contact surface.

Section 1.2.6
 1DZ-II Repair

Inspection: Check the brush spring for smooth movement,

and measure the static load.
Standard: 31.4 to 39.2 N (3.2 to 4.0 kgf)
[7.1 to 8.8 Ibfl
Limit: 21.6 N (2.2 kgf) [4.9 lbfl

Brush
Brush spring

Inspection: Check the insulation between the (+) side and (-)
side brush holders.
Standard: 0.1 MR or more

[Point 41
Inspection: Check the insulation between the commutator
and the armature coil.
Standard: I MR or more

Inspection: Perform a short-circuit test of the armature coil.

1. Thoroughly clean the armature surface before the test.
2. Put a piece of iron piece parallel to the armature using
an armature tester, and turn the armature.
Standard: The piece of iron is not pulled in and
does not vibrate

Section 1.2.6
1DZ-II Repair

Inspection: Check the continuity between the segments of

the armature coil.
Standard: Continuity between all segments

Inspection: Check the commutator.

3. Measure the radial runout.
Limit: 0.05 mm (0.0020 in.) or less

4. Measure the outside diameter.

Standard: 36 mm (1.42 in.)
Limit: 35 mm (1.38 in.)

5. Measure the undercut depth between the segments.

Standard: 0.7 mm (0.028 in.)
Limit: 0.2 mm (0.008 in.)

Section 1.2.6
 1DZ-II Repair

[Point 51
Disassembly: Remove the bearing.
SST 09286-76001-71
(09286-460 11)

[Point 61
Inspection: Check the magnet switch.
1. Check the continuity between the terminal 50 and C.
Standard: Continuity

2. Check the continuity between the terminal 50 and

magnet switch body.
Standard: Continuity

[Point 71
Inspection: Check the clutch and the gear.
1. Check the gear for wear and damage.
2. Make sure that the gear is locked when turned in the
drive direction (counterclockwise) and that it turns
smoothly when turned in the opposite direction
(clockwise).

Section 1.2.6
1DZ-II Repair

[Point 81
Disassembly: Press-fit the bearing using a press.

[Point 91
Disassembly: Reassemble the brush.
1. Prying the brush spring with a screwdriver, reassemble
the brush holder to the starter yoke.
2. Pull up the brush spring and reassemble the brush to the
brush holder.

[Point 101
Disassembly: Align the notch (a) on the end frame with the
grommet (b) on the lead wire.

[Point 111
Disassembly: Reassemble the felt washer to the armature
shaft bearing.

Section 1.2.6
 1DZ-II Repair

Disassembly: Align the notch on the yoke with the protrusion

on the magnet switch.

STARTER ASSEMBLY INDIVIDUAL INSPECTION

Note:
Each test must be completed within a short time (3 to 5
seconds).
1. Pull-in test
Check that the pinion gear comes out when wired as
shown.

2. Holding coil retention test

Disconnect the test lead wire from terminal C as shown
after the pull-in test. Make sure that the pinion gear
remains protruding.

3. Plunger return test

Disconnect the terminal as shown after the holding coil
retention test. Make sure that the pinion returns at this
time.

Section 1.2.6
1DZ-II Repair

4. No-load test
(1) Secure the starter in a vise.
) Use adequately large lead wires for a no-load test as
large current is involved.
) Read the ammeter after the pointer becomes
stabilized.
Standard: 90 A or less

Section 1.2.6
1DZ-II Repair

Section 1.2.6
 1DZ-II Repair

CHARGING SYSTEM

USED SSTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . 7-3
ALTERNATOR ................................ 7-4
ELECTRIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . 7-4
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
DISASSEMBLY, INSPECTION AND REASSEMBLY... 7-5

Section 1.2.7
 1DZ-II Repair

USED SSTs
I Illustration Part number Part name

HST pump bearing replacer

Alternator rear bearing puller

Alternator rear bearing replacer

Replacer set

Handle set

Section 1.2.7
 1DZ-II Repair

ON-VEHICLE INSPECTION
1. Check the specific gravity of the battery.
Standard: 1.25 to 1.28 (20°C (68°F))
2. Check the battery terminals.
3. Check the V belt.
4. Check the fuse.
5 . Check the wiring.
6. Check the system for unusual sound.
(1) Make sure that no unusual sound is heard from the
alternator when the engine is running.

7. Perform a no-load test.

(Regulated voltage and current check)
(I) Connect the ammeter and voltmeter as shown.
(2) Gradually increase the engine speed to 1500 rpm,
and measure the voltage.
Standard: 12 V 13.5 to 14.3 V (hot engine)
(3) Measure the current at engine speed of 1500 rpm.
Standard: 10 A or less

Note:
Fusible l h k The current reading instantly goes above 10 A
immediately after the engine starts. This does not
constitute a problem.

Section 1.2.7
 1DZ-II Repair

ALTERNATOR
ELECTRIC CIRCUIT DIAGRAM

COMPONENTS

Section 1.2.7
 1DZ-II Repair

DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

The reassembly procedure is the reverse of the disassembly procedure.
Number Item Disassembly Inspection Reassembly
1 Terminal insulator
2 Rear end cover
3 Brush holder with brush [Point I ] [Point 151
4 IC regulator [Point 21
5 Rectifier holder [Point 31 [Point 141
6 Alternator pulley [Point 41 [Point 131
7 Rear end frame [Point 51
8 Rotor assembly [Point 61 [Point 71 [Point 121
9 Rear bearing, spring washer [Point 81 [Point 111
10 Bearing cover, front bearing [Point 91 [Point 101

Section 1.2.7
 1DZ-II Repair

Point operation
[Point I ]
Inspection: Check the brush.
Measure the amount of protrusion A of the brush.
Standard: 10.5 mm (0.413 in.)
Limit: 1.5 mm (0.059 in.)
If the brush protrusion amount is below the limit, remove
the brush by melting the solder at the brush holder.

Fit the spring to the brush holder. Carefully position the

brush leaving a brush protrusion amount of 10.5 mm
(0.413 in.) and solder it to the brush holder.
Cut off unnecessary lead wires.
Coat insulation paint to the solder.

Caution:
Always replace both brushes at the same time.
.5 mm
413 in.)

[Point 21
Inspection: Check the IC regulator diode.
Check the continuity of the diode between terminals B
and F with the kR range of the circuit tester.
Standard: Test two times with different polarities.
The diode must be continuous in one
polarity and not continuous in the other.

[Point 31
Inspection: Check the rectifier holder.
1. Check the continuity with the k!2 range of the circuit
tester.
Standard: Test two times with different polarities.
The diode must be continuous in one
polarity and not continuous in the other.

Section 1.2.7
1DZ-II Repair

2. See the figure at left for the rectifier circuit.

The rectifier quality cannot be judged on the basis of the
resistance in the forward direction. Because of the diode
characteristics, the forward current varies greatly with
the source voltage. As a result the tester indication
depends on the tester type and resistance range.
Therefore, the rectifier is judged as OK if there is a large
difference in the resistance between the forward
direction and reverse direction.

Caution:
Do not use a 500 V megohmmeter since it will damage
the rectifier.

[Point 41
Disassembly: Set the alternator pulley in a vise and remove
the set bolts.

Caution:
Always use pads to protect the components.

[Point 51
Disassembly: After set nuts and set bolts are removed, hold
the rear end frame and separate it by applying
a shock to the rotor shaft end.

Caution:
When applying a shock, put the parts on top of a piece of
wood, etc.

[Point 61
Disassembly: As shown in the figure, use a block and
position the drive end frame in parallel to
press out the rotor.

Caution:
Do not drop the rotor and cause damage to parts such as
the slip ring and fan.

Section 1.2.7
 1DZ-II Repair

[Point 71
Inspection: Measure the resistance between the two slip
rings.
Standard: 3.0 R or less

Inspection: Measure the insulation resistance between the

slip rings and the rotor core.
Standard: oo R

Inspection: Check the slip rings.

1. If the slip ring is damaged, repair it using abrasive paper
(#400).
2. Measure the outside diameter of the slip ring.
Standard: 14.4 mm (0.567 in.)
Limit: 14.0 mm (0.551 in.)

Inspection: Check the stator coil in the drive end frame.

Measure the resistance between phases.
Standard: Approx. 1.0 R

Section 1.2.7
 1DZ-II Repair

[Point 81
Disassembly: Remove the rear bearing and the spring
washer.
SST 09820-76002-7 1
(09820-00021)

[Point 91
Disassembly: As shown in the figure, use a block and put the
drive end frame in a straight position to press
out the bearing.

Caution:
High speed bearings (x2) are used. Be sure to use the
specified type (marked with a Denso part number) when
replacing the bearings and do not subject the bearings
to impacts.
Block

[Point 101
Reassembly: Reassemble the front bearing.
SST 09950-76018-71
(09950-60010) .............................(1
09950-76020-71
(09950-70010). ............................(2)

[Point 111
Reassembly: Reassemble the rear bearing and the spring
washer.
SST 09820-76003-71
(09820-00030)

Section 1.2.7
 1DZ-II Repair

[Point 121
Reassemb1y:Put a plate washer or other appropriate
material between the SST and the rear end
frame so that pressure applies evenly to the
rear end frame.
SST 09381-41950-71

[Point 131
Reassembly: Set the alternator pulley in a vise and tighten
the set nuts.

Caution:
Always use pads to protect the components.

[Point 141
Reassembly: Reassemble the rectifier holder.
1. Make sure that the ends of the four stator coil terminals
fit in position in the terminal holders of the end frame.
2. First, tighten all the terminal mounting bolts temporarily,
and then tighten them properly.
3. Mount the rectifier mounting bolt.

I Brush holder boot [Point 151

Reassembly: Make sure that the brush holder boot is fitted
correctly.

Section 1.2.7
 1DZ-II Repair

APPENDIX

SST LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SERVICE STANDARDS . . . . . . . . . . . . . . . . . . . . . 8-6
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . 8-6
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 8-16
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 8-17
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 8-17
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . 8-18

Section 1.2.8
 1DZ-II Repair

SST LIST
Section
Illustration Part number Part name

Oil pan seal cutter

Valve guide bush remover &

replacer

Valve stem oil seal replacer

Valve spring compressor

Camshaft bearing remover &

replacer

Belt tension gauge

Oil filter wrench

Fuel filter wrench

Section 1.2.8
 1DZ-II Repair

Section
Illustration Part number Part name

Plunger stroke measuring tool

lnjection pump arm

Injection pump tool set

Nozzle holder retaining nut

wrench

lnjection pump spline shaft

puller

Bearing remover

Drive pinion bearing replacer

HST pump bearing replacer

Section 1.2.8
 1DZ-II Repair

r
-- -

Section
Illustration Part number Part name

Steering warm bearing puller

Alternator rear bearing puller

Alternator rear bearing replacer

Puller C set

Puller B set

Replacer set

Replacer B set

Handle set

Section 1.2.8
 1DZ-II Repair

r
Illustration Part number Part name
Section

Variable pin wrench set

Section 1.2.8
 1DZ-II Repair

SERVICE STANDARDS
ENGINE OVERHAUL
MANIFOLD

I Distortion limit mm (in.) EX

I

0.4 (0.016)

CYLINDER HEAD
I Bottom surface distortion limit mm (in.) I 0.15 (0.0059)
mm (in.) 1
I

IN manifold mounting surface distortion limit 0.20 (0.008)

I EX manifold mounting surface distortion limit mm (in.) I 0.20 (0.008) I
IN 1.2 to 1.6 (0.0472 to 0.0630)
Contact width mm (in.)
Valve seat EX 1.6 to 2.0 (0.0630 to 0.0787)
Contact angle 45"

VALVE GUIDE BUSHING

I Inside diameter mm (in.) 1 8.01 to 8.03 (0.3154 to 0.3161) 1
I Protrusion from head top surface mm (in.) ( 16.6 k 0.4 (0.654 + 0.016) I
VALVE SPRING
Standard 46.0 (1.811)
Overall length mm (in.)
Limit 45.5 (1.791)
Squareness mm (in.) 2.0 (0.08)

VALVE
IN 108.54 (4.2732)
Standard
EX 108.24 (4.2614)
Overall length mm (in.)
IN 107.90 (4.2480)
Limit
EX 107.60 (4.2362)
IN 7.97 to 7.99 (0.3138 to 0.3146)
Stem outside diameter mm (in.)
EX 7.96 to 7.97 (0.3134 to 0.3138)
0.02 to 0.06 (0.0008 to 0.0024)
Standard
Valve guide bushing oil clearance 0.04 to 0.07 (0.0016 to 0.0028)
mm (in.) 0.10 (0.0039)
Limit
EX 0.12 (0.0047)
I

IN 0.9 (0.035)
Valve head width limit mm (in.)
EX 1.O (0.039)
I Contact face angle .
Valve stem cap width mm (in.) Standard 1.31 to 1.49 (0.0516 to 0.0587)

Section 1.2.8
 1DZ-II Repair

VALVE ROCKER ARM & ROCKER SHAFT

Standard 18.470 to 18.490 (0.72717 to 0.72795)
Rocker shaft outside diameter mm (in.) -
Limit 18.44 (0.7260)
Standard 18.500 to 18.520 (0.72835 to 0.7291 3)
Rocker arm inside diameter mm (in.)
Limit 18.60 (0.7323)
Oil clearance between shaft Standard 0.007 to 0.049 (0.00028 to 0.00193)
and arm mm (in.) Limit 0.16 (0.0063)

Section 1.2.8
 1DZ-II Repair

VALVE LIFTER & PUSH ROD

Standard 22.1 70 to 22.190 (0.8728 to 0.8736)
Valve lifter outside diameter mm (in.)
01s 0.05 22.220 to 22.240 (0.8748 to 0.8756)
Oil clearance between valve lifter Standard 0.010 to 0.051 (0.00039 to 0.00201)
and cylinder block bore mm (in.) Limit 0.1 (0.004)
Push rod bend limit mm (in.) 0.25 (0.010)
I
TIMING GEAR & IDLE GEAR

1 Crank gear
N0.2
x idle gear No. 1, Standard
Limit

Standard
0.05 (0.0020)
0.3 (0.0118)
0.05 (0.0020)
ldle gear No.2 x camshaft gear
Gear Limit 0.3 (0.0118)
backlash
mm (in.) Idle gear No. I x injection Standard 0.05 (0.0020)

Standard 0.05 (0.0020)

ldle gear No.1 x oil pump gear
Limit 0.3 (0.0118)

(0.0012 to 0.0043)
Standard
ldle gear thrust clearance mm (in.) No.2: 0.100 to 0.260
(0.0039 to 0.0102)
I Limit I No.1: 0.3 (0.012), No.2: 0.5 (0.020)
I I No. 1: 45.000 to 45.025
ldle gear inside diameter

I I
ldle gear shaft outside diameter mm (in.) I Standard I No. 1: 44.950 to 44.975
(1.76969 to 1.77067)
No.2: 49.930 to 49,945

No.1: 0.025 to 0.075

3il clearance between idle gear Standard (0.00098 to 0.00295)
Yo. 1, No.2 and idle gear shaft No.2: 0.055 to 0.095
Vo.1, No.2 mm (in.) (0.00217 to 0.00374)
Limit 0.3 (0.012)
dle gear No.2 plate washer thickness
mm (in.)
1 Standard 1 2.45 to 2.50 (0.0965 to 0.0984)

Section 1.2.8
 1DZ-II Repair

CAMSHAFT & BEARING

Bend limit mm (in.) / 0.04 (0.0016)
Standard
Thrust clearance mm (in.)
Limit

Standard
Cam height mm (in.)
Limit

I No. I 1 47.159 to 47.175 (1.85665 to 1.85728)

Journal outside diameter mm (in.) Standard 1 No.2

Camshaft bearing inside

diameter mm (in.)
Standard I No.2 1 47.000 to 47.025 (1.85039 to 1.85138)

Bearing 01s value

Standard 0.025 to 0.066 (0.00098 to 0.00260)
Oil clearance mm (in.)
Limit 0.1 (0.0039)

CYLINDER BLOCK
Top surface distortion limit Top surface distortion
0.1 (0.004)
mm (in.) limit
Standard 1 86.00 to 86.03 (3.3858 to 3.3870)
Difference between
maximum and
Cylinder inside diameter mm (in.) minimum
1 Taper, ellipticity 0.02 (0.0008) or less
I Boring margin 0.02 (0.0008) or less
Cylinder liner outside A 89.030 to 89.045 (3.50512 to 3.50571)
diameter mm (in.) B 89.045 to 89.060 (3.50571 to 3.50630)
Cylinder liner bore diameter A 89.000 to 89.015 (3.50393 to 3;50453)
mm (in.) B 89.015 to 89.030 (3.50453 to 3.50512)
Valve lifter bore inside diameter Standard 22.200 to 22.221 (0.87402 to 0.87484)
mm (in.) 01s 0.05 22.245 to 22.271 (0.87579 to 0.87681)

Section 1.2.8
 1DZ-II Repair

PISTON & PISTON RING

Standard 1 85.950 to 85.980 (3.3839 to 3.3850)
1
I

Piston outside diameter mm (in.) 01s 0.50 86.450 to 86.460 (3.4035 to 3.4039)

Pin outside diameter mm (in.) 1 27.000 to 27.012 (1.06299 to 1.06346)

Pin fitting temperature " c (OF) /
Compression N0.1 0.27 to 0.39 (0.0106 to 0.0154)
Piston ring end ring No.2 0.45 to 0.60 (0.0177 to 0.0236)
gap mm (in.)
Oil ring 0.20 to 0.40 (0.0079 to 0.0157)

Ring to ring
groove ring No.2 0.04 to 0.08 (0.0016 to 0.0031)
clearance mm (in.)
Oil ring 0.03 to 0.07 (0.0012 to 0.0028)
I Standard 1I 0.040to0.060(0.00157to0.00236)
Piston clearance mm (in.)
Limit 0.15 (0.0059)

CONNECTING ROD & BUSHING

Standard 0.08 to 0.30 (0.0031 to 0.0118)
Connecting rod thrust clearance mm (in.)
Limit 0.40 (0.0157)
I I

Bushing inside diameter standard mm (in.) 1 27.011 to 27.023 (1.06343 to 1.06390)

Standard 0.007 to 0.015 (0000% t o 0 . 0 0 0 5 9 ) ~
Bushing oil clearance mm (in.)
Limit 0.05 (0.0020)
Connecting rod bearing oil clearance Standard 0.044 to 0.080 (0.00173 to 0.00315)
mm (in.) Limit 0.110 (0.0043)

Section 1.2.8
 1DZ-II Repair

CRANKSHAFT
Deflection limit mm (in.) I 0.05 (0.0020)
Standard 0.04 to 0.24 (0.0016 to 0.0094)
Thrust clearance mm (in.)
Limit 0.3 (0.012)

Thrust washer thickness mm (in.)

