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2l, 2l-t, 3l, 5l Engine Sup. Rm582e
2l, 2l-t, 3l, 5l Engine Sup. Rm582e
This SUPPLEMENT has been prepared to provide information covering general service repairs for the
2L, 2L-T, 3L and 5L ENGINES equipped on the TOYOTA HILUX.
Applicable models: LN141, 145, 146, 147, 150, 152, 165, 166, 167, 170, 171, 172, 191 series
For the service specifications and repair procedures of the above model other than those listed in this supple-
ment, refer to the following manuals.
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
1997 TOYOTA MOTOR CORPORATION
All rights reserved. This CD may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Aug. 8, 1997 01-- 970808-- 00
CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non--specialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.
S Must read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of ”IN” section.
S The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using non--specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.
S If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
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INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
ENGINE MECHANICAL
TURBOCHARGER TC
ENGINE FUEL
COOLING
LUBRICATION
STARTING
CHARGING
ALPHABETICAL INDEX
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INTRODUCTION
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the Section Title and major heading are given at the top of every
page.
2. GENERAL DESCRIPTION
At the beginning of each section, a General Description is given that pertains to all repair operations con-
tained in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
z Gasket
Bracket
Ground Strap
CONTINUED
Ground Cable
B01898
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IN--4
INTRODUCTION -- REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
P23717 (c) Observe the following:
(1) Before performing electrical work, disconnect the
negative (--) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the negative
(--) terminal cable which is grounded to the vehicle
body.
(3) To prevent damage to the battery terminal, loosen
the cable nut and raise the cable straight up without
twisting or prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals with
the nut loose, and tighten the nut after installation.
Do not use a hammer to tap the cable ends onto the
terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are secure and correct.
(e) Non--reusable parts
(1) Always replace cotter pins, gaskets, O--rings and oil
seals etc. with new ones.
(2) Non--reusable parts are indicated in the component
illustrations by the ”z” symbol.
(f) Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
(3) Precoated parts are indicated in the component il-
lustrations by the ”L” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
CONTINUED
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IN--5
INTRODUCTION -- REPAIR INSTRUCTIONS
(j) When replacing fuses, be sure the new fuse has the cor-
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
BE1367
FUSE FUSE
FUSIBLE LINK FL
CIRCUIT BREAKER CB
V00076
CONTINUED
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IN--6
INTRODUCTION -- REPAIR INSTRUCTIONS
PRECAUTION
IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two--way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle’s electronics systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Do not wind the antenna feeder together with the other wiring. As much as possible, also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Confirm that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
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IN--8
INTRODUCTION -- TERMS
TERMS
IN00S--03
PREPARATION
PP--1
PREPARATION -- ENGINE MECHANICAL
ENGINE MECHANICAL
SST (Special Service Tools)
09222--54011 Connecting Rod Bushing Remover
& Replacer
(09222--02031) Guide 2L
(09222--02041) Base 2L
RECOMMENDED TOOLS
09082--00040 TOYOTA Electrical Tester. VSV for intake sutter (5L)
EQUIPMENT
Caliper gauge
Cylinder gauge
Dial indicator
Engine tune--up tester
Micrometer
Pin hole grinder
Piston ring expander
Plastigage
Round file
Torque wrench
Vacuum gauge
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PP--5
PREPARATION -- TURBOCHARGING
TURBOCHARGING
PP0DJ--01
EQUIPMENT
Dial indicator
Torque wrench
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PP--7
PREPARATION -- ENGINE FUEL
ENGINE FUEL
PP0DL--01
(09269--54020) Socket 14 mm
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PP--8
PREPARATION -- ENGINE FUEL
PP0DM--01
RECOMMENDED TOOLS
09040--00010 Hexagon Wrench Set .
EQUIPMENT
Angle gauge
Brass brush Injection nozzle
Dial indicator with magnetic base
Graduated cylinder
Injection nozzle tester
Injection pump tester
Inner pressure gauge
Micrometer
Steel square
Timer measuring device
Torque wrench
Vernier calipers
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PP--10
PREPARATION -- ENGINE FUEL
PP0DO--01
COOLING
PP0DP--01
09231--14010 Punch
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PP--12
PREPARATION -- COOLING
PP0DQ--01
EQUIPMENT
Radiator cap tester
Torque wrench
Vernier calipers
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PP--13
PREPARATION -- COOLING
PP0DR--01
COOLANT
Item Capacity Classification
Engine coolant Ethylene--glycol base
2L, 3L, w/ Heater 9.5 liters (10.0 US qts, 8.4 lmp. qts)
w/o Heater 8.7 liters (9.2 US qts, 7.7 lmp. qts)
2L--T w/ Heater 9.7 liters (10.3 US qts, 8.5 lmp.qts)
5L w/ Heater 2WD 9.7 liters (10.3 US qts, 8.5 lmp. qts)
4WD 9.9 liters (10.5 US qts, 8.7 lmp. qts)
w/o Heater 2WD 8.9 liters (9.4 US qts, 7.8 lmp. qts)
4WD 9.1 liters (9.6 US qts, 8.0 lmp. qts)
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PP--14
PREPARATION -- LUBRICATION
LUBRICATION
PP0DS--01
LUBRICANT
Engine oil (2WD) API CF--4
Dry fill 6.5 liters (6.9 US qts, 5.7 lmp. qts) (You may also use API CF, CE or CD)
Drain and refill
w/ Oil filter change 5.8 liters (6.1 US qts, 5.1 lmp. qts)
w/o Oil filter change 5.3 liters (5.6 US qts, 4.7 lmp. qts)
STARTING
PP0DT--01
09286--46011 Injection Pump Spline Shaft Armature rear bearing for 2.2 kW
Puller
RECOMMENDED TOOLS
09082--00040 TOYOTA Electrical Tester.
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PP--17
PREPARATION -- STARTING
PP0DV--01
EQUIPMENT
Dial indicator Commutator
Heater Water temperature sensor
Magnetic finger
Press
Pull scale Brush spring
Sandpaper Commutator
Thermometer Water temperature sensor
Torque wrench
V--block
Vernier calipers Commutator, Brush
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SERVICE SPECIFICATIONS
STANDARD BOLT
SS00F--02
Hexagon head
bolt 2
Protruding 5T
lines
Grooved
Hexagon
flange bolt 2
Protruding 6T 6T
w/ washer lines
hexagon bolt
Hexagon head
bolt 3
Protruding 7T Welded bolt
lines
Hexagon head
4T
bolt 4
Protruding 8T
lines
CONTINUED V06821
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SS--2
SERVICE SPECIFICATIONS -- STANDARD BOLT
SS00G--02
in.∙lbf in.∙lbf
in.∙lbf in.∙lbf
V00079
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SS--3
SERVICE SPECIFICATIONS -- ENGINE MECHANICAL
ENGINE MECHANICAL
SS06N--01
SERVICE DATA
Compression at 250 rpm STD 2L--T 3,040 kPa (31.0 kgf/cm2, 441 psi) or more
pressure 2L, 3L, 5L 3,138 kPa (32.0 kgf/cm2, 455 psi) or more
Minimum 1,961 kPa (20.0 kgf/cm2, 284 psi)
Difference of pressure between each cylinder 490 kPa (5.0 kgf/cm2, 71 psi) or less
CONTINUED
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SS--4
SERVICE SPECIFICATIONS -- ENGINE MECHANICAL
Valve lifter Valve lifter inside diameter 40.892 -- 40.902 mm (1.6099 -- 1.6103 in.)
Cylinder head lifter bore diameter 40.960 -- 40.980 mm (1.6126 -- 1.6134 in.)
Oil clearance STD 0.058 -- 0.088 mm (0.0023 -- 0.0035 in.)
Maximum 0.10 mm (0.0039 in.)
CONTINUED
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SS--5
SERVICE SPECIFICATIONS -- ENGINE MECHANICAL
CONTINUED
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SS--6
SERVICE SPECIFICATIONS -- ENGINE MECHANICAL
Cylinder block Cylinder head surface warpage Maximum 0.20 mm (0.0079 in.)
Cylinder bore diameter STD 2L, 2L--T STD Mark 1 92.000 -- 92.010 mm (3.6220 -- 3.6224 in.)
Mark 2 92.010 -- 92.020 mm (3.6224 -- 3.6228 in.)
Mark 3 92.020 -- 92.030 mm (3.6228 -- 3.6232 in.)
3L STD Mark 1 96.000 -- 96.010 mm (3.7795 -- 3.7799 in.)
Mark 2 96.010 -- 96.020 mm (3.7799 -- 3.7803 in.)
Mark 3 96.020 -- 96.030 mm (3.7803 -- 3.7807 in.)
5L STD Mark 1 99.500 -- 95.010 mm (3.9173 -- 3.9177 in.)
Mark 2 99.510 -- 95.020 mm (3.9177 -- 3.9181 in.)
Mark 3 99.520 -- 95.030 mm (3.9181 -- 3.9185 in.)
Maximum 2L, 2L--T STD 92.23 mm (3.6311 in.)
O/S 0.50 92.73 mm (3.6508 in.)
O/S 0.75 92.98 mm (3.6606 in.)
O/S 1.00 93.23 mm (3.6705 in.)
3L STD 96.23 mm (3.7886 in.)
O/S 0.50 96.73 mm (3.8083 in.)
5L STD 99.73 mm (3.9264 in.)
O/S 0.50 100.23 mm (3.9461 in.)
