MANUAL 3C-E TOYOTA.pdf

Section :

Engine

Ref. No. : EG−0008 Date : Page :

Area Application : Others(Singapore) Model Name : LITEACE Model Code : CR42 Subject : SUPPLEMENTAL FOR REPAIR MANUAL This is to inform you of 3C−E engine service data for CR42. The attached pages are to be used with the following repair manual. Pub. No.

Publication Name

RM597E

3C−TE Engine Repair Manual

Production Effective : VIN

Production Date

−−−

From Aug. 2000

Aug., 2000 1 of 1

PREPARATION ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . .

PP−1

EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . ELECTRONIC CONTROL DIESEL . . . . . . . . .

PP−3 PP−5

ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PP−8 PP−11

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PP−13 PP−17

CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PP−20

PP−1 PREPARATION

−

ENGINE MECHANICAL

ENGINE MECHANICAL PP3J2−01

SST (Special Service Tools) 09843−18040

Diagnosis Check Wire No.2

09213−54015

Crankshaft Pulley Holding Tool

(09214−00021)

Bolt

(91651−60855)

Bolt

09330−00021

Companion Flange Holding Tool

09950−50012

Puller C Set

(09952−05010)

Slide Arm

(09951−05010)

Hanger 150

(09953−05010)

Center Bolt 100

(09953−05020)

Center Bolt 150

(09954−05030)

Claw No.3

PP−2 PREPARATION

EQUIPMENT Carbide cutter Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune−up tester Micrometer Piston ring compressor Piston ring expander Plastigage Tachometer Thermometer Torque wrench Valve seat cutter Vernier calipers

−

ENGINE MECHANICAL PP3J3−01

PP−3 PREPARATION

−

EMISSION CONTROL

EMISSION CONTROL PP3J5−01

RECOMMENDED TOOLS 09082−00040

TOYOTA Electrical Tester.

PP−4 PREPARATION

EQUIPMENT MITYVAC (Hand−held vacuum tester) Torque wrench Vacuum gauge

−

EMISSION CONTROL PP3J6−01

PP−5 PREPARATION

−

ELECTRONIC CONTROL DIESEL

ELECTRONIC CONTROL DIESEL PP3J7−01


Turbocharger Pressure Gauge

Intake air pressure sensor

PP−6 PREPARATION

−




PP−7 PREPARATION

EQUIPMENT Thermometer Torque wrench Vacuum gauge 19 mm deep socket wrench

−


PP−8 PREPARATION

−

ENGINE FUEL

ENGINE FUEL PP3JA−01


Injection Pump Stand Set

09245−54010

Injection Pump Stand Arm

09260−54012

Injection Pump Tool Set

(09262−54010)

Distributor Head Plug Wrench

(09269−54020)

Socket 14 mm

09268−64010

(09268−64020)

Injection Nozzle Wrench Set

Injection Nozzle Holder Retaining Nut Wrench

(09268−64030)

Injection Nozzle Holder Wrench

PP−9 PREPARATION

−

ENGINE FUEL PP3JB−01


Hexagon Wrench Set .

09082−00040


PP−10 PREPARATION

−

ENGINE FUEL PP3JC−01

EQUIPMENT Injection nozzle tester Injection pump tester Torque wrench 19 mm deep socket wrench

Fuel temperature sensor

PP−11 PREPARATION

−

COOLING

COOLING EQUIPMENT Radiator cap tester

PP138−05

PP−12 PREPARATION

−

COOLING PP139−06

COOLANT Item

Capacity

Engine coolant

Classification Ethylene−glycol base

w/ Rear heater w/o Rear heater

7.6 liters (8.0 US qts, 6.7 Imp. qts) 6.6 liters (7.0 US qts, 5.8 Imp. qts)

PP−13 PREPARATION

−

LUBRICATION

LUBRICATION PP3JD−01


Oil Filter Wrench

09816−30010

Oil Pressure Switch Socket

PP−14 PREPARATION

EQUIPMENT Oil pressure switch Precision straight edge Torque wrench

−

LUBRICATION PP3JG−01

PP−15 PREPARATION

−

LUBRICATION PP3JE−01

LUBRICANT Item Engine oil Dry fill Drain and refill w/ Oil filter change w/o Oil filter change

Capacity 5.6 liters (5.9 US qts, 4.9 Imp. qts) 5.0 liters (5.3 US qts, 4.4 Imp. qts) 4.3 liters (4.5 US qts, 3.8 Imp. qts)

Classification API grade CF−4 or CF (You may also use API CE or CD)

PP−16 PREPARATION

−

LUBRICATION PP3JF−01

SSM (Special Service Materials) 08833−00080

Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent

Oil pressure switch

PP−17 PREPARATION

−

STARTING

STARTING PP3JH−01


Injection Pump Spline Shaft

Bearings

Puller

09810−38140

Starter Magnet Switch Nut Wrench 14

09820−00030

Alternator Rear Bearing Replacer

Front bearing

PP−18 PREPARATION

−

STARTING PP3CZ−01



PP−19 PREPARATION

−

STARTING PP0KC−02

EQUIPMENT Dial indicator

Commutator

Magnetic finger

Steel ball

Press

Magnetic switch terminal kit part

Pull scale

Brush spring

Sandpaper

Commutator

Torque wrench V−block

Commutator

Vernier calipers

Commutator, Brush

PP−20 PREPARATION

−

CHARGING

CHARGING PP2DH−03


Injection Pump Camshaft Bearing

Alternator

Cone Replacer

09286−46011

Injection Pump Spline Shaft

Alternator

Puller

09820−00021

Alternator Rear Bearing Puller

09820−00030

Alternator Rear Bearing Replacer

09820−63010

Alternator Pulley Set Nut Wrench Set

09950−60010

Replacer Set

(09951−00300)

Replacer 30

(09951−00520)

Replacer 52

09950−70010

Handle Set

(09951−07100)

Handle 100

Alternator

Alternator

PP−21 PREPARATION

−

CHARGING PP0KE−04



PP−22 PREPARATION

−

CHARGING PP18A−06

EQUIPMENT Ammeter (A) Plastic hammer Torque wrench Vernier calipers

Rotor (Slip ring), Brush

SERVICE SPECIFICATIONS ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . .

SS−1

EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . ELECTRONIC CONTROL DIESEL . . . . . . . . .

SS−3 SS−4

ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SS−6 SS−8

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SS−9 SS−11

CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SS−13

SS−1 SERVICE SPECIFICATIONS

−

ENGINE MECHANICAL

ENGINE MECHANICAL SS1IH−01

SERVICE DATA Idle speed

−

700 − 800 rpm

Maximum speed

−

4,900 − 5,100 rpm

Camshaft

Journal diameter Circle runout Cam lobe height

Cylinder block

Cylinder bore diameter

Piston and piston ring

Piston diameter

Piston oil clearance Piston ring groove clearance

Piston ring end gap

Maximum STD Intake Exhaust Vacuum pump cam Minimum Intake Exhaust

27.979 − 27.995 mm (1.1015 − 1.1022 in.) 0.06 mm (0.0024 in.) 47.57 − 47.67 mm (1.8728 − 1.8768 in.) 48.30 − 48.40 mm (1.9016 − 1.9055 in.) 30.20 − 30.40 mm (1.1890 − 1.1968 in.) 46.90 mm (1.8465 in.) 47.85 mm (1.18839 in.)

STD STD Mark 1 Mark 2 Mark 3 Maximum STD O/S 0.50

86.000 − 86.010 mm (3.3858 − 3.3862 in.) 86.010 − 86.020 mm (3.3862 − 3.3866 in.) 86.020 − 86.030 mm (3.3866 − 3.3870 in.) 86.23 mm (3.3949 in.) 86.73 mm (3.4146 in.)

STD Mark 1 Mark 2 Mark 3 O/S 0.50 STD Minimum STD No.1 No.2 Oil Maximum STD No.1 No.2 Oil Maximum No.1 No.2 Oil

85.875 − 85.885 mm (3.3809 − 3.3813 in.) 85.885 − 95.895 mm (3.3813 − 3.3817 in.) 85.895 − 85.905 mm (3.3817 − 3.3821 in.) 86.375 − 86.405 mm (3.4006 − 3.4018 in.) 0.115 − 0.135 mm (0.0045 − 0.0053 in.) 0.150 mm (0.0059 in.) 0.061 − 0.104 mm (0.0024 − 0.0041 in.) 0.070 − 0.110 mm (0.0028 − 0.0043 in.) 0.030 − 0.070 mm (0.0012 − 0.0028 in.) 0.20 mm (0.0079 in.) 0.270 − 0.390 mm (0.0106 − 0.0150 in.) 0.400 − 0.550 mm (0.0157 − 0.0217 in.) 0.200 − 0.520 mm (0.0079 − 0.0205 in.) 0.990 mm (0.0390 in.) 1.15 mm (0.0452 in.) 1.12 mm (0.0315 in.)


−

ENGINE MECHANICAL SS1II−01

TORQUE SPECIFICATION Part tightened

N·m

kgf·cm

ft·lbf

7.4

75

65 in.·lbf

63.7 36.8

650 375

47 27

Alternator bracket x Cylinder block

37

380

27

Crankshaft pulley x Crankshaft

145

1,480

107

Fluid coupling x Fan bracket

7.4

75

65 in.·lbf

Glow plug x Cylinder head

13

130

9 in.·lbf

Glow plug connector x Glow plug

2.2

22

19 in.·lbf

No. 1 manifold stay x Intake flange

18

185

15

No. 1 manifold stay x Cylinder head cover

18

185

15

Injection pipe x Injection nozzle

29.4

300

22

Injection pipe x Injection pump

29.4

300

22

Intake flange x Intake manifold

18

185

13

Glow plug x Cylinder head

13

130

9

Nozzle leakage pipe x Injection nozzle

29.4

300

22

Injection nozzle x Cylinder head

63.7

650

47

EGR pipe x Exhaust manifold

24.5

250

17

EGR Valve x Intake manifold

19

195

14


18

185

13

No. 2 manifold stay x Intake manifold

18

185

13

Water bypass hose x Intake manifold

18

185

13

Vacuum pump x Cylinder head cover

19

195

14

Cylinder head cover x Cylinder head

13.7

135

10

59 Turn 90˚ Turn 90˚

600 Turn 90˚ Turn 90˚

44 Turn 90˚ Turn 90˚

88

900

65

36.8

375

27

No. 1 idler pulley x Cylinder head

7.4

75

65 in.·lbf

Camshaft bearing cap x Camshaft

18

185

13

No. 1 exhaust manifold heat insulator x Exhaust manifold

18

185

13

Water outlet x Cylinder head

18

185

13

46.5

475

34

18

185

13

Fan x Fluid coupling Fan bracket x Cylinder block

Cylinder head x Cylinder block

Bolt A Others

1st 2nd 3rd

Camshaft timing pulley x Camshaft No. 1 idler pulley x Cylinder head

Exhaust manifold x Cylinder head Water bypass outlet x Cylinder head

Adjust bolt

Oil nozzle x Cylinder head

7.4

75

65 in.·lbf

Rear engine hanger x Cylinder head

36.8

375

27

Camshaft oil seal retainer x Cylinder head

7.4

75

65 in.·lbf

Intake Manifold x Cylinder head

18

185

13


−

EMISSION CONTROL

EMISSION CONTROL SS1IJ−01


N·m

kgf·cm

ft·lbf

EGR valve x Intake flange

19

195

14

EGR valve x EGR pipe

93

950

69

24.5

250

18



−

ELECTRONIC CONTROL DIESEL

ELECTRONIC CONTROL DIESEL SS1IK−01

SERVICE DATA Throttle control motor

Resistance (2 and 1/3, 5 and 4/3)

at hot at cold

23 − 33 Ω 29 − 39 Ω

Timing control valve

Resistance

at 20˚C (68˚F)

10 − 14 Ω

Spill control valve

Resistance

at 20˚C (68˚F)

1−2Ω

E−VRV for EGR

Resistance

at 20˚C (68˚F)

11 − 13 Ω

Fuel temperature sensor Intake air temperature sensor

Resistance

at −20˚C (−4˚F) at 0˚C (32˚F) at 20˚C (68˚F) at 40˚C (104˚F) at 60˚C (140˚F) at 80˚C (176˚F)

Intake air pressure sensor

Power source voltage

Engine speed sensor

Resistance

10 − 20 kΩ 4 − 7 kΩ 2 − 3 kΩ 0.9 − 1.3 kΩ 0.4 − 0.7 kΩ 0.2 − 0.4 kΩ 4.5 − 5.5 V

at 20˚C (68˚F)

205 − 255 Ω


−

ELECTRONIC CONTROL DIESEL SS1IL−01


N·m

kgf·cm

ft·lbf

Throttl body x Intake flange

18

185

15

E−VRV for EGR x Cylinder head

7.4

75

65 in.·lbf

EGR valve x Intake flange

19

195

14

EGR valve x EGR pipe

93

950

69

21.6

220

16

Fuel temperature sensor x Injection pump


−

ENGINE FUEL

ENGINE FUEL SS1IM−01

SERVICE DATA Fuel heater

Resistance

Injection nozzle

Nozzle type Nozzle opening pressure

at 20˚C (68˚F

DN0PD650 New nozzle Reused nozzle

Adjusting shim thickness

0.5 − 2.0 Ω

14,710 − 15,690 kPa (150 − 160 kgf/cm2, 2,133 − 2,276 psi) 13,238 − 15,590 kPa (135 − 160 kgf/cm2, 1,920 − 2,276 psi) 0.900 mm (0.0354 in.) 0.925 mm (0.0364 in.) 0.950 mm (0.0374 in.) 0.975 mm (0.0384 in.) 1.000 mm (0.0394 in.) 1.025 mm (0.0404 in.) 1.050 mm (0.0413 in.) 1.075 mm (0.0423 in.) 1.100 mm (0.0394 in.) 1.125 mm (0.0443 in.) 1.150 mm (0.0453 in.) 1.175 mm (0.0463 in.) 1.200 mm (0.0472 in.) 1.225 mm (0.0482 in.) 1.250 mm (0.0492 in.) 1.275 mm (0.0502 in.) 1.300 mm (0.0512 in.) 1.325 mm (0.0522 in.) 1.350 mm (0.0531 in.) 1.375 mm (0.0541 in.) 1.400 mm (0.0551 in.) 1.425 mm (0.0561 in.) 1.450 mm (0.0571 in.) 1.475 mm (0.0581 in.) 1.500 mm (0.0591 in.) 1.525 mm (0.0600 in.) 1.550 mm (0.0610 in.) 1.575 mm (0.0620 in.) 1.600 mm (0.0630 in.) 1.625 mm (0.0620 in.) 1.650 mm (0.0650 in.) 1.675 mm (0.0659 in.) 1.700 mm (0.0669 in.) 1.725 mm (0.0679 in.) 1.750 mm (0.0689 in.) 1.775 mm (0.0699 in.) 1.800 mm (0.0709 in.) 1.825 mm (0.0719 in.) 1.850 mm (0.0728 in.) 1.875 mm (0,0758 in.) 1.900 mm (0.0748 in.) 1.925 mm (0.0758 in.) 1.950 mm (0.0768 in.)


−

ENGINE FUEL SS1IN−01


N·m

kgf·cm

ft·lbf

Injection pipe x Injection nozzle

29.4

300

22

Injection pipe x Injection pump

29.4

300

22

No. 1 manifold stay x Cylinder head

18

185

13


18

185

13

Intake flange x Intake manifold

18

185

13

E−VRV for EGR x Cylinder head

7.4

75

65 in.·lbf

Glow plug connector x Glow plug

2.2

22

19 in.·lbf

Nozzle leakage pipe x Injection nozzle

29.4

300

22

Injection nozzle x Cylinder head

63.7

650

47


24.5

250

17

EGR valve x Intake manifold

19

195

14

No. 2 manifold stay x Intake manifold

18

185

13


18

185

13

Water bypass pipe x Intake flange

18

185

13

46.58

475

42

Alternator bracket x Cylinder block

37

380

27

Alternator bracket x Fan bracket

37

380

27

63.7 36.8

650 375

47 27

Injetion pump x Oil pump

18

185

13

Fluid coupling x Fan bracket

7.4

75

65 in.·lbf

Injection pump drive pulley x Injection pump

64

650

47

Crankshaft pulley x Crankshaft

145

1,480

107

Injection pump stay x Cylinder block

18

185

13

Injection pump stay x Injection pump

59

600

44

Fuel inlet hollow screw x Injection pump

36.8

375

27

Cap nut x Fuel inlet hollow screw

26.5

270

20

Overflow screw x Injection pump

26.5

270

20

Distributive head plug x Injection pump

88

900

65

Delivery valve holder x Injection pump

58.85

600

43

Fuel temperature sensor x Injection pump

21.6

220

16

Nozzle holder retaining nut x Nozzle holder nut

Fan bracket x Cylinder block

Bolt A Others


−

COOLING

COOLING SS0JV−07

SERVICE DATA Radiator cap

Relief valve opening pressure

STD Minimum

93.3 − 122.7 kPa (0.95 − 1.25 kgf/cm2, 13.5 − 17.8 psi) 79 kPa (0.8 kgf/cm2, 11.5 psi)


−

LUBRICATION

LUBRICATION SS1IO−01

SERVICE DATA Oil pressure

at idle speed at 4,500 rpm

29 kPa (0.3 kgf/cm2, 43 psi) or more 245 − 588 kPa (2.5 − 6.0 kgf/cm2, 36 − 85 psi)


−

LUBRICATION SS1IP−01


N·m

kgf·cm

ft·lbf

15

150

11

Drain plug x Oil pan

34.5

350

25

Oil cooler x Oil filter bracket

58.8

600

43

No. 2 exhaust heat insulator x Cylinder block

42

428

31

No. 2 exhaust heat insulator x Oil filter bracket

18

185

13

Oil pressure switch x Oil filter bracket


−

STARTING

STARTING SS0UY−10

SERVICE DATA Starter (1.4 kW)

Rated voltage and output power No−load characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout Magnetic switch Contact plate for wear

Current rpm STD Minimum STD Minimum

12 V 1.4 kW 90 A or less at 11.5 V 3,000 rpm or more 15.5 mm (0.610 in.) 8.5 mm (0.335 in.) 17.6 − 23.5 N (1.8 − 2.4 kgf, 4.0 − 5.4 lbf) 11.8 N (1.2 kgf, 2.7 lbf)

STD Minimum STD Minimum Maximum

30.0 mm (1.181 in.) 29.0 mm (1.142 in.) 0.6 mm (0.024 in.) 0.2 mm (0.008 in.) 0.05 mm (0.0020 in.)

Maximum

0.9 mm (0.035 in.)