1 Standard 1 1.93 to 1.98 (0.0760 to 0.0780)
01s value 0.125 (0.00492), 0.250 (0.00984)
Standard 64.98 to 65.00 (2.55827 to 2.55906)
UIS 0.25 64.73 to 64.75 (2.54843 to 2.54921)
Journal outside diameter
(For finishing dimension for UIS) mm (in.)
I UIS 0.75 1 64.23 to 64.25 (2.52874 to 2.52953)

Standard 0.028 to 0.048 (0.00110 to 0.00189)

Crank journal oil clearance mm (in.)
Limit 0.1 (0.004)
I I

1 Standard 1 50.48 to 50.50 (1.9874 to 1.9882)

I
Crank pin outside diameter
U/S 0.50 49.99 to 50.00 (1.9681 to 1.9685)
(For finishing dimension for UIS) mm (in.)
I UIS 0.75 1 49.74 to 49.75 (1.9583 to 1.9587)
1 UIS 1.OO 1 49.49 to 49.50 (1.9484 to 1.9488)
Ellipticity limit 0.02 (0.0008)
Journal pin and crank pin mm (in.)
Taper limit 0.05 (0.0020)

ENGINE TUNE-UP
V belt tension I New belt 1 520 to 755 (53 to 77) [116.9 to 169.81
(Tension gauge) N (kgf) [Ibfl Belts in use 324 to 559 (33 to 57) [72.8 to 125.71
V belt deflection New belt 7 to 9 (0.28 to 0.35)
[Pressure 98.1 N (10 kgf) [22 Ibfl]
mm (in.) Belts in use 8 to 13 (0.31 to 0.51)

Total capacity 7.5 (1.98)

Lubricant oil capacity t (US gal)
Oil pan capacity 7.0 (1.85)
Injection timing (BTDC) 0
Injection pressure kPa (kg/cm2) [psi] 11800 k 500 (120 & 5) [I706 & 711
IN 0.18 to 0.22 (0.0071 to 0.0087)
Valve clearance (hot engine) mm (in.) -
EX 0.33 to 0.37 (0.0130 to 0.0146)
1 Standard I 2850 (29.0) [412]/260
Compression - I Limit I 2000 (20) [284]/260
kPa (kg1cm') [psiIlrprn
Difference
200 (2) [28]1260
between cylinder
I I

Idling speed rpm I See the repair manual for each model
No-load static maximum speed
Section 1.2.8
I See the repair manual for each model
 1DZ-II Repair

FUEL SYSTEM
NOZZLE & NOZZLE HOLDER
Nozzle I Valve opening pressure MPa (kgf/cm2) [psi] 11.77 f 0.49 (120 f 5) [I706 f 711
Adjusting washer thickness 0.900 to 1.950 (0.0354 to 0.0768)
(For adjusting nozzle valve opening pressure) mm (in.) (43 type every 0.025 mm (0.00098))

INJECTION PUMP
-
-

Roller ring assembly Roller ring height variation limit mm (in.)

Drive shaft Wear depth limit of oil seal contact surface mm (in.)
Wear limit of plunger contact surface (dimension L)
Cam plate
mm (in.)
Stepped wear limit of washer contact surface
Flyweight
(dimension A) mm (in.)
Plunger spring Squareness (dimension A) mm (in.)
Pump housing Bushing wear limit mm (in.)

Cam lift amount during injection timing check mm (in.)

INJECTION PUMP ADJUSTMENT

1. Adjustment condition
Nozzle valve opening pressure

I Test oil
MPa (kgf/cm2) [psi] 1 14.71 f 0.49 (150 f 5) [2133 to 22041

SAE J967 (IS0 4113)

I Feed oil pressure kPa (kgf/cm2) [psi] I
High pressure pipe (Inside diameter
diameter x length)
x outside
mm (in.)
1
I
02 x 06 x 840 (00.079 x 00.236 x 033.071)

Test oil temperature OC (OF) I 40 to 45 (104 to 113)

2. Temporary adjustment (Lever at full position)
In'ection rate
Model Reference point
Pump speed 5
cm 1200 st. Icyl Remarks
rpm (cu.in./200 st. Icyl)
Full load reference
point
1 900
Adjust with the full load set
screw.
High-speed lever set
point
1 1310
Adjust with the maximum
speed adjusting screw.
Full load reference Adjust with the full load set
900
point screw.
High-speed lever set Adjust with the maximum
1410
point speed adjusting screw.
Full load reference
8FDlO to 15 point 1 900
Adjust with the full load set
screw.
8FDK20 to 30
for DPF High-speed lever set
point
1 1310
Adjust with the maximum
speed adjusting screw.
Section 1.2.8
 1DZ-II Repair

In'ection rate
Model Reference point Pump speed B
cm 1200 s t . 1 ~ ~ 1 Remarks
rpm (cu.in.1200 st.1cyl)
Full load reference
point screw.
High-speed lever set Adjust with the maximum
point speed adjusting screw.
3. Pump internal pressure adjustment (Lever at full position)

'Vm Pump speed

392 to 490 (4.0 to 5.0) [56.9 to 71 . I ]

Adjust with regulating valve
588 to 686 (6.0 to 7.0) [85.3 to 99.51

Pump speed Pump internal ressure

rpm
P
kPa (kglcm ) [psi]
Remarks

Adjust with regulating valve

I4. 1200 411 to 471 (4.2 to 4.8) [59.7 to 68.31
Overflow rate inspection (Lever at full position)
Pump speed Overflow rate inspection
Remarks
rpm cm3/min. (cu.in./min.)
1200 283 to 533 (17.27 to 32.53) Use overflow screw on each pump.
5. Timer adjustment (Lever at full position)
I Pump speed rPm / 700 1200
I t o n stroke mm (in.) 1 0.45 to 1.25 (0.0177 to 0.0492) 1 2.35 to 3.15 (0.0925 to 0.1240) 1
6. Full load injection rate adjustment (Lever at full position)
Injection rate
Pump speed Variation
Model cm3/200 st. l c y ~ Remarks
rpm cm3 (cu.in,)
:cu.in./200 st.1cyl)
8.34 to 8.74 0.6 (0.037)
Full load injection rate setting
(0.509 to 0.533) or less

Full load injection rate setting

(0.485 to 0.509) or less

7.74 to 8.14 0.6 (0.037)

8FDK20 to 30 Full load injection rate setting
(0.472 to 0.497) or less
for DPF
7.7 to 8.1 0.6 (0.037)
Full load injection rate setting
(0.470 to 0.494) or less

Section 1.2.8
 1DZ-II Repair

7. Starting injection rate adjustment (Lever at full position)

In'ection rate
Model
Pump speed B
cm Q00 st.1cyl
Variation
cm3 (cu.in.)
Remarks
rpm

I Except for
2TD 20.25 1 loo 1
(cu.in.1200 st.1cyl)
7'74 to 8'14
(0.472 to 0.497)
1 (0'073)
or less
1 Gain in weight at the start

Only for 2TD 7.7 to 8.1 (0'073)

100 Gain in weight at the start
20.25 (0.470 to 0.494) or less

8. Full load injection rate inspection (Lever at full position)

In'ection rate
Model Lever angle
Pump speed B
cm 1200 st. Icyl
Variation
cm3 (cu.in.)
(cuh.1200 st.1cyl)

18" ? 5"
0.6 (0.037) or less
(at Full position)

14" 5 5"
0.6 (0.037) or less
(at Full position)

8FDlO to 15
18" ? 5"
8FDK20 to 30 0.6 (0.037) or less
(at Full position)
for DPE
-

8FD20 to 30 15" ? 5"

0.6 (0.037) or less
for DPF (at Full position)

20" ? 5"
0.5 (0.031) or less
(at Full position)

0.5 (0.031) or less

Section 1.2.8
 1DZ-II Repair

9. High speed lever setting

In'ection rate
Model Lever angle
Pump speed 4
cm 1500 st. Icyl Remarks
rPm (cu.in.1200 st.1cyl)
0.80 to 2.40 High speed lever
1310
(0.049 to 0.146) setting
18" k 5"
5'22 8'02
(at Full position) 1275 confirmation
(0.319 to 0.489)
I I

1400 / 0.90 (0.055) or less I Confirmation

1.06 to 2.66 High speed lever
1410
(0.065 to 0.162) setting
14" k 5"
3'34 to 6'14
(at Full position) 1375 confirmation
(0.204 to 0.375)
1500 0.90 (0.055) or less Confirmation
0.80 to 2.40 High speed lever
1310
(0.049 to 0.146) setting
8FDlO to 15
18" k 5"
8FDK20 to 30 5'22 to 8'02
(at Full position) 1275 confirmation
for DPF (0.319 to 0.489)

I 1400 1 0.90 (0.055) or less 1 Confirmation

1.06 to 2.66 High speed lever
1410
(0.065 to 0.162) setting
8FD20 to 30 15" k 5"
3'34 to 6'14
for DPF (at Full position) 1375 confirmation
(0.204 to 0.375)

I 1500 1 0.90 (0.055) or less 1 Confirmation

2.2 to 4.0 High speed lever
1310
(0.134 to 0.244) setting
20" k 5"
(at Full position)
1275 1 4.6 to 7.4
(0.281 to 0.452)
Confirmation

I 1400 1 0.90 (0.055) or less I Confirmation

10. Load sensing timer adjustment
In'ection rate
Lever angle
Pump speed 4
cm 1200 st. Icyl
Piston stroke
mm (in.)
Remarks
rPm (cu.in.1200 st. lcyl)

Full q Full

Start of effect
1 I2O0 1 (q full - 0.8) & 0.4
((q full - 0.049) k 0.024)
1 2'35 lo
(0.143 to 0.192)
By governor shah

(q full - 2.4) k 0.4 I.32 2.1

End of effect 1200 Confirmation
((q full - 0.146) k 0.024) (0.081 to 0.129)

Section 1.2.8
 1DZ-II Repair

11. Low speed lever setting

In'ection rate
Model Lever angle
Pump speed 41500 St.1C Y ~
Deviation
Remarks
rPm cm3(cu.in.J
(cu.in.1500 st. Icyl)
Except for 2.5 to 5.5 1.5 (0.092) Low speed lever
390
8FD20 to 30 (0.153 to 0.336) or less setting
for DPF 490 0.75 (0.046) or less - Confirmation
2.5 to 5.5 1.5 (0.092) Low speed lever
8FD20 to 30 390
(0.153 to 0.336) or less setting
for DPF
L
1 0.75 (0.046) or less I - 1 Confirmation
12. Idling speed, no-load maximum engine speed
Idling speed No-load maximum speed
Model
rpm rpm
I All models I 750 + 25 1 See the repair manual for each model

COOLING SYSTEM
THERMOSTAT
I Opening temperature " c (OF) I 80 to 84 (176 to 183) I
Fully opened temperature " c (OF) I 95 (203) I
I

Fully opened lift mm (in.) I 10 (0.39)

LUBRICATION SYSTEM
OIL PUMP
I Oil pump type Trochoid pump
Standard 0.10 to 0.17 (0.0039 to 0.0067)
Body clearance mm (in.)
Limit 0.2 (0.0079)
Standard 0.05 to 0.15 (0.0020 to 0.0059)
Tip clearance mm (in.)
Limit 0.2 (0.0079)
3.91 to 3.97 (0.1539 to 0.1563)
Rotor protrusion mm (in.) Standard
(Reference)

Section 1.2.8
 1DZ-II Repair

STARTING SYSTEM
STARTER
Motor type / DC series-wound reduction type
Rated voltage VI
Rated output kw I 2.5
Voltage V 11
No-load characteristics Current A 90 or less
I

Speed rPm 1 3500 or more

1
I I

Ellipticity mm (in.) Limit 0.05 (0.0020) or less

Standard 36 (1.42)
Outside diameter mm (in.)
Commutator Limit 35 (1.38)
Standard 0.7 (0.028)
Mica depth mm (in.)
Limit 0.2 (0.008)
Standard 20.5 (0.807)
Length mm (in.)
Limit 13 (0.512)
Brush 31.4 to 39.2 (3200 to 4000)
Spring installed load Standard
[7.1 to 8.81
N (gf) [ W
Limit 21.6 (2200) [4.9]

CHARGING SYSTEM
ALTERNATOR
Rated voltage V 12
Maximum output A 60
Output speed rPm 1500
Standard 10.5 (0.413)
Brush length mm (in.)
Limit 1.5 (0.059)
Standard 14.4 (0.567)
Slip ring outside diameter mm (in.)
Limit 14.0 (0.551)

Section 1.2.8
 1DZ-II Repair

TIGHTENING TORQUE
Tightening point Tightening torque N.m (kgfcm).[ft.lbfj
Cylinder block x cylinder head
x crankshaft bearing cap
x idle gear thrust plate
x camshaft thrust plate
x oil pan
x oil pump
x timing gear case
x rear oil seal retainer
x alternator bracket
x oil strainer
x oil regulator
Cylinder head x cylinder head cover
x intake manifold
x exhaust manifold
x valve rocker support
x nozzle holder
x water pump
Crank shaft x crankshaft pulley
Camshaft x camshaft timing gear
Connecting rod x connecting rod cap
Injection pump x timing gear case
x pump drive gear
x injection pipe
riming gear case x timing gear cover
Alternator bracket x alternator
Uater pump x fan, fan pulley
Valve rocker support x rocker shaft
Uater outlet x outlet housing
Vozzle holder x nozzle leakage lock nut
njection nozzle holder x injection pipe
ntake pipe x intake manifold

Section 1.2.8
SEC INDEX.fm 1 ページ ２００７年２月２２日　木曜日　午後４時５０分

SECTION INDEX
NAME SECTION

GENERAL 1.3.0
OPERATION DESCRIPTION 1.3.1
LPG REGULATOR OVERHAUL 1.3.2
ELECTRICAL TROUBLESHOOTING 1.3.3
APPENDIX 1.3.4

4Y-E LPG Device Repair

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LPG Device for 4Y-E Engine 0-1

GENERAL
Page
TYPE OF LPG DEVICES........................................0-2
0
ENGINE PERFORMANCE CURVES .....................0-3
1
ENGINE SPECIFICATIONS ...................................0-6
2
PRINCIPAL DIFFERENCES
FROM GASOLINE VEHICLE ...............................0-7 3
ABBREVIATIONS...................................................0-7 4
GENERAL RULES OF SERVICING WORK ..........0-8 5
BOLT & NUT TIGHTENING TORQUES.................0-9 6
BOLT STRENGTH CLASS IDENTIFICATION
METHOD AND TIGHTENING TORQUE ....................0-9 7
PRECOATED BOLTS 8
(BOLTS WITH SEAL LOCK AGENT
9
COATING ON THREADS) ..................................0-12
PERIODIC MAINTENANCE .................................0-13 10
INSPECTION METHOD ..........................................0-13 11
PERIODIC REPLACEMENT PARTS .........................0-13 12
13
14
15
16
17
18
19
20
21
E
Section 1.3.0
00.book 2 ページ ２００７年２月２２日　木曜日　午後４時４５分