Piston and piston Piston diameter 2L, 2L--T STD Mark 1 91.940 -- 91.950 mm (3.6197 -- 3.6201 in.)
ring Mark 2 91.950 -- 91.960 mm (3.6201 -- 3.6205 in.)
Mark 3 91.960 -- 91.970 mm (3.6205 -- 3.6209 in.)
O/S 0.50 92.440 -- 92.470 mm (3.6394 -- 3.6405 in.)
O/S 0.75 92.690 -- 92.720 mm (3.6492 -- 3.6504 in.)
O/S 1.00 92.940 -- 92.970 mm (3.6590 -- 3.6602 in.)
3L STD Mark 1 95.940 -- 95.950 mm (3.7772 -- 3.7776 in.)
Mark 2 95.950 -- 95.960 mm (3.7776 -- 3.7779 in.)
Mark 3 95.960 -- 95.970 mm (3.7779 -- 3.7783 in.)
O/S 0.50 96.440 -- 96.470 mm (3.7968 -- 3.7980 in.)
5L STD Mark 1 99.450 -- 99.460 mm (3.9153 -- 3.9157 in.)
Mark 2 99.460 -- 99.470 mm (3.9157 -- 3.9161 in.)
Mark 3 99.470 -- 99.480 mm (3.9161 -- 3.9165 in.)
O/S 0.50 99.950 -- 99.980 mm (3.9350 -- 3.9362 in.)
Piston oil clearance STD 2L, 2L--T, 3L 0.050 -- 0.070 mm (0.0020 -- 0.0028 in.)
5L 0.040 -- 0.060 mm (0.0016 -- 0.0024 in.)
Maximum 2L, 2L--T, 3L 0.14 mm (0.0055 in.)
5L 0.13 mm (0.0051 in.)
Piston ring groove clearance STD No.1 2L 0.031 -- 0.079 mm (0.0012 -- 0.0031 in.)
2L--T 0.061 -- 0.109 mm (0.0024 -- 0.0043 in.)
3L 0.031 -- 0.075 mm (0.0012 -- 0.0030 in.)
5L 0.057 -- 0.101 mm (0.0022 -- 0.0040 in.)
No.2 2L, 3L 0.060 -- 0.105 mm (0.0024 -- 0.0041 in.)
2L--T 0.070 -- 0.115 mm (0.0028 -- 0.0045 in.)
5L 0.060 -- 0.100 mm (0.0024 -- 0.0039 in.)
Oil 0.030 -- 0.070 mm (0.0012 -- 0.0028 in.)
Maximum 0.20 mm (0.0079 in.)
Piston ring end gap STD No.1 0.350 -- 0.590 mm (0.0138 -- 0.0232 in.)
No.2 2L, 2L--T 0.450 -- 0.720 mm (0.0177 -- 0.0283 in.)
3L 0.400 -- 0.670 mm (0.0157 -- 0.0264 in.)
5L 0.470 -- 0.720 mm (0.0185 -- 0.0283 in.)
Oil 0.200 -- 0.520 mm (0.0079 -- 0.0205 in.)
Maximum No.1 1.29 mm (0.0508 in.)
No.2 2L, 2L--T, 5L 1.42 mm (0.0559 in.)
3L 1.37 mm (0.0539 in.)
Oil 1.22 mm (0.0480 in.)
Piston protrusion from cylinder block 0.68 -- 0.97 mm (0.0268 -- 0.0382 in.)
CONTINUED
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SS--7
SERVICE SPECIFICATIONS -- ENGINE MECHANICAL
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
Injection pump x Timing belt case 20.5 210 15
Injection pump x Injection pump stay 18 185 13
Injection pipe x Injection pump 24.5 250 18
Plug bolt x Distributive head plug on injection pump 17 170 13
Intake flange x Intake manifold 12 120 9
No.2 idler pulley x Cylinder block 33 340 24
Injection pump drive pulley x Injection pump 64 650 47
Camshaft timing pulley x Camshaft 98 1,000 72
No.1 idler pulley x Cylinder block 12 mm head 19 195 14
14 mm head 44 450 33
TURBOCHARGING
SS06P--01
SERVICE DATA
Turbocharger Turbocharging pressure 60 -- 79 kPa (0.61 -- 0.81 kgf/cm2, 8.7 -- 11.5 psi)
Turbine wheel axial play Maximum 0.13 mm (0.0051 in.) or less
Turbine wheel radial play Maximum 0.18 mm (0.0071 in.) or less
Actuator push rod stroke 1.20 -- 1.70 mm (0.0472 -- 0.0669 in.)
Adjusting plate washer 0.5 mm (0.020 in.)
1.0 mm (0.039 in.)
2.0 mm (0.079 in.)
3.0 mm (0.118 in.)
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SS--10
SERVICE SPECIFICATIONS -- TURBOCHARGING
SS06Q--01
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
Turbocharger actuator x Compressor housing 19 195 14
Bearing housing side plate x Turbocharger 7.8 80 69 in.∙lbf
Turbo oil pipe x Turbocharger 19 195 14
Turbo water pipe x Turbocharger Nut 5.5 55 49 in.∙lbf
Bolt 12 120 9
ENGINE FUEL
SS06R--01
SERVICE DATA
Fuel heater Resistance at 20˚C (68˚F) 0.5 -- 2.0 Ω
Injection nozzles Nozzle opening pressure New nozzle 2L, 2L--T, 3L 14,810 -- 15,590 kPa (151 -- 159 kgf/cm2, 2,148 -- 2,262 psi)
5L 15,790 -- 16,570 kPa (161 -- 169 kgf/cm2, 2,290 -- 2,404 psi)
Reused nozzle 2L, 2L--T, 3L 14,220 -- 15,200 kPa (145 -- 155 kgf/cm2, 2,062 -- 2,205 psi)
5L 15,200 -- 16,181 kPa (155 -- 165 kgf/cm2, 2,205 -- 2,347 psi)
Adjusting shim thickness 0.900 mm (0.0354 in.) 0.950 mm (0.0374 in.)
1.000 mm (0.0394 in.) 1.050 mm (0.0413 in.)
1.100 mm (0.0433 in.) 1.150 mm (0.0453 in.)
1.200 mm (0.0472 in.) 1.250 mm (0.0492 in.)
1.300 mm (0.0512 in.) 1.350 mm (0.0531 in.)
1.400 mm (0.0551 in.) 1.450 mm (0.0571 in.)
1.500 mm (0.0591 in.) 1.550 mm (0.0610 in.)
1.600 mm (0.0630 in.) 1.650 mm (0.0650 in.)
1.700 mm (0.0669 in.) 1.750 mm (0.0689 in.)
1.800 mm (0.0709 in.) 1.850 mm (0.0728 in.)
1.900 mm (0.0748 in.) 1.950 mm (0.0768 in.)
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
Fuel heater x Fuel filter cap 3.19 32.5 28 in.∙lbf
Nozzle holder body x Nozzle holder retaining nut 46.58 475 42
Injection nozzle x Cylinder head 64 650 47
Nozzle leakage pipe x Injection nozzle 29.5 300 22
Injection pipe x Injection nozzle, Injection pump 24.5 250 18
Fuel inlet hollow screw x Injection pump body 36.8 375 27
Regulator valve x Injection pump body 8.85 90 78 in.∙lbf
Feed pump cover x Injection pump body 2.45 25 22 in.∙lbf
Timer cover, Governor cover x Injection pump body 8.35 85 74 in.∙lbf
Timer adjusting screw x Timer cover 14.2 145 10
Governor link support bolt x Injection pump body 13.75 140 10
Connector bracket (w/ TCV), Distributive head x Injection pump body 11.75 120 9
Delivery valve holder x Distributive head 58.85 600 43
Distributive head plug x Distributive head 68.65 700 51
Bolt for control lever x Governor cover 2L--T, w/ HAC 6.85 70 61 in.∙lbf
Diaphragm cover x Governor cover 2L--T 7.35 75 65 in.∙lbf
Pneumatic bellows cover x Governor cover w/ HAC 7.35 75 65 in.∙lbf
Bolt for lever control spring x Governor cover 2L--T, w/ HAC 11.3 115 8
Overflow screw x Governor cover 2L--T 24.55 250 18
No.2 adjusting lever x Governor adjusting shaft 8.35 85 74 in.∙lbf
No.2 adjusting lever x No.1 adjusting lever 6.05 62 54 in.∙lbf
Fuel cut solenoid x Distributive head 22.1 225 16
Lead wire x Fuel cut solenoid 1.7 17.5 15 in.∙lbf
Connector bracket x Distributive head w/o TCV 20.1 205 15
Pickup sensor x Injection pump body 20.6 210 15
Timing control valve x Injection pump body w/ TCV 8.35 85 74 in.∙lbf
Lead wire x Timing control valve w/ TCV 1.7 17.5 15 in.∙lbf
Overflow pipe x Injection pump body w/ TCV Upper union bolt 14.2 145 10
Lower union bolt 19.6 200 14
Overflow pipe clamp x Injection pump body, Connector bracket w/ TCV 8.35 85 74 in.∙lbf
Thermo wax x Injection pump body 8.35 85 74 in.∙lbf
Idle--up lever x Governor cover, Injection pump body w/ ACSD 8.35 85 74 in.∙lbf
Idle--up actuator x Governor cover w/o ACSD for w/ A/C 8.35 85 74 in.∙lbf
Fuel inlet pipe, Fuel return pipe x Injection pump 24.55 250 18
Injection pump x Timing belt case 20.5 210 15
Injection pump stay x Injection pump, Cylinder block 18 185 13
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SS--13
SERVICE SPECIFICATIONS -- COOLING
COOLING
SS06T--01
SERVICE DATA
Thermostat Valve opening temperature 86 -- 90˚C (187 -- 194˚F)
Valve lift at 100˚C (212˚F) 8 mm (0.31 in.) or more
Radiator cap Relief valve opening pressure STD 93 -- 123 kPa (0.95 -- 1.25 kgf/cm2, 13.5 -- 17.1 psi)
Minimum 59 kPa (0.6 kgf/cm2, 8.5 psi)
CONTINUED
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SS--14
SERVICE SPECIFICATIONS -- COOLING
SS06U--01
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
Engine coolant drain plug x Cylinder block 29 300 21
Water pump x Cylinder block 23 230 17
Fan x Fluid coupling 6.5 65 58 in.∙lbf
Fluid coupling x Water pump pulley 18.5 185 14
Water outlet x Water outlet housing 19 195 14
Support x Tank on radiator 13 130 10
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SS--15
SERVICE SPECIFICATIONS -- LUBRICATION
LUBRICATION
SS06V--01
SERVICE DATA
Oil pressure at idle speed 29 kPa (0.3 kgf/cm2, 43 psi) or more
at 3,000 rpm 294 -- 539 kPa (3.0 -- 5.5 kgf/cm2, 43 -- 78 psi)
Oil pump Tip clearance STD 0.110 -- 0.240 mm (0.0043 -- 0.0094 in.)