−

STARTING SS0UZ−08


N·m

kgf·cm

ft·lbf

Terminal 30 nut, Terminal C nut x Terminal bolt

17

173

12

End cover x Magnetic switch housing

2.5

26

22 in.·lbf

End cover x Brush holder

1.5

15

13 in.·lbf

Starter housing x Magnetic switch

5.9

60

52 in.·lbf

End cover x Starter housing

5.9

60

52 in.·lbf

Lead wire of field frame x Terminal C

5.9

60

52 in.·lbf


−

CHARGING

CHARGING SS0MW−09

SERVICE DATA Drive belt

Deflection Tension

Alternator

Rated output Slip ring diameter Brush exposed length

IC regulator

Regulating voltage

New belt Used belt New belt Used belt

9 − 11 mm (0.35 − 0.43 in.) 12 − 14 mm (0.47 − 0.55 in.) 490 − 588 N (50 − 60 kgf) 196 − 392 N (20 − 40 kgf)

STD Minimum STD Minimum

12 V 80 A 14.2 − 14.4 mm (0.559 − 0.567 in.) 12.8 mm (0.504 in.) 9.5 − 11.5 mm (0.374 − 0.453 in.) 1.5 mm (0.059 in.) 13.2 − 14.8 V


−

CHARGING SS0MX−07


N·m

kgf·cm

ft·lbf

Bearing retainer x Drive end frame

2.6

27

23 in.·lbf

Rectifier end frame x Drive end frame

4.5

46

40 in.·lbf

110.5

1,125

81

Rectifier holder x Rectifier end frame

3.9

40

34 in.·lbf

Rectifier holder x Coil lead on rectifier end frame

1.96

20

17 in.·lbf

Rectifier end frame x Brush holder, IC regulator

2.0

20

18 in.·lbf

Rear end cover x Rectifier holder

4.5

46

40 in.·lbf

Terminal insulator x Rectifier holder

4.1

42

36 in.·lbf

Alternator pulley x Rotor

DIAGNOSTICS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DI−1

HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

DI−1

CUSTOMER PROBLEM ANALYSIS CHECK . .

DI−2

PRE−CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DI−3

DIAGNOSTIC TROUBLE CODE CHART . . . . . .

DI−12

PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . .

DI−14

TERMINALS OF ECU . . . . . . . . . . . . . . . . . . . . . .

DI−15

PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . .

DI−17

CIRCUIT INSPECTION . . . . . . . . . . . . . . . . . . . . .

DI−19

DI−1 DIAGNOSTICS

−

ENGINE

ENGINE HOW TO PROCEED WITH TROUBLESHOOTING

DI925−01

When using hand−held tester, troubleshoot in accordance with the procedure on the following pages. Titles inside are titles of pages in this manual, with the page number indicated in the bottom portion. See the indicated pages for detailed explanations.

Vehicle Brought to Workshop 1

Customer Problem Analysis P. DI−1

2

Connect hand−held tester to DLC3 P. DI−3 If display indicates a communication fault in tool, inspect DLC3 P. DI−3

3

Check Diagnostic Trouble Code and Freeze Frame Data (Pre−check) Record or Print DTC and Freeze Frame Data P. DI−3

4

Clear DTC and Freeze Frame Data P. DI−3

5

Visual Inspection

6

Setting Check (Test) Mode Diagnosis P. DI−3

7

Problem Symptom Confirmation If the engine does not start, perform steps 10 and 12 first Malfunction occurs.

9 10

DTC check P. DI−1 Normal

Malfunction code. 11

Basic Inspection P. DI−1 12

14

8

Malfunction does not occur. Symptom Simulation RM597E, IN−13

Problem Symptoms Table P. DI−17

Parts Inspection 15

13

Circuit Inspection P. DI−19

Check for Intermittent Problems P. DI−3

Identification of Problem 16

Adjustment, Repair

17

Confirmation Test End

DTC Chart P.DI−12

DI−2 −

DIAGNOSTICS

ENGINE DI926−01

CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name

ENGINE CONTROL SYSTEM Check Sheet

Model and Model Year

Driver’s Name

Frame No.

Date Vehicle Brought in

Engine Model

License No.

Odometer Reading

Problem Symptoms

Customer’s Name

Engine does not Start

Engine does not crank

Difficult to Start

Engine cranks slowly Other

Poor Idling

Incorrect first idle Idling rpm is abnormal Rough idling Other

Poor Driveability

Hesitation Knocking

Engine Stall

Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Other Shifting from N to D

km miles

No initial combustion

Back fire Other

No complete combustion

High (

rpm)

Low (

Muffler explosion (after−fire)

Surging

Others

Date Problem Occurred

Condition When Problem Occurs

Problem Frequency

Constant Other

Sometimes (

times per

day/month)

Weather

Fine

Cloudy

Rainy

Snowy

Outdoor Temperature

Hot

Warm

Cool

Cold (approx.

Place

Highway Rough road

Engine Temp.

Cold

Engine Operation

Starting Just after starting ( Driving Constant speed Other A/C switch ON/OFF

Condition of Malfunction indicator Lamp Diagnostic Trouble Code Inspection

Normal mode (Pre−check) Check Mode

Suburbs Other Warming up

Inner City After warming up

Once only

Various/Other ˚F/ Uphill Any temp.

min.) Idling Acceleration

˚C) Downhill Other Racing Deceleration

Remains on

Sometimes lights up

Normal

Malfunction code(s) (code Freeze frame data (

)

Malfunction code(s) (code Freeze frame data (

)

Normal

Does not light up ) )

rpm)

DI−3 DIAGNOSTICS

−

ENGINE

PRE−CHECK 1. (a)

FI2547

Hand−Held Tester

DLC3 H11456

DI927−01

DIAGNOSIS SYSTEM Description S When troubleshooting Multiplex OBD (M−OBD) vehicles, the only difference from the usual troubleshooting procedure is that you need to connect the vehicle to the hand−held tester, and read off various data output from the vehicle’s engine ECU. The vehicle’s on−board computer lights up the S check engine warning light on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components. In addition to the check engine warning light lighting up when a malfunction is detected, the applicable diagnostic trouble codes are recorded in the engine ECU memory. (See page DI−12) If the malfunction has been repaired, the check engine warning light goes off automatically but the diagnostic trouble codes remain recorded in the engine ECU memory. To check the diagnostic trouble codes, connect the S hand−held tester to the Data Link Connector 3 (DLC3) on the vehicle or read the number of blinks of the check engine warning light when TC and CG terminals on the DLC3 are connected. The hand− held tester also enables you to erase the diagnostic trouble codes and activate the several actuators and check freeze frame date and various forms of engine data. (For operating instructions, see the hand−held tester instruction book.) The diagnosis system operates in the normal mode S during a normal vehicle use. It also has a check (test) mode for technicians to simulate malfunction symptoms and troubleshoot. Some diagnostic trouble codes use 2 trip detection logic* to prevent an erroneous detection and ensure thorough the malfunction detection. By switching the engine ECU to the check (test) mode using hand−held tester when troubleshooting, a technician can cause the check engine warning light to light up for a malfunction that is only detected once or momentarily. (hand−held tester only) (See page DI−12)

DI−4 DIAGNOSTICS

−

ENGINE

*2 trip detection logic: When a logic malfunction is first detected, the malfunction is temporarily stored in the engine ECU memory. If the same malfunction is detected again during the second drive test, this second detection causes the check engine warning light to light up. The 2 trip repeats the same mode twice time. (However, the ignition switch must be turned OFF between the 1st trip and 2nd trip). S Freeze frame data: Freeze frame data records the engine condition when a malfunction is detected, as freeze frame data records the engine conditions (fuel system, calculator load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air−fuel ratio was lean or rich, etc. at the time of the malfunction. (b) Check the DLC3. The vehicle’s engine ECU uses ISO 14230 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 14230 format. S

1 2 34 5 6 78 9 10 111213141516 DLC3 A04550

Terminal No.

Connection/Voltage or Resistance

Condition

7

Bus+ Line/Pulse generation

During transmission

4

Chassis Ground − Body Ground/1 Ω or less

Always

16

Battery Positive − Body Ground/9 − 14 V

Always

HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the hand−held tester to the DLC3, turned the ignition switch ON and operated the hand−held tester, there is a problem on the vehicle side or tool side. If the communication is normal when the tool is connected S to another vehicle, inspect the DLC3 on the original vehicle. If the communication is still impossible when the tool is S connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual.

DI−5 DIAGNOSTICS

2. (a)

FI2547

DLC3 H11456

ENGINE

Normal Mode: INSPECT DIAGNOSIS Check the check engine warning light. (1) The check engine warning light comes on when the ignition switch is turned ON and the engine is not running.

HINT: If the check engine warning light does not light up, troubleshoot the combination meter. (2) when the engine is started, the check engine warning light should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC using hand−held tester. NOTICE: When the diagnosis system is switched from the normal mode to the check (test) mode, all the DTCs and freeze frame data recorded in the normal mode will be erased. So before switching modes, always check the DTCs and freeze frame data, and note them down. (1) Prepare the hand−held tester. (2) Connect the hand−held tester to the DLC3. (3) Turn the ignition switch ON and the hand−held tester main switch ON. (4) Use the hand−held tester to check the DTCs and freeze frame data. (for operating instructions, see the hand−held tester’s instruction book.) (5) Confirm the details of the DTCs.

(c)

Hand−Held Tester

−

Check the DTC not using hand−held tester. (1) Turn the ignition switch ON. (2) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3 together. SST 09843−18040

DI−6 DIAGNOSTICS

(3) Normal 0.25 sec. ON ON ON ON

OFF OFF OFF

0.25 sec. 0.5 sec.

1.5 sec.

4.5 sec.

12 and 31 4.5 sec.

2.5 sec.

ON OFF

0.5 sec.

One Cycle

Repeat

Start FI0294 BR3589

A08718

Flashing ON

(7)

OFF

(8)

FI3605

ENGINE

Read the DTC from the check engine warning light. As an example, the blinking patterns for codes; normal, 12 and 31 are as shown in the illustration.

HINT: If theTC is not output, check the diagnostic connector (DLC3) circuit (See page DI−36). (4) Check the details of the malfunction using the DTC chart on page DI−12. (5) After completing the check, disconnect terminals 13 (TC) and 4 (CG) and turn off the display. HINT: In the event of 2 or more malfunction codes, the indication will begin from the smaller numbered code to the larger in order. NOTICE: When simulating symptoms without a hand−held tester to check the DTCs, use the normal mode. For code on the DTCs chart subject to ”2 trip detection logic”, turn the ignition switch OFF after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated twice, the check engine warning light lights up and the DTCs are recorded in the engine ECU. 3. Check (Test) Mode: INSPECT DIAGNOSIS Hand−held tester only: Compared to the normal mode, the check mode has a further sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check (test) mode. (a) Check the DTC. (1) Initial conditions. Battery voltage 12 V or more S Throttle valve fully closed. S S Transmission in the neutral position (2) Turn the ignition switch OFF. (3) Prepare the hand−held tester. (4) Connect the hand−held tester to the DLC3. (5) Turn the ignition switch ON and push the hand−held tester main switch ON.

(6)

0.13 Sec.

−

Switch the hand−held tester from the normal mode to the check (test) mode (Check that the check engine warning light flashes.). Start the engine (The check engine warning light goes off after the engine starts.). Simulate the conditions of the malfunction described by the customer.

NOTICE: Leave the ignition switch ON until you have checked the DTCs, etc.

DI−7 DIAGNOSTICS

−

(9)

ENGINE

After simulating the malfunction conditions, use the hand−held tester diagnosis selector to check the DTCs and freeze frame data, etc.

HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from the check (test) mode to the normal mode, so all the diagnostic codes, etc. are erased. (10) After checking the DTCs, inspect the applicable circuit. (b) Clear the DTC. The following actions will erase the DTCs and freeze frame data. Operating the hand−held tester to erase the S codes. (See the hand−held tester’s instruction book for operating instructions.) Disconnecting the battery terminals, ECD S fuse. NOTICE: If the hand−held tester switches the engine ECU from the normal mode to the check (test) mode or vice−versa, or if the ignition switch is turned from ON to ACC or OFF during the check (test) mode, the DTCs and freeze frame data will be erased.

Interface Box

Vehicle Harness

(c)

ECU

Break−Out−Box

N09348

Measure the engine ECU terminal values using break− out box and hand−held tester. (1) Connect up the break−out−box and hand−held tester to the vehicle. (2) Read the engine ECU input/output values by following the prompts on the tester screen.

HINT: Hand−held tester has a ”Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the hand−held tester/break−out−box operator’s manual for further details.

4. FAIL−SAFE CHART If any of the following codes is recorded, the engine ECU enters fail−safe mode. DTC No.

Fail−Safe Operation

Fail−Safe Deactivation Conditions

12

TCV duty is fixed at 19.5 %

2 of more TDC signals are detected for 4 engine revolution

13

SFuel cut STCV duty is fixed at 2.0 % SClose diesel throttle valve

2 of more NE signals are detected for 0.5 sec.

DI−8 DIAGNOSTICS

−

ENGINE

Accelerator pedal closed position SW ON : Accelerator pedal position is fixed at 0 % Accelerator pedal closed position SW OFF : Accelerator pedal position is fixed at 8 %

+B OFF

Accelerator pedal closed position SW ON : Accelerator pedal position is fixed at 0 % Accelerator pedal closed position SW OFF : Accelerator pedal position is fixed at 8 %

+B OFF

Accelerator pedal position below 10 %

+B OFF

When the idle SW is faulty. Accelerator pedal closed position SW ON: Accelerator pedal position is fixed at 0 % Accelerator pedal closed position SW OFF: Accelerator pedal position is fixed at 8 %

+B OFF

When the idle SW is okay. Idle SW ON : Accelerator pedal position is fixed at 0 % Idle SW OFF : Accelerator pedal position below 10 %

+B OFF

Accelerator pedal position below 10 %

+B OFF

22

Engine coolant temp. is fixed at 9˚C (48˚F)

Return to normal condition

24

Intake air temp. is fixed at 130˚C (266˚F)


35

Intake air pressure is fixed at 101.5 kPa (761 mmHg, 30 in.Hg)


39

Fuel temp. is fixed at 20˚C (68˚F)


42

Vehicle speed is fixed at 0 km/h (0 mph)

Vehicle speed > 0 km/h (0 mph)

19(1)

19(2)

19(3)

19(4)

5. CHECK FOR INTERMITTENT PROBLEMS Hand−held tester only: By putting the vehicle’s engine ECU in the check (test) mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (1) Clear the DTC (See step 2). (2) Set the check (test) mode (See step 3). (3) Perform a simulation test (See Pub. No. RM597E, on page IN−19). (4) Check the connector and terminal (See Pub. No. RM597E, on page IN−19). (5) Handle the connector (See Pub. No. RM597E, on page IN−19). 6. BASIC INSPECTION When the malfunction code is not confirmed in the DTC check, troubleshooting should be carried out in all the possible circuits to be considered as causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore use of this check is essential in the engine troubleshooting.

1

Is battery positive voltage 11 V or more when engine is stopped?

NO

YES

Charge or replace battery.

DI−9 DIAGNOSTICS

2

−

ENGINE

Is engine cranked?

NO

Proceed to problem symptoms table on page DI−17.

YES

3

Check air filter. PREPARATION: Remove the air filter. CHECK: Visually cleck that the air filter is not excessively dirty or oily. HINT: If necessary, clear the air filter with compressed air excessively dirty or oily. P00495

NG

Repair or replace.

OK

4

Check fuel quality.

CHECK: Check that only diesel fuel is used. S Check that the fuel does not contain any impurity. S NG

Replace fuel.

OK

5

Check engine oil (See page LU−2).

NG

OK

Add or replace.

DI−10 DIAGNOSTICS

6

−

ENGINE

Check coolant (See page CO−2).

NG

Replace coolant.

OK

7

Check injection timing (See Pub. No. RM597E, EM section).

NG

Adjust injection timing.

OK

8

Check idle speed and maximum speed (See page EM−1).

NG

Repair or replace injection pump.

OK

9

Check diagnostic connector (DLC3) circuit (See page DI−36).

NG

Repair or replace.

OK

10

Check vacuum pump (See page EC−4).

NG

OK

Repair or replace.

DI−11 DIAGNOSTICS

−

ENGINE

Proceed to problem symptoms table on page DI−17. Hand−Held Tester

DLC3 H11456

(c)

7. REFERENCE VALUE OF ENGINE ECU DATA NOTICE: The values given below for ”Normal Condition” are representative values, so a vehicle may still be normal even if its values from those listed here. So do not solely depend on the Normal condition here when deciding whether a part is faulty or not. HINT: Engine engine ECU data can be read by hand−held tester. (a) Connect the hand−held tester to the DLC3. (b) Monitor the engine ECU data by following the prompts on the tester screen. Please refer to the hand−held tester operator’s manual for further detail.

Reference Value Item

INJECTION VOLUME

Inspection Condition

50 − 60 mm3

Engine racing at 2,000 rpm *1

50 − 60 mm3


52 − 62 mm3

Engine at idling INJECTION TIMING

ENGINE SPD

*1

13 − 16˚CA

Engine racing at 2,000 rpm

*1

18 − 21˚CA

Engine racing at 3,000 rpm

*1

13.5 − 25.5˚CA

RPM kept stable (Comparison with tachometer) Engine at idling *1

PIM

Reference Value

Engine at idling *1

No great changes 92 − 105 kPa (690−788 mmHg, 27.2−31.0 in.Hg)


92 − 105 kPa


91 − 104 kPa

COOLANT TEMP

Engine at normal operating temp.

80 − 95˚C (189 − 203˚F) *2

INTAKE AIR


Ambient temp. − 100˚C

FUEL TEMP


Ambient temp. − 90˚C

Accelerator pedal fully closed ACCELE POSITION

VEHICLE SPD

Accelerator pedal fully opened

6 − 34 % 58 − 96 %

From closed position to wide open accelerator pedal

Gradually increases

During driving (Comparison with speed meter)

No large differences

A/C SIG

A/C switch ON

ON

IDL SIG

Accelerator pedal full closed

ON

STARTER SIG

During cranking

ON

A/C CUT SIG

A/C switch OFF

ON

EGR SYSTEM

Idling

ON

PS OIL PRESS SW

Power steering oil pressure switch signal

ACCEL CLOSE SW

Accelerator pedal fully closed

Turn steering wheel : ON ON

*1: All the accessories and A/C are switched OFF. *2: If the water temperature sensor circuit is open or short, the engine ECU operates the fail safe operation.