0-2 LPG Device for 4Y-E Engine

TYPE OF LPG DEVICES

1. Types of LPG cylinders
Pneumatic Cushion
Gas weight Cylinder length Specification
models models
General purpose — STD
15 kg (33.1 lb) 637 mm (25.1 in)
With level gauge and quick coupling — OPT
General purpose STD —
20 kg (44.1 lb) 797 mm (31.4 in)
With level gauge and quick coupling OPT —

2. Types of LPG cylinder brackets

Cylinder
Fuel hose connecting
External Removal/installation method Bracket opening direction
Weight position
diameter
20.0 kg 797 mm Sinple type (STD)
(44.1 lb) (31.4 in) Swing down type (OPT) Right Bottom
15.0 kg 637 mm
n n n
(33.1 lb) (25.1 in)

Section 1.3.0
00.book 3 ページ ２００７年２月２２日　木曜日　午後４時４５分

LPG Device for 4Y-E Engine 0-3

ENGINE PERFORMANCE CURVES

4Y Engine (8FGU15 to 25, 8FGCU20 to 32)

0
Gasoline
(Exclusive, Convertible) 1
LPG (Exclusive, Convertible)
2
3
Shaft torque

4
5
6
7
8
9
Shaft output

10
11
12
13
14
15
Fuel consumption ratio

16
17
18
19
20
Engine speed
21
E
Section 1.3.0
00.book 4 ページ ２００７年２月２２日　木曜日　午後４時４５分

0-4 LPG Device for 4Y-E Engine

4Y Engine (8FGU30, 32)

Gasoline (Exclusive)

Gasoline
(Convertible with LPG)
LPG (Exclusive, Convertible)
Shaft torque
Shaft output

Gasoline
Fuel consumption ratio

(Exclusive, Convertible)
LPG (Exclusive, Convertible)

Engine speed

Section 1.3.0
00.book 5 ページ ２００７年２月２２日　木曜日　午後４時４５分

LPG Device for 4Y-E Engine 0-5

4Y Engine (8FGU15 to 32 series, 8FGCU15, 18 and 8FGCSU20)

0
Gasoline 1
(Exclusive, Convertible)
LPG 2
(Exclusive, Convertible)

3
Shaft torque

4
5
6
7
8
9
Shaft output

10
11
12
13
14
Fuel consumption ratio

15
16
17
18
19
Engine speed
20
21
E
Section 1.3.0
00.book 6 ページ ２００７年２月２２日　木曜日　午後４時４５分

0-6 LPG Device for 4Y-E Engine

ENGINE SPECIFICATIONS
4Y
8FGU15 to 25
8FGU30, 32 8FGCU15, 18 and 8FGCSU20
8FGCU20 to 32
A B C A B C A B C
N·m 160 165 162 160 160
Maximum shaft m m m m
(kgf·m) (16.3) (16.8) (16.5) (16.3) (16.3)
torque
rpm 2100 m m 2570 m 2200 2100 m m
kW 38 44 43 42 36
Maximum shaft m m m m
(PS) (51) (59) (58) (57) (48)
output
rpm 2570 m m 2570 m m 2250 m m
Minimum fuel g/kW·h 298 233 233 310 298
m m m m
consumption (g/PS·h) (219) (171) (171) (228) (219)
ratio rpm 2000 m m 2000 m 1600 2000 m m
Idle speed rpm 750 m m 750 m m 750 m m
No-load
maximum rpm 2570 m m 2570 m m 2250 m m
governed speed

A: Gasoline (Exclusive)
B: Gasoline (Convertible)
C: LPG (Exclusive, Convertible)

Section 1.3.0
00.book 7 ページ ２００７年２月２２日　木曜日　午後４時４５分

LPG Device for 4Y-E Engine 0-7

PRINCIPAL DIFFERENCES FROM GASOLINE VEHICLE

LPG
Gasoline vehicle
Exclusive vehicle Convertible vehicle
Gasoline tank and
Fuel tank LPG cylinder Gasoline tank
LPG cylinder
Adapter For LPG For LPG Not provided
Regulator For LPG For LPG Not Provided
Fuel pump Not provided For gasoline For gasoline
Fuel filter For LPG For gasoline, For LPG For gasoline
Solenoid valve For LPG For LPG Not provided

ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASSY Assembly O/S Oversize
ABDC After bottom dead center OPT Option
ATDC After top dead center RH Right hand
BBDC Before bottom dead center rpm Revolution per minute
BTDC Before top dead center SST Special service tool
BDC Bottom dead center STD Standard
EX Exhaust SUB-ASSY Sub-assembly
IN Intake T= Tightening torque
LH Left hand U/S Undersize

Section 1.3.0
00.book 8 ページ ２００７年２月２２日　木曜日　午後４時４５分

0-8 LPG Device for 4Y-E Engine

GENERAL RULES OF SERVICING WORK

1. Preparation before disassembly
• Prepare necessary mechanic tools, measuring instruments and SST before starting operation.
• When disassembling a complicated assembly, put punch or matching marks at places not affecting the
function to facilitate reassembly operation. When repairing an electrical system, start operation after
disconnecting the cable from the battery negative terminal.
2. Inspection during disassembly
• Each time a part is removed, check the part installed state, deformation, damage, roughening state and
scratching.
3. Orderly arrangement of disassembled parts
• Disassembled parts shall be arranged orderly. Distinguish the parts to be replaced from the parts to be reused.
4. Cleaning of disassembled parts
• Parts to be reused shall be cleaned and washed thoroughly.
5. Inspection and measurement
• Detailed inspection and measurement shall be carried out as required for parts to be reused.
6. Installation
• Install good parts according to the correct procedure and observing the determined standards (tightening
torques, adjustment values, etc.).
• Be sure to use genuine parts for replacement of existing parts.
• Be sure to use new packings, gaskets and cotter pins because they are non-reusable parts.
• Coat seal packing on gaskets depending on the places, coat oil on the sliding contact places, coat oil or
grease at specified places, and coat MP grease on oil seal lips before reassembly.
7. Adjustment and operation check
• Adjust to the service standard values by using gages, a multimeter, etc.

Section 1.3.0
00.book 9 ページ ２００７年２月２２日　木曜日　午後４時４５分

LPG Device for 4Y-E Engine 0-9

BOLT & NUT TIGHTENING TORQUES

Standard Bolt & Nut Tightening Torque
Tightening torques of standard bolts and nuts are not indicated throughout the manual.
Use the procedures and table below to judge the standard tightening torque.
1. Judge the tightening torque for the hexagon head bolt, welded bolt or stud bolt having the standard bearing
surface according to the tightening torque table by identifying the bolt strength class from the table below.
2. Judge the tightening torque for the hexagon flange bolt based on the threading diameter.
3. The nut tightening torque can be judged from its corresponding bolt type by using procedure 1.

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND

TIGHTENING TORQUE
Identification by Actual Part

Type Shape and Strength class Strength class

4 = 4T
5 = 5T
Number in relief or hallmark on head
6 = 6T
7 = 7T
8 = 8T

No mark 4T

Hexagon head bolt

(standard bearing
surface) Bolt with two raised lines on head 5T

Bolt with three raised lines on head 7T

Bolt with four raised lines on head 8T

Welded bolt 4T

No mark 4T

Stud bolt

About 2 mm (0.08 in.) groove(s) on one/both edge(s) 6T

Section 1.3.0
00.book 10 ページ ２００７年２月２２日　木曜日　午後４時４５分

0-10 LPG Device for 4Y-E Engine

Identification by Part No.

Type Part No. Shape

91 611-4 0 62 5
Nominal
Nominal length (mm)
diameter
Hexagon bolt Nominal diameter (mm)
Strength class
Nominal length

92 1 32 -4 06 14
Nominal length (mm) Nominal
Stud bolt diameter
Nominal diameter (mm)
Strength class
Length

Tightening Torque Table

Nominal diameter Pitch Standard tightening torque

Strength class
mm mm N·m kgf·cm ft·lbf

6 1.0 5.4 55 4.0

8 1.25 13 130 9.4
10 1.25 25 260 18.8
4T
12 1.25 47 480 34.7
14 1.5 75 760 54.9
16 1.5 113 1150 83.0

6 1.0 6.5 65 4.7

8 1.25 16 160 11.6
10 1.25 32 330 23.8
5T
12 1.25 59 600 43.3
14 1.5 91 930 67.1
16 1.5 137 1400 101.1

6 1.0 7.8 80 5.8

8 1.25 19 195 14.1
10 1.25 39 400 28.9
6T
12 1.25 72 730 52.7
14 1.5 108 1100 79.4
16 1.5 172 1750 126.6

6 1.0 11 110 7.9

8 1.25 25 260 18.8
10 1.25 52 530 38.3
7T
12 1.25 95 970 70.0
14 1.5 147 1500 108.3
16 1.5 226 2300 166.1

6 1.0 12 125 9.0

8 1.25 29 300 21.7
10 1.25 61 620 44.9
8T
12 1.25 108 1100 79.4
14 1.5 172 1750 126.6
16 1.5 265 2700 195.3

Section 1.3.0
00.book 11 ページ ２００７年２月２２日　木曜日　午後４時４５分

LPG Device for 4Y-E Engine 0-11

Identification by Bolt Shape (Hexagon flange bolt)

Class 4.8T 6.8T 8.8T 10.9T 11.9T

No mark

Hexagon flange
bolt

- -
No mark

Tightening Torque Table (Hexagon flange bolt)

Nominal diameter Pitch Standard tightening torque

Strength class
mm mm N·m kgf·cm ft·lbf

6 1.0 5.5 56 4
8 1.25 13 130 9
10 1.25 27 280 20
4.8T
12 1.25 50 510 37
14 1.5 78 800 58
16 1.5 120 1220 88

6 1.0 7.5 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6.8T
12 1.25 71 720 52
14 1.5 110 1120 81
16 1.5 170 1730 125

6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8.8T
12 1.25 110 1120 81
14 1.5 175 1780 129
16 1.5 270 2750 199

6 1.0 15.5 160 12

8 1.25 38 390 28
10 1.25 80 820 59
10.9T
12 1.25 145 1480 107
14 1.5 230 2350 170
16 1.5 360 3670 266

6 1.0 17.5 180 13

8 1.25 42 430 31
10 1.25 89 910 66
11.9T
12 1.25 160 1630 118
14 1.5 260 2650 192
16 1.5 400 4080 295

Section 1.3.0
00.book 12 ページ ２００７年２月２２日　木曜日　午後４時４５分

0-12 LPG Device for 4Y-E Engine

PRECOATED BOLTS
(BOLTS WITH SEAL LOCK AGENT COATING ON THREADS)
1. Do not use the precoat bolt as it is in either of the following
cases:
(1) After it has been removed.
(2) When it has been moved by tightness check, etc.
(loosened or tightened)
Note:
For torque check, tighten the bolt at the lower limit of the
allowable tightening torque range; if the bolt moves, retighten
Seal lock agent
it according to the steps below.
2. How to reuse precoated bolts
(1) Wash the bolt and threaded hole.
(The threaded hole must be washed even when replacing
the bolt with a new one.)
(2) Completely dry the washed parts by blowing with air.
(3) Apply the specified seal lock agent to the bolt threaded
portion.

Section 1.3.0
00.book 13 ページ ２００７年２月２２日　木曜日　午後４時４５分

LPG Device for 4Y-E Engine 0-13

PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection. Repair or replacement if required.
C: Cleaning *1: Soapy water *2: Detector
Inspection Period Months 1 3 6 12
Item Hours 170 500 1000 2000
Gas leak from piping and joint I*1 { m m m
2
Damage of piping and joint I* { m m m
Tar removal from regulator C { m m m
Regulator adjustment status I { m m m
Regulator function I { m m
Adapter I { m m
Filter clogging C { m m
Loosened installation and functioning of solenoid valve I { m m
Gas cylinder I { m m m
Looseness and damage of gas cylinder mounting I { m m m

PERIODIC REPLACEMENT PARTS

Item Replacement timing
O-ring for LPG cylinder valve Every 24 months
LPG high and low-pressure rubber hoses Every 24 months
LPG regulator diaphragm and O-ring Every 36 months or 2500 hours
Fuel filter Every 36 months or 2500 hours

Section 1.3.0
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01.book 1 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 1-1

OPERATION DESCRIPTION
Page
OUTLINE OF LPG DEVICE....................................1-2
0
FUEL FILTER FOR LPG ........................................1-3
1
SOLENOID VALVE .................................................1-3
2
ADAPTER...............................................................1-4
REGULATOR..........................................................1-5
3
SPECIFICATIONS ....................................................1-5 4
REGULATORS SYSTEM COMPONENTS ................. 1-11 5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
Section 1.3.1
01.book 2 ページ ２００７年２月２２日　木曜日　午後４時４６分

1-2 LPG Device for 4Y-E Engine

OUTLINE OF LPG DEVICE

LPG (in liquid form supplied from the cylinder) passes through the LPG filter in the engine room to remove foreign
matter and reaches to the regulator through the main solenoid valve. LPG is reduced and gasified in the regulator,
and supplied to engine with its pressure kept at a certain rate.
Engine coolant is led to the regulator for use as the heat source for LPG gasification.

Ignition Regulator set

Battery switch
Fuse
Injector path
Slow solenoid valve

Regulator Main path

Coolant path
Main
LPG solenoid
filter valve
Adapter
Injector

Cylinder
Valve

LPG

Engine

Section 1.3.1
01.book 3 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 1-3

FUEL FILTER FOR LPG

The filter is mounted between the LPG cylinder and the right before
the solenoid valve to remove various kinds of foreign materials in
From To
LPG. It consists of a filter element and permanent magnet, and the
LPG
cylinder
Main
solenoid
filter element is detachable for easy cleaning and has sufficiently 0
valve strong construction to withstand LPG vapor pressure.

Filter
When low-grade LPG is used, vary small impurity particles flow into
the regulator causing start difficulty due to clogging of the slow
1
element path. The filtering performance has been improved to be able to
remove foreign matters of 2 2m or more in size. 2
Filtering Performance 2 2m
3
SOLENOID VALVE
Solenoid coil
To
Regulator 4
The solenoid valve is mounted between the LPG filter and the

From
regulator, and controls gas flow according to the engine condition.
For example, when the engine is running, the solenoid valve is ON 5
LPG filter and supplies fuel. Once the engine stops running, it turns OFF and
cuts off the gas flow. 6
When the current flows through the solenoid valve, which consists
IN OUT
of a slide valve, back spring, and solenoid coil, magnetic force is
generated. The slide valve overcomes the spring force by such
7
Back spring
magnetic force to move forward the IN side, and fuel flows.
When the current stop flowing through the solenoid valve, the slide 8
valve is forced to back to the OUT side by the LPG pressure and
spring force to shut off the flow. 9
10
11
12
13
14
15
16
17
18
19
20
21
E
Section 1.3.1
01.book 4 ページ ２００７年２月２２日　木曜日　午後４時４６分

1-4 LPG Device for 4Y-E Engine

ADAPTER
The adapter is installed on the right upper position of the electric
governor, and mixes air with gaseous LPG decompressed in the
Seat regulator. The air-mixed fuel is led to the engine. The adapter has a
diameter FCM (Fuel/air Control Motor) at the ventury part and the FCM
Ventury controls the amount of fuel based on the engine ECU signal. The
diameter motor has a taper-shaped needle valve that moves right or left
Seat based on the engine ECU signal. This sliding of the valve changes
Ventury angle the opening space of the fuel path.

Needle
FCM
valve

Electronic
governor

Specifications
Ventury diameter mm (in) 24 (0.9)
Needle valve seat diameter mm (in) 11 (0.4)
Needle valve seat angle G 60

FCM specifications
Magnetized way 1-2 magnetized type
Stroke mm (in) 5 (0.2)
[0.05 (0.002) / step]
Pulse generation rate pulse / second 140

Section 1.3.1
01.book 5 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 1-5

REGULATOR
The regulator supplies vaporized LPG after pressure reduction to the engine while maintaining the pressure at a fixed
level.

0
1
2
3
4
5
6
7
8
9
10
11
12
SPECIFICATIONS 13
First chamber pressure
First seat inner diameter
kPa (psi)
mm (in)
24.5 to 34.3 (3.6 to 5.0)
3.2 (0.1)
14
Secondary seat inner diameter mm (in) 6.0 (0.2)
15
Slow system flow shut off method Solenoid valve
Drain cock Optionally available 16
17
18
19
20
21
E
Section 1.3.1
01.book 6 ページ ２００７年２月２２日　木曜日　午後４時４６分

1-6 LPG Device for 4Y-E Engine

Regulator Function
The LPG is gasified by depriving the engine coolant, led into the regulator, of heat. The regulator consists of chamber
A where LPG vaporization starts, chamber B (first reducing chamber) where the gasified LPG pressure is reduced,
chamber C (second reducing chamber) for reducing the pressure down to almost atmospheric level to supply fuel
using the adopter venturi vacuum, and chamber D for forced fuel supply during engine start and idling.