Maximum 0.30 mm (0.0118 in.)
Body clearance STD 0.114 -- 0.219 mm (0.0057 -- 0.0086 in.)
Maximum 0.40 mm (0.0157 in.)
Side clearance STD 0.035 -- 0.085 mm (0.0014 -- 0.0033 in.)
Maximum 0.15 mm (0.0059 in.)
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SS--16
SERVICE SPECIFICATIONS -- LUBRICATION
SS06W--01
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
Drain plug x Oil pan 34.5 350 25
Oil pump cover x Oil pump 10 105 7
Plug x Oil pump 37 375 27
Oil pump (Timing belt case) x Cylinder block 22.5 230 17
Oil pump (Timing belt case) x Injection pump 20.5 210 15
Oil strainer x Cylinder block Bolt 18 180 13
Nut 21 210 15
STARTING
SS06Z--01
SERVICE DATA
Pre--heating Light lighting time
system Super glow type Approx. 2.2 seconds
Variable delay type Approx. 5 seconds
Starter (2.0 kW) Rated voltage and output power 12 V 2.0 kW
No-- load characteristics Current 100 A or less at 11.5 V
rpm 4,000 rpm or more
Brush length STD 15.0 mm (0.591 in.)
Minimum 9.0 mm (0.354 in.)
Brush spring installed load STD 21.5 -- 27.5 N (2.2 -- 2.8 kgf, 4.9 -- 6.2 lbf)
Minimum 12.7 N (1.3 kgf, 2.9 lbf)
Commutator
Diameter STD 35.0 mm (1.378 in.)
Minimum 34.0 mm (1.339 in.)
Undercut depth STD 0.7 mm (0.028 in.)
Minimum 0.2 mm (0.008 in.)
Circle runout Maximum 0.05 mm (0.020 in.)
Field frame
Shunt coil resistance at 20˚C (68˚F) 1.5 -- 1.9 Ω
Magnetic switch
Contact plate for wear Maximum 0.9 mm (0.035 in.)
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
Glow plug resistor x Intake manifold 34 350 25
Water temperature sensor x Cylinder block 17.5 178 13
Glow plug x Cylinder head 13 130 10
Terminal 30 nut, Terminal C nut x Terminal bolt 2.0 kW, 2.2 kW 17 173 13
2.7 kW 30 306 22
CHARGING
SS06X--01
SERVICE DATA
Battery Specific gravity at 20˚C (68˚F) 1.25 -- 1.29
Voltage at 20˚C (68˚F) 12.5 -- 12.9 V
CONTINUED
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SS--20
SERVICE SPECIFICATIONS -- CHARGING
SS06Y--01
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
Bearing retainer x Drive end frame 2.6 26.5 23 in.∙lbf
Rectifier end frame x Rectifier holder 3.9 40 35 in.∙lbf
Rectifier end frame x Drive end frame 5.9 60 52 in.∙lbf
Rectifier holder x Coil lead on rectifier end frame 2.0 20 18 in.∙lbf
IC regulator x Rectifier end frame 2.0 20 18 in.∙lbf
IC regulator x Rectifier holder 2.0 20 18 in.∙lbf
Brush holder x Rectifier holder 2.0 20 18 in.∙lbf
Brush holder x 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 41.5 36 in.∙lbf
Vacuum Pump x Rectifier end frame 7.8 80 69 in.∙lbf
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ENGINE MECHANICAL
COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 1
INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . EM-- 3
IDLE SPEED AND MAXIMUM SPEED . . . . . . EM-- 5
INTAKE SHUTTER (5L) . . . . . . . . . . . . . . . . . . . EM-- 7
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . EM-- 9
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . EM-- 12
COMPRESSION EM058--01
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE GLOW PLUGS
3. DISCONNECT INJECTION PUMP (FUEL CUT SOLE-
NOID) CONNECTOR
A01001
SST (Compression) (b) Connect SST (compression gauge ) to the SST (attach-
ment).
SST 09992 -- 00025 (09992 -- 00211)
(c) Fully open the throttle valve, and start the engine.
(d) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine revolution
A01002 of 250 rpm or more.
(e) Repeat steps (a) through (d) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
2L--T 3,040 kPa (31.0 kgf/cm2, 441 psi) or more
2L, 3L, 5L 3,138 kPa (32.0 kgf/cm2, 455 psi) or more
Minimum pressure: 1,961 kPa (20.0 kgf/cm2, 284 psi)
Difference between each cylinder:
490 kPa (5.0 kgf/cm2, 71 psi) or less
CONTINUED
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EM--2
ENGINE MECHANICAL -- COMPRESSION
INSPECTION
HINT:
Inspect and adjust the injection timing when the engine cold.
Dial
Indicator SST A01003
A01004
A01005
Turn CONTINUED
A01006
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EM--4
ENGINE MECHANICAL -- INJECTION TIMING
Greater than (e) Adjust plunger stroke by slightly tilting the injection pump
Specification body.
If the stroke is less than specification, tilt the pump toward the
engine.
If the stroke is greater than specification, tilt the pump away
Less than from the engine.
Specification (f) Tighten these nuts and bolts:
S 2 nuts holding injection pump to timing belt case
A01008 Torque: 20.5 N∙m (210 kgf∙cm, 15 ft∙lbf)
S Bolt (2L--T) or 2 bolts (2L, 3L, 5L) holding injection
pump to injection pump stay
Torque: 18 N∙m (185 kgf∙cm, 13 ft∙lbf)
S 4 nuts holding injection pipes to injection pump
Torque: 24.5 N∙m (250 kgf∙cm, 18 ft∙lbf)
(g) Recheck the plunger stroke.
5. REMOVE SST AND DIAL INDICATOR
6. w/ ACSD:
REMOVE METAL PLATE
(a) Remove the SST and dial indicator.
SST 09275 -- 54011
(b) Install a new gasket and the plug bolt of the distributive
head plug.
Torque: 17 N∙m (170 kgf∙cm, 12 ft∙lbf)
7. START ENGINE AND CHECK FOR FUEL LEAKS
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EM--5
ENGINE MECHANICAL -- IDLE SPEED AND MAXIMUM SPEED
INSPECTION
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All accessories switched OFF
(d) All vacuum lines properly connected
(e) Valve clearance set correctly
(f) Injection timing set correctly
(g) Transmission in neutral position
(h) w/ PS:
Steering wheel at straight--ahead position
2. CONNECT TACHOMETER
S03723 CONTINUED
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EM--6
ENGINE MECHANICAL -- IDLE SPEED AND MAXIMUM SPEED
Seal
Wire
A01009
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EM--7
ENGINE MECHANICAL -- INTAKE SHUTTER (5L)
INSPECTION
1. INSPECT INTAKE SHUTTER OPERATION
(a) Start the engine.
(b) When running the engine, check the diaphragm rod is ful-
Closed
Open ly open position.
(c) When the engine stops (IG OFF), check that the dia-
B01342
phragm rod is fully closed position.
(d) A few seconds after the engine stops (IG OFF), check that
the diaphragm rod is fully open position.
Disconnect
2. INSPECT VENTURI
(a) Start the engine.
(b) Disconnect the vacuum hose from the actuator.
(c) Apply vacuum directly to the actuator with the engine id-
ling.
(d) Check that the engine runs rough or dies.
(e) Reconnect the vacuum hoses to the proper locations.
Connect B01343
CONTINUED
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EM--8
ENGINE MECHANICAL -- INTAKE SHUTTER (5L)
B01339
B01340
Filter
B01341
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EM--9
ENGINE MECHANICAL -- CYLINDER HEAD
INSPECTION
1. INSPECT VALVES
Overall Length Check the valve overall length.
Standard overall length:
Intake
2L, 2L--T, 3L 103.29 -- 103.69 mm (4.0665 -- 4.0823 in.)