DI−12 DIAGNOSTICS

−

ENGINE DI928−01

DIAGNOSTIC TROUBLE CODE CHART

HINT: Parameters listed in the chart may not be exactly the same as you reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check(test) mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.” in the DTC chart. *1 Check Engine Warning Light Normal Mode/ Test Mode)

*2 Memory

DTC No. (See Page)

Detection Item

12 (DI−19)

Crankshaft Position Sensor Circuit Malfunction

S Open or short in crankshaft position sensor circuit S Crankshaft position sensor S Engine ECU

ON/ON

f

13 (DI−20)

Engine Speed Sensor Circuit Malcunction

S Open or short in engine speed sensor circuit S Engine speed sensor S Engine ECU

ON/ON

f

Timing Control System Malfunction

S Open or short in timing control valve circuit S Fuel filter (Clogging) S Fuel (Freezing, Air in) S Injection pump (Internal pressure and timing control valve) S Engine ECU

ON/N.A.

f

Diesel Throttle Control Circuit Malfunction

S Openn or short in throttle control motor circuit S Throttle control motor S Throttle full switch S Open or short in throttle full switch circuit S Engine ECU

ON/N.A.

f

Interior IC Malfunction

S Engine ECU

ON/N.A.

f

18 (DI−25)

Spill Control Circuit Malfunction

S Open or short in spill control valve circuit S Spill control valve S Engine ECU

ON/N.A.

f

19(1) (DI−26)

Accelerator Pedal Position Sensor Circuit Malfunction (Open/ Short)

S Open or short in accelerator pedal position sensor circuit S Accelerator pedal position sensor S Engine ECU

ON/ON

f

19(2) (DI−27)

Accelerator Pedal Position Sensor Circuit Malfunction (IDL Switch / Range)


ON/N.A.

f

19(3) (DI−28)

Accelerator Pedal Closed Position Switch Circuit Malfunction (Short)

S Short in accelerator pedal closed position switch circuit S Accelerator pedal closed position switch S Engine ECU

ON/N.A.

f

19(4) (DI−28)

Accelerator Pedal Closed Position Switch Circuit Malfunction (Open)

S Open in accelerator pedal closed position switch circuit S Accelerator pedal closed position switch S Engine ECU

ON/N.A.

f

22 (DI−29)

Water Temp. Sensor Circuit Malfunction

S Open or short in water temp. sensor circuit S Water temp. sensor S Engine ECU

ON/ON

f

24 (DI−30)

Intake Air Temp. Sensor Circuit Malfunction

S Open or short in intake air temp. sensor circuit S Intake air temp. sensor S Engine ECU

OFF/ON

f

32 (DI−31)

Injection Pump System Malfunction

S Injection pump correction unit cuicuit S Injection pump correction unit S Engine ECU

OFF/N.A.

f

14 (DI−21)

15 (DI−22)

17

Trouble Area

DI−13 DIAGNOSTICS

−

ENGINE

35 (DI−32)

Vacuum Sensor Circuit Malfunction

S Open or xhort in vacuum sensor circuit S Vacuum sensor S Engine ECU

ON/ON

f

39 (DI−33)

Fuel Temp. Sensor Circuit Malfunction

S Open or short in fuel temp. sensor circuit S Fuel pressure sensor S Engine ECU

ON/ON

f

42 (DI−34)

Vehicle Speed Sensor Signal Circuit Malfunction

S Open or short in fuel temp. sensor circuit S Vehicle speed sensor S Combination meter S Engine ECU

ON/ON

f

*1: ”ON” displayed in the diagnosis mode column indicates that the check engine warning light is lighted up when a malfunction is detected. ”OFF” indicates that the ”CHECK ENGINE” does not light up during malfunction diagnosis, even if a malfunction is detected. ”N.A.” indicates that the item is not included in malfunction diagnosis. 2 * : ”f” in the memory column indicates that a diagnostic trouble code is recorded in the ECU memory when a malfunction occurs. Accordingly, output of diagnostic results in normal or test mode is done with the ignition switch ON.

DI−14 DIAGNOSTICS

−

ENGINE DI929−01

PARTS LOCATION

Diesel Throttle Control Motor

Combination Meter Throttle Body Accel Pedal Position Sensor Turbo Pressure Sensor

DLC3

EGR Valve

Intake Air Temp. Sensor

Check Connector Crankshaft Position Sensor

Engine ECU

VSV for EGR Engine Room J/B, R/B Injecton Pump Water Temp. Sensor Engine Speed Sensor

Spill Control Valve

ST Relay

Injection Pump Correction Unit Fuel Temp. Sensor

EFI Relay

Timing Control Valve

GLOW Relay

A15386

DI−15 DIAGNOSTICS

−

ENGINE DI92A−01

TERMINALS OF ECU ECM Terminals

E10

E9

13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9

E7

E8

6 5 4 3 2 1 12 11 10 9 8 7

11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12

A02958

Symbols (Terminals No.)

Wiring Color

Condition

STD Voltage (V)

BATT (E7−1) − E1 (E10−14)

B−Y − BR

Always

9 ∼ 14

+B (E7−12) − E1 (E10−14)

B−R − BR

IG switch ON

9 ∼ 14

Y − BR

IG switch ON

4.5 ∼ 5.5

Y−G − BR−W

IG switch ON

4.5 ∼ 5.5


0.3 ∼ 1.5


2.9 ∼ 4.9


0.3 ∼ 1.5

Acceleratot pedal fully opened

2.9 ∼ 4.9


9 ∼ 14

Acceleratot pedal fully opened

0∼3

VC (E9−1) − E2 (E9−9) VCC (E8−6) − E2C (E8−4) VA (E8−5) (E8 5) − E2C (E8−4) (E8 4)

VAS (E8 (E8−12) 12) − E2C (E8−4) (E8 4)

LG − BR−W BR W

G R − BR−W G−R BR W

IDL (E8−9) (E8 9) − E2C (E8−4) (E8 4)

Y − BR−W BR W

VLU (E9−10) (E9 10) − E2 (E9−9) (E9 9)

G − BR

Idling (at engine warmed up)

0.6 ∼ 1.4

Idling (at engine cold)

3.0 ∼ 4.2

Apply vacuum 40 kPa (300 mmHg, 11.8 in.Hg)

0.2 ∼ 0.8

Apply vacuum 60 kPa (518 mmHg, 20.4 in.Hg)

3.2 ∼ 3.8

PIM (E9 (E9−2) 2) − E2 (E9−9) (E9 9)

LG R − BR LG−R

THA (E9−3) − E2 (E9−9)

L−R − BR

Idling, air intake temp. 0˚C (32˚F) to 80˚C (176˚F)

0.5 ∼ 3.4

THW(E9−4) − E2 (E9−9)

W−R − BR

Idling, engine coolant temp. 60˚C (140˚F) to 120˚C (248˚F)

0.2 ∼ 1.0

THF (E9−5)− E2 (E9−9)

LG−B − BR

IG switch ON (at engine cold)

0.5 ∼ 3.4

STA (E7−11) − E1 (E10−14)

B − BR

Cranking

TDC+ (E10−17) − TDC− (E10−16)

R−G

Idling

Pulse generation (See page DI−19)

NE+ (E10−19) − NE− (E10−18)

W−B

Idling

Pulse generation (See page DI−20)

SP1(E7−9) − E1(E10−14)

V − BR

IG switch ON Rotate driving wheel slowly

Pulse generation

IG switch ON TCV (E10−11) − E01 (E10−13)

G−O − BR

SPV+ (E10−12) − E1 (E10−14)

L − BR

SPV− (E10−25) − E1 (E10−14)

Y − BR

EGR (E10 (E10−24) 24) − E01 (E10 (E10−13) 13)

G R − BR G−R

S/TH (E10 (E10−10) 10) − E01 (E10 (E10−13) 13)

BR W − BR BR−W

LU (E10−8) − E01 (E10−13)

B−W − BR

Idling IG switch ON Idling IG switch ON EGR ON

6.0 or more

9 ∼ 14 Pulse generation (See page DI−21) 9 ∼ 14 Pulse generation (See page DI−25) 9 ∼ 14 Pulse generation

VSV OFF (idling)

9 ∼ 14

VSV ON (after IG switch OFF for 2 sec.)

0∼3

IG switch ON (engine warmed up)

Pulse generation

DI−16 DIAGNOSTICS MREL (E7−3) − E1 (E10−14)

B−R − BR

SREL (E7−2) (E7 2) − E01 (E10−13) (E10 13)

G Y − BR G−Y

IGSW (E7−14) − E1 (E10−14)

B−O − BR

AC1 (E8 (E8−2) 2) − E1 (E10 (E10−14) 14)

Y L − BR Y−L

ACT (E8−8) − E1 (E10−14)

LG−B − BR

PDL (E8−3) (E8 3) − E1 (E10−14) (E10 14)

L R − BR L−R

TAC (E8−7) − E1 (E10−14)

B − BR

TC (E7−4) − E1 (E10−14)

P−B − BR

W (E7 (E7−5) 5) − E1 (E10−14) (E10 14)

R Y − BR R−Y

G IND (E8−1) G−IND (E8 1) − E1 (E10−14) (E10 14)

R B − BR R−B

−

ENGINE

IG switch ON

9 ∼ 14

Cranking

9 ∼ 14

Idling (engine start and after 600 sec.)

0 ∼ 1.5

IG switch ON

9 ∼ 14

A/C switch ON (at idling)

0 ∼ 1.5

A/C switch OFF

9 ∼ 14

IG switch ON

9 ∼ 14

at A/C cut controlled (Driving below 30km/h, accelerator pedal fully opened for 5 sec.)

0∼3


9 ∼ 14


0∼3

Idling

Pulse generation

IG switch ON

9 ∼ 14

Check engine warning light lights up

0∼3

except check engine warning light lights up

9 ∼ 14

Glow indicator light lights up

0∼3

except glow indicator light lights up

9 ∼ 14

DI−17 DIAGNOSTICS

−

ENGINE DI92B−01

PROBLEM SYMPTOMS TABLE

When the malfunction code is not confirmed the DTC check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order given in the table below. Symptom

Suspect Area

See page

Does not crank (Difficult to start)

1. Starter and starter relay

, ST−16

No initial combustion (Difficult to start)

1. ECU power source circuit 2. Pre−heating system 3. Compression 4. Engine ECU 5. Injection pump

DI−35 DI−38 L ED−21 FU−10

Cold engine (Difficult to start)

1. Pre−heating system 2. STA signal circuit 3. Water temperature sensor 4. Injection nozzle 5. Fuel filter 6. Diesel throttle body 7. Engine ECU 8. Injection pump

DI−38 DI−37 DI−29 FU−5 L ED−1 ED−21 FU−10

Hot engine (Difficult to start)

1. STA signal circuit 2. Injection nozzle 3. Fuel filter 4. Diesel throttle body 5. Engine ECU 6. Injection pump

DI−37 FU−5 L ED−1 ED−21 FU−10

Soon after starting (Engine stall)

1. Fuel filter 2. Diesel throttle body 3. Engine ECU 4. Injection pump

L ED−1 ED−21 FU−10

Others (Engine stall)

1. ECU power source circuit 2. Diesel throttle body 3. Engine ECU 4. Injection pump

DI−35 ED−1 ED−21 FU−10

Incorrect first idle (Poor idling)

1. Water temperature sensor 2. Fuel filter 3. Engine ECU 4. Injection pump

DI−29 L ED−21 FU−10

High engine idle speed (Poor idling)

1. A/C signal circuit 2. Water temperature sensor 3. Engine ECU 4. Injection pump

DI−39 DI−29 ED−21 FU−10

Lower engine idle speed (Poor idling)

1. A/C signal circuit 2. Injection nozzle 3. EGR system 4. Water temperature sensor 5. Diesel throttle body 6. Compression 7. Valve clearance 8. Fuel line (Air beed) 9. Engine ECU 10. Injection pump

DI−39 FU−5 DI−41 ED−1 ED−1 L L − ED−21 FU−10

DI−18 DIAGNOSTICS

−

ENGINE Suspect Area

Symptom

See page

Rough idling (Poor idling)

1. Injection nozzle 2. Fuel line (Air beed) 3. Pre−heating system 4. EGR system 5. Diesel throttle body 6. Compression 7. Valve clearance 8. Engine ECU 9. Injection pump

FU−5 − DI−38 DI−41 ED−1 L L ED−21 FU−10

Hunting at hot engine (Poor idling)

1. Injection nozzle 2. ECU power source circuit 3. Compression 4. Fuel line (Air beed) 5. Valve clearance 6. Engine ECU 7. Injection pump

FU−5 DI−35 L − ED−21 ED−21 FU−10

Hunting at cold engine (Poor idling)

1. Pre−heating system 2. Injection nozzle 3. ECU power source circuit 4. Water temperature sensor 5. Compression 6. Fuel line (Air beed) 7. Valve clearance 8. Engine ECU 9. Injection pump

DI−38 FU−5 DI−35 ED−1 L − ED−21 ED−21 FU−10

Hesitation/ Poor acceleration (Poor driveability)

1. Injection nozzle 2. Fuel filter 3. EGR system 4. Compression 5. Engine ECU 6. Injection pump

FU−5 L DI−41 L ED−21 FU−10

Knocking (Poor driveability)

1. Injection nozzle 2. EGR system 3. Water temperature sensor 4. Engine ECU

FU−5 DI−41 ED−1 ED−21

Black smoke (Poor driveability)

1. Injection nozzle 2. EGR system 3. Diesel throttle body 4. Intake air temperature sensor 5. Engine ECU 6. Injection pump

FU−5 DI−41 ED−1 ED−12 ED−21 ED−21

White smoke (Poor driveability)

1. EGR system 2. Pre−heating system 3. Injection nozzle 4. Fuel filter 5. Diesel throttle body 6. Water temperature sensor 7. Intake air temperature sensor 8. Engine ECU 9. Injection pump

DI−41 DI−38 FU−5 L ED−1 ED−1 ED−12 ED−21 ED−21

Surging/ Hunting (Poor driveability)

1. Injection nozzle 2. Engine ECU 3. Injection pump

FU−5 ED−21 ED−21

L: See Pub. No. RM597E.

DI−19 DIAGNOSTICS

−

ENGINE DI92C−01

DTC

12

Crankshaft Position Sensor Circuit Malfunction

CIRCUIT DESCRIPTION The crankshaft position sensor in the Engine Control System contains signal plate and a pickup coil for TDC signal. The TDC signal plate has 1 tooth on its outer circumference. The TDC signal sensor generates 1 signal for every engine revolution. The engine ECU detects the top dead center by the TDC signals. The engine speed sensor in the Engine Control System contains signal plate and a pickup coil for NE signal. The NE signal plate has 52 teeth and is mounted in the injection pump. The NE signal sensor generates 52 signals of engine 2 revolutions. The engine ECU detects the engine speed and cam lift position of the injection pump. The engine ECU uses TDC signal and NE signals for injection timing control. And NE signal is used for injection volume control, also. DTC No. 12

DTC Detection Condition

Trouble Area

No TDC signal to engine ECU at 400 rpm or more

S Open or short in crankshaft position sensor circuit S Crankshaft position sensor S Engine ECU

WIRING DIAGRAM C16 Crankshaft Position Sensor

Engine ECU

1

R

17 TDC+ E10

2

G

16 TDC− E10

2

W

19 NE+ E10

1

B

18 NE− E10

E11 Engine Speed Sensor (inside the Injection Pump)

E1 A04909

INSPECTION PROCEDURE See Pub. No. RM597E on page DI−21.

DI−20 DIAGNOSTICS

−

ENGINE DI92D−01

DTC

13

Engine Speed Sensor Circuit Malfunction

CIRCUIT DESCRIPTION See Pub. No. RM597E on page DI−23. DTC No.

DTC Detection Condition No NE signal to engine ECU for 0.5 sec. at 680 rpm or more

13

No NE signal to engine ECU for 2.0 sec. or more during cranking

WIRING DIAGRAM See Pub. No. RM597E on page DI−23.


Trouble Area S Open or short in Engine speed sensor circuit S Engine speed sensor S Engine ECU

DI−21 DIAGNOSTICS

−

ENGINE DI92E−01

DTC

14

Timing Control System Malfunction

CIRCUIT DESCRIPTION The engine ECU control the injection timing by actuating the timing control valve. The timing control valve is mounted on the injection pump and delay one by duty control of pump internal fuel pressure. The engine ECU detects the injection advance angle by TDC and NE signals. DTC No.

14


Trouble Area

After engine warm up and during actual injection timing is different from target value of engine ECU calculated.

S Open or short in timing control valve circuit S Fuel filter (Clogging) S Fuel (Freezing, Air in) S Injection pump (Internal pressure and timing control valve) S Engine ECU

WIRING DIAGRAM Engine ECU

From Terminal 3 of EFI Relay (See page DI−35)

B−R

7 ED1

B−R

T5 Timing Control Valve L−B 2 1

11 E10 TCV

A15582


DI−22 DIAGNOSTICS

−

ENGINE DI92F−01

DTC

15

Diesel Throttle Control Circuit

CIRCUIT DESCRIPTION Throttle control motor is operated by the engine ECU and it opens and closes the throttle valve. The fully opening of the throttle valve is detected by the throttle fully open position switch which is mounted on the throttle body. If this DTC is stored, the engine ECU cuts the power for the throttle control motor. DTC No.


Trouble Area S Open or short in diesel throttle motor circuit S Diesel throttle motor S Diesel throttle position switch S Engine ECU

15


D17 Diesel Throttle Control Motor R

20 E4

LU+A

Y

30 E4

LU−A

P

19 E4

LU+B

6 4

3 1 W−B

29 LG E4 D18 Diesel Throttle Position Switch 12 L−R E4 1 2

LU−B THOP

EN A09824

A15430

INSPECTION PROCEDURE See Pub. No. RM597E on page DI−27. HINT: Read freeze frame data using hand−held tester, as freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, it is usefulfor determining whether the vehicle was running or stopped, the engine was warmed up or not, the air−fuel ratio was lean or rich, etc. at the time of the malfunction.

DI−23 DIAGNOSTICS

1

−

ENGINE

Check thlottle control motor circuit. Signal Waveform

10 V /Div.

GND

A09818

PREPARATION: (a) Connect the oscilloscope between terminals LU+A/LU− A/LU+B/LU−B and E01 of the engine ECU connector. (b) Start the engine. CHECK: Check the waveform between terminals LU+A/LU−A/LU+B/ LU−B and E01 of the engine ECU connector when the engine is racing. OK: Correct waveform is as shown. OK

Check and replace engine ECU.

NG

2

Check throttle control motor.

B12764

PREPARATION: Disconnect the throttle motor connector. CHECK: Measure the resistance between terminals 2 and 1/3 of S the throttle control motor. Measure the resistance between terminals 5 and 4/6 of S the throttle motor. OK: Resistance: 18 − 22 Ω NG

Replace throttle body assembly (See page ED−1).

OK

3

Check for open and short in harness and connector between throttle control motor and engine ECU.

NG

OK

Replace throttle position sensor.