LPG flowing into chamber A of the regulator pushes elastic face valve 1 open by vapor pressure allowing it to enter
first reducing chamber B where it is vaporized by pressure reduction. When the pressure in chamber B becomes in
the range of 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) (3.6 to 5.0 psi), first diaphragm pushes first regulator spring, so
first diaphragm hook acuates first valve lever to close elastic face valve 1. When LPG flows out to second reducing
chamber C, the first pressure drops and first valve lever is operated by first regulator spring to open elastic face valve
1 to cause fuel to flow into first reducing chamber B again. Opening and closing of elastic face valve is repeated to
maintain the first pressure at a fixed level. The pressure of the fuel entering from chamber B into chamber C through
elastic face valve 2 is reduced to atmospheric level. Chamber C is connected to the adapter.
The vacuum of the ventury nozzle at the adapter operates second diaphragm to open elastic face valve 2 via second
valve lever. The valve is closed by the force of second regulator spring to maintain a constant pressure (atmospheric
pressure).

Injector path
(to injector) Slow path

Chamber D
Slow solenoid valve
Main path (to adaptor)

Elastic face valve 2

Chamber B
Chamber C

Secondary diaphragm
First diaphragm hook Second valve lever

First regulator spring

First diaphragm

First valve lever

Elastic face valve 1

Chamber A

Section 1.3.1
01.book 7 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 1-7

1. When starting the engine

When the ignition switch and LPG switch are both turned to ON, the LPG led from the IN port flows into chamber
A. Upon entering chamber A, the LPG pushes open the elastic face valve 1 by its own vapor pressure, and
enters the primary pressure reduction chamber B for pressure reduction and vaporization. When the pressure in
chamber B reaches in the range of 24.5 to 34.3 kPa (3.6 to 5.0 psi), first diaphragm pushes first regulator spring
to operate first valve lever by means of first diaphragm hook. As a result elastic face valve is closed and the
pressure in the primary pressure reduction chamber B remains at a constant level. When the starting motor runs,
the current flowing in the coil of the slow solenoid operates the valve to connect chambers B and D. Since the
pressure in chamber B at 24.5 to 34.3 kPa (3.6 to 5.0 psi) is higher than the atmospheric pressure, LPG flows
into chamber D. The LPG entering chamber D flows through the slow path, and main path into the adapter, and
is then supplied to the engine from the venturi nozzle to start initial explosion. When the throttle valve at the
electric governor is opened slightly then, vacuum is generated in the venturi of the adapter. The vacuum in the
adapter acts on the secondary pressure reduction chamber C via the main path. At this time, secondary
diaphragm is operated to open elastic face valve 2 via second valve lever to cause LPG to flow from the primary
pressure reduction chamber B to the secondary pressure reduction chamber C.
As a result, a large amount of LPG enters the adapter for consecutive combustion.

Injector path
(to injector) Slow path

Chamber D
Slow solenoid valve
Main path (to adaptor)

Elastic face valve 2

Chamber B
Chamber C

Secondary diaphragm
First diaphragm hook Second valve lever

First regulator spring

First diaphragm IN port

First valve lever

Elastic face valve 1

Chamber A

Section 1.3.1
01.book 8 ページ ２００７年２月２２日　木曜日　午後４時４６分

1-8 LPG Device for 4Y-E Engine

2. During idling
When the engine is idling, current flows to the slow solenoid valve coil to operate the valve, resulting in opening
of the closed path to connect chambers B with D. Since the pressure in chamber B is high enough, the
depressurized LPG flows chamber D. Though most of the fuel flown to chamber D is led to the adapter through
the slow path, main path, and venturi nozzle of the adapter, and then supplied to the engine, fuel is also
delivered to the engine by the LPG injector to compensate the air-fuel ratio. The idle adjusting screw controls
main flow rate of fuel. Since vacuum at the adapter is very low during idling, elastic face valve 2 is not opened
and the fuel is supplied not from the chamber C, but from the slow path.

Idle adjusting screw

Injector Slow path

path
Main path

Chamber D

Slow
Elastic
solenoid
face
valve Ventury nozzle
valve 2
Chamber B

Adapter

LPG injector

Chamber C

Section 1.3.1
01.book 9 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 1-9

3. During normal operation

When the throttle valve is opened, vacuum arises at the adapter venturi nozzle, which is applied to chamber C
through the main path. This vacuum pulls second diaphragm to open elastic face valve 2. As a result, LPG flows
from chamber B to chamber C, and enters the adapter venturi nozzle through the main path.
As a current also flows in the slow solenoid valve, LPG also flows from chamber B to chamber D, and through
the slow path to the venturi nozzle, and is also supplied to the engine by the LPG injector through the injector
path.
While the engine is running in medium load range, LPG fuel is mostly supplied through the main path, and LPG
injector injects the shortage amount of fuel to the ideal air-fuel ratio.
While the engine is in high load range, the FCM at adapter changes the amount of fuel flow to adjust the overall
fuel amount, on the other hand, the injector supplies a fixed amount of fuel with engine.

Injector Slow path

path
Main path

Chamber D

Slow
Elastic
solenoid Ventury nozzle
face
valve
valve 2
Chamber B Adapter
Second FCM
diaphragm

LPG injector
Throttle
valve

Chamber C

Section 1.3.1
01.book 10 ページ ２００７年２月２２日　木曜日　午後４時４６分

1-10 LPG Device for 4Y-E Engine

4. When stopping the engine

When the engine stopped, the current to the slow solenoid valve is cut off to close the path between chambers B
and D, resulting in suspension of LPG supply through the slow path. Since the vacuum at the adapter venturi
does not exist, LPG supply through the slow path also stops.

Slow path

Chamber D

Slow
solenoid
valve
Chamber B

Adapter

LPG injector

Section 1.3.1
01.book 11 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 1-11

REGULATORS SYSTEM COMPONENTS

LPG Cutoff Device
The solenoid valve for slow path control is integrated with the regulator. The solenoid valve is opened and closed
according to the engine speed, starter signal etc. detected by means of engine ECU. When the ignition switch is ON,
with the engine not running, the valve is closed not to flow LPG to the adapter.

Ignition
switch ST

ON LPG-
AM Gasoline Starter
switch relay
Gasoline LPG

Starter
EFI LPG motor
main Solenoid
relay relay
Igniter

Slow Main
solenoid solenoid

Engine ECU

Battery

Section 1.3.1
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02.book 1 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-1

LPG REGULATOR OVERHAUL

Page
PRECAUTION FOR LPG FORKLIFT OPERATION
AND REPAIR ........................................................2-2 0
REGULATOR..........................................................2-3 1
REMOVAL·INSTALLATION .....................................2-10 2
DISASSEMBLY·REASSEMBLY ...............................2-12 3
LPG LEAK INSPECTION .....................................2-17 4
ENGINE ADJUSTMENT.......................................2-18
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
Section 1.3.2
02.book 2 ページ ２００７年２月２２日　木曜日　午後４時４６分

2-2 LPG Device for 4Y-E Engine

PRECAUTION FOR LPG FORKLIFT OPERATION AND REPAIR

Handle LPG with special attention, because it is inflammable and may cause explosion resulting in the fatal accident.
1. Never smoke tobacco, strike a match and light a lighter near the LPG forklift. Never park and stop the LPG
forklift near a stove, gas burner, electric heater, electric apparatus (a motor, etc), bonfire, etc. (near the fire).
Avoid the direct sunlight, if possible.
2. Never operate the LPG forklift near the fire.
3. When Operating, inspecting and repairing the LPG forklift, put up “CAUTION INFLAMMABLE” to avoid any fire.
4. When repairing the LPG forklift, remove the engine key so that it cannot be operated by persons other than the
operator.
5. Use a gas leak detector, soapsuds or neutral detergent solution to detect gas leak. Never use other device or
liquid, etc.
6. To check gas leak at night, be sure to light a flashlamp outside the chamber before approaching to the LPG
forklift (to prevent a hazard by switching spark).
7. When gas should leak, ventilate air after confirming that there is no fire.
8. Pay special attention to keep the LPG cylinder. Keep it in the place free from the fire and install a gas leak
detector.
9. When a LPG forklift is used for a long time, impurities in fuel and tank rust accumulate in its inside. The operation
of the LPG devices becomes defective by various causes. In this case, the LPG devices must be inspected,
repaired and washed. When disassembling and reassembling the regulator, pay special attention to its
adjustment and airtightness.
10. Be sure to apply liquid packing to the threaded parts of each part (the union, solenoid valve, etc.). Never apply
liquid packing to the first and the second threads of the screw tip.

Section 1.3.2
02.book 3 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-3

REGULATOR
General

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
Section 1.3.2
02.book 4 ページ ２００７年２月２２日　木曜日　午後４時４６分

2-4 LPG Device for 4Y-E Engine

Components

First valve ASSY Idle adjust screw

O-ring

Solenoid valve

Second cover

Second Second diaphragm

valve
ASSY

First diaphragm

First cover

Section 1.3.2
02.book 5 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-5

SSTs for LPG Regulator Overhaul

0
5
1 1
6
2
7
2 3
4
3 9-3
5
9-1
6
8 7
8
9-
9-2

9
10
No. Part No. Part Name
1 09813-26600-71 Gauge 11
2 09814-22000-71 Tool
3 09815-22000-71 Tool 12
4 80339-76026-71 Automatic choke pipe plug
5 09817-23600-71 Union 13
6 09819-23600-71 Gauge
7 09819-22000-71 Gauge 14
8 23627-22000-71 Spring
9 09820-23600-71 Tester SUB-ASSY
15
9-1 09823-23600-71 Union
9-2 09822-22000-71 Gauge 16
9-3 09821-22000-71 Bellows

17
18
19
20
21
E
Section 1.3.2
02.book 6 ページ ２００７年２月２２日　木曜日　午後４時４６分

2-6 LPG Device for 4Y-E Engine

How to Deal with Tamper Proof Ring

General
It is not basically necessary to adjust VF voltage and regulator
primary pressure, but at regulator overhauling, remove the tamper
proof rings to adjust them. Follow the procedure described below to
treat the tamper proof rings.
Disassembly:
1. Cut off the head of the tamper proof ring using a hacksaw
shown in the illustration.
2. Remove the idle adjusting screw and/or regulator primary
pressure adjust screw.
3. Using a pair of nippers, remove the ring.

Reassembly:
1. Install the idle adjusting screw temporarily.
Idle adjusting
screw (1) Set the mixture adjust screw temporarily to the following
dimension:
Temporal set value: 6.2 mm (0.25 in)
(0.25 in)
6.2 mm

(2) Make sure to install a new cap (21673-13370-71) after

this adjustment is made on the vehicle.
Make sure to adjust the engine speed after installing the
regulator on the vehicle.

2. Install the regulator primary pressure adjusting screw.

(1) Install the screw and nut.
SST (2) Using SST, adjust the protrusion of the screw.
SST 09819-22000-71

3. Install the tamper proof ring (21673-13370-71).

Section 1.3.2
02.book 7 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-7

Troubleshooting
Inspection 1
SST 1. Remove the idle adjusting screw and install the SST.
SST (Union) tightening torque:
SST T=0.2 to 0.3 N·m (2 to 3 kgf·cm) [0.14 to 0.19 ft·lbf]
SST
2. Supply compressed air at 400 kPa (4 kgf/cm2) [57
psi] through the IN port and maintain the air
pressure.
Note:
Don't apply compressed air more than 780 kPa (8
Compressed kgf/cm2) [110 psi].
air
3. Check that the SST gauge indicates 0.

OK 0 NG More than 0

Slow solenoid valve defect

Inspection 2
SST
1. Put the SST to the injector port to prevent air from
blowing.
SST
SST 2. Apply 12 V to the slow solenoid valve.
3. See that the SST gauge indicates 24.5 to 34.3 kPa
(0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi].

Compressed
air 12 V

OK 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) NG 0 NG Other than 24.5 to 34.3 kPa
[3.6 to 5.0 psi]. (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi].
Slow solenoid • In appropriate adjustment of first pressure
valve defect • Elastic face valve 1 defect
• Elastic face valve 2 defect
• First diaphragm defect
• Clogging of slow path
Inspection 3
SST
1. Stop supllying the compressed air in state of
Inspection 2.
SST
SST 2. Read the SST gauge.

12 V

OK The pointer stays at the same position NG The pointer gradually moves toward the 0
as that of inspection 2. position.

To flow (1)
Section 1.3.2
02.book 8 ページ ２００７年２月２２日　木曜日　午後４時４６分

2-8 LPG Device for 4Y-E Engine

From Inspection 3

OK

Inspection 4
1. Stop supplying the compressed air in the state of
Inspection 2.

2. Breathe air into the inner vent port and read the
SST gauge.

Air

OK The pointer moves to 0 position. NG The pointer stays at the position.

Normal • Second diaphragm defect

• Elastic face valve 2 (in C chamber) defect.

Flow (1) (from inspection 3)

NG

Inspection 5
Apply soapy water on portions A to F of the regulator to
check any air leakage in state of Inspection 2.
B

Compressed D
air
E
A
F
Leak from A or F. Leak from A, C, D, or E.
Result Result
1 2
Leak from B: Re-check after retightening each part. (Since the fitting at A is
Defect of idle adjusting screw O-ring. applied with a sealing agent, reassemble it.)
OK No leak from NG Leak from D
Leak from F: any portion
Body defect.
To Inspection 3 • Elastic face valve 2 contact
defect
• First diaphragm defect
• Loosen of elastic face valve
2 mounting screw

Section 1.3.2
02.book 9 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-9

Individual Inspection
1. Inspect the slow solenoid.
Check that the operating sound is heard when applying 12 V to
the slow solenoid.

12 V

2. Inspect the main solenoid.

Check that the operating sound is heard when applying 12 V to
the main solenoid.

12 V

Section 1.3.2
02.book 10 ページ ２００７年２月２２日　木曜日　午後４時４６分

2-10 LPG Device for 4Y-E Engine

REMOVAL·INSTALLATION
Caution:
• Perform working at a well-ventilated job site and never put fire sources around the vehicle.
• Perfectly discharge LPG from the piping before starting removal.
• Disconnect the battery negative terminal before handling the fuel system.
• After installation, using soapy water, check no LPG leak from any part of each piping before starting the
engine.
• After installation, adjust the idling speed. (See page 2-17)

Removal Procedure
1 Fully discharge LPG from the fuel piping. [Point 1]
2 Disconnect the battery cable from the negative terminal.
3 Drain engine coolant.
4 Disconnect the wiring from the main and slow solenoid valves.
5 Disconnect the fuel piping.
6 Disconnect the coolant piping.
7 Remove the filter and main solenoid.
8 Remove the regulator ASSY.

Installation Procedure
The install procedure is the reverse of the removal procedure.
Note:
After installation, adjust the idling speed. (See page 2-17)

Section 1.3.2
02.book 11 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-11

Point Operations
[Point 1]
2 Removal:
Discharge LPG from the piping according to the procedure
below.
(1) Close the LPG supply piping valve 1 (green).
1 (2) Close the LPG outlet valve 2 (amber).
(3) Start the engine, and run the engine in the idling state until
it stops naturally.

Section 1.3.2
02.book 12 ページ ２００７年２月２２日　木曜日　午後４時４６分

2-12 LPG Device for 4Y-E Engine

DISASSEMBLY·REASSEMBLY
Caution:
Perform working at a well-ventilated job site and never put fire sources around the vehicle.
Note:
• Wash the outer surface of the regulator and keep the work bench clean.
• First, perform individual check of the filter for clogging and the solenoid valve for any abnormality, and
then disassemble the regulator only when its internal abnormality is found by the inspection according
to the troubleshooting given in this manual.
• Disassemble the regulator carefully, or defects such as diaphragm or valve contacts may occur.
T = N·m (kgf·cm) [ft·lbf]

Disassembly Procedure
1 Remove the regulator second cover and diaphragm. [Point 1]
2 Remove the second valve ASSY. [Point 2]
3 Remove the first cover, first diaphragm and spring. [Point 3]
4 Remove the first valve ASSY. [Point 4]
5 Remove the slow solenoid valve.
6 Remove the idle adjust screw and O-ring. [Point 5]

Reassembly Procedure
The install procedure is the reverse of the removal procedure.

Section 1.3.2
02.book 13 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-13

[Point 1]
Reassembly:
4 2 1. Install the diaphragm by matching its pin with the concave
portion of the second valve lever.
2. Tighten the screws in the illustrated order.
1 Tightening torque:
3 T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.5 ft·lbf]

Pin Concave portion

[Point 2]
Reassembly:
Seat portion Install the spring by holding it manually so as not to be freed
from the convex portion of the lever.
Spring Carefully perform the work to prevent the lever seat portion
from being pressed against the housing.