EM2534 5L 104.10 -- 104.50 mm (4.0984 -- 4.1142 in.)
Exhaust
2L, 2L--T, 3L 103.14 -- 103.54 mm (4.0606 -- 4.0764 in.)
5L 103.95 -- 104.35 mm (4.0925 -- 4.1083 in.)
Minimum overall length:
Intake
2L, 2L--T, 3L 102.79 mm (4.0468 in.)
5L 103.60 mm (4.0787 in.)
Exhaust
2L, 2L--T, 3L 102.64 mm (4.0409 in.)
5L 103.45 mm (4.0728 in.)
If the overall length is less than minimum, replace the valve.
2. INSPECT CAMSHAFT
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
2L 53.850 -- 53.870 mm (2.1201 -- 2.1209 in.)
2L--T 53.450 -- 53.470 mm (2.1043 -- 2.1051 in.)
3L, 5L 54.290 -- 54.310 mm (2.1374 -- 2.1382 in.)
Exhaust 54.990 -- 55.010 mm (2.1650 -- 2.1657 in.)
EM2011
Minimum cam lobe height:
Intake
2L 53.35 mm (2.1004 in.)
2L--T 52.49 mm (2.0665 in.)
3L, 5L 53.79 mm (2.1177 in.)
Exhaust 54.49 mm (2.1453 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
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EM--10
ENGINE MECHANICAL -- CYLINDER HEAD
EM05D--01
INSTALLATION
1. CHECK PISTON PROTRUSIONS FOR EACH CYL-
INDER
(a) Clean the cylinder block with solvent.
(b) Set the piston of the cylinder to be measured to slightly
before TDC.
(c) Place a dial indicator on the cylinder block, set the mea-
25 mm
suring tip as shown in the illustration.
(0.98 in.) A00998
(d) Set the dial indicator at 0 mm (0 in.).
HINT:
S Use a dial indicator measuring tip as shown in the illustra-
tion.
S Make sure that the measuring tip is square to the cylinder
block gasket surface and piston head when taking the
measurements.
Measuring Tip (e) Find where the piston head protrudes most by slowly turn-
ing the crankshaft clockwise and counterclockwise.
Protrusion
A00999
CONTINUED
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EM--11
ENGINE MECHANICAL -- CYLINDER HEAD
DISASSEMBLY
RE MO V E CO NNE CTI NG RO D CAP S AND CHE CK O I L
CLEARANCE
Measure the Plastigage at its widest point.
Standard oil clearance:
STD 0.036 -- 0.064 mm (0.0014 -- 0.0025 in.)
A03116 U/S 0.25, U/S 0.50
2L 0.023 -- 0.073 mm (0.0009 -- 0.0029 in.)
2L--T, 3L, 5L 0.033 -- 0.079 mm (0.0013 -- 0.0031 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
Link Continues
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EM--13
ENGINE MECHANICAL -- CYLINDER BLOCK
EM05F--01
Mark INSPECTION
1, 2 or 3 1. INSPECT CYLINDER BORE DIAMETER
No.4 HINT:
No.3
No.2 There are 3 sizes of the standard cylinder bore diameter,
No.1 marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the
top or under of the cylinder block.
Mark
1, 2 or 3
Front
A00981
A03117 A00985
C 10 mm Maximum diameter:
A03118 (0.39 in.) 2L, 2L--T
A03086 A00984
STD 92.23 mm (3.6311 in.)
O/S 0.50 92.73 mm (3.6508 in.)
O/S 0.75 92.98 mm (3.6606 in.)
O/S 1.00 93.23 mm (3.6705 in.)
3L
STD 96.23 mm (3.7886 in.)
O/S 0.50 96.73 mm (3.8083 in.)
CONTINUED
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EM--14
ENGINE MECHANICAL -- CYLINDER BLOCK
5L
STD 99.73 mm (3.9264 in.)
O/S 0.50 100.23 mm (3.9461 in.)
Piston diameter:
2L, 2L -- T
STD Mark 1 91.940 -- 91.950 mm (3.6197 -- 3.6201 in.)
Distance Mark 2 91.950 -- 91.960 mm (3.6201 -- 3.6205 in.)
Mark 3 91.960 -- 91.970 mm (3.6205 -- 3.6209 in.)
O/S 0.50 92.440 -- 92.470 mm (3.6394 -- 3.6405 in.)
3L
STD Mark 1 95.940 -- 95.950 mm (3.7772 -- 3.7776 in.)
Mark 2 95.950 -- 95.960 mm (3.7776 -- 3.7779 in.)
Mark 3 95.960 -- 95.970 mm (3.7779 -- 3.7783 in.)
O/S 0.50 96.440 -- 96.470 mm (3.7968 -- 3.7980 in.)
5L
STD Mark 1 99.450 -- 99.460 mm (3.9153 -- 3.9157 in.)
Mark 2 99.460 -- 99.470 mm (3.9157 -- 3.9161 in.)
Mark 3 99.470 -- 99.480 mm (3.9161 -- 3.9165 in.)
O/S 0.50 99.950 -- 99.980 mm (3.9350 -- 3.9362 in.)
Front
CONTINUED
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EM--16
ENGINE MECHANICAL -- CYLINDER BLOCK
S04423
A03120 CONTINUED
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EM--17
ENGINE MECHANICAL -- CYLINDER BLOCK
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHINGS
SST (a) Using SST and a press, press out the bushing.
SST 2L
09222 -- 64012 (09222 -- 02022, 09222 -- 02041)
2L -- T, 3L, 5L
SST 09222 -- 54011 (09222 -- 03016, 09222 -- 03026)
(b) Using a round file, lightly file off any roughness from the
small end of the connecting rod.
A03129
(c) Attach the bushing to SST with the ball of SST inside the
oil hole of the bushing.
Oil Hole SST 2L
09222 -- 64012 (09222 -- 02031)
2L -- T, 3L, 5L
Ball 09222 -- 54011 (09222 -- 03021)
SST
A03130
(d) Align the oil holes of a new bushing and the connecting
rod.
Oil
Hole
A03131
(f) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page) between the
bushing and piston pin.
A03134
A03135
CONTINUED
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EM--20
ENGINE MECHANICAL -- CYLINDER BLOCK
2L, 2L--T, 3L Front Mark Size Mark (b) Using a micrometer, measure the piston diameter at right
(Arrow) (2L) angles to the piston pin center line, the indicated distance
Size from the piston head.
Mark Distance:
(2L--T, 3L) 2L, 2L--T 58.27 -- 58.33 mm (2.2941 -- 2.2965 in.)
3L 56.27 -- 56.33 mm (2.2153 -- 2.2177 in.)
Distance 5L 61.27 -- 61.33 mm (2.4122 -- 2.4146 in.)
REASSEMBLY
No.1
INSTALL PISTON RINGS
Using a piston ring expander, install the No.1 and No.2 piston
rings with the code mark facing upward.
Code
Code mark:
No.2 Mark
No.1 2L, 2L--T T1 or 1N
3L T1 or N1
5L 1N
A03124 A03123 A03114
No.2 2L, 2L--T 2T or 2N
3L T or 2N
5L 2N
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TURBO CHARGING
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . TC- 1
PRECAUTION ....................... TC-- 1/2
TROUBLESHOOTING ....................... TC-- 3/4
ON-VEHICLE INSPECTION . . . . . . . . . . . . . TC-- 5
COMPONENTS ....................... TC-- 6/7
REMOVAL ....................... TC -- 8
INSPECTION ....................... TC -- 9
REPLACEMENT ....................... TC -- 10/11
INSTALLATION ....................... TC -- 12/13
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TC--1
TURBOCHARGING -- TURBOCHARGER
TURBOCHARGER TC001--01
PRECAUTION
1. DO NOT STOP ENGINE IMMEDIATELY AFTER PULL-
ING TRAILER OR AFTER HIGH SPEED OR UPHILL
DRIVING
IDLE ENGINE FOR 20 -- 120 SECONDS, DEPENDING
ON HOW HARD VEHICLE HAS BEEN DRIVEN
2. AVOID SUDDEN ACCELERATION OR RACING IM-
MEDIATELY AFTER STARTING COLD ENGINE
3. IF TURBOCHARGER IS FOUND TO BE DEFECTIVE
AND MUST BE REPLACED, CHECK FOR CAUSE, AND
REPAIR OR REPLACE THESE ITEMS AS NEC-
ESSARY:
S Engine oil level and quality
S Conditions under which turbocharger was used
S Oil lines leading to turbocharger
CONTINUED
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TC--2
TURBOCHARGING -- TURBOCHARGER
B00926
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TC--3
TURBOCHARGING -- TURBOCHARGER
TC002--01
TROUBLESHOOTING
HINT:
Before troubleshooting the turbocharger, first check the engine itself. (valve clearance, engine compression,
injection timing etc.)
1. INSUFFICIENT ACCELERATION, LACK OF POWER OR EXCESSIVE FUEL CONSUMPTION
Possible Cause Check Procedure and Correction Method
1. TURBOCHARGING PRESSURE Check turbocharging pressure. (See page TC -- 5)
TOO LOW Turbocharging pressure:
60 -- 79 kPa (0.61 -- 0.81 kgf/cm2, 8.7 -- 11.5 psi)
If pressure is below specifications, begin diagnosis
from item 2.