DI−24 DIAGNOSTICS

Check and replace engine ECU.

−

ENGINE

DI−25 DIAGNOSTICS

−

ENGINE DI92G−01

DTC

18

Spill Control Circuit Malfunction

CIRCUIT DESCRIPTION See Pub. No. RM597E on page DI−23. DTC No. 18


Trouble Area

Open or short in spill control valve at 500 rpm or more

S Open or short in spill control valve circuit S Spill control valve S Engine ECU

WIRING DIAGRAM S11 Spill Control Valve 2

1

Engine ECU

L

12 SPV+ E10

B−W

25 SPV− E10

+B

E01

A04912


DI−26 DIAGNOSTICS

−

ENGINE DI92H−01

DTC

19 (1)

Accelerator Pedal Position Sensor circuit Malfunction (Open /Short)

CIRCUIT DESCRIPTION DTC No.


Trouble Area

Open or short in accelerator pedal position sensor circuit for 0.05 sec. or more

19 (1)


HINT: After confirming DTC 19 (1) use the hand−held tester to confirm the accelerator pedal opening percentage and accelerator pedal close position switch condition.

WIRING DIAGRAM

A28 Accelerator Pedal Position Sensor

Engine ECU

4

B−O

6 E5

VCC

5

B

5 E5

VA

1

B−Y

12 VAS E5

3

B−R

9 E5

2

W−B

4 E2C E5

BR

A

A29 Accelerator Pedal Closed Position Switch R−W 1 2

5V

+B

IDL +B E1

3 PDL E5

J7 J/C

ID

A15583


DI−27 DIAGNOSTICS

−

ENGINE DI92I−01

DTC

19 (2)

Accelerator Pedal Position Sensor Circuit Malfunction (IDL Switch/Range Malfunction)



Trouble Area

Conditions (a) or (b) continue 0.5 sec. or more: (a) IDL ON and VA > 1.4 (b) IDL ON and VAS >1.4 19(2)

Conditions (a) or (b) continue 0.05 sec. or more: (a) IDL OFF and VA< 0.6 (b) IDL OFF and VAS < 0.6 Conditions (a) and (b) continue 0.5 sec. or more: (a) 0.6 V < VA < 4.4 V and 0.6 V < VAS < 4.4 V (b) VA−VAS > 0.5

WIRING DIAGRAM See Pub. No. RM597E on page DI−40.



DI−28 DIAGNOSTICS

−

ENGINE DI92J−01

DTC

19 (3)

Accelerator Pedal Closed Position Switch Circuit Malfunction (Short)

DTC

19 (4)

Accelerator Pedal Closed Position Switch Circuit Malfunction (Open)

CIRCUIT DESCRIPTION See Pub. No. RM597E, DI−45. DTC No.


Trouble Area

19(3)

Conditions (a), (b) and (c) continue 0.5 sec. or more: (a) PDL ON (b) VA>1.4 (c) VAS>1.4

S Short in accelerator pedal closed position switch circuit S Accelerator pedal closed position switch S Engine ECU

19(4)

PDL does not turn ON even once while driving vehicle (2 trip detection logic)

S Open in accelerator pedal closed position switch circuit A l t pedal d l closed l d position iti switch it h S Accelerator S Engine ECU

WIRING DIAGRAM See Pub. No. RM597E, DI−45.

INSPECTION PROCEDURE See Pub. No. RM597E, DI−45.

DI−29 DIAGNOSTICS

−

ENGINE DI92K−01

DTC

22

Water Temp. Sensor Circuit Malfunction



Trouble Area

22

Open or short in water temp. sensor circuit for 0.5 sec. or more

S Open or short in water temp. sensor circuit S Water temp. sensor S Engine ECU

HINT: After confirming DTC22, use the hand−held tester to confirm the water temperature from the CURRENT DATA. Temperature displayed

Malfunction

−40˚C (−40˚F)

Open circuit

130˚C (266˚F) or more

Short circuit

WIRING DIAGRAM Engine ECU W2 Water Temp. Sensor

5V W−R 2 BR 1

4 THW E6 9 E6

R

E2 E1

A10940


DI−30 DIAGNOSTICS

−

ENGINE DI92L−01

DTC

24

Intake Air Temp. Sensor Circuit Malfunction



Trouble Area

24

Open or short in intake air temp. sensor circuit for 0.5 sec. or more

S Open or short in intake air temp. sensor circuit S Intake air temp. sensor S Engine ECU

HINT: After confirming DTC 24, use the hand−held tester to confirm the water temperature from the CURRENT DATA. Temperature Displayed

Malfunction

−40˚C(−40˚F)

Open circuit

130˚C(266˚F) or more

Short circuit


I9 Intake Air Temp. Sensor

5V Y−B

13 ED1

Y−B

3 THA E6

BR

12 ED1

BR

9 E2 E6

2

1

R

E1

A15414


DI−31 DIAGNOSTICS

−

ENGINE DI92M−01

DTC

32

Injection Pump Correction System Malfunction

CIRCUIT DESCRIPTION S S

See Pub. No. RM597E on page DI−53. The correction system is correcting a few vary between each injection pumps. DTC No. 32


Trouble Area S Injection pump correction unit circuit S Injection pump correction unit S Engine ECU

Injection pump correction unit circuit

WIRING DIAGRAM I15 Injection Pump Correction Unit

Engine ECU 5V 1

6 DATA E9

G

5V 4

14 CLK E9

R J5 J/C

2

BR

BR A

A EC

A04914


DI−32 DIAGNOSTICS

−

ENGINE DI92N−01

DTC

35

Vacuum Sensor Circuit Malfunction

CIRCUIT DESCRIPTION See Pub. No. RM597E on page DI−64. DTC No. 35


Trouble Area

Open or short in vacuum sensor circuit for 2 sec. or more.

S Open or short in vacuum sensor circuit S Vacuum sensor S Engine ECU

WIRING DIAGRAM Engine ECU V1 Vacuum Sensor Y

1 VC E6

LG−R

2 PIM E6

BR

9 E2 E6

3

2

1

5V

A05611


DI−33 DIAGNOSTICS

−

ENGINE DI92O−01

DTC

39

Fuel Temp. Sensor Circuit Malfunction

CIRCUIT DESCRIPTION See Pub.No. RM597E on page DI−71. DTC No.

DTC Detecting Condition

Trouble Area

39

Open or short in fuel temp. sensor circuit for 0.5 sec. or more

S Open or short in fuel temp. sensor circuit S Fuel temp. sensor S Engine ECU

WIRING DIAGRAM Engine ECU F23 Fuel Temp. Sensor

5V Y−R

5 THF E9

BR

9 E9

2

1

R

E2 E2

A10940

INSPECTION PROCEDURE See Pub.No. RM597E on page DI−71.

DI−34 DIAGNOSTICS

−

ENGINE DI92P−01

DTC

42

Vehicle Speed Sensor Signal Circuit Malfunction


42

DTC Detecting Condition

Trouble Area

All conditions below are detected continuously for 8 sec. or more: (a) Vehicle speed signal: 0 km/h (0 mph) (b) Engine speed: 2,000 − 3,300 rpm (c) Engine coolant temp.: 60˚C (176˚F) or more (d) Accelerator pedal opening angle : 45% or more (e) Diesel throttle opening angle : 60 % or more

S Open or short in vehicle speed sensor circuit S Vehicle speed sensor S Combination meter S Engine ECU

WIRING DIAGRAM

Engine ECU Combination Meter

5V 19 C6

SB

13 J35

J/C

13 J34

R−Y

9 SP1 E7

A15584


DI−35 DIAGNOSTICS

−

ENGINE DI92Q−01

ECU Power Source Circuit CIRCUIT DESCRIPTION See Pub. No. RM597E on page DI−83.

WIRING DIAGRAM I10 Ignition Switch

Instrument Panell J/B

5 4

2 1H

B

B−R 6

II2

R−W

2 5

ALT

R−W

14 IGSW E7

10 E7

BATT

Engine Room J/B 2

AM2

B−O

10 EC2

R−W

W−R 2

IGN

J2 J/C

Engine ECU

11 1C

2

1

EFI

B−O

2 EC2

B−O

3 MREL E7

B−R

7 ED1

B−R

12 +B E7

EFI Relay

3

2 2

2

2

BR

W−B J23 J/C Battery

A

A

W−B

A

A W−B EB

EA

14 E1 E10

J5 J/C

EC

A15581


DI−36 −

DIAGNOSTICS

ENGINE DI92R−01

Diagnostic Connector (DLC3) Circuit CIRCUIT DESCRIPTION See Pub. No. RM597E, on page DI−106.

WIRING DIAGRAM Ignition SW B−Y 2

1

Instrument Panel J/B 7 GAUGE Fuse 1 3K 3A

Combination Meter 4 3 SB C7 C7 CHECK ENGINE

1

II2 W 2

2

2 IJ

13 IH

L−Y

SB

D15 DLC3 L−Y

J35

BAT

J/C

R−Y

AM1

W−B A

ALT

J20 J/C

5 E7

W

CG TC

TAC

2

SIL Battery

Engine ECU

J34

Engine Room J/B

P−B

4 TC E7

G−B

7 E7 TAC

B

15 SIL E7

IF

A15578


DI−37 −

DIAGNOSTICS

ENGINE DI92S−01

Starter Signal Circuit Malfunction CIRCUIT DESCRIPTION See Pub. No. RM597E, on page DI−97.

WIRING DIAGRAM Driver Side J/B B−W

1 1H

Engine ECU 6 1C

ST

L−O

J6J/C C

I11 Ignition SW 5

4

3 IF3

L−O

C

C

B

11 E7

STA

B−R L−O

1

II2 B−R

Engine Room J/B

2

2 5 AM2

1

AM1 ST Relay

ALT 2

3

2

2 B

2

2 ED2

W−B A

J23J/C A

B B−R

1 EE1 B

Battry

1 1

S3

A W−B

W−B

S2 EA

EB

Starter A15579

INSPECTION PROCEDURE See Pub. No. RM597E, on page DI−97.

DI−38 DIAGNOSTICS

−

ENGINE DI92U−01

Pre−Heating Control Circuit CIRCUIT DESCRIPTION See Pub. No. RM597E, on page DI−87.

WIRING DIAGRAM

4 1H

Engine ECU

Combination Meter

Center J/B 23 1L

GAUGE

SB

GLOW

4 C7

9 C7

SB

5 J/C 5 J35 J34

P

1 E8

GIND

2 E7

SREL

B−Y Ignition SW 2

1

1 II2

W

W

V

5 EC2

V

Engine Room J/B 2

2B

AM1 ALT 2

4

1

3

Glow Plug relay

2

2

2 W A

1 ED2 G1 W Glow Plug 1

A

W−B J23 J/C A W−B

Battery

EB

W−B

EA

A15580

INSPECTION PROCEDURE See Pub. No. RM597E, on page DI−87.

DI−39 DIAGNOSTICS

−

ENGINE DI92V−01

A/C Signal Circuit CIRCUIT DESCRIPTION See Pub. No. RM597E, DI−100.

WIRING DIAGRAM Engine ECU A/C Amplifier 1 A10

O

3 IH2

Y−L

2 AC1 E5

A04922


DI−40 DIAGNOSTICS

−

ENGINE DI92W−01

A/C Cut Control Circuit CIRCUIT DESCRIPTION See Pub. No. RM597E, DI−103.

WIRING DIAGRAM A/C Amplifier Engine ECU

+B 7 A10

LG−B

2 IH2

LG−B

8 ACT E5

A04923


DI−41 −

DIAGNOSTICS

ENGINE DI92X−01

EGR Control Circuit CIRCUIT DESCRIPTION See Pub. No. RM597E, DI−93.


From Terminal 3 of EFI Relay (See page DI−35)

B−R

7 ED1

V11 VRV for EGR B−R 1

2

L−W

24 E10 EGR

A15582


ENGINE MECHANICAL IDLE SPEED AND MAXIMUM SPEED . . . . . .

EM−1

TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .

EM−2 EM−7

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . .

EM−11

EM−1 ENGINE MECHANICAL

−

IDLE SPEED AND MAXIMUM SPEED

IDLE SPEED AND MAXIMUM SPEED INSPECTION

Hand−held Tester

EM0QL−04

1. (a) (b) (c) (d) (e) (f) (g) (h)

INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All accessories switched OFF All vacuum lines properly connected ECD system warning connectors fully plugged Valve clearance set correctly Ignition timing check correctly

2. (a) (b)

CONNECT HAND−HELD TESTER Connect a hand−held tester to the DLC3. Please refer to the hand−held tester operator’s manual for further details.

DLC3 H11456

Tachometer

Battery

TAC

SST

DLC3 B13703

If you have no hand−held tester, connect a tachometer tester probe to terminal TAC of the DLC3 with SST. SST 09843−18040 3. INSPECT IDLE SPEED (a) Start the engine. (b) Check the idle speed. Idle speed: 700 − 800 rpm 4. INSPECT MAXIMUM SPEED (a) Start the engine. (b) Depress the accelerator pedal all the way. (c) Check the maximum speed. Maximum speed: 4,900 − 5,100 rpm 5. DISCONNECT HAND−HELD TESTER


−

TIMING BELT

TIMING BELT ON−VEHICLE INSPECTION

EM1O0−01

1. REMOVE FAN AND FLUID COUPLING ASSEMBLY Remove the 4 nuts, fan and fluid coupling assembly.

2. INSPECT FAN BRACKET Check that the fan bracket pulley turns smoothly. If necessary, replace the fan bracket.

A15388

3. INSPECT FLUID COUPLING Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. 4. REINSTALL FAN AND FLUID COUPLING ASSEMBLY Install the fan and fluid coupling assembly with the 4 nuts. Torque: 7.4 N·m (75 kgf·cm, 65 ft·lbf)

B09281


−

TIMING BELT

REMOVAL 1. (a) (b) (c) 2.

EM1O1−01

REMOVE GLOW PLUGS Remove the 2 bolts and No. 1 manifold stay. Remove the 4 grommets, 4 nuts and glow plug connector. Remove the 4 glow plugs. REMOVE DRIVE BELTS (See page CH−1)

3. REMOVE FAN AND FLUID COUPLING ASSEMBLY Remove the 4 nuts, fan and fluid coupling assembly.

B13731

4. (a)

REMOVE CRANKSHAFT PULLEY Using SST, remove the pulley bolt. SST 09213−54015 (09214−00021) x 2, 09330−00021

(b)

Using SST, remove the pulley. SST 09950−50010 (09951−05000, 09952−05010, 09953−05010, 09953−05020, 09954−05030)

SST

B13732

SST

B13733

5. REMOVE NO. 2 TIMING BELT COVER Remove the 5 bolts, 3 clips, timing belt cover and gasket.

A15390


−

TIMING BELT

6. REMOVE NO. 1 TIMING BELT COVER Remove the 5 bolts and timing belt cover.

A15391

7. REMOVE ALTERNATOR BRACKET Remove the 4 bolts and alternator bracket.

A15387

8. REMOVE FAN BRACKET Remove the 5 bolts and fan bracket.

A15392


TIMING BELT EM1O2−01

INSTALLATION

A B

−

C

C A

1. INSTALL FAN BRACKET Install the fan bracket with the 5 bolts. Torque: 63.7 N·m (650 kgf·cm, 47 ft·lbf) for bolt A 36.8 N·m (375 kgf·cm, 27 ft·lbf) for others HINT: Each length in indicated in the illustration.

A15392

Bolt A

35 mm (1.38 in.) length for 17 mm head

Bolt B


Bolt C


2. INSTALL ALTERNATOR BRACKET Install the alternator bracket with the 4 bolts. Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

A15387

3. (a)

Length = 880 mm (34.6 in.)

B04578

INSTALL NO. 1 TIMING BELT COVER Check that the timing belt cover gasket have cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps: Using a screwdriver and gasket scraper, remove all S the old gasket material. Thoroughly clean all components to remove all the S loose material. Remove the backing paper from a new gasket and S install the gasket evenly to the part of the timing belt cover shaded black in the illustration. After installing the gasket, press down on it so that S the adhesive firmly sticks to the timing belt cover. (b) Install the timing belt cover and gasket with the 5 bolts.


−

TIMING BELT

4. INSTALL NO. 2 TIMING BELT COVER Install the timing belt cover and gasket with the 5 bolts and 3 clips.

A15390

5. (a) (b) SST

6.

INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide the pulley to the crankshaft. Using SST, install the pulley bolt. SST 09213−54015 (91651−60855) x 2, 09330−00021 Torque: 145 N·m (1,480 kgf·cm, 107 ft·lbf) INSTALL DRIVE BELTS (See page CH−1)

A15393

B13731

7. INSTALL FAN AND FLUID COUPLING ASSEMBLY Install the fan and fluid coupling assembly with the 4 nuts. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) 8. INSTALL GLOW PLUGS (a) Install the 4 glow plugs. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (b) Install the glow plug connector with the 4 nuts and 4 grommets. Torque: 2.2 N·m (22 kgf·cm, 19 in.·lbf) (c) Install the No. 1 manifold stay with the 2 bolts. Torque: 18 N·m (185 kgf·cm, 15 ft·lbf)


−

CYLINDER HEAD

CYLINDER HEAD EM1O3−01

COMPONENTS Injection Pipe

Injection Pipe Clamp

18 (185, 13)


29.4(300,22)

29.4 (300, 22)

18 (185, 13)

No. 1 Manifold Stay

Grommet

Throttle Full Switch Connector

2.2 (22, 19 in.·lbf)

Throttle Control Motor Connector

Nozzle Leakage Pipe

E−VRV Connector for EGR

29.4 (300, 22)

z Gasket

7.4 (75, 65in.·lbf)

Throttle Body and Intake Flange Assembly

Glow Plug 13 (130, 9)

z Gasket Injection Nozzle

z Gasket

E−VRV for EGR

Glow Plug Connector

63.7 (650,47)

Nozzle Seat Fuel Return Hose

z Gasket z 24.5(250,17)

PCV Hose

EGR Valve and Pipe Assembly z Gasket

z 19 (195, 14)

Vacuum Hose 18 (185, 13)

No. 2 Manifold Stay

Water Bypass Hose and Pipe

18 (185, 13)

N·m (kgf·cm, ft·lbf) z Non−reusable part

: Specified torque A15576


−

CYLINDER HEAD

19 (195, 14)

Vacuum Pump z Gasket

No. 2 Timing Belt Cover

13.2 (135, 10)

Clip Oil Filler Cap

x 10 Cylinder Head Cover

Gasket Clip

Clip

Gasket

See pub. No. 597E, page EM−49 1st 59 (600, 44) 2nd Turn 90˚ 3rd Turn 90˚

Set Key

Cylinder Head Assembly

No. 1 Engine Hanger Camshaft Timing Pulley 88(900,65)

Tension Spring 36.8 (375, 27)

37 (380, 27)

Alternator Bracket

No. 3 Timing Belt Cover

Fan Bracket

7.4 (75, 65 in.·lbf)

z Cylinder Head Gasket

36.8(375,27)

63.7 (650, 47)

Fan Pulley Timing Belt Fan and Fluid Coupling Assembly No. 1 Timing Belt Cover x5 145(1,480,107)

Timing Belt Guide Crankshaft Pulley N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part

A15384


−

CYLINDER HEAD

Camshaft Bearing Cap

18 (185, 13)

Camshaft Set Key No. 1 Exhaust Manifold Heat Insulator

Adjusting Shim Valve Lifter

18 (185, 13)

18 (185, 13)

Keeper

7.4 (75, 65 in.·lbf)

Spring Retainer Valve Spring

Exhaust Manifold 46.5 (475, 34)

z

Spring Seat

z

z z

z Oil Nozzle

z

Water Outlet z Gasket

z Oil Seal

36.8 (375, 27)

z Oil Seal

18 (185, 13)

x6

z Gasket

z Gasket Camshaft Oil Seal Retainer

Water Bypass Outlet

Rear Engine Hanger

Water Bypass Union Water Bypass Hose Water Temperature Sender Gauge

36.8 (375, 27)

Cylinder Head 7.4 (75, 65 in.·lbf)

z Valve Guide Bushing Valve

7.4 (75, 65 in.·lbf)

No.1 Idler Pulley

z Gasket Intake Manifold

N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part

18 (185, 13) A15385


−

CYLINDER HEAD EM1O4−01

INSPECTION 1. (a) (b)

INSPECT CAMSHAFT FOR RUNOUT Place the camshaft on V−blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the camshaft.