Convex portion

Reassembly:
Follow the steps below when the second valve ASSY is
Snap ring Spring washer replaced with a new one:
(1) Insert the seat.
(2) Install the spring washer.
(3) Install the snap ring.
(4) Perform valve airtightness test in the state of step 3
Seat above. (See page 2-13)
(5) Apply adhesive agent (Castle Super Cement) on the snap
ring and spring washer. Do not let the adhesive agent
adhere on the valve seat portion.

Inspection:
B Inspect the second valve lever height.
SST
Check contact with the lever when passing through the A side
A of the SST, and no contact when passing through the B side.
SST 09819-23600-71

Section 1.3.2
02.book 14 ページ ２００７年２月２２日　木曜日　午後４時４６分

2-14 LPG Device for 4Y-E Engine

If not satisfied, use the SST to bend the lever for adjustment.
SST (2)
SST 09814-22000-71................................. (1)
09815-22000-71................................. (2)
During lever height adjustment, do not push the valve seat
SST (1) against the port.

8 [Point 3]
1 5 Disassembly:
9 Since the spring force is applied at each portion, do not try
3 7 quick removal but loosen each bolt equally for removal.
Reassembly:
Tighten each bolt equally step by step so as not to let springs
6 4 be fallen. Tighten in the illustrated order for final tightening.

2 Tightening torque:
T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.5 ft·lbf]

Disassembly:
Diaphragm hook Since the diaphragm hook is engaged with the first valve lever,
move the diaphragm in the direction of the arrow in the
illustration for removal.
Reassembly:
Engage the diaphragm hook onto the first valve lever tip.

First valve lever

[Point 4]
Disassembly:
1. Remove the first valve ASSY.
2. Disassemble the first valve.

Reassembly:
1. Reassemble the first valve ASSY.
Note:
O-ring Replace the O-ring with a new one.
2. Install the first valve sub-assembly.
Tightening torque:
T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.3 ft·lbf]

Section 1.3.2
02.book 15 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-15

3. Check the first valve air-tightness.

(1) Put the SST (spring) between the lever tip and regulator
body.
SST 23627-22000-71

SST

(2) Connect the SST (gauge) to the fuel inlet.

SST SST 09820-23600-71

(3) Check that the air does not leak from the valve until air
pressure become in the range of 49.0 to 58.8 kPa (0.5 to
0.6 kg/cm2) [2.7 to 7.0 psi]. If air leaks before the air
pressure reaches at the range, replace the elastic face
valve 1.

4. Check and adjust the first lever height.

SST (1) Push the first valve at the elastic face valve side.

T (2) Check contact with the lever when passing through the S
side of the SST, and no contact when passing through the
S T side.
SST 09813-26600-71
Reference height:
11.8 to 12.3 mm (0.47 to 0.48 in) from the regulator contact
surface.

5. Using SSTs, adjust the first valve lever height if it is not within
the specified range.
SST 09814-22000-71................................. (1)
09815-22000-71................................. (2)
Note:
SST (2) • Do not apply force to the valve seat, or the valve seat will
be damaged.
• Be sure to set the SST with a cut on the valve lever.
SST (1)

6. Hang the diaphragm hook at the tip of the first valve lever and
set the diaphragm to the regulator body.
7. Install the regulator first cover to the body, with pushing the
diaphragm spring manually.
Tightening torque:
T = 3.5 to 4.4 N·m (36 o 45 kgf·cm) [2.6 to 3.3 ft·lbf]

Section 1.3.2
02.book 16 ページ ２００７年２月２２日　木曜日　午後４時４６分

2-16 LPG Device for 4Y-E Engine

8. Adjust the first diaphragm adjust screw.

(1) Loosen the adjust screw nut.
SST
(2) Using SST, adjust the protrusion of the screw.
SST 09819-22000-71
Reference height: 13.9 mm (0.5 in)
9. Adjust the pressure of first reducing chamber. (See page 2-17)

[Point 5]
Idle adjusting screw Reassembly:
Temporarily adjust the idle adjusting screw.
After tightening until the tip end of the adjusting screw come
into contact with the body loosen the screw by 3 turns.
Note:
• Do not tighten the adjusting screw too hard.
• After installing the regulator on the vehicle, be sure to
adjust the VF voltage. (See page 2-18)

Second Valve Airtightness Check

SST (2)
1. Temporarily install the second valve ASSY.
SST (1)
2. Remove the idle adjusting screw and install the SSTs.
SST (3)
SST (union) tightening torque:
T = 0.2 to 0.3 N·m (2 to 3 kgf·cm) [0.14 to 0.19 ft·lbf]
SST 09817-23600-71................................. (1)
09820-23600-71................................. (2)
3. Put the SST to the injector port.
SST 80339-76026-71................................. (3)
4. Apply 12 V to the slow solenoid valve.

5. Inject compressed air through the SSTs and make adjustment

of the seat position to ensure no air leakage by tilting the valve,
as shown in the illustration.

Section 1.3.2
02.book 17 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-17

LPG LEAK INSPECTION

Caution:
• After repairing each part of the LPG system, use soapy water to check no LPG leakage from any part
before starting the engine.
• Never use fire for inspecting gas leakage.
• Never use a match or lighter for illumination at the time of inspection at night.
1. Open the valve between the LPG cylinder and hose. (The LPG is led to the regulator by this operation.)
2. Remove the idle adjust screw and install the SST.
SST 09817-23600-71
3. Apply 12 V to the main and slow solenoid valves.
4. Using soapy water or aqueous solution of a neutral detergent, check no gas leakage from each joint (illustrated
below).
5. Be sure to wipe the liquid off after the leak check.

Section 1.3.2
02.book 18 ページ ２００７年２月２２日　木曜日　午後４時４６分

2-18 LPG Device for 4Y-E Engine

ENGINE ADJUSTMENT
Note:
To measure values described below, use the multifunction
display or plug-in analyzer.
1. Warm up the engine until the coolant temperature be 80GC
(176GF) or higher.
2. Check the engine idle speed.
Standard: 750 ± 150 rpm

3. Check the initial advanced ignition timing.

(1) Using SST, connect the terminal TC and E1 of the
diagnosis connector.
SST 09238-13130-71
Notice:
Be sure to connect the correct terminals.
If connecting wrong terminals, malfunction may occur.

(2) Using a timing light, check the ignition timing.

Standard: 7G BTDC/750 rpm

4. Adjust the initial advaced ignition timing.

(1) If the ignition timing is not as specified above, loosen the
two distributor clamp bolts and turn the distributor for
adjustment.
When delayed: Turn counterclockwise.
When advanced: Turn clockwise.
(2) After adjustment, tighten the bolts and check the ignition
timing again.

5. Check LPG regurator primary pressure

SST (2) (1) Install the SST to the LPG regulator.
SST 09817-23600-71................................. (1)
SST (1)
09820-23600-71................................. (2)
(2) Start the engine.
(3) Check the LPG regulator primary pressure.
Standard:
24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi]
Note:
The pressure remains as above one.

Section 1.3.2
02.book 19 ページ ２００７年２月２２日　木曜日　午後４時４６分

LPG Device for 4Y-E Engine 2-19

6. Adjust LPG regurator primary pressure

(1) Start the engine.
(2) Loosen the adjust screw nut and adjust the primary
pressure by turning the screw.
Standard:
24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.5 to 5.0 psi]

7. Check and adjust VF voltage

(1) Warm up the heated oxygen sensor by maintaining the
engine speed at 1800 rpm for approximately 2 minutes.
(2) Check the oxygen sensor feedback signal (OX) value
changes alternately between 0 and 1.
Standard:
The feedback signal (OX) value changes alternately more
than 4 times for 20 seconds.
Note:
Maintain the engine rpm at 1800 rpm.
(3) Measure the VF voltage while engine idling.
Standard: 2.5 ± 0.5 V

(4) If the standard condition is not satisfied adjust the VF

voltage into the specified range by turning the idle adjust
screw of the regulator slowly.
Reference:
COUNTERCLOCKWISE CLOCKWISE
VF
Condition Measures
voltage
Air fuel ratio: Turn the screw
0V
RICH CLOCKWISE
Air fuel ratio: Turn the screw
5V
LEAN COUNTERCLOCKWISE

(5) After racing the engine several times, check that the VF
voltage is within the specified range.
Note:
• Adjust the VF voltage to the 2.5 V as possible.
• If VF voltage is 2.5 V, but OX signal value is not changed
alternately, disconnect and reconnect the battery negative
cable, and perform this step (7) again.

Section 1.3.2
…..This Page Intentionally Left Blank…..
03.book 1 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-1

ELECTRICAL TROUBLESHOOTING
Page
BEFORE TROUBLESHOOTING............................3-2
0
CONNECTOR HANDLING.........................................3-2
1
WIRE HARNESS AND CONNECTOR INSPECTION
PROCEDURE ........................................................3-2 2
BEFORE BEGINNING TROUBLESHOOTING ......3-4 3
DIAGNOSIS (SELF DIAGNOSIS FUNCTION).......3-5
4
GENERAL ...............................................................3-5
5
HOW TO INTERPRET THE FLOW-CHARTS ........3-6
6
ANALYZER .............................................................3-7
EXPLANATION ........................................................3-7 7
ANALYZER MENU SCREEN LIST..............................3-8 8
ABOUT TROUBLE SHOOTING 9
BY ERROR CODES .............................................3-9
10
TABLE OF DIAGNOSIS CODES ..............................3-10
11
TROUBLESHOOTING BY SYMPTOMS ..............3-12
PARTS INSPECTION AND ADJUSTMENT.........3-37
12
13
14
15
16
17
18
19
20
21
E
Section 1.3.3
03.book 2 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-2 LPG Device for 4Y-E Engine

BEFORE TROUBLESHOOTING
CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When unplugging a connector, first remove the lock then,
without pulling the harness, pull out the connector while
holding the main unit.
To connect, push the connector fully until it is locked in
position.

3. When applying tester probes, always do so from the rear of the

connector (harness side).
4. When this is not possible, such as with waterproof tester
probes, make sure that inserting will not deform the connector
terminal.
5. Do not touch connector terminals directly with your hand.
6. When bringing tester probes into contact with live terminals,
prevent two tester probes from coming into contact with each
other.

WIRE HARNESS AND CONNECTOR

INSPECTION PROCEDURE
When any trouble occurs, first inspect the connectors and wire
harness of the related circuit according to the following procedure.

Continuity Inspection
1. Disconnect connectors at both ends of the relevant harness.
2. Measure the resistance between corresponding terminals of
the connectors at both ends.
Standard: 10 : or less
Note:
Move the wire harness slightly from side to side and up and
down while measuring.
Reference:
The cause of disconnections is almost always the connector as
disconnections in the vehicle's central wiring are rare. Inspect
especially the sensor connectors with sufficient care.

Short Circuit Check

1. Disconnect connectors at both ends of the relevant harness.
2. Measure the resistance between the corresponding connector
terminal and N1. Always inspect the connectors at both ends.
Standard: 1 M: or above
Note:
Move the wire harness slightly from side to side and up and
down while measuring.

Section 1.3.3
03.book 3 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-3

3. Measure the resistance between the relative terminals of the

appricable connector.
Standard: 1 M: or above
Note:
The wiring may short-circuit due to pinching by the body or 0
defective clamping.
1
2
Visual and Contact Pressure Checks 3
1. Disconnect connectors at both ends of the relevant harness.
2. Perform a visual check to make sure that there is no rust or
4
foreign matter contaminating the connector terminal.
3. Check that the caulking is not loose or damaged, and, after
5
checking that there is no damage, gently tug the connector or
wire harness to make sure that it cannot be pulled out. 6
7
4. Insert a male terminal same as that of the terminal to a female 8
connector and check the extracting force.
Defective contact may exist at a terminal where the extracting
force is less than that of other terminals.
9
Note:
If a problem, such as rust or foreign matter on the terminal, or
10
a drop in the contact pressure of male/female terminals
occurs, a solution that often works is simply disconnecting 11
and re-connecting the connected connector to change the
contact conditions. Try disconnecting and re-connecting 12
several times. If such a defect is recognized, it is likely that
there is a defective terminal contact.
13
14
15
16
17
18
19
20
21
E
Section 1.3.3
03.book 4 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-4 LPG Device for 4Y-E Engine

BEFORE BEGINNING TROUBLESHOOTING

It is not appropriate to begin trouble shooting for the 4Y engine on the basis of results only. It can lead to mistaken
corrective action, wasted time, and sometimes to an increase in abnormalities. Therefore, please pay careful
attention to the details surrounding the time when a fault occurs, to be supplied by the customer based on the
following.

Diagnostic Procedure
First, it is necessary to get the "fault history and service history" for the vehicle, and then to gather definite
information about the fault occurrence such as "when", "at what times", "in what places", "during what operations or
actions", and "what happened afterwards".
Also, try to recreate the conditions for the fault occurrence. (a. The fault cannot be recreated, b. The fault can be
recreated: Upon doing what?)
General items
Customer name Date of shipment of vehicle Date of fault occurrence / hour meter
reading

Vehicle model Frame No. Engine No. (punched)

Fuel used
UGasoline ULPG UGasoline/LPG combination (Reference LPG fuel company name: )

Condition of the defect (Tick the items that apply)

Defect phenomena
1. Cannot start a. Does not crank b. Combustion does not start c. Incomplete combustion
2. Does not start well Poor cranking (when cold · when warm · at all times)
3. Poor idle a. Poor idle speed b. Unstable idle speed c. Hunting (Regular fluctuation in idle speed)
a. Directly after startup (when cold · when warm) b. During reduction of speed
4. Engine stalling c. After reduction of speed d. Without warning e. After engine running rough
f. When steering g. During material handling h. Can be re-started immediately
a. Insufficient power output b. Hesitation
5. Defective operational status c. Surging (swaying forward and backward during acceleration)
d. Knocking e. Back fire f. After fire
a. Excessive fuel consumption b. Excessive oil consumption c. Overheat
6. Others
d. Water / Oil leakage e. Abnormal noise f. Others ( )
Phenomena at the time of the defect's occurrence
The time when the fault began a. Since the vehicle was new b. Recently (From which month and year)
to occur c. After putting in for maintenance
Frequency of occurrence a. Always b. In certain conditions c. Occasionally
Sunny · Cloudy · Rain ·
Weather Temperature Approximately GC Humidity Approximately %
Snow · Thunderstorm
Temperature conditions Coolant: a. When cool b. When warm Temperature inside engine room: GC
a. No relation b. When idling c. When revving d. When accelerating
e. When travelling at constant speed f. When reducing speed
g. When travelling uphill
Operation conditions
h. During material handling operations When not loaded (when steering · lifting · tilting)
When loaded (Load weight: approx. kg) (when steering · lifting · tilting)
i. Other (when using the inching brake · when steering · other)
Lamps a. Lights constantly b. Lights occasionally c. Does not light

Section 1.3.3
03.book 5 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-5

DIAGNOSIS (SELF DIAGNOSIS FUNCTION)

GENERAL
When the computer detects a problem in the system, the fault is made known by a lighting a warning lamp and
displaying an error code on the combination meter, while at the same time failsafe functions operate to stop the 0
engine or control the engine to a low speed.

Diagnosis display system

1
Error code display
1. Diagnosis display system
The diagnosis is displayed by means of an error code as
2
shown in the illustration to the left, and by the lights turning on.
When the IG switch is turned ON, the lamp lights once to allow 3
checking for the bulb, and then turns off again if the status is
normal. 4
When the IG switch is ON, if an abnormality occurs when the
An orange colored lamp lights Lamp blinks
vehicle is stopped, travelling, or when it is performing materials
handling operations, on detection of the abnormality an error
5
(Engine ECU only)
code is displayed, the engine light turns on, and the spanner
lamp flashes as a warning. 6
When this happens, stop the vehicle quickly and check the
error code. 7
2. Diagnosis display system
The diag memory has a system using the hour meter and tilt lever, a system using the option display, and a 8
system using a plug-in analyzer.
Here the display system using the hour meter and tilt lever is described. 9
(1) Open the diag memory menu from the main menu (Refer to 8FG Repair Manual).
(2) With each press and release of the knob switch, the respective error code and time of occurrence are 10
alternately displayed at 2 second intervals.
Note: 11
• The maximum number of error codes that can be in the memory is 10, and the smaller diag number
represents a newer error. 12
• An error code appearing just when the key is turned ON may have its stored time such as 0.0.
(3) Connect the matching connector and turn the key switch to OFF. 13
Knob switch
14
Diagnosis memory menu
15
Press the knob switch to return it. 16
17
Switches automatically
every 2 seconds
18
19
20
21
E
Section 1.3.3
03.book 6 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-6 LPG Device for 4Y-E Engine

HOW TO INTERPRET THE FLOW-CHARTS

Turn the key switch OFF and ON again

Is there an error code 31-1?

Inspect the VF voltage. NG

Drive controller defect
Standard: 2.5 ± 0.5 V

OK To next procedure depending on result

Single frames indicate measurement using a circuit

tester and normal procedures.

Double frames indicate items that can be inspected

using mask function.