2. RESTRICTED INTAKE SYSTEM Check intake air system, and repair or replace parts as
necessary. (See page TC -- 8)
3. LEAK IN INTAKE AIR SYSTEM Check intake air system, and repair or replace parts as
necessary. (See page TC -- 8)
4. RESTRICTED EXHAUST SYSTEM Check exhaust system, and repair or replace parts as
necessary. (See page TC -- 8)
5. LEAK IN EXHAUST SYSTEM Check exhaust system, and repair or replace parts as
necessary. (See -- page TC -- 8)
2. ABNORMAL NOISE
Possible cause Check Procedure and Correction Method
1. TURBOCHARGING HEAT Check for loose, improperly installed or deformed Insu-
INSULATOR RESONANCE lator nut and bolts, and repair or replace as necessary.
2. EXHAUST PIPE LEAKING OR Check for deformed exhaust pipe, loose bolts or dam-
VIBRATING aged gasket, and repair or replace as necessary.
CONTINUED
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TC--4
TURBOCHARGING -- TURBOCHARGER
ON -- VEHICLE INSPECTION
1. INSPECT INTAKE AIR SYSTEM
Check for leakage or clogging between the air cleaner housing
and turbocharger inlet and between the turbocharger outlet and
cylinder head.
S Clogged air cleaner .... Clean or replace element
S Hoses collapsed or deformed ....Repair or replace
S Leakage from connections .... Check each
connection and repair
S Cracks in components .... Check and replace
2. INSPECT EXHAUST SYSTEM
Check for leakage or clogging between the cylinder head and
turbocharger inlet and between the turbochager outlet and ex-
haust pipe.
S Deformed components .... Repair or replace
S Foreign material in passages .... Remove
S Leakage from components .... Repair or replace
S Cracks in components .... Check and replace
COMPONENTS
PCV Hose
Wire Clamp
Clamp
No.1 Turbo Insulator
z z z Gasket
z 52 (530, 38)
z
z z No.3 Turbo
Insulator
Exhaust
Manifold Turbocharger
Stay Assembly
25.5 (260, 19)
z Gasket
z Gasket
Oil Hose
Turbocharger
Bearing Housing
Side Plate
z Gasket
z Actuator Kit Part
z
Actuator 26 (260, 19)
Hose z Gasket
E--Ring
Actuator z z
z Gasket
z Gasket
Turbo Water Pipe
z z
19 (195, 14)
Turbo Oil Pipe
REMOVAL
(1) (2)
1. DRAIN ENGINE COOLANT
2. REMOVE INTAKE PIPE AND INTAKE FLANGE AS-
(3) SEMBLY
(a) Disconnect these parts:
(1) PCV hose from intake pipe
(2) Wire clamp from bracket
(3) Gas filter from clamp
B00945
(b) Remove the 3 nuts, and disconnect the intake flange from
the intake manifold. Remove the gasket.
(c) Loosen the hose clamp, and disconnect the air hose from
the turbocharger. Remove the intake pipe and intake
flange assembly.
3. REMOVE TURBO HEAT INSULATORS
(a) Remove the bolt, nut and No.1 turbo heat insulator.
(b) Remove the bolt and No.2 turbo heat insulator.
(c) Remove the 2 bolts and No.3 turbo heat insulator.
4. DISCONNECT TURBO WATER HOSES FROM TURBO
WATER PIPE
Oil
Hose
B00946
INSPECTION
1. INSPECT TURBINE SHAFT ROTATION
Grasp the edge of the turbine shaft, and turn it. Check that the
turbine shaft turns smoothly.
Turn If the turbine shaft does not turn or if it turns with a heavy drag,
replace the turbocharger.
B00929
REPLACEMENT
REPLACE ACTUAOR
(a) Remove the actuator.
(1) Remove the actuator hose.
(2) Remove the 2 bolts holding the actuator to the com-
pressor housing.
(3) Remove the E--ring holding the actuator push rod to
the waste gate valve link, and remove the actuator.
B00937
CONTINUED
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TC--11
TURBOCHARGING -- TURBOCHARGER
B00935
SST (5) Using SST, apply 83 kPa (0.85 kgf/cm2, 12.0 psi) of
pressure to the actuator, and measure the actuator
push rod stroke.
SST 09992 -- 00242
Standard stroke: 1.20 -- 1.70 mm (0.0472 -- 0.0669 in.)
If the stroke is outside specifications, reselect the plate wash-
Stroke ers.
(d) Install the actuator hose.
B00936 (e) Apply yellow paint from the actuator bolts to the actuator
bracket to indicate that they have been correctly installed.
(f) Check the turbocharging pressure. (See page TC -- 5)
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TC--12
TURBOCHARGING -- TURBOCHARGER
TC008--01
INSTALLATION
NOTICE:
After replacing the turbocharger assembly, pour approx.
20 cm3 (1.2 cu in.) of fresh oil into the oil inlet hole and turn
the turbine wheel by hand to splash oil on the bearing.
1. I NS TALL BE ARI NG HO US I NG S I DE P LATE TO
TURBOCHARGER
Install a new gasket and the side plate with the 2 bolts.
B00933
Torque: 7.8 N∙m (80 kgf∙cm, 69 in.∙lbf)
2. INSTALL TURBINE OUTLET BLBOW TO TURBO-
CHARGER
Install a new gasket and the outlet elbow with 4 new nuts.
Torque: 26 N∙m (260 kgf∙cm, 19 ft∙lbf)
CONTINUED
Front
B00948
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TC--13
TURBOCHARGING -- TURBOCHARGER
ENGINE FUEL
REPLACEMENT
1. REMOVE FUEL FILTER ASSEMBLY FROM FUEL
FILTER SUPPORT
2. REPLACE FUEL FILTER
(a) Loosen the drain plug, and drain the fuel from the fuel fil-
ter.
B00940
B00941
B00943
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FU--2
ENGINE FUEL -- FUEL HEATER
INSPECTION
1. REMOVE FUEL HEATER
B00910
2 B00909
TEST
INJECTION PRESSURE TEST
Opening pressure:
2L, 2L--T, 3L
New nozzle 14,810 -- 15,590 kPa (151 -- 159 kgf/cm2, 2,148 -- 2,262 psi)
Reused nozzle 14,220 -- 15,200 kPa (145 -- 155 kgf/cm2, 2,062 -- 2,205 psi)
B01388 5L
New nozzle 15,790 -- 16,570 kPa (161 -- 169 kgf/cm2, 2,290 -- 2,404 psi)
Reused nozzle 15,200 -- 16,181 kPa (155 -- 165 kgf/cm2, 2,205 -- 2,347 psi)
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PAGE 1 of 3
INJECTION PUMP – COMPONENTS FU-4/10
DISASSEMBLY FU11/12
INSPECTION FU-13
ADJUSTMENT
1. PRE-TEST CHECK AND PREPARATION FU-14/17
2. 2L-T: CHECK BOOST COMPENSATOR FOR AIR TIGHTNESS FU-18
3. w/ HAC: CHECK HIGH ALTITUDE COMPENSATOR FOR AIR TIGHTNESS FU-18
4. PRE-SET FULL LOAD INJECTION VOLUME FU-18
2L w/ ACSD: (Part No. 22100-5B320, 5B360) FU-18
2L w/o ACSD: (Part No.22100-54770, 54780, 54800, 54810) FU-19
2L-T: (Part No. 22100-5B460, 5B670) FU-19
3L: (Part No. 22100-54850, 54860, 54870, 54880) FU-19
3l: (Part No. 22100-54710, 5B510) FU-19
5L w/ HAC: (Part No. 22100-5B720) FU-19
5L w/o HAC: (Part No. 22100-5B710) FU-19/20
5. w/o HAC: PRE-SET LOAD SENSING TIMER FU-20
6. PRE-SET MAXIMUM SPEED FU-20/21
2L w/ ACSD: (Part No. 22100-5B320, 5B360) FU-21
2L w/o ACSD: (Part No. 22100-54770, 54780, 54800, 54810) FU-21
2L-T: (Part No. 22100-5B460, 5B670) FU-21
3L: (Part No. 22100-54710, 5B510) FU-21
3L: (Part No. 22100-54850, 54860, 54870, 54880) FU-21
5L: (Part No. 22100-5B710, 5B720) FU-21/22
7. ADJUST PUMP INNER PRESSURE FU-22
8. CHECK OVERFLOW VOLUME FU-22/23
9. w/ ACSD: RELEASE COLD STARING SYSTEM FU-23
10. ADJUST TIMER FU-23
2L w/ ACSD: (Part No. 22100-5B320, 5B360) FU-23
2Lw/o ACSD: (Part No. 22100-54770, 54780, 54800, 54810) FU-23
2L-T: (Part No. 22100-5B460, 5B670) FU-24
3L w/ ACSD: (Part No. 22100-5B510) FU-24
3L w/o ACSD: (Part No. 22100-54710, 54850, 54860, 54870, 54880) FU-24
5L w/ ACSD: (Part No. 22100-5B710) FU-24