EM0035

2. INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake

47.57 − 47.67 mm (1.8728 − 1.8768 in.)

Exhaust

48.30 − 48.40 mm (1.9016 − 1.9055 in.)

Minimum cam lobe height:

EM2011

Intake

46.90 mm (1.8465 in.)

Exhaust

47.85 mm (1.8839 in.)

If the cam lobe height is less than minimum, replace the camshaft. 3. Reference: INSPECT CAM LOBE FOR VACUUM PUMP Using a micrometer, measure the cam lobe height. Sranderd cam lobe height: 30.20 − 30.40 mm (1.1890 − 1.1968 in.)

4. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. Journal diameter: 27.979 − 27.995 mm (1.1015 − 1.1022 in.) If the journal diameter is not as specified, check the oil clearance.

EM2538


−

CYLINDER BLOCK

CYLINDER BLOCK EM0I5−02

COMPONENTS 18 (184, 13) 42 (428, 31)

88.2 (900, 65)

Exhaust Manifold No. 2 Heat Insulator

Oil Filter and Bracket Assembly

Rear End Plate

Flywheel

x8

36.8 (375, 27)

z Gasket

56.4 (575, 42)

z Gasket Water Pump

7.4(75,65in.·lbf)

z Gasket

z Gasket Check Valve 34 (350, 25)

31.4 (320, 23)

Water Temperature Sensor Crankshaft Position Sensor z Gasket

Key

7.4 (75, 65 in.·lbf)

Thermostat

31.4(320,23)

Water Inlet

Injection Pump 18 (185, 13) 64 (650, 47)

31.4(320,23)

Oil Pump z Crankshaft Front Oil Seal

x5

z Gasket

No. 2 Oil Pan

x2

31.4 (320, 23)

z Gasket

x7

12 (125, 8.9)

13.2 (135, 10)

Oil Strainer 18 (185, 13)

No.1 Oil Pan 12 (125, 8.9)

z Gasket N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part

Drain Plug 34.5(350,25)

x 22

12 (125, 8.9) A15273


−

CYLINDER BLOCK

No. 1 Piston Ring No. 2 Piston Ring Coil

Oil Ring

Piston z Snap Ring

z Snap Ring Piston Pin z Connecting Rod Bushing Connecting Rod

Connecting Rod Bearing

Connecting Rod Cap

Injection Pump Bracket

64 (650, 47)

Cylinder Block Oil Orifice

18 (185, 13)

7.8 (80, 69in.·lbf)

z Crankshaft Rear Oil Seal

Cylinder Block

Upper Crankshaft Thrust Washer Upper Main Bearing

x6 Rear Oil Seal Retainer Oil Nozzle 7.4 (75, 65 in.·lbf)

Crankshaft Lower Main Bearing Lower Crankshaft Thrust Washer


Lower Crankshaft Thrust Washer Main Bearing Cap

115 (1,170, 85) A15272


−

CYLINDER BLOCK EM1O5−01

INSPECTION

Mark 1, 2 or 3 No. 3

1. INSPECT CYLINDER BORE DIAMETER HINT: There are 3 sizes of the standard cylinder bore diameter, marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the top or under of the cylinder block.

No. 4

No. 2 No. 1

No. 4

S02236 S02239

Mark 1, 2 or 3

Front

No. 1

A04898

(1) (2)

A B C EM0086 EM0365

No. 3 No. 2

(1) Thrust Direction (2) Axial Direction 15 mm (0.59in.) Middle 10 mm (0.39in.) A04899

Using a cylinder gauge, measurer the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 86.000 − 86.030 mm (3.3858 − 3.3870 in.) Mark 1

86.000 − 86.010 mm (3.3858 − 3.3862 in.)

Mark 2

86.010 − 86.020 mm (3.3862 − 3.3866 in.)

Mark 3

86.020 − 86.030 mm (3.3866 − 3.3870 in.)

Maximum diameter: STD

86.23 mm (3.3949 in.)

O/S 0.50

86.73 mm (3.4146 in.)

If the diameter is greater than maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.


Front Mark (Cavity)

42.4 mm A04672

−

CYLINDER BLOCK

2. INSPECT PISTON DIAMETER AND OIL CLEARANCE HINT: There are 3 sizes of the standard piston diameter, marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the piston top. (a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line 42.4 mm (1.6693 in.) form the piston head. Piston diameter: STD

Mark 1 Mark 2 Mark 3 O/S 0.50

No. 2

No. 3

No. 4

No. 4

Front Mark (Cavity) S02236 S02239 A05008

86.375 − 86.405 mm (3.4006 − 3.4018 in.)

(b)

Mark 1, 2 or 3 No. 1

85.875 − 85.885 mm (3.3809 −3.3813 in.) 85.885 − 85.895 mm (3.3813 − 3.3817 in.) 85.895 − 85.905 mm (3.3817 − 3.3821 in.)

No. 3 No. 1 No. 2 Mark 1, 2 or 3

Measure the cylinder bore diameter in the thrust directions (See step 1). (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.115 − 0.135 mm (0.0045 − 0.0053 in.) Maximum oil clearance: 0.15 mm (0.0059 in.) If the oil clearance is greater than maximum replace all the 4 pistons and rebore all the 4 cylinders. If necessary, replace the cylinder block. HINT: (Use new cylinder block) Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block.

A04974

No. 1 Ring

EM5681

3. INSPECT PISTON RING GROOVE CLEARANCE No.1 Ring: Install a new piston ring to the piston. Using a feeler gauge, measure the clearance between the piston ring and the wall of the ring groove. Standard groove clearance: 0.061 − 0.104 mm (0.0024 − 0.0041 in.) Maximum groove clearance: 0.20 mm (0.0079 in.) If the clearance is greater than maximum, replace the piston.


−

CYLINDER BLOCK

No. 2 and Oil Rings: Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Standard groove clearance:

No. 2 and Oil Rings

EM5553

No. 2

0.070 − 0.110 mm (0.0028 − 0.0043 in.)

Oil

0.030 − 0.070 mm (0.0012 − 0.0028 in.)

Maximum groove clearance: 0.20 mm (0.0079 in.) If the clearance is greater than maximum, replace the piston. 4. INSPECT PISTON RING END GAP (a) Insert the piston ring into the cylinder bore. (b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block.

120 mm

S04423

(c)

Using a feeler gauge, measure the end gap. Standard end gap: No. 1

0.270 − 0.390 mm (0.0106 − 0.0150 in.)

No. 2

0.400 − 0.550 mm (0.0157 − 0.0217 in.)

Oil

0.200 − 0.520 mm (0.0079 − 0.0157 in.)

Maximum end gap:

EM7639

No.1

0.990 mm (0.0390 in.)

No.2

1.150 mm (0.0452 in.)

Oil

1.120 mm (0.0315 in.)

If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block.

EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRAWING . . . . . . . . . . . . . . . . . EXHAUST GAS RECIRCULATION

EC−1

(EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .

EC−3

EC−1 EMISSION CONTROL

−

PARTS LAYOUT AND SCHEMATIC DRAWING

PARTS LAYOUT AND SCHEMATIC DRAWING EC0IQ−02

LOCATION

Throttle Body Accelerator Pedal Position Sensor

Intake Air Pressure Sensor

Vacuum Pump

Intake Air Temp. Sensor

E−VRV for EGR EGR Pipe

Engine ECU

Engine Speed Sensor

EGR Valve Water Temp. Sensor

B13742


−

PARTS LAYOUT AND SCHEMATIC DRAWING EC09B−05

DRAWING

Vacuum Pump

Throttle Body

Vacuum Damper

E−VRV for EGR

EGR Valve

Engine Speed Sensor

Injection Pump

Accelerator Pedal Position Sensor

Engine ECU

Water Temperature Sensor

Intake Air Temperature Sensor

Intake Air Pressure Sensor

B13704


−

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC0JH−01

COMPONENTS

19 (195, 14)


z Gasket

z Gasket

Vacuum Hose (from R−VRV for EGR)

EGR Valve

93 (950, 69)

EGR Pipe

24.5 (250, 18)

: Specified torque B13682


−


INSPECTION

EC0JI−01

HINT: In a malfunction where the EGR system is always on, black smoke or white smoke may be output from the exhaust pipe. If this occurs, inspect the EGR system also. NOTICE: Always stop the engine when installing or removing the vacuum gauges, or removing the vacuum hoses. Vacuum Gauge

1. (a) (b) (c)

(d) B13677

(e)

(f)

2.

INSPECT EGR SYSTEM Install the vacuum gauge. Using a 3 way connector, connect a vacuum gauge to the hose between the EGR valve and E−VRV. Inspect the seating of EGR valve. Start the engine and check that the engine starts and run at idle. Inspect the cold engine condition. (1) The coolant temperature should be below 55˚C (99˚F). (2) Check that the vacuum gauge indicates 0 at idle. Inspect the hot engine condition. (1) Warm up the engine, the coolant temperature should be above 70˚C (104˚F). (2) Check that the vacuum gauge indicates about 40.0 kPa (300 mmHg, 11.8 in.Hg) at idle. (3) Check that the vacuum gauge indicates about more than 20 kPa (150 mm Hg, 5.9 in.Hg) at 1,500 rpm. (4) When the accelerator pedal is quickly depress to the full open, check that the vacuum gauge indicator drops momentarily. (5) Keep the engine speed at more than 4,600 rpm. (6) Check that the vacuum gauge indicates 0. (7) When the accelerator pedal is releaced, check that the vacuum gauge indicator drops momentarily while the engine speed decreases from more than 4,000 rpm to idle. Remove the vacuum gauge.

CHECK VACUUM PUMP (1) Disconnect the vacuum hose from the outlet pipe. (2) Connect a vacuum gauge to the output pipe. (3) Warm up the engine and check that the vacuum gauge indicates above 86.7 kPa (650 mmHg, 25.59 in.Hg). (4) Reconnect the vacuum hose to the outlet pipe. If a problem is found, repair the vacuum pump.

Vacuum Gauge

Disconnect

B13678


3. (a) (b)

B13679

(c)

−


INSPECT EGR VALVE Remove the EGR valve. Under the condition of applying the vacuum to the diaphragm chamber, check the valve operation. Vacuum

EGR Valve

Less than 13 kPa (100 mmHg, 3.8 in.Hg)

Closed

More than 27 kPa (200 mmHg, 8.0 in.Hg)

Open

When applying more than 67 kPa (500 mmHg, 19 in.Hg) of the vacuum, check if there is any leakage of the vacuum. (d) Check the valve for sticking and heavy carbon deposits. If a problem is found, replace it. (e) Reinstall the EGR valve. 4. INSPECT E−VRV FOR EGR (See page ED−10) 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR (See page ED−17) 6. INSPECT ENGINE SPEED SENSOR (See page ED−15) 7. INSPECT INTAKE AIR TEMPERATURE SENSOR (See page ED−12) 8. INSPECT WATER TEMPERATURE SENSOR (See Pub. No. RM597E, page ED−10) 9. INSPECT INTAKE AIR PRESSURE SENSOR (See page ED−13) 10. INSPECT ENGINE ECU (See page DI−15)

ELECTRONIC CONTROL DIESEL THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . .

ED−1

TIMING CONTROL VALVE . . . . . . . . . . . . . . . . SPILL CONTROL VALVE . . . . . . . . . . . . . . . . . .

ED−6 ED−7

EFI MAIN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . E−VRV FOR EGR . . . . . . . . . . . . . . . . . . . . . . . .

ED−8 ED−9

FUEL TEMPERATURE SENSOR . . . . . . . . . . . INTAKE AIR TEMPERATURE SENSOR . . . . .

ED−11 ED−12

INTAKE AIR PRESSURE SENSOR . . . . . . . . .

ED−13

ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . ACCELERATOR PEDAL

ED−15

POSITION SENSOR . . . . . . . . . . . . . . . . . . . . ACCELERATOR PEDAL

ED−16

CLOSED POSITION SWITCH . . . . . . . . . . . . INJECTION PUMP CORRECTION UNIT . . . .

ED−18 ED−19

ENGINE ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ED−20

ED−1 ELECTRONIC CONTROL DIESEL

−

THROTTLE BODY

THROTTLE BODY

Ohmmeter

ED04P−01

ON−VEHICLE INSPECTION 1. (a) (b)

B13632

INSPECT THROTTLE FULL SWITCH Disconnect the switch connector. Using an ohmmeter, check the continuity between the terminals. Continuity: Throttle Valve

Continuity

Fully closed

No continuity

Fully open

Continuity

If the continuity is not as specified, replace the throttle body (See page ED−4). (c) Reconnect the switch connector.

2. (a)

INSPECT THROTTLE CONTROL MOTOR OPERATION Initial conditions. (1) Warm up the engine, the coolant temperature should be above 70˚C (158˚F) and below 105˚C (217˚F). (2) The intake air temperature should be above 10˚C (54˚F) and below 65˚C (145˚F). (3) Starter is off. (b) When the engine is idling, check that the throttle lever is in a place of approximately 5 mm (0.20 in.) away from stopper (A). (c) When the accelerator pedal is quickly depressed to the full open, check that the throttle lever is in a place around stopper (B). (d) When the engine is stopped, check that the throttle lever once returns to stopper (A). If the continuity is not as operate, replace the throttle body (See page ED−4).

5 mm (b) (A)

(c) (B)

(d) (A)

B13735


−

THROTTLE BODY

3. 3 2 1 6 5 4

Ohmmeter

B13633

INSPECT THROTTLE CONTROL MOTOR RESISTANCE NOTICE: ”Cold” and ”Hot” in the following sentences express the temperature of the coils themselves. ”Cold” is from −10˚C (14˚F) to 50˚C (122˚F) and ”Hot” is from 50˚C (122˚F) to 100˚C (212˚F). (a) Disconnect the motor connector. (b) Using an ohmmeter, measure the resistance between terminals 2 and 1/3, and 5 and4/6. Resistance: Cold

23 − 33 Ω

Hot

29 − 39 Ω

If the resistance is not as specified, replace the throttle body (See page ED−4). (c) Reconnect the motor connector.


−

THROTTLE BODY ED04Q−01

COMPONENTS


18 (185, 15)

Water Bypass Hose

Throttle Body



z Gasket

B13683


−

THROTTLE BODY

REMOVAL REMOVE THROTTLE BODY (a) Disconnect the throttle control motor connector. (b) Disconnect the throttle full switch connector. (c) Disconnect the 2 water bypass hoses.

(d)

B13635

Remove the 4 bolts, throttle body and gasket.

ED04R−01


−

THROTTLE BODY

INSTALLATION

ED04S−01

INSTALL THROTTLE BODY (a) Install a new gasket to the throttle body as shown in the illustration.

B13636

(b) (c) (d) (e)

B13635

Install the throttle body with the 4 bolts. Torque: 18 N·m (185 kgf·cm, 15 ft·lbf) Connect the 2 water bypass hoses. Connect the throttle full switch connector. Connect the throttle control motor connector.


−

TIMING CONTROL VALVE

TIMING CONTROL VALVE Ohmmeter

B13666

INSPECTION

INSPECT TIMING CONTROL VALVE (a) Disconnect the valve connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: 10 − 14 Ω at 20˚C (68˚F) If the resistance is not specified, replace the valve. (c)

TCV Battery +B

B13667

ED03V−02

Inspect the valve solenoid operation. (1) Connect the battery positive (+) the terminal to the valve terminal +B. (2) Connect the battery negative (−) terminal to the valve terminal TCV. (3) Check that the solenoid makes a ”clicks” sound. If the operation is not as specified, replace the valve. NOTICE: Do not apply voltage for more than 30 seconds to S avoid burning out the solenoid. If repeating this step, wait until the solenoid coils beS come cool enough that it can be touched by hand. (d) Reconnect the valve connector.


−

SPILL CONTROL VALVE

SPILL CONTROL VALVE Ohmmeter

B13668

INSPECTION

ED02U−04

INSPECT SPILL CONTROL VALVE (a) Disconnect the valve connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: 1 − 2 Ω at 20˚C (68˚F) If the resistance is not specified, replace the injection pump assembly (See page FU−13). (c) Reconnect the valve connector.


−

EFI MAIN RELAY

EFI MAIN RELAY INSPECTION

EFI Main Relay

1.

ED04W−01

REMOVE EFI MAIN RELAY (Marking: EFI)

B07523

Continuity Ohmmeter

Ohmmeter 1

2 5 3

2. (a)

INSPECT EFI MAIN RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.

No Continuity

S04947

1

2

Ohmmeter 5

3 Battery

Continuity

S04946

3. (a) (b)

INSPECT EFI MAIN RELAY OPERATION Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL EFI MAIN RELAY


−

E−VRV FOR EGR

E−VRV FOR EGR ED04T−01

COMPONENTS

z Gasket

Vacuum Hose (from Vacuum Pump) E−VRV Connector for EGR

Vacuum Hose (from EGR Valve)

7.4 (75, 65 in.·lbf)

E−VRV for EGR

EGR Valve

19(195,14)

Electric EGR Control Valve Assembly

19(195,14)


: Specified torque B13684


−

E−VRV FOR EGR

INSPECTION

Ohmmeter

Continuity B13699

ED04U−01

HINT: When the E−VRV malfunctions, replace the E−VRV together with EGR valve and hose. 1. INSPECT E−VRV (a) Inspect the E−VRV for open circuit. Using an ohmmeter, check that there is continuity between the terminals. Resistance: 11 − 13 Ω at 20˚C (68˚F) If there is no continuity, replace the electric EGR control valve assembly.