Section 1.3.3
03.book 7 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-7

ANALYZER
EXPLANATION
Analyzer function supports operations for inspecting/investigating faulty section by displaying the condition of the
control system, using communication between each controller and the multifunction display or plug-in analyzer.
By switching the multifunction display to analyzer mode, or connect the plug-in analyzer to the diagnosis connector,
operative conditions of the sensor actuator that is used for traveling functions, or the error information detected by
the controller can be read. This is very useful for checking operative condition of each function and saving time for
repairing when there is a defect.
The analyzer functions can be used to make servicing faster and easier.
Refer to 8FG series repair manual for how to use the analyzer functions.

The analyzer functions include the following functions.

1. Diagnosis memory function (DIAG MEMORY)
The controller stores a maximum of the past 10 error codes (diagnosis codes) for faults that have occurred in the
electrical system. The diagnosis function is the function that reads these error codes and displays them on the
display.
The error code and its time of occurrence as a key ON hour meter time are displayed on the display.
2. In/out monitor function (I/O MONITOR)
This function displays the analog input value of each sensor relating to driving, material handling, FHRS, SAS,
and OPS on the display. By monitoring this display it is possible to judge whether each circuit and sensor has a
fault or not.
I/O ENGINE CTRL: The display shows various kinds of input value such as the analog input voltage from each
sensor to the controller, as well as control correction values and the status of the output to
the relay.

Section 1.3.3
03.book 8 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-8 LPG Device for 4Y-E Engine

ANALYZER MENU SCREEN LIST

ANALYZER MENU screen Display item Description
DIAG MEMORY 1. - 10. Indications of errors occurred
I/O ENGINE CTRL IGSW Key switch (IG)
STA Key switch (ST)
BATT Battery voltage
G/LP Fuel changeover switch
SEL Fuel specification discrimination signal
ADJ Engine specification discrimination signal
MREL EFI main relay drive signal
FC Circuit opening relay drive signal
LPR LP gas main relay drive signal
LFC LP gas slow solenoid drive signal
OXHT O2 sensor heater drive signal
THA Intake temperature sensor voltage
THW Coolant temperature sensor voltage
PIM Intake pipe negative pressure sensor voltage
VPA1 Accelerator sensor (1) voltage
VPA2 Accelerator sensor (2) voltage
PA Accelerator opening angle
VTA1 Throttle position sensor (1) voltage
VTA2 Throttle position sensor (2) voltage
TA Throttle opening angle
IM Electronic throttle motor current
NE Engine speed
IGT Ignition timing (spark advance amount)
OX O2 sensor voltage
VF VF voltage (LPG/CNG)
LINJ Injector correction value (LPG/CNG)
FCM Air-fuel ratio motor correction value (LPG/CNG)

Section 1.3.3
03.book 9 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-9

ABOUT TROUBLE SHOOTING BY ERROR CODES

1. Defective contact of connectors may cause error codes to appear and disappear. Therefore before performing
troubleshooting, check the battery cable connection, turn the key switch ON, and check that the error code
appears.
If the error code does not appear, inspect the connection status of the relevant connector.
2. Once an error occurs, the error code is stored in the controller. Even if an error code appears only temporarily
and then disappears due to a defective contact, the error code will still be stored.
3. This volume contains a flow chart relating to symptoms that are particular to LPG.
When an error code is showing, refer to 8FGU/8FDU15-32, 8FGCU20-32 Repair Manual Vol.1 (Pub. No.
CU053) and 8FGCU15-18 Repair Manual Vol.2 (Pub. No. CU055) and perform inspection and repair first. When
an error code is not showing, refer to the page for the relevant symptom and perform inspection and repair.

Section 1.3.3
 03.book
TABLE OF DIAGNOSIS CODES

3-10
Detection
Indication Memory Spanner Error mode Phenomenon on vehicle
ECU
01-3 01-3 Blinking 4Y-ECS Fuel feedback control abnormality (LPG/CNG) rich
The engine speed is unstable and it may stop.
01-4 01-4 Blinking 4Y-ECS Fuel feedback control abnormality (LPG/CNG) lean
01-5 01-5 Blinking 4Y-ECS O2 sensor open abnormality The engine speed is unstable and it may stop.
01-6 01-6 Blinking 4Y-ECS O2 sensor heater open abnormality Display only
02-1 02-1 Blinking 4Y-ECS Intake temperature sensor-open abnormality The engine may become out of adjustment at low
02-2 02-2 Blinking 4Y-ECS Intake temperature sensor short abnormality temperatures.
03-1 03-1 Blinking 4Y-ECS Intake pipe pressure sensor-open abnormality
The engine may begin to run rough
03-2 03-2 Blinking 4Y-ECS Intake pipe pressure sensor short abnormality
04-1 04-1 Blinking 4Y-ECS Water temperature sensor open abnormality The engine may become out of adjustment at low
04-2 04-2 Blinking 4Y-ECS Water temperature sensor short abnormality temperatures.
10 ページ ２００７年２月２２日　木曜日　午後４時４７分

05-1 05-1 Blinking 4Y-ECS Throttle position sensor 1 open abnormality

05-2 05-2 Blinking 4Y-ECS Throttle position sensor 1 short abnormality
05-3 05-3 Blinking 4Y-ECS Throttle position sensor 2 open abnormality Limited speed of traveling and materials handling
05-4 05-4 Blinking 4Y-ECS Throttle position sensor 2 short abnormality due to limited engine power output
05-5 05-5 Blinking 4Y-ECS Throttle position sensor offset abnormality

Section 1.3.3
05-6 05-6 Blinking 4Y-ECS Throttle position sensor out of range abnormality
06-1 06-1 Blinking 4Y-ECS Throttle motor drive circuit open abnormality
06-2 06-2 Blinking 4Y-ECS Throttle motor drive circuit short abnormality
LPG Device for 4Y-E Engine

06-3 06-3 Blinking 4Y-ECS Throttle motor power supply circuit open abnormality Limited speed of traveling and materials handling
06-4 06-4 Blinking 4Y-ECS Throttle motor power supply circuit short abnormality due to limited engine power output
06-5 06-5 Blinking 4Y-ECS Throttle motor seizing abnormality
06-6 06-6 Blinking 4Y-ECS Electronic throttle system abnormality
07-1 07-1 Blinking 4Y-ECS Air-fuel ratio motor open abnormality The engine speed is unstable and it may stop.
08-1 08-1 Blinking 4Y-ECS Low voltage (battery line open) abnormality Display only
09-1 09-1 Blinking 4Y-ECS Ignition signal abnormality The engine speed is unstable and it may stop.
0A-1 0A-1 Blinking 4Y-ECS Fuel specification determination signal abnormality Display only
0A-2 0A-2 Blinking 4Y-ECS Fuel specification changeover switch abnormality Display only
0A-3 0A-3 Blinking 4Y-ECS Fuel specification type does not match Engine may stop
Limited speed of traveling and materials handling
0A-4 0A-4 Blinking 4Y-ECS Engine specification determination abnormality
due to limited engine power output
 03.book
Detection
Indication Memory Spanner Error mode Phenomenon on vehicle
ECU
4Y-ECS Cam angle sensor open abnormality Engine stop
18-1 18-1 Blinking
ASC Engine speed sensor open abnormality Partial limitation of the drive control function.
4Y-ECS Cam angle sensor open abnormality (on start up) Engine will not start
18-2 18-2 Blinking
ASC Engine speed sensor GND short abnormality Partial limitation of the drive control function.
18-3 18-3 Blinking 4Y-ECS Crank angle sensor open abnormality Display only
AD-2 AD-2 Blinking 4Y-ECS CAN communication SAS/OPS data reception abnormality Partial limitation of the drive control function.
4Y-ECS
C4-1 C4-1 Blinking Accelerator sensor 1 open abnormality
ASC
4Y-ECS
C4-2 C4-2 Blinking Accelerator sensor 1 short abnormality
ASC
4Y-ECS
C4-3 C4-3 Blinking Accelerator sensor 2 open abnormality Limited speed of traveling and materials handling
11 ページ ２００７年２月２２日　木曜日　午後４時４７分

ASC
due to limited engine power output
4Y-ECS
C4-4 C4-4 Blinking Accelerator sensor 2 short abnormality
ASC
4Y-ECS
C4-5 C4-5 Blinking Accelerator sensor offset abnormality
ASC
C4-6 C4-6 Blinking 4Y-ECS Accelerator sensor out of range abnormality

Section 1.3.3
LPG Device for 4Y-E Engine
3-11
03.book 12 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-12 LPG Device for 4Y-E Engine

TROUBLESHOOTING BY SYMPTOMS
Symptom Chart
Symptom Page for reference
Does not start Starting motor turns over but engine does not start 3-13
Unstable idle speed 3-15
Poor idle adjustment Idle speed low and unstable 3-17
Idle speed high 3-18
Knocking 3-19
Poor drivability Hesitation 3-20
Insufficient power output 3-22
Engine stalling in general 3-25
Engine stalling a short time after start up 3-28
Engine stall Engine stalling when A/C, lights, or defogger are turned on, or when the steering
3-30
is operated
Engine stalling on releasing the accelerator 3-31

Charts by System
LPG injector system 3-33
Air-fuel ratio control motor system 3-35
Slow solenoid valve system 3-36

Section 1.3.3
03.book 13 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-13

z <DOES NOT START> STARTING MOTOR TURNS OVER BUT ENGINE DOES NOT START
Probable cause
• Ignition system defect (When combustion does not start)
• Fuel system defect (When combustion does start, but does not continue.)
• Regulator primary pressure abnormality during cranking (When the pressure is high there is a possibility of rich
air-fuel ratio)
Note:
When low vapour pressure LPG fuel is used in winter, engine may stall when longer idling or while traveling
and be difficult to start immediately afterwards. In this case pour warm water over the LPG regulator to
vaporize the fuel, and at the same time turn the LPG switch OFF to stop the fuel supply momentarily and
crank after fully opening the accelerator.

NG Inspect the ignition system.

Inspect ignition
(Refer to parts inspection and
adjustment 10, 11, 12, 13)
OK

NG
Inspect LPG filter Replace LPG filter

OK

Inspect main solenoid valve operating noise

Inspect the wire harness and
Inspect the operation sound of the solenoid NG connectors to the main solenoid OK
valve when the ignition switch is turned ON. Replace main solenoid valve
valve. (Refer to the wiring
Standard: diagram at the back of the book)
The valve makes an operation noise
NG
OK
Repair wire harness and
connectors

Inspect slow solenoid valve operating noise

Inspect the wire harness and
Inspect the operation sound of the solenoid NG connectors to the slow solenoid OK
valve when the ignition switch is turned ON. Replace slow solenoid valve
valve. (Refer to the wiring
Standard: diagram at the back of the book)
The valve makes an operation noise
NG
OK
Repair wire harness and
connectors

Inspect LPG injector piping internal pressure

SST
(1) Disconnect the fuel hose between the LPG regulator and the LPG
injector at the regulator side.
(2) Connect the SST to the LPG regulator, and inspect the pressure
during cranking.
SST 09820-23600-71
Standard: The pressure rises.

OK NG

Section 1.3.3
03.book 14 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-14 LPG Device for 4Y-E Engine

OK NG

Repair or replace LPG regulator

Inspect LPG regulator primary pressure NG Adjust primary pressure of LPG regulator.
(Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2)
OK

NG
Defect of ignitor or engine ECU Check starting ability

OK

Finish

Section 1.3.3
03.book 15 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-15

z <POOR IDLE ADJUSTMENT> UNSTABLE IDLE SPEED

Probable cause
• Air leakage
• 1 or more cylinders misfiring
• VF voltage abnormality during idling
• Ignition timing off
Note:
When fuel of a low vapor pressure is used in winter, insufficient vaporization may cause unstable idle speed.
Only a
particular Inspect spark plugs
Inspect power balance cylinder
NG (1) Check that there is no obvious NG
Cause one cylinder at a time to misfire Replace spark plug
deposition.
by removing its resistive cord, and
(2) Inspect the plug gap.
inspect for a drop in idle speed.
Standard:
OK 0.7 to 1.0 mm (0.028 to 0.039 in)
OK
Inspect for air leakage
NG Repair air
between the throttle body Inspect distributor cap and
leak NG Replace distributor cap and
and cylinder head. resistive cord (Refer to parts
resistive cord
inspection and adjustment 10, 11)
OK
OK

Inspect compression
(Refer to parts inspection and
adjustment 15)

OPT.
Inspect inner vent piping and LPG regulator drain cock
Close
(1) Inspect the installation of the inner vent piping. STD.
Standard: Connected.
(2) Remove the drain plug (STD.), or open the LPG regulator drain cock
(OPT.), remove any tar and close the drain cock again.
Caution:
Be sure to intall the drain plug (STD.), or close the cock after Open
removing tar. Drain plug

Inspect initial advance timing NG

Adjust initial advance timing
(Refer to page 2-16)
OK

Section 1.3.3
03.book 16 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-16 LPG Device for 4Y-E Engine

Inspect VF voltage
(Refer to parts inspection and adjustment 14) NG
Adjust VF voltage
Standard: 2.5 ± 0.5V
OK

Inspect injector function NG To injector system

(Refer to parts inspection and adjustment 6) (Refer to 3-32)
OK

Inspect compression NG
Inspect and repair engine
(Refer to parts inspection and adjustment 15)
OK

Inspect spark plugs

(1) Check that there is no obvious deposition. NG
Clean or replace spark plug
(2) Inspect the plug gap.
Standard: 0.7 to 1.0 mm (0.028 to 0.039 in)
OK

Inspect distributor cap and resistive cord

NG
(Refer to parts inspection and adjustment 10, Replace distributor cap and/or resistive cord
11)
OK

Inspect ignition coil NG

Replace ignition coil
(Refer to parts inspection and adjustment 12)
OK

NG
Inspect LPG filter Clean or replace LPG filter

OK

Inspect LPG regulator primary pressure NG Adjust primary pressure of LPG regulator.
(Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2)
OK

Inspect LPG regulator (secondary system) NG Repair LPG regulator

(Refer to page 2-5) (Refer to section 2)
OK

Switch to a fuel with high vaporization

NG
pressure and inspect the idle speed. Fuel is defective
(Winter only)
OK

Engine ECU defect

Section 1.3.3
03.book 17 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-17

z <POOR IDLE ADJUSTMENT> IDLE SPEED LOW AND UNSTABLE

Probable cause
• Air-fuel ratio over-lean
• Blockage around the electric throttle valve

Inspect the VF voltage.

(Refer to parts inspection and adjustment 14)
Standard: 2.5 ± 0.5 V NG
Adjust VF voltage
Note:
A over-lean air-fuel ratio may result in a low
and unsable idle speed.
OK

Check whether the engine idle speed changes.

Idle speed gradually increases The idle speed remains low

to within standard value and does not change

Finish

Inspect electronic throttle

Operate the accelerator pedal and inspect to NG • Check throttle system
see that the throttle PA value changes smoothly. • Clean or replace electric throttle
Standard: PA value changes smoothly.
OK

Inspect LPG regulator

Check LPG regulator for tar accumulation and • Tighten drain plug/close cock
NG
drain plug loosening/cock opening • Clean LPG regulator
Standard: Tar is not accumulated and plug is (Refer to section 2)
not loosened/cock is not opened
OK

NG
Check adaptor for tar accumulation Clean adaptor

OK

Inspect FCM operation NG

Clean or replace FCM
(Refer to parts inspection and adjustment 5)
OK

Replace engine ECU

Section 1.3.3
03.book 18 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-18 LPG Device for 4Y-E Engine

z <POOR IDLE ADJUSTMENT> IDLE SPEED HIGH

Probable cause
• Throttle valve return defect
• Air leakage
• VF voltage abnormality
Note:
Inspect parts related to the items listed above.

Section 1.3.3
03.book 19 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-19

z <POOR DRIVABILITY> KNOCKING

Probable cause
• Excess deposition in combustion chamber or on spark plug electrode
• Ignition timing off

Check initial advance timing NG Adjust initial advance timing

(Refer to page 2-16) (Refer to page 2-16)
OK

Inspect spark plugs

(1) Check that there is no obvious deposition. NG
Replace spark plug
(2) Inspect the plug gap.
Standard : 0.7 to 1.0 mm (0.028 to 0.039 in)
OK

Excess deposition in combustion chamber, or

on piston head portion

Section 1.3.3
03.book 20 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-20 LPG Device for 4Y-E Engine

z <POOR DRIVABILITY> HESITATION

Probable cause
• Electronic throttle abnormality
• VF voltage abnormality
• Initial advance timing off
• O2 sensor abnormality
Caution:
Since pulsating combustion occurs on fuel cut operation at high rpm, operate in a range below the rpm at
which hesitation occurs.
Reference:
When not loaded: Rated no-load maximum speed
When traveling: Rated under-load maximum speed

NG
Inspect LPG filter Replace LPG filter

OK

Inspect electronic throttle

Operate the accelerator pedal and inspect to see that the NG
Inspect throttle system
throttle PA value changes smoothly.
Standard: PA value changes smoothly.
OK

Inspect VF voltage
(Refer to parts inspection and adjustment 14) NG
Inspect changes in VF voltage and OX value (0 or 1) at
1800 r/min. (idle OFF).
Standard: 2.5 ± 0.5 V*
OK *: 0 V, 2.50 V, or 5.0 V will be displayed when the
plug-in analyzer is used for the inspection.