5L w/o ACSD: (Part No. 22100-5B720) FU-24/25
11. ADJUST FULL LOAD INJECTION VOLUME FU-25/26
2L w/ ACSD: (Part No. 22100-5B320, 5B360) FU-26
2L w/o ACSD: (Part No. 22100-54770, 54780, 54800, 54810) FU-26
2L-T: (Part No. 22100-5B460, 5B670) FU-26
3L: (Part No. 22100-54850, 54860, 54870, 54880) FU-26
3L: (Part No. 22100-54710, 5B510) FU-26
5L w/ HAC: (Part No. 22100-5B720) FU-26
5L w/o HAC: (Part No. 22100-5B710) FU-27
CONTINUED
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PAGE 2 OF 3
12. ADJUST MAXIMUM SPEED FU-27
2L w/ ACSD: (Part No. 22100-5B320, 5B360) FU-27
2L w/o ACSD: (Part No. 22100-54770, 54780, 54800, 54810) FU-27
2L-T: (Part No. 22100-5B460, 5B670) FU-28
3L: (Part No. 22100-54710, 5B510) FU-28
3L: (Part No. 22100-54850, 54860, 54870, 54880) FU-28
5L: (Part No. 22100-5B710, 5B720) FU-28
13 CHECK IN INJECTION VOLUME FU-29
2L w/ HAC: (Part No. 22100-54800, 54810) FU-29
2L w/o HAC for w/ ACSD: (Part No. 22100-5B320, 5B360) FU-29
2L w/o HAC for w/o ACSD: (Part No. 22100-54770, 54780) FU-29
2L-T: (Part No. 22100-5B460, 5B670) FU-30
3L w/ HAC: (Part No. 22100-54870, 54880) FU-30
3L w/o HAC: (Part No. 22100-54710, 5B510) FU-30
3L w/o HAC: (Part No. 22100-54850, 54860) FU-31
5L w/ HAC: (Part No. 22100-5B720) FU-31
5L w/o HAC: (Part No. 22100-5B710) FU-31/33
14 L-T: ADJUST FULL LOAD MINIMUM INJECTION VOLUME FU-33
15 2L-T: ADJUST BOOST COMPENSATOR FU-33
16 2L-T: CHECK FOR CHARACTERISTIC TENDENCY FU-34
17 2L-T: CHECK HYSTERESIS FU-34
18 w/o HAC (2L, 3L), 2L-T, 5L: ADJUST LOAD SENSING TIMER FU-35
MEASURE THE INJECTION VOLUME
2L, 3L, 5L: FU-35
2L-T: FU-35
MEASURE THE INJECTION VOLUME AT THE DROP POINT (STARTING POINT) FU-35
2L, 3L, 5L: FU-35
2L-T: FU-35
PUMP INNER PRESSURE STOPS DROPPING FU-36
2L w/ ACSD: (Part N. 22100-5B320, 5B360) FU-36
2L w/o ACSD: (Part No. 22100-54770, 54780) FU-36
2L-T: (Part No. 22100-5B460, 5B670) FU-36
3L: (Part No. 22100-54710, 5B510) FU-36
3L: (Part No. 22100-54850, 54860) FU-36
5L w/ ACSD: (Part No. 22100-5B710) FU-36
5L w/o ACSD: (Part No. 22100-5B720) FU-37
CHECK THE TIMER PISTON FLUCTUATION WHEN THE ADJUSTING LEVER IS MOVED
FROM THE MAXIMUM SPEED SIDE TO THE IDLE SPEED SIDE FU-37
2L w/ ACSD: (Part No. 22100-5B320, 5B360) FU-37
2L w/o ACSD: (Part No. 22100-54770, 54780) FU-37
2L-T: (Part No. 22100-5B460, 5B670) FU-37
3L w/ ACSD: (Part No. 22100-5B510) FU-37
3L w/o ACSD: (Part No. 22100-54710, 54850, 54860) FU-37
5L w/o ACSD: (Part NO. 22100-5B720) FU-37/38
CONTINUED
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PAGE 3 OF 3
INJECTION PUMP
FU00G--01
COMPONENTS
Turbo Water No.1 Timing Belt Cover
Hose (2L--T)
Gasket
Hose Clamp Timing Belt
(2L--T)
Drive Belt
Water Pump
Pulley
Crankshaft
Fan and Fluid 235 (2,400, 173)
Pulley 2L--T
Coupling Assembly Clamp
PCV Hose
Collar Wire Clamp
Glow Plug Wire
Spacer
Glow Plug Connector
13 (130, 9)
Glow Plug
Gas Filter
Collar
z Gasket
Injection Pump Intake Pipe
Drive Pulley and Intake
Flange Assembly
Collar
PCV Hose
N∙m (kgf∙cm, ft∙lbf) : Specified torque
zNon--reusable part B01368
CONTINUED
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FU--5
ENGINE FUEL -- INJECTION PUMP
w/ TCV
Connector for
Pickup Sensor
Connector for
Timing Control
Valve and Fuel
Cut Solenoid
Pipe Clamp
Injection Pipe
Pipe Clamp
Accelerator Link
Connecting Link
Boost Compersator Hose
Fuel Return Hose
(2L--T)
No.2 Cylinder Block Idle--Up Vacuum Hose (w/ A/C)
Insulator
(Europe and Australia) Fuel Return Hose
CONTINUED
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FU--6
ENGINE FUEL -- INJECTION PUMP
z Gasket
Fuel Inlet Pipe
z Gasket
Injection Pump
(2L--T)
z Gasket z Gasket
Injection Pump
(w/ HAC)
Injection Pump
(w/o HAC)
z Gasket
Fuel Return Pipe
z Gasket
CONTINUED
N∙m (kgf∙cm, ft∙lbf) : Specified torque
zNon--reusable part B01363
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FU--7
ENGINE FUEL -- INJECTION PUMP
2L--T
Diaphragm Cover
Spring Seat
Idle--Up Lever
CONTINUED
z Non--reusable part B01359
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FU--8
ENGINE FUEL -- INJECTION PUMP
w/ HAC
z Gasket
Rubber Cap
Rubber Cap
No.2 Adjusting
Level
Pnematic Bellows
No.1 Adjusting
Lever Full Load Set Screw
Push Rod
Return Spring
Idle--Up
Rubber Cap
Pnematic Bellows Actuator
Spring (w/ A/C)
CONTINUED
z Non--reusable part B01360
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FU--9
ENGINE FUEL -- INJECTION PUMP
w/o HAC
No.2 Adjusting
Lever
No.1 Adjusting
Lever Full Load Set Screw
Return Spring Plate Washer
z O--Ring
Idle Speed Idle--Up
Adjusting Actuator
Governor Cover
z O--Ring Screw w/o ACSD
Plate Washer for w/ A/C
Lead Wire
Speed Control (w/ Pickup Sensor for w/o TCV)
Adjusting Spring
Lever Shaft
Spring Seat
Fuel Cut Lead Wire
Damper Spring Solenoid (w/o Pickup Sensor)
Spring z O--Ring
Valve
Connector Bracket Strainer
(w/ TCV) Wave
Washer
Lead Wire
Lead Clamp (w/ Pickup Sensor for w/ TCV)
w/ Pickup Sensor
for w/ TCV Lead Clamp Connector Bracket (w/o TCV)
Pickup Sensor
(w/ TCV) z Gasket Timing Control
Pickup Sensor
Valve (w/ TCV)
(w/o TCV) z O--Ring z O--Ring
Set Key
Thermo Wax (w/ ACSD)
11.3 (115, 8)
Idle--Up Actuator
Pipe Clamp (w/ TCV) (w/ A/C)
Pipe Clamp (w/ TCV)
z Gasket
Overflow Pipe (w/ TCV)
z Gasket
z Gasket
z Gasket
15.7 (160, 12) Idle--Up Lever
(w/ ACSD)
CONTINUED
N∙m (kgf∙cm, ft∙lbf) : Specified torque
z Non--reusable part B01361
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FU--10
ENGINE FUEL -- INJECTION PUMP
Bearing Retainer
z E--Ring
Governor Sleeve
No.2 Flyweight Washer
Flyweight Holder
No.1 Flyweight Washer
Governor Gear Bearing
Adjusting Washer Stop Ring
Governor Shaft Face Camplate
Flyweight Coupling Spring
z O--Ring
z Gasket
Governor Link
Regurator Valve Fuel Inlet Hollow Screw Coupling
8.85 (90, 78 in.∙lbf) 36.8 (375, 27)
z Gasket Roller and Washer
O--Ring
O--Ring Clip
Pump Body Roller Ring Stopper Pin
RH Timer Cover Slide Pin
z Gasket Set Key
z Oil Seal
z Joint Rubber
4 mm
DISASSEMBLY
2L -- T:
Hexagon
Wrench DISASSEMBLE BOOST COMPENSATOR
(a) Using a 4 mm hexagon wrench, remove the bolt and gas-
ket.
(b) Remove the rubber cap and overflow screw.
B01345
5 mm
Hexagon
Wrench
B01347
Spring
B01348
Spring Seat (3) Remove the nut, and disassemble these parts:
Diaphram . 2 spring seats
. Diaphragm
. Push rod
Spring Seat
Push Rod
B01387
CONTINUED
S03281
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FU--12
ENGINE FUEL -- INJECTION PUMP
4 mm
Hexagon
Wrench
B01350
B01351
B01352
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FU--13
ENGINE FUEL -- INJECTION PUMP
FU00I--01
INSPECTION
INSPECT SPRING LENGTH
Using vernier calipers, measure the free length of each spring.
Spring free length: mm (in.)
Delivery valve spring 24.4 (0.961)
Plunger spring 30.0 (1.181)
Coupling spring 16.6 (0.654)
EM0801
Pneumatic bellows spring (w/ HAC) 30.0 (1.181)
Boost compensator spring (2L--T) 19.4 (0.764)
If the free length is not as specified, replace the spring(s).