(b)

Inspect the E−VRV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the electric EGR control valve assembly.

Ohmmeter

No Continuity B13700

(c)

Inspect the E−VRV for air tightness. Check that when vacuum is applied to the vacuum outlet port shown, the needle of the vacuum pump indicates an increase of 47 kPa (350 mmHg, 13.9 in.Hg) or more. If a problem is found, replace the electric EGR control valve assembly.

Vacuum

B13701

(d) Vacuum 6V

B13702

Inspect the E−VRV operation. (1) Apply about 6 V of DC power to the terminals. (2) Check that when vacuum is applied to the vacuum outlet port shown, the needle of the vacuum pump does not move. If the operation is not as specified, replace the electric EGR control valve assembly. 2. REINSTALL E−VRV Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)


−

FUEL TEMPERATURE SENSOR

FUEL TEMPERATURE SENSOR INSPECTION 1. (a) (b)

ED040−02

REMOVE FUEL TEMPERATURE SENSOR Disconnect the sensor connector. Using a 19 mm deep socket wrench, remove the sensor and O−ring.

B13669

2. INSPECT FUEL TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the sensor. 3. REINSTALL FUEL TEMPERATURE SENSOR (a) Install a new O−ring to the sensor. (b) Using a 19 mm deep socket wrench, install the sensor. Torque: 21.6 N·m (220 kgf·cm, 16 ft·lbf) (c) Connect the sensor connector.

Ohmmeter

Resistance kΩ

30 20 10 5

Acceptable

3 2 1 0.5 0.3 0.2 0.1 −20 0

S01196 S01699

20 40 60 80 100

(−4) (32) (68) (104) (140)(176) (212)

Temperature ˚C (˚F)

Z17274


−

INTAKE AIR TEMPERATURE SENSOR

INTAKE AIR TEMPERATURE SENSOR INSPECTION 1. (a) (b)

ED04V−01

REMOVE INTAKE AIR TEMPERATURE SENSOR Disconnect the sensor connector. Remove the sensor.

B13706

2. INSPECT INTAKE AIR TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the sensor. Connect the sensor connector. 3. REINSTALL INTAKE AIR TEMPERATURE SENSOR

Ohmmeter

Resistance kΩ

30 20 10 5 3 2

Acceptable

1 0.5 0.3 0.2 0.1 −20 0 20 40 60 80 100 (−4) (32) (68) (104)(140)(176)(212)

Temperature ˚C (˚F) Z17273


Voltmeter

−

INTAKE AIR PRESSURE SENSOR


ED04N−02

INSPECTION 1. E2

(a) (b) (c)

Disconnect VC B13738

(d) (e)

2.

PIM

(a) (b) (c)

Voltmeter E2

(d)

(e)

Disconnect

Vacuum B13739

INSPECT POWER SOURCE VOLTAGE OF INTAKE AIR PRESSURE SENSOR Disconnect the intake air pressure sensor connector. Turn the ignition switch ON. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.75 − 5.25 V Turn the ignition switch OFF. Reconnect the intake air pressure sensor connector.

INSPECT SUPPLY POWER OF INTAKE AIR PRESSURE SENSOR Turn the ignition switch ON. Disconnect the vacuum hose from the intake air pressure sensor. Connect a voltmeter to terminals PIM and E2 of the engine ECU, and measure the output voltage under ambient atmospheric pressure. Apply vacuum to the intake air pressure sensor in 13.3 kPa (100 mmHg, 3.94 in.Hg) segments to 40.0 kPa (300 mmHg, 11.81 in.Hg). Measure the voltage drop from step (c) above for each segment. Voltage drop: Applied vacuum kPa (mmHg, in.Hg)

Voltage drop V

13.3 (100, 3.94)

0.3 − 0.5

26.7 (200, 7.87)

0.6 − 0.8

40.0 (300, 11.81)

0.95 − 1.15


(f)

PIM

(g)

Voltmeter E2

Disconnect

(h) Pressure B13740

−


Using SST (turbocharger pressure gauge), apply pressure to the intake air pressure sensor in 19.6 kPa (0.20 kgf/cm2, 2.84 psi) segments to 98.0 kPa (1.00 kgf/cm2, 14.2 psi). SST 09992−00241 Measure the voltage up from step (c) above for each segment. Voltage up: Applied pressure kPa (kgf/cm2, psi)

Voltage up V

19.6 (0.20, 2.84)

0.4 − 0.7

39.2 (0.40, 5.69)

0.8 − 1.2

58.8 (0.60, 8.53)

1.4 − 1.8

78.5 (0.80, 11.4)

2.0 − 2.3

98.0 (1.00, 14.2)

2.5 − 2.8

Reconnect the vacuum hose to the intake air pressure sensor.


−

ENGINE SPEED SENSOR

ENGINE SPEED SENSOR Ohmmeter

B13670

INSPECTION

ED03F−04

INSPECT ENGINE SPEED SENSOR (a) Disconnect the sensor connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: 205 − 255 Ω at 20˚C (68˚F) If the resistance is not specified, replace the injection pump assembly (See page FU−13). (c) Reconnect the sensor connector.


−

ACCELERATOR PEDAL POSITION SENSOR

ACCELERATOR PEDAL POSITION SENSOR COMPONENTS

ED043−02

Accelerator Pedal Position Sensor

Accelerator Pedal Position Sensor Connector Accelerator Pedal Closed Position Switch Connector

N·m (kgf·cm, ft·lbf) : Specified torque

Accelerator Pedal Assembly

B13716


−

ACCELERATOR PEDAL POSITION SENSOR

INSPECTION INSPECT ACCELERATOR PEDAL POSITION SENSOR (See pub. No. RM597E, page DI−33) If necessary, replace the accelerator pedal assembly.

ED037−04


−

ACCELERATOR PEDAL CLOSED POSITION SWITCH

ACCELERATOR PEDAL CLOSED POSITION SWITCH

Ohmmeter

ED038−05

INSPECTION

2 1

Depressed

Released

B13717

INSPECT ACCELERATOR PEDAL CLOSED POSITION SWITCH (a) Disconnect the switch connector. (b) Using an ohmmeter, check the continuity between the terminals. Continuity: Accelerator Pedal

Continuity

Released

Continuity (0 − 20 Ω)

Depressed

No continuity

If the continuity is not as specified, replace the accelerator pedal assembly (See page ED−16). (c) Reconnect the switch connector.


−

INJECTION PUMP CORRECTION UNIT

INJECTION PUMP CORRECTION UNIT INSPECTION

Correction Unit

ED03B−04

INSPECT INJECTION PUMP CORRECTION UNIT (See pub. No. RM597E, DI−60) If necessary, replace the injection pump assembly (See page FU−13). B13671


−

ENGINE ECU

ENGINE ECU FI0JB−07

COMPONENTS

Cowl Side Trim

Front Door Scuff Plate

Engine ECU x5

Engine ECU Connector B13779


INSPECTION INSPECT ENGINE ECU (See page DI−15)

−

ENGINE ECU FI0JC−03

ENGINE FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . .

FU−1

INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . .

FU−10

FU−1 ENGINE FUEL

−

INJECTION NOZZLE

INJECTION NOZZLE FU00P−03

COMPONENTS Injection Pipe


18 (185, 13)


29.4(300,22)

29.4 (300, 22)

18 (185, 13)

No. 1 Manifold Stay

Grommet


2.2 (22, 19 in.·lbf)


29.4 (300, 22)

z Gasket

E−VRV Connector for EGR 7.4 (75, 65 in.·lbf)

E−VRV for EGR

Glow Plug Connector Nozzle Leakage Pipe


z Gasket

Injection Nozzle 63.7 (650,47)

Nozzle Seat z Gasket

z Gasket

z

24.5 (250, 17)

EGR Valve and Pipe Assembly z Gasket

z 19 (195, 14)

Vacuum Hose 18 (185, 13)

No. 2 Manifold Stay


18 (185, 13)


B13718

FU−2 ENGINE FUEL

−

INJECTION NOZZLE

Nozzle Holder Body 46.58 (475,42)

Pressure Spring

Distance Piece Nozzle Holder Retaining Nut

Adjusting Shim

Pressure Pin

Nozzle Assembly

N·m (kgf·cm, ft·lbf) : Specified torque

B13798

FU−3 ENGINE FUEL

−

INJECTION NOZZLE

REMOVAL 1.

3.

REMOVE EGR VALVE AND PIPE ASSEMBLY (See page EM−7) REMOVE THROTTLE BODY AND INTAKE FLANGE ASSEMBLY (See page EM−7) DISCONNECT E−VRV for EGR (See page ED−9)

4. (a) (b) (c)

REMOVE INJECTION PIPE Remove the 2 nuts and injection pipe clamp (outside). Loosen the 8 union nuts, remove the 4 injection pipes. Remove the injection pipe clamp (inside).

5. (a) (b)

REMOVE GLOW PLUG CONNECTOR Remove the 4 grommets. Remove the 4 nuts and glow plug connector.

6. (a) (b)

REMOVE NOZZLE LEAKAGE PIPE Disconnect the fuel return hose from the leakage pipe. Remove the 4 nuts, leakage pipe and 4 gaskets.

2.

FU00Q−02

B13727

B13729

B13728

7. REMOVE INJECTION NOZZLES Using SST, remove the 4 injection nozzles, 4 seats and 4 gaskets. SST 09268−64010 (09268−64020) HINT: Arrange the injection nozzles in correct order.

SST

B13726

FU−4 ENGINE FUEL

−

INJECTION NOZZLE

DISASSEMBLY

SST

FU1348

FU00R−03

DISASSEMBLE INJECTION NOZZLES (a) Using SST, remove the nozzle holder body. SST 09268−64010 (09268−64020, 09268−64030) NOTICE: When disassembling the nozzle, be careful not to drop the inner parts. (b) Remove the pressure spring, shim, pressure pin, distance piece and the nozzle assembly.

FU−5 ENGINE FUEL

−

INJECTION NOZZLE

INSPECTION 1. (a)

FU00S−03

NOZZLE CLEANING To wash the nozzles, use a wooden stick and brass brush. Wash them in clean diesel fuel.

HINT: Do not touch the nozzle mating surface with your fingers.

(b)

Using a wooden stick, remove the carbon adhering to the nozzle needle tip.

FU1349

(c)

Using a brass brush, remove the carbon from the exterior of the nozzle body (except lapped surface). (d) Check the seat of the nozzle body for burns or corrosion. (e) Check the nozzle needle tip for damage or corrosion. If any of these conditions are present, replace the nozzle assembly.

FU1350

2. INSPECT NOZZLE ASSEMBLY (a) Wash the nozzle in clean diesel fuel. HINT: Do not touch the nozzle mating surface with your fingers. (b) Tilt the nozzle body about 60 degrees and pull the needle out about one third of its length.

One third of its length

About 60 degrees FU1351

(c)

When released, the needle should sink down into the body vent smoothly by its own weight. (d) Repeat this test, rotating the needle slightly each time. If the needle does not sink freely, replace the nozzle assembly.

FU1352

FU−6 ENGINE FUEL

−

INJECTION NOZZLE

REASSEMBLY 1. (a)

SST

FU1353

FU00T−03

ASSEMBLE INJECTION NOZZLE HOLDERS Assemble the nozzle holder retaining nut, the nozzle assembly, distance piece, pressure pin, pressure spring, adjusting shim and nozzle holder body, and finger tighten the retaining nut. (b) Using SST, tighten the nozzle holder body. SST 09268−64010 (09268−64020, 09268−64030) Torque: 46.58 N·m (475 kgf·cm, 42 ft·lbf) NOTICE: Over torquing could cause nozzle deformation and needle adhesion or other defects. 2. PERFORM PRESSURE AND SPRAY PATTERN TEST (See page FU−7)

FU−7 ENGINE FUEL

−

INJECTION NOZZLE FU00U−04

TEST 1. (a)

FU2702

FU2728

INJECTION PRESSURE TEST Install the injection nozzle to the injection nozzle hand tester and bleed air from the union nut. CAUTION: Do not plate your finger over the nozzle injection hole. (b) Pump the tester handle a few times as fast as possible to discharge the carbon from the injection hole. (c) Pump the tester handle slowly and observe the pressure gauge. (d) Read the pressure gauge just as the injection pressure begins to drop. Opening pressure: New nozzle

14,710 − 15,690 kPa (150 − 160 kgf·cm2, 2,133 − 2,276 psi)

Reused nozzle

13,238 − 15,690 kPa (135 − 160 kgf·cm2, 1,920 − 2,276 psi)

HINT: Proper nozzle operation can be determined by a switching sound. If the opening pressure is not as specified, disassemble the nozzle holder and change the adjusting shim on the top of the pressure spring. Adjusting opening pressure 13,729 − 15,690 kPa (140 − 160 kgf·cm2, 1,991 − 2,276 psi) Adjusting shim thickness: 0.900(0.0354)

1.300(0.0512)

1.700(0.0669)

0.950(0.0374)

1.350(0.0531)

1.750(0.0689)

1.000(0.0394)

1.400(0.0551)

1.800(0.0709)

1.050(0.0413)

1.450(0.0571)

1.850(0.0728)

1.100(0.0433)

1.500(0.0591)

1.900(0.0748)

1.150(0.0453)

1.550(0.0610)

1.950(0.0768)

1.200(0.0472)

1.600(0.0630)

−

1.250(0.0492)

1.650(0.0650)

−

HINT: S

S

(e)

Varying the adjusting shim thickness by 0.05 mm (0.0020 in.) changes the injection pressure by about 951 kPa (9.7 kgf·cm2, 138 psi) Only one adjusting shim should be used. There should be dripping after injection.

FU−8 ENGINE FUEL

Good

−

INJECTION NOZZLE

2. LEAKAGE TEST While maintaining pressure at about 981 − 1,961 kPa (10 − 20 kgf·cm2, 142 − 284 psi) below opening pressure (adjust by tester handle), check that there is no dripping for 10 seconds from the injection hole or around the retaining nut. If the nozzle drips with in 10 seconds, replace or clean and overhaul the nozzle assembly.

Faulty FU1347

3. (a)

SPRAY PATTERN TEST The injection nozzle should shudder at a certain pumping speed between 15 − 60 times (old nozzle) or 30 − 60 times (new nozzle) per minute. (b) Check the spray pattern during shuddering. If the spray pattern is not correct during shuddering, the nozzle must be replaced or cleaned. Good

Faulty

FU1481

FU−9 ENGINE FUEL

−

INJECTION NOZZLE

INSTALLATION

SST

FU00V−02

1. (a)

B13726

INSTALL INJECTION NOZZLES Place 4 new gaskets and the 4 nozzle seats into the injection nozzle holes of the cylinder head. (b) Using SST, install the 4 injection nozzles. SST 09268−64010 (09268−64020) Torque: 63.7 N·m (650 kgf·cm, 47 ft·lbf) NOTICE: Over torquing could cause nozzle deformation and needle adhesion or other defects.

2. (a) (b)

INSTALL NOZZLE LEAKAGE PIPE Install 4 new gaskets and the leakage pipe with the 4 nuts. Torque: 29.4 N·m (300 kgf·cm, 22 ft·lbf) Connect the fuel return hose to the leakage pipe.

B13728

3. (a) (b)

INSTALL GLOW PLUG CONNECTOR Install the glow plug connector with the 4 nuts. Torque: 2.2 N·m (22 kgf·cm, 19 in.·lbf) Install the 4 grommets.

B13729

4. (a) (b) (c) 5. 6. B13727

7.

INSTALL INJECTION PIPES Install the injection pipe clamp to the intake manifold. Install the 4 injection pipes. Torque: 29.4 N·m (300 kgf·cm, 22 ft·lbf) Install the injection pipe clamp with the 2 nuts. CONNECT E−VRV for EGR (See page ED−9) INSTALL THROTTLE BODY AND INTAKE FLANGE ASSEMBLY (See page EM−7) INSTALL EGR VALVE AND PIPE ASSEMBLY (See page EM−7)

FU−10 ENGINE FUEL

−

INJECTION PUMP

INJECTION PUMP ON−VEHICLE INSPECTION 1. 2. 3. 4.

INSPECT ENGINE SPEED SENSOR (See page ED−15) INSPECT SPILL CONTROL VALVE (See page ED−7) INSPECT INJECTION PUMP CORRECTION UNIT (See pub. No. RM597E, page DI−60) INSPECT TIMING CONTROL VALVE (See page ED−6)

FU06Y−03

FU−11 ENGINE FUEL

−

INJECTION PUMP FU03P−04

COMPONENTS Injection Pipe Clamp

Injection Pipe

Injection Pipe Clamp 29.4 (300, 22)

z Gasket Clamp

29.4 (300, 22)


18 (185, 13)

18 (185, 13)

No. 1 Manifold Stay Throttle Control Motor Connector

Clamp No. 2 Timing Belt Cover

18 (185, 13)


Clip


37 (380, 27)

Alternator Bracket

z Gasket z Gasket

19 (195, 14)

z Gasket

7.4 (75, 65 in.·lbf) 36.8 (375, 27)

Vacuum Hose

24.5 (250,18)

EGR Valve and Pipe Assembly

Fan Bracket

Injection Pump Fan Pulley

63.7 (650, 47)

18 (185, 13)

Timing Belt Fan and Fluid Coupling Assembly x5

18 (185, 13)

Spill Control Valve Connector

Timing Belt Guide

Engine Speed Sensor Connector Injection Pump Correction Unit Connector

No. 1 Timing Belt Cover Crankshaft Pulley 145 (1,480, 107)

64 (650, 47)

N·m (kgf·cm, ft·lbf) : Specified torque z Non reusable part

No. 2 Manifold Stay

Injection Pump Drive Pulley

Fuel Temp. Sensor Connector

Timing Control Valve Connector B13723

FU−12 ENGINE FUEL

−

INJECTION PUMP

Fuel Inlet Hollow Screw 36.8 (375, 27)

26.5 (270, 20)

Cap Nut z Gasket

Injection Pump Stay

Fuel Inlet Pipe

24.5 (250, 18)

Overflow Screw

z Gasket

z Gasket

z O−Ring

z Gasket

88 (900, 65)

Distributive Head Plug

Fuel Outlet Pipe z Gasket Spill Control Valve

58.85 (600,43)

Delivery Valve Holder

z Gasket Engine Speed Sensor

Delivery Valve

Spring

z O−Ring

Injection Pump

Injection Pump Correction Unit

z O−Ring

Timing Control Valve

z O−Ring Fuel Temp. Sensor 21.6 (220, 16)

N·m (kgf·cm, ft·lbf) : Specified torque z Non reusable part

B13715 B1

FU−13 ENGINE FUEL

−

INJECTION PUMP

REMOVAL 1. 2.