Inspect initial advance timing

NG
(Refer to page 2-16) Adjust initial advance timing
Standard: 7.0q
OK

Inspect, repair, or replace the feedback-related

components (injectors, O2 sensor, etc.) and
the relevant wire harnesses and connectors
(Refer to parts inspection and adjustment)

Section 1.3.3
03.book 21 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-21

Inspect LPG regulator primary pressure NG Adjust primary pressure of LPG regulator
(Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2)
OK

Inspect injector operation and inspect for

NG
blockages To injector system (3-33)
(Refer to parts inspection and adjustment 6, 7)
OK

Inspect O2 sensor feedback NG

O2 Sensor system defect
(Refer to parts inspection and adjustment 14)
OK

Inspect spark plugs

(1) Check that there is no obvious deposition. NG
Clean or replace spark plug
(2) Inspect the plug gap.
Standard: 0.7 to 1.0 mm (0.028 to 0.039 in)
OK

Inspect distributor cap and resistive cord

NG
(Refer to parts inspection and adjustment 10, Replace distributor cap and resistive cord
11)
OK

Inspect ignition coil NG

Replace ignition coil
(Refer to parts inspection and adjustment 12)
OK

Inspect air-fuel ratio control motor operation NG To air-fuel ratio control motor system
(Refer to parts inspection and adjustment 5) (Refer to page 3-35)
OK

Inspect inner vent system

(1) Check inner vent tube for damage, bent or NG
Repair or replace
disconnection
(2) Check resonator for damage
OK

Inspect wire harness and connectors related to NG

Repair or replace
the air-fuel ratio controll system
OK

Replace engine ECU

Section 1.3.3
03.book 22 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-22 LPG Device for 4Y-E Engine

z <POOR DRIVABILITY> INSUFFICIENT POWER OUTPUT

Probable cause
• Air-fuel ratio abnormality (over-lean)
• Initial advance timing off
Note:
• After disconnecting the battery terminal or removing the LPG fuse, the fuel system learning value will be
cleared. This may cause temporary insufficient power output. (Power output will return after being
driven for a short while.)
• If a fuel with low pressure vaporization is used in winter, it is possible that the air-fuel ratio may be
abnormal (over-rich).

NG
Inspect LPG filter Replace LPG filter

OK

NG Inspect, identify fault, and repair, cleaning

Inspect water temperature (THW)
system
OK

Inspect the full open status of the throttle valve

Inspect the aperture (TA) of the throttle valve NG
Inspect electronic throttle system
when the accelerator pedal is depressed once.
Standard: 96 %
OK

Inspect vacuum piping of vacuum sensor

NG
Standard: No hoses disconnected, blocked Repair vacuum piping
or bent
OK

Inspect initial advance timing NG Adjust initial advance timing

(Refer to page 2-16) (Refer to page 2-16)
OK

Inspect O2 sensor feedback NG

O2 Sensor system defect
(Refer to parts inspection and adjustment 14)
OK

Inspect inner vent system

(1) Check inner vent tube for damage, bent or NG
Repair or replace
disconnection
(2) Check resonator for damage
OK

Section 1.3.3
03.book 23 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-23

Inspect VF voltage
(Refer to parts inspection and adjustment 14)
NG
Inspect changes in VF voltage and OX value
(0 or 1) at 1800 r/min. (idle OFF).
Standard: 2.5 ± 0.5 V*
*: 0 V, 2.50 V, or 5.0 V OK
will be displayed
when the plug-in Inspect, repair, or replace the feedback-related
analyzer is used for components (injectors, O2 sensor, etc.) and
the inspection. the relevant wire harnesses and connectors
(Refer to parts inspection and adjustment)

Inspect spark plugs

(1) Check that there is no obvious deposition. NG
Clean or replace spark plug
(2) Inspect the plug gap.
Standard: 0.7 to 1.0 mm (0.028 to 0.039 in)
OK

Inspect compression NG
Inspect and repair engine body
(Refer to parts inspection and adjustment 15)
OK

Inspect distributor cap and resistive cord

NG
(Refer to parts inspection and adjustment 10, Replace distributor cap and resistive cord
11)
OK

Inspect ignition coil NG

Replace ignition coil
(Refer to parts inspection and adjustment 12)
OK

Repair wire harness between engine ECU -

Inspect battery voltage (BATT) NG LPG fuse
Standard: 10 to 14 V (Refer to the wiring diagram at the back of the
book)
OK

Disconnect the vacuum sensor

During idling, measure the voltage
connector and measure the voltage
between PIM - E2 of the engine ECU. NG OK
between VC - E2 terminals of the Replace vacuum sensor
Standard: 3.0 to 4.0 V (For engine stop)
vehicle harness.
OK Standard: 4.5 to 5.0 V

Section 1.3.3
03.book 24 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-24 LPG Device for 4Y-E Engine

OK NG

Inspect wire harness and connectors

between engine ECU and vacuum
sensor NG Repair wire harness
(Refer to the wiring diagram at the back connectors
of the book)
OK

Replace engine ECU

NG (Standard value or
Inspect LPG regulator primary pressure more, or not airtight) Repair LPG regulator
(Refer to parts inspection and adjustment 1) (Refer to section 2)
OK NG (Standard value or below)
Adjust primary pressure of LPG regulator.
(Refer to parts inspection and adjustment 2)

• LPG regulator (secondary system) defect OK NG

• Engine ECU defect
• Or unsuitable fuel used (winter only)
Finish

Inspect and repair blockages

in fuel piping system

Section 1.3.3
03.book 25 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-25

z <ENGINE STALL> ENGINE STALLING IN GENERAL

Probable cause
• Charging system
• LPG regulator primary pressure adjustment defect
• Air leak in (over-lean) intake system
• Ignition timing defect
• Idling air-fuel ratio adjustment defect
• LPG slow solenoid defect
• Injector defect
Note:
• Pay attention to the warning light lighting when the engine stall occurs.
• Be careful about inappropriate LPG in winter (low vaporization pressure).
• When using low vaporization pressure fuel, if the engine stalls during idling, or when travelling when the
engine is not sufficiently warmed up, there is a high possibility that the air-fuel ratio is over-rich. Open
the accelerator up fully and crank it for a while, and wait for the engine to start.

Stays off • Combination meter power supply

Check the charge warning lamp
• Inspect and repair charge warning light
Light comes Light comes on before engine stall
on during Inspect and repair charging system
engine stall

Stays off Inspect the "check engine"

Check the "check engine" warning light Inspect and repair
warning light by short circuiting NG the "check engine"
between the engine ECU MZL -
Light comes Light comes warning lamp
E1 terminals.
on during on before system
Standard: Turns on
engine stall engine stall
OK

Inspect the engine ECU

Measure the voltage between +B - E1 terminals of the NG Replace engine

engine ECU.
ECU
Standard: 10 to 14 V
OK

Measure the voltage between IGSW - E1 terminals of the NG Inspect and repair
engine ECU. the ignition switch
Standard: 10 to 14 V (Ignition switch ON) system
OK

Measure the voltage between MREL - E1 terminals of the NG Replace engine

engine ECU.
ECU
Standard: 10 to 14 V (Ignition switch ON)
OK

Inspect and repair the main relay system

NG
Inspect LPG filter Clean or replace LPG filter

OK

Section 1.3.3
03.book 26 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-26 LPG Device for 4Y-E Engine

Inspect LPG regulator primary pressure NG Adjust primary pressure of LPG regulator.
(Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2)
OK
NG (Does not start at all)
Check the vehicle re-starts Inspect ignition

OK OK OK NG
Recreation test LPG regulator defect or Inspect and repair
unsuitable fuel used (winter only) ignition system

Inspect for air leakage between the adapter NG

Repair air leak
and cylinder head.
OK
Inspect initial advance timing NG
Adjust initial advance timing
(Refer to 2-13)
OK
Inspect VF voltage NG
(Refer to parts inspection and adjustment 14)
OK

Inspect, repair, or replace the feedback-related

components (injectors, O2 sensor, etc.) and
the relevant wire harnesses and connectors
(Refer to parts inspection and adjustment)

Inspect slow solenoid valve NG To slow solenoid valve system

(Refer to parts inspection and adjustment 4) (Refer to page 3-36)

OK
Inspect injector system operation and inspect NG (Non-operational) To injector system
for blockages (Refer to page 3-33)
(Refer to parts inspection and adjustment 6, 7)
NG (Outside standard value)

Section 1.3.3
03.book 27 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-27

Inspect LPG regulator primary pressure OK LPG regulator (secondary system) defect or
(Refer to parts inspection and adjustment 1) unsuitable specification fuel (winter only)

NG NG (Airtightness defect)
(Outside Repair LPG regulator
standard (Refer to section 2)
value)

Adjust LPG regulator primary pressure NG Inspect and repair blockages in fuel piping
(Refer to parts inspection and adjustment 2) system

OK

Check that the engine restarts

OK

Finish

Section 1.3.3
03.book 28 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-28 LPG Device for 4Y-E Engine

z <ENGINE STALL> ENGINE STALLING A SHORT TIME AFTER START UP

Probable cause
• LPG regulator primary pressure adjustment defect
• Blocked injector, air control valve, or by-pass route
• Charging system defect
• LPG solenoid defect
• Fuel supply cut
Note:
• Pay attention to the fuel used during winter.

Replace main solenoid

valve
OK

Inspect main solenoid valve operating Inspect the wire harness

Does the engine re-start? NG noise and connectors of the
NG main solenoid valve.
Inspect the solenoid valve operation (Refer to the wiring
OK noise when the ignition switch is turned diagram at the back of
ON the book)
Inspect the charge warning light Standard: The valve makes an
operation noise NG
OK NG OK Repair wire harness and
connectors
Inspect and repair
the charger
Replace slow solenoid
valve
OK

Inspect slow solenoid valve operating Inspect the wire harness

noise and connectors of the
NG slow solenoid valve.
Inspect the slow solenoid valve (Refer to the wiring
operation noise when the ignition diagram at the back of
switch is turned ON the book)
Standard: The valve makes an
operation noise NG
OK Repair wire harness and
connectors

Inspect LPG injector piping internal pressure

SST
(1) Disconnect the fuel hose between the LPG
regulator and the LPG injector at the
regulator side.
(2) Connect the SST to the LPG regulator, and
inspect the pressure during cranking.
SST: 09820-23600-71
Standard: The pressure rises.

OK NG

Repair or replace LPG

regulator (See section 2)

Section 1.3.3
03.book 29 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-29

Inspect initial advance timing NG

Adjust initial advance timing
(Refer to page 2-16)
OK

Inspect VF voltage NG
(Refer to parts inspection and adjustment 14)
Inspect changes in VF voltage and OX value
(0 or 1) at 1800 r/min. (idle OFF).
Standard: 2.5 ± 0.5 V*
*: 0 V, 2.50 V, or 5.0 V OK
Inspect, repair, or replace the feedback-related
will be displayed components (injectors, O2 sensor, etc.) and
when the plug-in the relevant wire harnesses and connectors
analyzer is used for
(Refer to parts inspection and adjustment)
the inspection.

Inspect LPG filter NG

Clean or replace LPG filter
(Refer to page 2-8)
OK

Inspect LPG regulator primary pressure NG Adjust primary pressure of LPG regulator
(Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2)
OK

• Unsuitable fuel used

• Engine ECU defect

Section 1.3.3
03.book 30 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-30 LPG Device for 4Y-E Engine

z <ENGINE STALL> ENGINE STALLING WHEN A/C, LIGHTS, OR DEFOGGER ARE TURNED ON, OR WHEN THE STEERING IS
OPERATED
Probable cause
• LPG regulator primary pressure adjustment defect
• Pay attention to air-fuel ratio abnormalities (injector blocked, idle adjustment defect)
• Battery defect

Inspect battery voltage (BATT) NG

Charge or replace the battery
Standard: 10 to 14 V
OK

Inspect VF voltage NG
(Refer to parts inspection and adjustment 14)
Inspect changes in VF voltage and OX value
(0 or 1) at 1800 r/min. (idle OFF).
Standard: 2.5 ± 0.5 V*
*: 0 V, 2.50 V, or 5.0 V OK
Inspect, repair, or replace the feedback-related
will be displayed components (injectors, O2 sensor, etc.) and
when the plug-in
the relevant wire harnesses and connectors
analyzer is used for (Refer to parts inspection and adjustment)
the inspection.

Inspect initial advance timing NG Adjust initial advance timing

(Refer to page 2-16) (Refer to page 2-16)
OK

Inspect LPG regulator primary pressure NG Adjust primary pressure of LPG regulator
(Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2)
OK

Inspect inner vent system

(1) Check inner vent tube for damage, bent or NG
disconnection Repair or replace
(2) Check resonator for damage
OK

• Inspect LPG regulator (secondary system)

(Refer to page 2-10)

Section 1.3.3
03.book 31 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-31

z <ENGINE STALL> ENGINE STALLING ON RELEASING THE ACCELERATOR

Probable cause
• Idling air-fuel ratio adjustment defect
• Ignition timing off
• Air leakage
• Injector defect
• LPG filter defect

Inspect VF voltage NG
(Refer to parts inspection and adjustment 14)
Inspect changes in VF voltage and OX value
(0 or 1) at 1800 r/min. (idle OFF). Inspect, repair, or replace the feedback-related
Standard: 2.5 ± 0.5 V* components (injectors, O2 sensor, etc.) and
the relevant wire harnesses and connectors
*: 0 V, 2.50 V, or 5.0 V OK
(Refer to parts inspection and adjustment)
will be displayed
when the plug-in
analyzer is used for
the inspection.

Inspect initial advance timing NG

Adjust initial advance timing
(Refer to page 2-16)
OK

Inspect main solenoid valve NG

Replace main solenoid valve
(Refer to parts inspection and adjustment 3)
OK

Inspect slow solenoid valve NG To slow solenoid valve system

(Refer to parts inspection and adjustment 4) (Refer to page 3-36)
OK

YES Inspect distributor pickup coil

Does knocking occur on racing of the engine?
(Refer to parts inspection and adjustment 12)
NO OK NG

Replace distributor
pickup coil

Inspect wire harness and connectors between

engine ECU - pickup coil
(Refer to wiring diagram)
OK NG

Inspect or replace Repair wire harness

engine ECU and connectors

NG
Inspect the air intake system for air leaks Repair air leak

OK

Section 1.3.3
03.book 32 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-32 LPG Device for 4Y-E Engine

NG
Inspect LPG filter Replace LPG filter

OK

Inspect injector system operation and inspect NG To LPG injector system

for blockages (Refer to page 3-33)
(Refer to parts inspection and adjustment 6, 7)
OK

Inspect LPG regulator primary pressure NG

Adjust LPG regulator primary pressure
(Refer to parts inspection and adjustment 1)
OK

Engine ECU defect

Section 1.3.3
03.book 33 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-33

z LPG INJECTOR SYSTEM

Inspect the injectors for air-tightness NG

Clean or replace injectors
(Refer to parts inspection and adjustment 6)
OK

Perform startup operation inspection and NG (Only during startup)

idle operation inspection of injectors. To *A
(Refer to parts inspection and adjustment 6)
OK NG
To *B

Measure the voltage between Measure the voltage between Inspect LPG injectors
NG INJ - E1 terminals of the OK (Refer to parts
RES - E1 terminals of the engine ECU.
Standard: 10 to 14 V engine ECU. inspection and
Standard: 10 to 14 V adjustment 6, 7)
OK
NG

Inspect the solenoid resistor

(1) Inspect the resistance
value of the solenoid NG Replace the solenoid
resistor. resistor
Standard: 5.7 to 6.3 : (20°C)
[68°F]
OK

Inspect the wire harness and

connectors between engine NG Repair wire harness
ECU - solenoid resistor
and connectors
(Refer to the wiring diagram at
the back of the book)
OK

Inspect or replace engine

ECU

Measure the voltage between INJ - E1 Inspect wire harness and

NG Repair wire harness
terminals of the engine ECU. connectors between INJ - E1
and connectors
Standard: 10 to 14 V of the engine ECU
OK

Inspect LPG injectors

Inspect or replace engine ECU
(Refer to parts inspection and
adjustment 6, 7)
*A

Measure the voltage between STA - E1 NG

terminals of the engine ECU. Inspect and repair the STA system
Standard: 10 to 14 V
OK

Inspect or replace engine ECU

Section 1.3.3
03.book 34 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-34 LPG Device for 4Y-E Engine