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FU--14
ENGINE FUEL -- INJECTION PUMP
FU00J--01
ADJUSTMENT
1. PRE -- TEST CHECK AND PREPARATION
(a) The specifications for test nozzle and nozzle holders are
as follows.
Test nozzle: DN12SD12 (DENSO)
Test nozzle opening pressure:
14,220 -- 15,200 kPa
(145 -- 155 kgf/cm2, 2,062 -- 2,205 psi)
(b) Check the accuracy of the tachometer.
Allowable error: ± 40 rpm
(c) Install the angle gauge stand.
(d) Mount the injection pump body on the pump tester.
HINT:
Place a mark on the key groove portion of the coupling.
S04623
B00057
Fuel Inlet Hollow Screw Fuel Inlet Pipe (f) Remove the fuel inlet hollow screw.
(g) Connect the fuel inlet pipe with an adapter.
Torque: 24.55 N∙m (250 kgf∙cm, 18 ft∙lbf)
w/ HAC w/o HAC (h) Install an overflow hose with the 2 gaskets and an over-
Overflow Screw flow screw.
Torque: 24.55 N∙m (250 kgf∙cm, 18 ft∙lbf)
HINT:
Always use the overflow screw installed on the pump to be ad-
justed.
(i) Using a 5 mm hexagon wrench, remove the 2 bolts and
Overflow Hose RH timer cover.
S04630 S04650 B00052
CONTINUED
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FU--15
ENGINE FUEL -- INJECTION PUMP
(j) Install the inner pressure gauge with the timer measuring
device.
Timer Measuring Part No. 95095--10231, 95095--10480 (DENSO)
Device Torque: 8.35 N∙m (85 kgf∙cm, 74 in.∙lbf)
HINT:
Bleed the air by the air bleed screw.
Air Bleed (k) Connect SST (turbocharger pressure gauge) to the boost
Screw compensator
5 mm Hexagon Wrench S04645 SST 09992 -- 00242
Adjusting Valve
D C B A Fuel Filter
Nozzle
Measuring Fuel Feed
Cylinder Pump
Fuel Tank
B01354
Adjusting Valve
D C B A Fuel Filter
Nozzle
Measuring Fuel Feed
Cylinder Pump
Fuel Tank
S02310
CONTINUED
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FU--16
ENGINE FUEL -- INJECTION PUMP
Adjusting Valve
D C B A Fuel Filter
Nozzle
Measuring Fuel Feed
Cylinder Pump
Fuel Tank
S03392
(n) Install an angle gauge to the stand, and set it to the adjust-
ing lever.
Part No. 95095 -- 10360 (Stand w/ angle gauge)
(o) Secure the adjusting lever fully on the maximum speed
side.
CONTINUED
SST S03391
(3) Check that fuel is flowing out when the mark is in the
position shown in the illustration.
If not, it is improperly assembled.
(4) Disassemble and change the camplate position
180˚ in the opposite direction.
HINT:
At this time, disconnect the fuel cut solenoid wire harness.
SST S03391
B00426
HINT:
30 Seconds S Measure the volume of each injection cylinder with a mea-
suring cylinder.
S Before measuring the injection volume, first hold the cylin-
der tilted for at least 30 seconds to discard all the fuel.
CONTINUED
2L--T Pressure 2. 2L -- T:
CHECK BOOST COMPENSATOR FOR AIR
TIGHTNESS
(a) Operate the boost compensator with 0 kPa (0 kgf/cm2, 0
psi) to 120 ± 6.7 kPa (1.22 ± 0.07 kgf/cm2, 17.4 ± 1.0 psi)
of pressure for 10 seconds for each and repeat this opera-
tion 4 times.
(b) Apply 133 kPa (1.36 kgf/cm2, 19.3 psi) of pressure to the
B01355 boost compensator.
(c) Measure the time it takes for pressure to drop to 131 kPa
(1.34 kgf/cm2, 19.1 psi).
Pressure drop: 10 seconds or more
3. w/ HAC:
w/ HAC
CHECK HIGH ALTITUDE COMPENSATOR FOR AIR
TIGHTNESS
(a) Apply 73 kPa (548 mmHg, 21.56 in.Hg) of vacuum to the
high altitude compensator.
(b) Measure the time it takes for vacuum to drop to 72 kPa
(540 mmHg, 21.26 in.Hg).
Vacuum Vacuum drop: 5 seconds or more
S04631 4. PRE -- SET FULL LOAD INJECTION VOLUME
(a) Set the adjusting lever to maximum position.
(b) 2L--T:
Apply 62.7 kPa (0.64 kgf/cm2, 9.1 psi) of pressure to the
boost compensator.
(c) w/ HAC:
Apply 101 kPa (760 mmHg, 29.83 in.Hg) of vacuum to the
high altitude compensator.
(d) Measure the injection volume.
2L w/ ACSD:
(Part No. 22100--5B320, 5B360)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
11.04 -- 11.36
1,200 200
(0.67 -- 0.69)
CONTINUED
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FU--19
ENGINE FUEL -- INJECTION PUMP
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
10.42 -- 10.74
1,200 200
(0.64 -- 0.66)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
13.70 -- 14.02
1,000 200
(0.84 -- 0.86)
3L:
(Part No. 22100 -- 54850, 54860, 54870, 54880)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
11.56 -- 11.88
1,200 200
(0.71 -- 0.72)
3L:
(Part No. 22100 -- 54710, 5B510)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
10.96 -- 11.28
1,200 200
(0.67 -- 0.69)
5L w/ HAC:
(Part No. 22100 -- 5B720)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
12.82 -- 13.14
1,600 200
(0.78 -- 0.80)
5L w/o HAC:
(Part No. 22100 -- 5B710)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
12.18 -- 12.50
1,200 200
(0.74 -- 0.76)
CONTINUED
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FU--20
ENGINE FUEL -- INJECTION PUMP
Pry
B01365
S04642
S04643
Full Load Set Screw (h) Adjust by turning the full load set screw.
HINT:
The injection volume will increase about 3 cc (0.18 cu in.) with
each 1/2 turn of the screw.
S04644
(c) w/ HAC:
Apply 101 kPa (760 mmHg, 29.83 in.Hg) of vacuum to the
high altitude compensator.
(d) Measure the injection volume.
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
4.0 -- 5.6
2,575 200
(0.24 -- 0.34)
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
4.0 -- 5.6
2,450 200
(0.24 -- 0.34)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
4.3 -- 6.3
2,400 200
(0.26 -- 0.38)
3L:
(Part No. 22100 -- 54710, 5B510)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
4.6 -- 6.2
2,200 200
(0.28 -- 0.38)
3L:
(Part No. 22100 -- 54850, 54860, 54870, 54880)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
4.6 -- 6.2
2,300 200
(0.28 -- 0.38)
5L:
(Part No. 22100 -- 5B710, 5B720)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
4.6 -- 6.2
2,300 200
(0.28 -- 0.38)
CONTINUED
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FU--22
ENGINE FUEL -- INJECTION PUMP
Maximum Speed Adjusting Screw (e) Cut off the seal wire.
(f) Adjust the injection volume with the maximum speed ad-
justing screw.
7. ADJUST PUMP INNER PRESSURE
(a) Set the adjusting lever to maximum position.
(b) 2L--T:
Apply 62.7 kPa (0.64 kgf/cm2, 9.1 psi) of pressure to the
boost compensator.
S04648 (c) w/ HAC:
Apply 101 kPa (760 mmHg, 29.83 in.Hg) of vacuum to the
high altitude compensator.
(d) Measure the pump inner pressure at the below listed rpm.
2L, 3L, 5L:
Pump rpm Inner pressure kpa (kgf/cm2, psi)
500 314 -- 372 (3.2 -- 3.8, 46 -- 54)
2,100 648 -- 706 (6.6 -- 7.2, 94 -- 102)
2L--T:
Pump rpm Inner pressure kpa (kgf/cm2, psi)
500 353 -- 411 (3.6 -- 4.2, 51 -- 60)
2,100 687 -- 745 (7.0 -- 7.6, 100 -- 108)
CONTINUED
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FU--23
ENGINE FUEL -- INJECTION PUMP
HINT:
Always use the overflow screw installed on the pump to the ad-
justed.
B00431
w/ TCV OFF
2,000
8.00 -- 8.80 (0.3150 -- 0.3465)
w/ TCV OFF
2,300
8.76 -- 9.24 (0.3449 -- 0.3638)
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
Pump rpm Piston stroke mm (in.)
800 0.70 -- 1.50 (0.0276 -- 0.0591)
1,200 2.10 -- 2.90 (0.0827 -- 0.1142)
2,000 4.90 -- 5.70 (0.1929 -- 0.2244)
2,300 5.86 -- 6.34 (0.2307 -- 0.2496)
CONTINUED
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FU--24
ENGINE FUEL -- INJECTION PUMP
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Pump rpm Piston stroke mm (in.)
800 1.20 -- 2.00 (0.0472 -- 0.0787)
1,200 2.80 -- 3.60 (0.1102 -- 0.1417)
2,000 6.70 -- 7.50 (0.2638 -- 0.2953)
2,300 7.26 -- 7.74 (0.2858 -- 0.3047)
3L w/ ACSD:
(Part No. 22100 -- 5B510)
Pump rpm Piston stroke mm (in.)