(g)

(a) (h)

(c) (e) (d) (f)

B13741

FU09B−01

3.

REMOVE TIMING BELT (See page EM−3) REMOVE INJECTION PUMP DRIVE PULLEY (See pub. No. RM597E, page EM−14) REMOVE INJECTION PIPES (See page FU−3)

4. (a) (b) (c) (d) (e) (f) (g) (h)

DISCONNECT CONNECTORS AND HOSES Disconnect the spill valve connector. Disconnect the timing control valve connector. Disconnect the engine speed sensor connector. Disconnect the fuel temperature sensor connector. Disconnect the injection pump correction unit connector. Disconnect the fuel inlet hose. Disconnect the fuel return hose. Disconnect the fuel outlet hose.

5. (a)

REMOVE INJECTION PUMP Remove the 3 bolts and injection pump stay.

B13724

(b)

Before removing the injection pump, check if the matchmarks are aligned. If not place new matchmarks for reinstallation. (c) Remove the 2 nuts and injection pump.

B13725

FU−14 ENGINE FUEL

−

INJECTION PUMP

DISASSEMBLY 1. 2. SST

FU09C−01

MOUNT PUMP ASSEMBLY TO SST (STAND) SST 09241−76022, 09245−54010 REMOVE SET KEY OF DRIVE PULLEY FROM DRIVE SHAFT

B13708

3. (a)

(a)

(b) (c)

(b)

REMOVE FUEL PIPES AND INLET HOLLOW SCREW Remove the overflow screw, fuel outlet pipe and 2 gaskets. Remove the cap nut, bolt, fuel inlet pipe and 2 gaskets. Remove the fuel inlet hollow screw and gasket.

(c) B13709

8 mm Hexagon Wrench

4. (a)

REMOVE TIMING CONTROL VALVE Using an 8 mm hexagon wrench, remove the 2 bolts and injection pump stay.

(b)

Using a 5 mm hexagon wrench, remove the 2 bolts and timing control valve.

B13710

5 mm Hexagon Wrench

B13711

5. REMOVE FUEL TEMPERATURE SENSOR Using a 19 mm deep socket wrench, remove the fuel temperature sensor and O−ring.

B13712

FU−15 ENGINE FUEL

−

INJECTION PUMP

6. REMOVE DISTRIBUTIVE HEAD PLUG Using SST, remove the distributive head plug. SST 09260−54012 (09262−54010)

SST

B13713

7. (a)

SST

B13714

REMOVE DELIVERY VALVE HOLDERS Using SST, remove the 4 delivery valve holders and springs. SST 09260−54012 (09269−54020) (b) Remove the 4 delivery valves and 4 gaskets. NOTICE: Do not touch the sliding surfaces of the delivery valve with your hand. HINT: Arrange the delivery valves, springs and holders in order.

FU−16 ENGINE FUEL

−

INJECTION PUMP

INSPECTION

Z18058

FU03S−04

NOTICE: Do not touch the sliding surfaces of the delivery valves. INSPECT DELIVERY VALVES Pull up the valve, release it. Check that it sinks smoothly to the valve seat. If operation is not as specified, replace the valve as a set. HINT: Before using a new valve set, wash off the rust prevention compound with diesel fuel. Then re−wash with diesel fuel and perform the above tests.

FU−17 ENGINE FUEL

−

INJECTION PUMP

REASSEMBLY

FU09D−01

1.

MOUNT PUMP BODY TO SST (STAND) SST 09241−76022, 09245−54010

2. (a)

INSTALL DELIVERY VALVE HOLDERS Install new gaskets and the valves into the distributive head. Install the springs into the delivery valve holders. Using SST, install the delivery valve holders. SST 09260−54012 (09269−54020) Torque: 58.85 N·m (600 kgf·cm, 43 ft·lbf)

SST

B13708

SST

(b) (c)

S04413

3. (a) (b)

INSTALL DISTRIBUTIVE HEAD PLUG Install a new O−ring to the distributive head plug. Using SST, install the head plug. SST 09260−54012 (09262−54010) Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)

4. (a) (b)

INSTALL FUEL TEMPERATURE SENSOR Install a new O−ring to the fuel temperature sensor. Using a 19 mm deep socket wrench, install the fuel temperature sensor. Torque: 21.6 N·m (220 kgf·cm, 16 ft·lbf)

5. (a)

INSTALL TIMING CONTROL VALVE Using a 5 mm hexagon wrench, install the timing control valve with the 2 bolts.

SST

B13713

B13712

5 mm Hexagon Wrench

B13711

FU−18 ENGINE FUEL

5 mm Hexagon Wrench

−

INJECTION PUMP

(b)

Using an 8 mm hexagon wrench, install the injection pump stay.

6.

INSTALL FUEL INLET HOLLOW SCREWS FUEL PIPES Install a new gasket and the hollow screw. Torque: 36.8 N·m (375 kgf·cm, 27 ft·lbf) Install the fuel inlet pipe with 2 new gaskets and the cap nut. Torque:24.5 N·m (250 kgf·cm, 18 ft·lbf) Install fuel outlet pipe with a new gasket and the overflow screw. Torque: 26.5 N·m (270 kgf·cm, 20 ft·lbf) REMOVE INJECTION PUMP FROM SST (STAND) SST 09241−76022, 09245−54010 INSTALL SET KEY OF INJECTION PUMP DRIVE PULLEY ON DRIVE SHAFT

B13710

(c)

(a) (b)

(b)

(a)

(c) B13709

7. 8.

FU−19 ENGINE FUEL

−

INJECTION PUMP

INSTALLATION 1. (a) (b)

FU09E−01

INSTALL INJECTION PUMP Align the punching lines of the injection pump flange and water pump. Install the injection pump with the 2 nuts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

B13725

(c)

A

C

B B13724

(f)

(a)

(g)

(c)

(d) (e)

(g)

B13741

Temporarily install the injection pump stay and pipe clamp with the 2 bolts (A, B). (d) Install the injection pump bolt (C). Torque: 59 N·m (600 kgf·cm, 44 ft·lbf) (e) Torque the 2 bolts (A, B). Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) NOTICE: Before tightening to the standard torque, check whether the pump stay is up against the injection pump 2. (a) (b) (c) (d) (e) (f) (g) 3. 4. 5.

CONNECT CONNECTORS AND HOSES Connect the spill valve connector. Connect the timing control valve connector. Connect the engine speed sensor connector. Connect the fuel temperature sensor connector. Connect the fuel inlet hose. Connect the fuel return hose. Connect the injection pump correction unit connector. INSTALL INJECTION PIPE (See page FU−9) INSTALL INJECTION PUMP DRIVE PULLEY (See pub. No. RM 597E, EM−20) INSTALL TIMING BELT (See page EM−5)

COOLING COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CO−1

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CO−3

CO−1 COOLING

−

COOLANT

COOLANT INSPECTION

CO0ET−01

1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add engine coolant up to the ”FULL” line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or water filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. (c) Reinstall the radiator cap.

CO−2 COOLING

−

COOLANT CO0EU−03

REPLACEMENT

Drain Plug

B13823

COLD Mark F Mark L Mark

B13432

1. DRAIN ENGINE COOLANT (a) Remove the radiator cap. CAUTION: To avoid the danger of being, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Loosen the radiator drain plug (on the left side of the radiator lower tank) and drain the coolant. (c) Close the drain plug.

2. FILL ENGINE COOLANT (a) Fill the system with coolant around the filling portion. HINT: Use a good brand of ethylene−glycol base coolant and S mix it according to the manufacture’s directions. S Use recommended coolant which includes more than 50 % ethylene−glycol (but not more than 70 %). NOTICE: Do not use an alcohol type coolant. S The coolant should be mixed with demineralized waS ter or distilled water. Capacity:

(b) (c)

w/ Heater

7.6 liters (8.0 US qts, 6.7 lmp. qts)

w/o Heater

6.6 liters (7.0 US qts, 5.8 lmp. qts)

Install the radiator cap. Start the engine and keep it with the speed of 2500 to 3000 rpm for 5 minutes.

HINT: Check that the thermostat is open and the radiator reservoir is hot. (d) Stop the engine, and wait until the coolant becomes cold enough. (e) Check that the water level of coolant is within marking ”COLD”. When it is below marking ”COLD”, fill some water up to marking ”COLD”. (f) Start the engine, and check the water level is between marking ”F” and ”L”.

CO−3 COOLING

−

RADIATOR

RADIATOR ON−VEHICLE INSPECTION

CO0F4−02

1. REMOVE RADIATOR CAP CAUTION: to avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.

Radiator Cap Tester

30˚ or More Radiator Cap CO1242

Radiator Cap Tester

B13433

2. INSPECT RADIATOR CAP NOTICE: If the radiator cap has contaminations, always rinse S it with water. Before using a radiator cap tester, wet the relief valve S and pressure valve with engine coolant or water. Using a radiator cap tester, pump the tester and measure the relief valve opening pressure. Standard opening pressure: 93.3 − 122.7 kPa (0.95 − 1.25 kgf/cm2, 13.5 − 17.8 psi) Minimum opening pressure: 79 kPa (0.8 kgf/cm2, 11.5 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap.

3. (a)

INSPECT COOLING SYSTEM FOR LEAKS Fill the radiator and engine with coolant, and attach a radiator cap tester to the water filler. (b) Warm up the engine. (c) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 4. REINSTALL RADIATOR CAP

LUBRICATION OIL AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . .

LU−1

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LU−4

LU−1 LUBRICATION

INSPECTION

20W−50 15W−40 10W−30 5W−30 40 30 −7 20

4 40

16 60

27 80

OIL AND FILTER

OIL AND FILTER

Recommended Viscosity (SAE):

˚C −29 −18 ˚F −20 0

−

38 100

TEMPERATURERANGEANTICIPATED BEFORE NEXT OIL CHANGE

B05542

Oil Pressure Gauge

1. CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API CF−4 or CF (You may also use API CE or CD) If you use SAE 10W−30 or higher viscosity oil in extremely low temperatures, the engine may become difficult to start, so SAE 5W−30 engine oil is recommended. 2. CHECK ENGINE OIL LEVEL After warming up the engine and then 5 minutes after the engine stops, oil level should be between the L and F marks of the dipstick. If low, check for leakage and add oil up to L and F mark. NOTICE: Do not fill with engine oil above the F mark. 3. (a) (b) (c) (d)

Oil Pressure Switch B13672

CHECK OIL PRESSURE Using SST, Remove the oil pressure switch. SST 09816−30010 Install the oil pressure gauge. Allow the engine to warm up to normal operating temperature. Check the oil pressure. Oil pressure: At idle

29 kPa (0.3 kgf/cm2, 4.3 psi) or more

At 4,500 rpm

245 − 588 kPa (2.5 − 6.0 kgf/cm2, 36 − 85 psi)

(e)

Remove the oil pressure gauge.

(f)

Apply adhesive to 2 or3 threads of the oil pressure switch. Adhesive: Part No. 08833−00080, THREE BOND 1344 LOCTITE 242 or equivalent Using SST, reinstall the oil pressure switch. SST 09816−30010 Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Start the engine and check for the oil leaks.

Adhesive

(g)

(h) S02870

LU07B−02

LU−2 LUBRICATION

−

OIL AND FILTER

REPLACEMENT

LU07C−02

CAUTION: Prolonged and repeated contact with mineral oil will S result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Core should be taken, therefore when changing S engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or use water−less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. In order to preserve the environment, used oil and S used oil filters must be disposed of only at designated disposal sites. 1. (a) (b)

SST

2. (a)

DRAIN ENGINE OIL Remove the oil filler cap. Remove the oil drain plug, and drain the oil into a container. REPLACE OIL FILTER Using SST, remove the oil filter. SST 09228−10002

B13673

(b) (c) (d)

Clean the oil filter contact surface on the oil filter mounting. Lubricate the filter rubber gasket with clean engine oil. Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting.

B13674

3/4 Turn

(e) SST

B13675

Using SST, give it an additional 3/4 turn to seat the filter. SST 09228−10002

LU−3 LUBRICATION

3. (a) (b)

−

OIL AND FILTER

REFILL ENGINE OIL Clean the drain plug, and install a new gasket and it. Torque: 34.5 N·m (350 kgf·cm, 25 ft·lbf) Fill with new engine oil. Capacity:

Drain and refill Dry fill

(c) 4. 5.

w/ Oil filter charge w/o Oil filter change

5.0 liters (5.3 US qts, 4.4 Imp. qts) 4.3 liters (4.5 US qts, 3.8 Imp. qts) 5.6 liters (5.9 US qts, 4.9 Imp. qts)

Reinstall the oil filler cap. START ENGINE AND CHECK FOR OIL LEAKS RECHECK ENGINE OIL LEVEL

LU−4 LUBRICATION

−

OIL COOLER

OIL COOLER LU07J−02

COMPONENTS

Oil Filter

No. 2 Exhaust Heat Insulator

42 (428, 31)

58.8 (600, 43) 18 (185, 13)

Oil Cooler

z O−Ring

Water Bypass Hose


B13681

LU−5 LUBRICATION

−

OIL COOLER

REMOVAL 1. 2.

LU0NY−01

DRAIN ENGINE COOLANT REMOVE OIL FILTER (See page LU−2)

3. REMOVE NO. 2 EXHAUSUT HEAT INSULATOR Remove the nut, bolt and heat insulator. 4. DISCONNECT WATER BYPASS HOSES FROM OIL COOLER

B13778

5. (a) (b) SST

B13676

REMOVE OIL COOLER Using SST, remove the nut and oil cooler. SST 09229−55010 Remove the O−ring from the oil cooler.

LU−6 LUBRICATION

−

OIL COOLER

INSPECTION

OUT

IN

B13737

INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler.

LU07L−02

LU−7 LUBRICATION

−

OIL COOLER

INSTALLATION

New O−Ring

1. (a) (b)

LU0NZ−01

INSTALL OIL COOLER Clean the oil cooler contact surface on the oil cooler mounting. Install a new O−ring to the oil cooler.

B13777

(c) (d) SST Cutout

Protrusion

(e)

2.

Apply a light coat of engine oil on the threads and under the nut. Align the cutout of the oil cooler with the protrusion of the oil filter bracket. Using SST, install the oil cooler with the nut. SST 09229−55010 Torque: 58.8 N·m (600 kgf·cm, 43 ft·lbf) CONNECT WATER BYPASS HOSES TO OIL COOLER

B13707

B13778

3. INSTALL NO. 2 EXHAUST HEAT INSULATOR Install the heat insulator with the nut and bolt. Torque: 42 N·m (428 kgf·cm, 31 ft·lbf) for nut 18 N·m (185 kgf·cm, 13 ft·lbf) for bolt 4. INSTALL OIL FILTER (See page LU−2) 5. FILL WITH ENGINE COOLANT (See page CO−2) 6. START ENGINE AND CHECK FOR LEAKS 7. CHECK ENGINE OIL LEVEL

STARTING PRE−HEATING SYSTEM . . . . . . . . . . . . . . . . . .

ST−1

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . .

ST−3 ST−16

ST−1 STARTING

−

PRE−HEATING SYSTEM

PRE−HEATING SYSTEM ST070−02

ON−VEHICLE INSPECTION

Sec. 300

10 0

20 (68)

55 (131)

Water Temperature B04255 B04256

3.

INSPECT ENGINE ECU (See page DI−15)

˚C (˚F)

Light Lighting Time

After Glow Time

HINT: Refer to Diagnosis for inspection procedure. 1. INSPECT LIGHTING TIME OF GLOW INDICATOR LIGHT Turn the ignition switch ”ON”, measure the lighting time. Light lighting time: Refer to the chart graph 2. INSPECT AFTER GLOW TIME Turn the ignition switch ”ON”, measure the time battery voltage is applied to terminal S−REL of the engine ECU. After glow time: Refer to the chart graph

Sec. 3 2 1 0

−20 −10 0 10 20 (−4)(−14)(32)(50)(68) Water Temperature

80 ˚C (176) (˚F)

B04393

ST−2 STARTING

−

PRE−HEATING SYSTEM

INSPECTION

Cover Glow Plug Relay Connector

1. (a) (b)

ST0MY−01

REMOVE GLOW PLUG RELAY (Marking: GLOW) Remove the relay box cover. Remove the grow plug relay.

B10647

2. (a)

INSPECT GLOW PLUG RELAY Inspect the glow plug relay continuity. (1) Using an ohmmeter, check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay.

Ohmmeter No Continuity 2 Ohmmeter 4

2 4

1 3 Continuity

S03356

Ohmmeter Continuity 2 4

1 3

Battery

S03357

(b)

Inspect the glow plug relay operation. (1) Apply battery voltage across terminals 3 and 4. (2) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL GLOW PLUG RELAY

ST−3 STARTING

−

STARTER

STARTER ST0MZ−01

COMPONENTS Idler Gear

Starter Housing

Bearing Magnetic Switch Assembly

z Front Bearing

Return Spring

Armature

Starter Clutch Assembly

z Rear Bearing Steel Ball z Dust Protector z O−Ring Field Frame (Field Coil) z O−Ring Brush Holder End Cover z Dust Protector

B13771

Magnetic Switch Assembly Terminal Nut

17(173,12)

Terminal Insulator Contact Plate

Terminal Bolt

z Terminal C Kit Part

Wave Washer Terminal Insulator O−Ring

End Cover

z Gasket

Plunger

z Terminal 30 Kit Part

O−Ring Lead Terminal Terminal Bolt Contact Plate N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part

Wave Washer Packing Terminal Insulator Terminal Nut

Terminal Insulator

17 (173, 12)

B13772

ST−4 STARTING

−

STARTER

DISASSEMBLY 1. 2. (a) (b) (c) B13826

(d) 3. (a)

ST073−03

REMOVE DUST PROTECTORS REMOVE FIELD FRAME AND ARMATURE Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Remove the 2 through bolts. Pull out the field frame together with the armature from the magnetic switch. Remove the O−ring from the field frame. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Remove the 2 bolts.

B13758

Bearing

Idler Gear

Starter Housing

(b)

Remove the starter housing, return spring, bearing, idler gear and starter clutch assembly from the magnetic switch.

Return Spring Starter Clutch Assembly

B13759

Magnetic Finger

4. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole.

ST0948

5. (a) (b)

P24183

REMOVE BRUSH HOLDER Remove the 2 screws and end cover from the field frame. Remove the O−ring from the field frame.