*B

Inspect injector operation with the coolant OK Measure the voltage between OK
temperature sensor connector disconnected. the THW - E1 terminals of the Replace engine ECU
(1) Disconnect the connector from the coolant engine ECU.
temperature sensor. Standard: 4.5 to 5.5 V
(2) With the engine idling, disconnect the NG
injector connector and check the idling
condition.
Standard: The engine speed decreases. Inspect the coolant
temperature sensor NG Replace coolant
NG (Refer to parts inspection and temperature sensor
adjustment 9)
OK

Inspect wire harness and

connectors between the
engine ECU and coolant NG Repair wire harness
temperature sensor and connectors
(Refer to the wiring diagram at
the back of the book)
OK

Replace engine ECU

Inspect voltage between connectors on vehicle wire

harness side with injector connector disconnected
(1) Disconnect the injector connector. Inspect and replace
(2) Turn the ignition switch on. OK injectors
(3) Inspect the voltage between connector terminals on (Refer to parts inspection
the vehicle wire harness side when the engine is and adjustment 6, 7)
stopped and when it is idling.
Standard: When engine is stopped 0 V
When engine is raced Pulsation occurs
NG

Inspect voltage between connector 1 terminal on vehicle wire

harness side and body earth, with injector connector disconnected
(1) Turn the ignition switch on. NG Inspect and repair
(2) Inspect voltage between connector 1 terminal on vehicle wire injector power supply
harness side and body earth. system
Standard: 10 to 14 V (Battery voltage)
OK

Inspect wire harness and connectors between engine ECU and

NG Repair wire harness and
injectors
connectors
(Refer to the wiring diagram at the back of the book)
OK

Inspect or replace engine ECU

Section 1.3.3
03.book 35 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-35

z AIR-FUEL RATIO CONTROL MOTOR SYSTEM

Inspect air-fuel ratio control motor operation OK

System normal
(Refer to parts inspection and adjustment 5)
NG

Measure the voltage between THA - E2

Disconnect the intake temperature
OK terminals of the engine control computer OK Inspect and replace
sensor and carry out the above
Standard: 0.5 to 3.5 V (When cold) engine control computer
inspection again
0.2 to 1.0 V (When warm)
NG
NG

Inspect intake temperature sensor

NG Replace intake
(Refer to parts inspection and
temperature sensor
adjustment 8)
OK

Inspect wire harness and connectors

between the engine ECU and intake
NG Repair wire harness and
temperature sensor
connectors
(Refer to the wiring diagram at the back
of the book)
OK

Inspect or replace engine ECU

Inspect the input voltage of the air-fuel ratio control motor

(1) Disconnect the connectors of the air-fuel ratio

control motor.
(2) Turn the ignition switch on. Inspect and repair the
(3) Inspect the voltages between the connector NG power supply system for
terminals 2 and 5 on the wire harness side and the air-fuel ratio control
body earth. motor
Standard: Between terminal 2 - body earth
10 to 14 V (Battery voltage)
Between terminal 5 - body earth
10 to 14 V (Battery voltage)
OK

Inspect air-fuel ratio control motor NG Replace air-fuel ratio

(Refer to parts inspection and adjustment 5) control motor
OK

Inspect wire harness and connectors between

NG Repair wire harness and
engine ECU - air-fuel ratio control motor
connectors
(Refer to the wiring diagram at the back of the book)
OK

Inspect or replace engine ECU

Section 1.3.3
03.book 36 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-36 LPG Device for 4Y-E Engine

z SLOW SOLENOID VALVE SYSTEM

Inspect slow solenoid valve for airtightness NG

Replace slow solenoid valve
(Refer to parts inspection and adjustment 4)
OK

Inspect slow solenoid valve operation OK

System normal
(Refer to parts inspection and adjustment 4)
NG

Inspect voltage between connector terminal 2 and terminal 1 on OK

Inspect and replace the slow solenoid valve
the slow solenoid valve wire harness side.
(1) Disconnect the connectors of the slow solenoid valve.
(2) Inspect the voltages between the connector terminal
2 - terminal 1 on the wire harness side when the ignition switch Slow solenoid valve harness side
is turned ON.
Standard: Momentarily 10 to 14 V (Battery voltage)
NG

Inspect voltage between connector terminal 2 on the slow solenoid

valve wire harness side and body earth.
(1) Disconnect the connectors of the slow solenoid valve. NG Inspect and repair the power supply system for
(2) Inspect the voltage between the connector terminal 2 on the the slow solenoid valve
wire harness side and body earth when the ignition switch is
turned ON.
Standard: Momentarily 10 to 14 V (Battery voltage)
OK

Inspect wire harness and connectors between engine ECU - slow

NG
solenoid valve Repair wire harness and connectors
(Refer to the wiring diagram at the back of the book)
OK

Inspect or replace engine ECU

Section 1.3.3
03.book 37 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-37

PARTS INSPECTION AND

SST (2)
ADJUSTMENT
SST (1) 1. Check LPG regurator primary pressure.
(1) Remove the tamper proof ring. (Refer to 2-5-1)
(2) Install the SST to the LPG regulator.
SST 09817-23600-71 ......................... (1)
09820-23600-71 ......................... (2)
(3) Crank the engine.
(4) Check the LPG regulator primary pressure.
Standard:
24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi]
Note:
The pressure remains as above one.

2. Adjust LPG regurator primary pressure

(1) Remove the tamper proof ring. (Refer to 2-5-1)
(2) Turn the ignition switch ON.
(3) Loosen the adjust screw nut and adjust the primary
pressure by turning the screw.
Standard:
24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi]
(4) Adjust the VF voltage. (See step 14.)

3. Inspect main solenoid valve

(1) Turn the ignition switch ON.
(2) Check the solenoid valve operating sound.
Standard: Solenoid valve makes operating sound.

(3) Disconnect the solenoid connector.

(4) Measure the resistance of the solenoid valve.
Standard resistance: 8.0 to 9.0 : (20qC) [68qF]

2 1

Section 1.3.3
03.book 38 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-38 LPG Device for 4Y-E Engine

4. Inspect slow solenoid valve

(1) Disconnect the injector hose from the LPG injector.
(2) Turn the ignition switch ON and OFF promptly.
(3) Check that the LPG blows.
Standard: LPG blows for a split second.
(4) Turn the ignition switch OFF.
(5) Disconnect the solenoid connector.
(6) Turn the ignition switch ON.
(7) Check for the LPG leakage.
Standard: No leakage occurs.

5. Inspect air fuel ratio control motor

(1) Start the engine.
(2) Put a sound scope on the air fuel ratio control motor.
(3) Check the air fuel ratio control motor operating sound.
Standard: Motor makes click sound for several seconds.
(4) Remove the air fuel ratio control motor.
Note:
Do not disconnect the connector.

(5) Put masking tape on the contact surface with the adaptor,
to prevent air from blowing.
(6) Measure the length (A) when the engine stops and is
idling.
Standard:
13 to 14 mm (0.51 to 0.55 in) when engine stops
14 to 18 mm (0.55 to 0.71 in) when engine is idling
Notice:
Do not apply excessive force to the needle valve portion.

Section 1.3.3
03.book 39 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-39

(7) Disconnect the connector from the FCM.

(8) Measure the resistance between the terminals.
Standard:
3 2 1
Terminals Resistance
15 to 25 : at cold temp.
2-1, 3
6 5 4 20 to 30 : at hot temp.
15 to 25 : at cold temp.
5-4, 6
20 to 30 : at hot temp.

Note:
Cold temp. = -10 to 50qC (14 to 122qF)
Hot temp. = 50 to 100qC (122 to 212qF)

(9) Check the air fuel ratio control motor operation.

(a) Apply battery positive (+) voltage to the terminal 2,
negative (-) voltage to terminals in the order of 1, 3,
4, and 6.
(b) Check that the needle valve movement.
Standard:
The needle valve gradually moves to the CLOSE side.
(c) Apply battery positive (+) voltage to the terminal 5,
negative (-) voltage to terminals in the order of 1, 3,
4, and 6.
CLOSE side
(d) Check that the needle valve movement.
Standard:
The needle valve gradually moves to the OPEN side.
Notice:
Do net apply excessive force to the needle valve portion.
OPEN side

Section 1.3.3
03.book 40 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-40 LPG Device for 4Y-E Engine

6. Inspect LPG injector

(1) Put a sound scope on the LPG injector.
(2) Check the injector operating sound while cranking the
engine.
Standard: Injector makes operating sound.
Reference:
Injector injects fuel twice per engine revolution while
cranking.
(3) Start the engine.
(4) Lightly pinch the injector hose with fingers and check the
pulsation.
Standard: Pulsation occurs continuously.
(5) Check the idle condition when disconnecting the injector
connector.
Standard:
The engine idle speed decreases when disconnecting the
connector.

(6) Check air tightness of the LPG injector.

(a) Disconnect the LPG injector connector and remove
the injector with the hose connected.
Note:
Do not disconnect the injector hose.
(b) Check for the leakage of LPG from the injector while
turning the ignition switch ON and OFF.
Standard: No leakage occurs.

(7) Measure the resistance of the LPG injector.

Standard: 3.5 to 4.5 : at 20qC (68qF)

2 1

Section 1.3.3
03.book 41 ページ ２００７年２月２２日　木曜日　午後４時４７分

LPG Device for 4Y-E Engine 3-41

7. Clean LPG injector

(1) With a clean shop rag, wipe off the carbon around the
nozzle.
(2) Insert and desert a wire with diameter of less than 1.2 mm
(0.047 in), while applying compressed air of 343 to 490
kPa (3.5 to 5.0 kgf/cm2, 49.8 to 71.1 psi) from the intake
port.
Notice:
Insert the wire within the range of 20 mm (0.79 in).

8. Inspect air temperature sensor

(1) Remove the air temperature sensor.
(2) Measure the resistance of the sensor.
Standard:
Temperature Resistance
20qC (68qF) 2 to 3 k:
80qC (176qF) 0.2 to 0.4 k:

9. Inspect coolant temperature sensor

(1) Remove the coolant temperature sensor.
(2) Measure the resistance of the sensor.
Standard:
Temperature Resistance
20qC (68qF) 2 to 3 k:
80qC (176qF) 0.2 to 0.4 k:

Section 1.3.3
03.book 42 ページ ２００７年２月２２日　木曜日　午後４時４７分

3-42 LPG Device for 4Y-E Engine

10. Inspect distributor cap

(1) Check the distributor cap and center piece contact
visually.
Standard:
• There is no crack on the distributor cap.
• There is no damage on the center piece.
• Center piece moves smoothly.
• The cap inside is not considerably dirty.
11. Inspect resistive code
(1) Measure the resistance of the resistive codes.
Standard: 25 k:

12. Inspect ignition coil

(1) Disconnect the 4 resistive codes from the spark plug.
(2) Remove the distributor cap.
(3) Remove the distributor rotor.
(4) Remove the dust-proof cover.
(5) Inspect the primary coil.
(a) Measure the resistance between the terminals A and
C.
Standard:
Condition Resistance
Cold 20qC (68qF) 0.33 to 0.55 :
Hot 80qC (176qF) 0.42 to 0.65 :

(6) Inspect the secondary coil.

(a) Measure the resistance between the terminals B and
C.
Standard:
Condition Resistance
Cold 20 qC (68 qF) 6.7 to 12.9 k:
Hot 80 qC (176 qF) 8.6 to 15.1 k:

(7) Inspect the insulation of the ignition coils.

(a) Measure the resistance between the terminal A and
body ground D.
Standard: 1 M: or higher

Section 1.3.3
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LPG Device for 4Y-E Engine 3-43

13. Inspect signal generator

(1) Disconnect the pickup coil connector.
(2) Measure the resistance between the terminals.
Standard:
2 1 Condition Resistance
Cold 20qC (68qF) 370 to 550 :
Hot 80qC (176qF) 475 to 650 :

(3) Remove the distributor cap, rotor, and dust-proof cover.

(4) Using a feeler gauge, measure the air gap between the
signal rotor tooth and pickup coil projection.
Standard: 0.2 to 0.4 mm (0.008 to 0.016 in)

14. Adjust VF voltage

(1) Warm up the heated oxygen sensor by maintaining the
engine speed at 1800 rpm for approximately 2 minutes.
(2) Using plug-in analyzer or multi-function display, check
that OX value alternates between 0 and 1.
VF voltage
Note:
Maintain the engine rpm at 1800 rpm.
OX value Standard:
The OX value alternates more than 4 times, between 0 and
1 for 10 seconds.
(3) Measure the VF voltage while engine idling.
Standard: 2.5 ± 0.5 V

(4) If the VF voltage is not within the specified range, adjust

the VF voltage to the specified value by turning the idle
adjust screw slowly.
Reference:
COUNTERCLOCKWISE CLOCKWISE
VF voltage Condition Measures
Turn the screw
0V Air fuel ratio: RICH
CLOCKWISE
Turn the screw
5V Air fuel ratio: LEAN
COUNTERCLOCKWISE

(5) After racing the engine several times, check that the VF
voltage is within the specified range.
Note:
Adjust the VF voltage to nearly 2.5 V.

Section 1.3.3
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3-44 LPG Device for 4Y-E Engine

15. Check cylinder compression pressure

(1) Warm up the engine to the normal operating temperature.
(2) Disconnect the distributor connectors.
(3) Disconnect the resistive codes from the spark plugs.
(4) Remove the spark plugs.

(5) Check the cylinder compression pressure.

(a) Install a compression gauge into the spark plug hole.
(b) Fully depress the accelerator pedal.
(c) While cranking the engine, measure the
compression pressure.
Standard:
1000 to 1373 kPa (10.2 to 14.0 kgf/cm2) [145 to 199 psi]
Note:
The difference between each cylinder is within 196 kPa (2.0
kgf/cm2) [28 psi]
(d) If the cylinder compression in 1 or more cylinders is
low, pour a small amount of engine oil into the spark
plug hole and perform steps (a) through (c) for the
cylinders with low compression.
• If the compression pressure increases, piston
rings and/or cylinder bore may be worn or
damaged.
• If the compression stays low, valves may be
sticking, valve seating may be improper, or gas
leakage through the gasket may occur.

Section 1.3.3
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LPG Device for 4Y-E Engine 4-1

APPENDIX
Page
SST LIST ................................................................4-2
0
SERVICE STANDARDS .........................................4-4
1
WIRING DIAGRAM.................................................4-5
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
Section 1.3.4
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4-2 LPG Device for 4Y-E Engine

SST LIST
Section
Illustration Part number Part name
2 3

09238-13130-71 Sub harness { {

09814-22000-71 Tool { {

09815-22000-71 Tool { {

09813-26600-71 Gauge { {

80339-76026-71 Automatic choke pipe plug { {

09817-23600-71 Union { {

09819-22000-71 Gauge { {

Section 1.3.4
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LPG Device for 4Y-E Engine 4-3

Section
Illustration Part number Part name
2 3

09819-23600-71 Gauge { {
0
1
2
3
23627-22000-71 Spring { {
4
5
6
09820-23600-71 Tester SUB-ASSY { {
7
8
9
09240-26600-71 Plug-in Analyzer { {
10
11
12
13
14
15
16
17
18
19
20
21
E
Section 1.3.4
04.book 4 ページ ２００７年２月２２日　木曜日　午後４時４８分

4-4 LPG Device for 4Y-E Engine

SERVICE STANDARDS
FILTER
Tightening Torque T=N·m (kgf·cm) [ft·lbf]
Cover set bolt 6.4 to 7.8 (65 to 80) [4.7 to 5.8]
Element tightening nut 1.0 to 1.2 (100 to 150) [0.7 to 1.1]
REGULATOR
Protrusron of the idle adjust screw
11.8 to 15.0 (120 to 150) [8.7 to 11.0]
(Distance from the body face to the screw tip)
Mounting height of the first spring adjuster mm (in) 13.9 (0.5)
Pressure in the first reducing chamber kPa (kgf/cm2) [psi] 24.5 to 34.3 (0.25 to 0.35) [3.6 to 5.0]
First valve lever height
11.8 to 12.3 (0.47 to 0.48)
(From first cover contact surface) mm (in)
Second valve lever height
0 to 2.0 (0 to 0.08)
(From second cover contact surface) mm (in)
Tightening Torque T=N·m (kgf·cm) [ft·lbf]
Regulator first cover set screw 3.5 to 4.4 (36 to 45) [2.6 to 3.5]
First valve set screw 3.5 to 4.4 (36 to 45) [2.6 to 3.5]
First spring adjuster lock nut 3.5 to 4.4 (36 to 45) [2.6 to 3.5]
Regulator second cover set screw 3.5 to 4.4 (36 to 45) [2.6 to 3.5]
Second valve set screw 3.5 to 4.4 (36 to 45) [2.6 to 3.5]
Slow solenoid valve set screw 3.5 to 4.4 (36 to 45) [2.6 to 3.5]
Intake union 3.5 to 4.4 (36 to 45) [2.6 to 3.5]

Section 1.3.4
 4-5

WIRING DIAGRAM