ST−5 STARTING

(c)

6.

P07264

−

STARTER

Using a screwdriver, hold the spring back disconnect the brush holder. Disconnect the 4 brushers, and remove the brush holder. REMOVE ARMATURE FROM FIELD FRAME

ST−6 STARTING

−

STARTER

INSPECTION

Ohmmeter

ST0N0−01

1. INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature.

Continuity

P10584

2. INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature.

Ohmmeter No Continuity

P10585

3.

P10586

INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe. 4. INSPECT COMMUTATOR CIRCLE RUNOUT (a) Place the commutator on V−blocks. (b) Using a dial gauge measure the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. 5. INSPECT COMMUTATOR DIAMETER Using vernier calipers, measure the commutator diameter. Standard diameter: 30.0 mm 1.181 in.) Minimum diameter: 29.0 mm (1.142 in.) If the diameter is less than minimum, replace the armature.

P10587

6. INSPECT UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth: 0.6 mm (0.024 in.) Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade. ST0040

ST−7 STARTING

−

STARTER

7. INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame.

Ohmmeter Continuity

P10588

8. INSPECT FIELD COIL FOR GROUND Using an ohmmeter, check that there is no continuity between the coil end field frame. If there is continuity, replace the field frame.


P10589

9. INSPECT BRUSH LENGTH Using vernier calipers, measure the brush length. Standard length: 15.5 mm (0.610 in.) Minimum length: 8.5 mm (0.335 in.) If the length is less than minimum, replace the brush holder and field frame.

Brush Holder Side

Length Field Frame Side

P07215 P10591

Length

B04075

10. INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring separates from the brush. STD installed load: 17.6 − 23.5 N (1.8 − 2.4 kgf, 4.0 − 5.4 lbf) Minimum installed load: 11.8 N (1.2 kgf, 2.7 lbf) If the installed load is not as specified, replace the brush springs. ST0019

ST−8 STARTING

Ohmmeter

No Continuity

P07214

Free Lock

−

STARTER

11. INSPECT BRUSH HOLDER INSULATION Using an ohmmeter, check that there is no continuity between the positive (+) and negative (−) brush holders. If there is continuity, repair or replace the brush holder. 12. INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idle gear and clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the ring gear of the flywheel for wear or damage. 13. INSPECT CLUTCH PINION GEAR Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. If necessary, replace the clutch assembly. 14. INSPECT FRONT AND REAR BEARINGS Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing.

P24184

15.

Ohmmeter Continuity Terminal 50

DO MAGNETIC SWITCH PULL−IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, check and replace the magnetic switch.

Terminal C B13775

16.

Ohmmeter Continuity Switch Body

Terminal 50

B13776

DO MAGNETIC SWITCH HOLD−IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch.

ST−9 STARTING

SST

−

STARTER

REPLACEMENT 1. (a)

REPLACE REAR BEARING Using SST, remove the bearing. SST 09286−46011

(b)

Using a press, press in a new bearing.

2. (a)

REPLACE FRONT BEARING Using SST, remove the bearing. SST 09286−46011

ST0N1−01

P10593

P10594

SST

P10595

(b)

Using SST and press, press in a new bearing. SST 09820−00030 NOTICE: Be careful of the installation direction.

Upward

SST

Downward

P10596

3. (a)

Clamp

B13773

REPLACE TERMINAL KIT PARTS Remove the 3 bolts, end cover, gasket and plunger.

ST−10 STARTING

−

STARTER

(b)

Inspect the contact plate for wear. Using vernier calipers, measure the contact plate for depth of wear. Maximum wear: 0.9 mm (0.035 in.) If the depth of wear is greater than the maximum, replace the contact plate. Wear P25253

(c)

Remove the terminal kit parts. (1) Using SST, loosen the terminal nuts. SST 09810−38140 (2) Terminal C: Remove the terminal nut, wave washer, terminal insulator (outside), O−ring, terminal bolt, contact plate and terminal insulator (inside). (3) Terminal 30: Remove the terminal nut, wave washer, terminal insulator (outside), packing, O−ring, terminal bolt, contact plate and terminal insulator (inside).

(d)

Temporarily install new terminal 30 kit parts. (1) Install a new terminal insulator (inside). (2) Install a new contact plate. (3) Install a new terminal bolt. (4) Install a new O−ring. (5) Install a new packing to a new terminal insulator, and install them.

SST

P25254

(3) Long (2)

Short

Inside (4) (5)

(1)

(7) Indentation

Protrusion

(6)

B13760

HINT: Match the protrusion of the insulator with the indentation of the housing. (6) Install a new wave washer. (7) Install a new terminal nut. NOTICE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction.

ST−11 STARTING

(7) (6)

(4)

(1)

Short (2) (3)

Inside Lead Terminal

40 mm 37 mm

STARTER

(e)

Long (5)

−

B13827

Temporaily install new tarminal C kit parts. (1) Install a new terminal insulator (inside). (2) Install a new contact plate. (3) Install a new terminal bolt. (4) Install a new O−ring. (5) Install a new terminal insulator (outside). (6) Install a new wave washer. (7) Install a new terminal nut. NOTICE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction.

(f)

Wooden Block

Contact 20 mm Plate

P25255

Tighten the terminal nut. (1) Put a wooden block on the contact plate and press it down with a hand press. Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force: 981 N (100 kgf, 221 lbf) NOTICE: Check the diameter of the hand press ram. S Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of the force is applied. Gauge pressure: 100 kgf 2 Ram diameter (cm) 2 (kgf/cm ) = x 3.14 (π) 2 221 lbf (psi) =

Ram diameter (in.)

2 2 (kPa) = (kgf/cm ) x 98.1 (kPa) = (psi) x 6.9 S

2

x 3.14 (π)

If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.

ST−12 STARTING

SST

−

STARTER

(2) Using SST, tighten the nuts to the specified torque. SST 09810−38140 Torque: 17 N·m (173 kgf·cm, 12 ft·lbf) NOTICE: If the nut is over tightened, it may cause cracks on the inside of the insulator.

P25256

(g)

(h)

P25257

Clean the contact surfaces of the contact plate and plunger. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. Reinstall the magnetic switch end cover. Install the plunger, new gasket and end cover with the 3 bolts. Torque: 2.5 N·m (26 kgf·cm, 22 in.·lbf)

ST−13 STARTING

−

STARTER

REASSEMBLY

ST076−03

HINT: Use high−temperature grease to lubricate the bearings and gears when assembling the starter. 1. PLACE ARMATURE INTO FIELD FRAME Apply grease to the armature bearings and insert the armature into the field frame.

2. (a) (b)

INSTALL BRUSH HOLDER Place the brush on the armature. Using a screwdriver, hold the brush spring back and connect the brush into the brush holder. Connect the 4 brushes. NOTICE: Check that the positive (+) lead wires are not grounded. (c) Install a new O−ring to the groove of the field frame. P07264

(d) (e)

Install a new O−ring to the screw. Install the end cover to the field frame with the 2 screws. Torque: 1.5 N·m (15 kgf·cm, 13 in.·lbf)

3. (a) (b)

INSERT STEEL BALL INTO CLUTCH SHAFT HOLE Apply grease to the steel ball. Insert the steel ball into the clutch shaft hole.

4.

INSTALL STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Apply grease to the return spring. Insert the return spring into the magnetic switch hole.

P24183

ST0949

(a) (b)

P24185

ST−14 STARTING

Bearing

Idler Gear

Starter Housing

−

STARTER

(c)

Place the starter clutch assembly, bearing and idler gear to the starter housing.

(d)

Install the starter housing to the magnetic switch with the 2 bolts. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

5. (a) (b)

INSTALL FIELD FRAME AND ARMATURE ASSEMBLY Install a new O−ring to the groove of the field frame. Align the protrusion of the field frame with the cutout of the magnetic switch.

Return Spring Starter Clutch Assembly

B13759

B13758

B13828

(c)

Install the field frame and armature assembly with the 2 through bolts. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) (d) Connect the lead wire to terminal C, and install the nut. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) 6. INSTALL DUST PROTECTORS Install 2 new dust protectors. B13826

ST−15 STARTING

STARTER

TEST

Terminal 50

Battery

Terminal C

−

ST077−03

NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. 1. DO PULL−IN TEST (a) Disconnect the field coil lead wire from terminal C. (b) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward. B03791

2. DO HOLDING TEST With battery connected as above with the clutch pinion gear out, disconnect the negative (−) lead from terminal C. Check that the pinion gear remains out.

Disconnect

Battery

B03792

3. INSPECT CLUTCH PINION GEAR RETURN Disconnect that the clutch pinion gear returns inward.

Disconnect

Battery

B03793

Ammeter Terminal 30

Terminal 50

Battery

B03794

4. (a) (b)

DO NO−LOAD PERFORMANCE TEST Connect the battery and ammeter to the starter as shown. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current. Specified current: 90 A or less at 11.5 V

ST−16 STARTING

Cover Starter Relay

−

STARTER RELAY

STARTER RELAY INSPECTION 1.

ST07E−03

REMOVE STARTER RELAY (Marking: ST)

B10646

Ohmmeter

2. (a)

Continuity

1

5

Ohmmeter

3 No Continuity

2

INSPECT STARTER RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.

P07170

(b)

Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is no continuity, replace the relay. 3. REINSTALL STARTER RELAY

Ohmmeter 1 5 3 Continuity

2 Battery

P07171

CHARGING CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . .

CH−1

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . .

CH−3

CH−1 CHARGING

−

CHARGING SYSTEM

CHARGING SYSTEM ON−VEHICLE INSPECTION

CORRECT WRONG

CH0H4−01

1. (a)

INSPECT DRIVE BELTS Visually check the belt for cracks, oiliness or ear. Check that the belt does not teach the bottom of the pulley groove. If the belt has any of the above defects, replace it.

Clearance

B04187

MA0035

(b)

B10648

Ammeter

Disconnect Wire from Terminal B

Voltmeter Battery Alternator P08129

Check the drive belt deflection by pressing on the belt at the points indicated in the illustration with 98 N (10 kgf, 22 lbf) or pressure. Drive belt deflection: New belt

9 − 11 mm (0.35 − 0.43 in.)

Used belt

12 − 14 mm (0.47 − 0.55 in.)

If the belt deflection is not as specified, adjust it. Using a tension gauge, check the drive belt tension. Drive belt tension: New belt

490 − 588 N (50 − 60 kgf)

Used belt

196 − 392 N (20 − 40 kgf)

If the belt tension is not as specified, adjust it. HINT: ’New belt’ refers to a belt which has been used less than S 5 minutes on a running engine. ’Used belt’ refers to a belt which has been used on a runS ning engine for 5 minutes or move. After in stalling a new belt, run the engine for about 5 minS utes and recheck the belt tension. 2. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/alternator tester is available connect the tester to the charging circuit as per manufacturers instructions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: Disconnect the wire from terminal B of the alternaS tor, and connect it to the negative (−) tester probe of the ammeter. Connect the positive (+) tester probe of the ammeS ter to terminal B of the alternator. Connect the positive (+) tester probe of the voltmeS ter to terminal B of the alternator. Ground the negative (−) tester probe of the voltmeS ter. (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or Less

CH−2 CHARGING

−

CHARGING SYSTEM

Standard voltage: 13.2 − 14.8 V If the voltmeter reading is more than standard voltage, replace the IC regulator.

Terminal F

B13736

If the voltmeter reading is less than standard voltage, check the IC regulator and alternator as follows: With terminal F grounded, start the engine and S check the voltmeter reading of terminal B. If the voltmeter reading is more than standard voltS age, replace the IC regulator. If the voltmeter reading is less than standard voltS age, check the alternator. 3. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at HI. (b) Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than the standard amperage, repair the alternator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage.

CH−3 CHARGING

−

ALTERNATOR

ALTERNATOR CH0C8−05

COMPONENTS Bearing Retainer

z Rear Bearing Rotor

Drive End Frame (Stator)

Alternator Washer

Bearing Cover

Pulley

Rear End Cover z Front Bearing

110.5 (1,125, 81)

Terminal Insulator

Brush Holder Cover

Rubber Insulator

Brush Holder Brush Spring Brush IC Regulator N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part

Rectifier Holder Rectifier End Frame

B12372

CH−4 CHARGING

−

ALTERNATOR

DISASSEMBLY

CH0G0−02

1. (a)

REMOVE REAR END COVER Remove the nut and terminal insulator.

(b)

Remove the bolt, 3 nuts and end cover.

2. (a) (b)

REMOVE BRUSH HOLDER AND IC REGULATOR Remove the 5 screws, brush holder and IC regulator. Remove the brush holder cover from the brush holder.

3. (a) (b)

REMOVE RECTIFIER HOLDER Remove the bolt, 4 screws and rectifier holder. Remove the 4 rubber insulators.

4. (a)

REMOVE PULLEY Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820−63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the rotor shaft.

B12373

B12374

B12375

B12376

SST (A) SST (B)

(b) Turn B12377

CH−5 CHARGING

(c) (d)

−

ALTERNATOR

Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).

SST (B) SST (C)

Insert

B13743

(e)

To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one−half of a turn. (f) Remove the alternator from SST (C).

SST (C)

SST (A) Turn

B13744

SST (A) SST (B)

(g) (h)

Turn SST (B), and remove SST (A and B). Remove the pulley nut and pulley.

5. (a)

REMOVE RECTIFIER END FRAME Remove the 4 nuts.

(b)

Using SST, remove the rectifier end frame. SST 09286−46011 Remove the alternator washer from the rotor REMOVE ROTOR FROM DRIVE END FRAME

Turn

B13745

B13746

(c) 6. SST

B13747

CH−6 CHARGING

−

ALTERNATOR

INSPECTION

CH0FZ−02

1. (a)

INSPECT ROTOR Check the rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. If there is no continuity, replace the rotor.

Ohmmeter

Continuity CH0784

(b)

Check the rotor for ground. Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. Ohmmeter

No Continuity B02105

(c) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (d) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 − 14.4 mm (0.559 − 0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor.

CH1023

Ohmmeter

2. (a)

INSPECT STATOR (DRIVE END FRAME) Check the stator for open circuit. Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly

Continuity B11368


B11369

(b)

Check the stator for ground. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly

CH−7 CHARGING

−

ALTERNATOR

3. INSPECT BRUSHES Using vernier calipers, measure the exposed brush length. Standard exposed length: 9.5 − 11.5 mm (0.374 − 0.453 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes (See page CH−8).

Length

P13534

4. (a)

Ohmmeter Positive (+) Terminal Rectifier Terminal

P13568

Ohmmeter Negative (−) Terminal

P13566

INSPECT RECTIFIERS (RECTIFIRE HOLDER) Check the positive (+) rectifire. (1) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (a). (3) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. (b) Check the negative (−) rectifire. (1) Using an ohmmeter, connect one tester probe to each negative (−) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (a). (3) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 5. INSPECT BEARINGS Check that the bearing is not rough or worn. If necessary, replace the bearing (See page CH−8).

CH−8 CHARGING

−

ALTERNATOR

REPLACEMENT

CH0H5−01

1. (a)

REPLACE FRONT BEARING Remove the 4 screws and bearing retainer.

(b)

Using SST and a press, press out the bearing. SST 09950−60010 (09951−00300), 09950−70010 (09951−07100)

(c)

Using SST and a press, press in a new bearing. SST 09950−60010 (09951−00520), 09950−70010 (09951−07100) Install the bearing retainer with the 4 screws. Torque: 2.6 N·m (27 kgf·cm, 23 in.·lbf)

B13748

SST

B13749

SST

(d)

B13750

2. (a)

REPLACE REAR BEARING Using SST, remove the bearing cover (outside) and bearing. SST 09820−00021 NOTICE: Be careful not to damage the fan.

SST

N00581

(b) (c)

P13567

Remove the bearing cover (inside). Place the bearing cover (inside) on the rotor.

CH−9 CHARGING

−

ALTERNATOR

(d)

Using SST and a press, press in a new bearing. SST 09820−00030

(e)

Using SST, push in the bearing cover (outside). SST 09285−76010

3. (a) (b)

REPLACE BRUSHES Unsolder and remove the brush and spring. Run the wire of a new brush through the hole in the brush holder, and insert the spring and brush into the brush holder.

(c)

Solder the brush wire to the brush holder at specified exposed length. Exposed length: 9.5 − 11.5 mm (0.374 − 0.453 in.) Check that the brush moves smoothly in the brush holder. Cut off the excess wire. Apply insulation paint to the soldered area.

SST

N00578

SST

P00074

P13729

(d) (e) (f) Length CH0414

CH−10 CHARGING

−

ALTERNATOR

REASSEMBLY Pulley

CH0G1−02

1. (a) (b)

INSTALL ROTOR TO DRIVE END FRAME Place the drive end frame on the pulley. Install the rotor to the drive end frame.

2. (a)

INSTALL RECTIFIER END FRAME Place the alternator washer on the rotor.

(b)

Using a plastic hammer, lightly tap in the end frame.

(c)

Install the 4 nuts. Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf)

3. (a)

INSTALL PULLEY Install the pulley to the rotor shaft by tightening the pulley nut by hand. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820−63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the pulley shaft.

B13751

B13752

B13753

B13746

SST(A) SST (B)

(b) Turn

(c) B13745

CH−11 CHARGING

−

ALTERNATOR

(d) (e)

Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).

(f)

(g)

To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110.5 N·m (1,125 kgf·cm, 81 ft·lbf) Remove the alternator from SST (C).

(h)

Turn SST (B), and remove SST (A and B).

SST (C)

B00224

SST (C)

SST (A)

Turn

B13754

SST (A) SST (B)

Turn

B12377

4. INSTALL RECTIFIER HOLDER (a) Install the 4 rubber insulators on the lead wires. NOTICE: Be careful of the rubber insulators installation direction. Inside

B13755

(b)

B12376

Install the rectifier holder while pushing it with the bolt and 4 screws Torque: Bolt: 3.9 N·m (40 kgf·cm, 34 in.·lbf) Screw: 1.96 N·m (20 kgf·cm, 17 in.·lbf)

CH−12 CHARGING

−

ALTERNATOR

5. INSTALL IC REGULATOR AND BRUSH HOLDER (a) Install the brush holder cover to the brush holder. NOTICE: Be careful of the holder installation direction.

P13624

(b)

Place the IC regulator together with the brush holder horizontally on the rectifier end frame.

(c)

Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector. Torque: 2.0 N·m (20 kgf·cm, 18 in.·lbf) Fit the brush holder cover.

Upward

P12620

Approx. 1 mm

(d)

P12622

6. (a)

INSTALL REAR END COVER Install the end cover with 3 nuts. Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf) for nut

(b)

Install the terminal insulator with the nut. Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY

B12374

7.

B12373

MANUAL 3C-E TOYOTA.pdf

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