800 2.10 -- 2.90 (0.0827 -- 0.1142)
1,200 3.50 -- 4.30 (0.1378 -- 0.1693)
2,000 6.40 -- 7.20 (0.2520 -- 0.2835)
2,300 7.06 -- 7.54 (0.2780 -- 0.2968)
3L w/o ACSD:
(Part No. 22100 -- 54710, 54850, 54860, 54870, 54880)
Pump rpm Piston stroke mm (in.)
800 0.60 -- 1.40 (0.0236 -- 0.0551)
1,200 1.80 -- 2.60 (0.0709 -- 0.1024)
2,000 4.40 -- 5.20 (0.1732 -- 0.2047)
2,300 4.86 -- 5.34 (0.1913 -- 0.2102)
5L w/ ACSD:
(Part No. 22100 -- 5B710)
Pump rpm Piston stroke mm (in.)
800 1.65 -- 2.45 (0.0650 -- 0.0965)
1,200 3.41 -- 4.21 (0.1343 -- 0.1657)
1,900 6.49 -- 7.29 (0.2555 -- 0.2870)
2,200 6.96 -- 7.44 (0.2740 -- 0.2929)
5L w/o ACSD:
(Part No. 22100 -- 5B720)
Pump rpm Piston stroke mm (in.)
850 0.23 -- 1.03 (0.0091 -- 0.0406)
1,200 1.77 -- 2.57 (0.0697 -- 0.1012)
2,000 5.30 -- 6.10 (0.2087 -- 0.2402)
2,300 6.36 -- 6.84 (0.2504 -- 0.2693)
HINT:
Check that the hysteresis is within 0.3 mm (0.012 in.).
CONTINUED
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FU--25
ENGINE FUEL -- INJECTION PUMP
S03389
Long Spring
Piston Stroke
Short Spring
Pump rpm
B00433
2L w/ TCV, 2L--T, 3L w/ ACSD, 5L If tendency is not as specified, select and replace the timer (in-
ner) spring.
HINT:
Timer Spring The timer stroke will increase with a long spring and decrease
with a short spring.
Free
Length
Timer Inner
Spring
Free
Length
S03807
S02315 B00053
S03942
CONTINUED
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FU--26
ENGINE FUEL -- INJECTION PUMP
(b) 2L--T:
Apply 62.7 kPa (0.64 kgf/cm2, 9.1 psi) of pressure to the
boost compensator.
(c) w/ HAC:
Apply 101 kPa (760 mmHg, 29.83 in.Hg) of vacuum to the
high altitude compensator.
(d) Measure the full load injection volume.
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
11.04 -- 11.36
1,200 200
(0.67 -- 0.69)
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
10.42 -- 10.74
1,200 200
(0.64 -- 0.66)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
13.70 -- 14.02
1,000 200
(0.84 -- 0.86)
3L:
(Part No. 22100 -- 54850, 54860, 54870, 54880)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
11.56 -- 11.88
1,200 200
(0.71 -- 0.72)
3L:
(Part No. 22100 -- 54710, 5B510)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
10.96 -- 11.28
1,200 200
(0.67 -- 0.69)
5L w/ HAC:
(Part No. 22100 -- 5B720)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
12.82 -- 13.14
1,600 200
(0.78 -- 0.80)
CONTINUED
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FU--27
ENGINE FUEL -- INJECTION PUMP
5L w/o HAC:
(Part No. 22100 -- 5B710)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
12.18 -- 12.50
1,200 200
(0.74 -- 0.76)
Full Load Set Screw (e) Adjust by turning the full load set screw.
HINT:
The injection volume will increase about 3 cc (0.18 cu in.) with
each 1/2 turn of the screw.
S04644
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
No. of
Adjusting Injection volume of each cylinder
Pump rpm measuring Remark
lever angle cc (cu in.)
strokes
Plus 23.5 -- 33.5˚ 2,575 200 4.0 -- 5.6 (0.24 -- 0.34) Adjust
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
No. of
Adjusting Injection volume of each cylinder
Pump rpm measuring Remark
lever angle cc (cu in.)
strokes
Plus 23.5 -- 33.5˚ 2,450 200 4.0 -- 5.6 (0.24 -- 0.34) Adjust
CONTINUED
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FU--28
ENGINE FUEL -- INJECTION PUMP
2L -- T:
(Part No. 22100--5B460, 5B670)
No. of
Adjusting Injection volume of each cylinder
Pump rpm measuring Remark
lever angle cc (cu in.)
strokes
2,250 6.72 -- 8.92 (0.41 -- 0.54) --
Plus 23.5 -- 33.5˚ 2,400 200 4.3 -- 6.3 (0.26 -- 0.38) Adjust
3L:
(Part No. 22100--54710, 5B510)
No. of
Adjusting Injection volume of each cylinder
Pump rpm measuring Remark
lever angle cc (cu in.)
strokes
Plus 23.5 -- 33.5˚ 2,200 200 4.6 -- 6.2 (0.28 -- 0.38) Adjust
3L:
(Part No. 22100--54850, 54860, 54870, 54880)
No. of
Adjusting Injection volume of each cylinder
Pump rpm measuring Remark
lever angle cc (cu in.)
strokes
Plus 23.5 -- 33.5˚ 2,300 200 4.6 -- 6.2 (0.28 -- 0.38) Adjust
5L:
(Part No. 22100--5B710, 5B720)
No. of
Adjusting Injection volume of each cylinder
Pump rpm measuring Remark
lever angle cc (cu in.)
strokes
Plus 23.5 -- 33.5˚ 2,300 200 4.6 -- 6.2 (0.28 -- 0.38) Adjust
Maximum Speed Adjusting Screw (d) Adjust by turning the maximum speed adjusting screw.
CONTINUED
S04648
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FU--29
ENGINE FUEL -- INJECTION PUMP
CONTINUED
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FU--30
ENGINE FUEL -- INJECTION PUMP
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Boost No. of Injection volume Variation
Adjusting
Pump rpm pressure measuring of each cylinder limit Remark
lever angle
kPa (kg/cm2, psi) strokes cc (cu in.) cc (cu in.)
13.6 -- 18.4 1.2
100 0 (0, 0) Volume during starting
(0.83 -- 1.12) (0.07)
10.94 -- 11.74 0.5
700 0 (0, 0) --
(0.67 -- 0.72) (0.03)
Plus 23.5 -- 33.5˚ 200
13.70 -- 14.02 0.4
1,000 62.7 (0.64, 9.1) Basic full load injection volume
(0.84 -- 0.86) (0.02)
11.48 -- 12.48 0.5
1,800 62.7 (0.64, 9.1) --
(0.70 -- 0.76) (0.03)
3L w/ HAC:
(Part No. 22100 -- 54870, 54880)
No. of Injection volume Variation
Adjusting HAC vacuum
Pump rpm measuring of each cylinder limit Remark
lever angle kPa (mmHg, in.Hg)
strokes cc (cu in.) cc (cu in.)
11.6 -- 16.4 1.2
100 101 (760, 29.83) Volume during starting
(0.71 -- 1.00) (0.07)
12.2 -- 14.8
350 101 (760, 29.83) -- --
(0.74 -- 0.90)
10.44 -- 11.44 0.5
500 101 (760, 29.83) --
(0.64 -- 0.70) (0.03)
Plus 23.5 -- 33.5˚ 200
11.56 -- 11.88 0.4
101 (760, 29.83) Basic full load injection volume
(0.71 -- 0.72) (0.02)
1,200
9.44 -- 10.04
70.7 (530, 20.88) -- --
(0.58 -- 0.61)
10.19 -- 11.09 0.5
2,000 101 (760, 29.83) --
(0.62 -- 0.68) (0.03)
3L w/o HAC:
(Part No. 22100 -- 54710, 5B510)
No. of Injection volume Variation
Adjusting
Pump rpm measuring of each cylinder limit Remark
lever angle
strokes cc (cu in.) cc (cu in.)
11.6 -- 16.4 1.2
100 Volume during starting
(0.71 -- 1.00) (0.07)
11.4 -- 14.0
350 -- --
(0.70 -- 0.85)
9.64 -- 11.04 0.5
Plus 23.5 -- 33.5˚ 500 200 --
(0.59 -- 0.67) (0.03)
10.96 -- 11.28 0.4
1,200 Basic full load injection volume
(0.67 -- 0.69) (0.02)
9.39 -- 10.69 0.5
1,900 --
(0.57 -- 0.65) (0.03)
CONTINUED
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FU--31
ENGINE FUEL -- INJECTION PUMP
3L w/o HAC:
(Part No. 22100 -- 54850, 54860)
No. of Injection volume Variation
Adjusting
Pump rpm measuring of each cylinder limit Remark
lever angle
strokes cc (cu in.) cc (cu in.)
11.6 -- 16.4 1.2
100 Volume during starting
(0.71 -- 1.00) (0.07)
12.2 -- 14.8
350 -- --
(0.74 -- 0.90)
10.44 -- 11.44 0.5
Plus 23.5 -- 33.5˚ 500 200 --
(0.64 -- 0.70) (0.03)
11.56 -- 11.88 0.4
1,200 Basic full load injection volume
(0.71 -- 0.72) (0.02)
10.19 -- 11.09 0.5
2,000 --
(0.62 -- 0.68) (0.03)
5L w/ HAC:
(Part No. 22100 -- 5B720)
No. of Injection volume Variation
Adjusting HAC vacuum
Pump rpm measuring of each cylinder limit Remark
lever angle kPa (mmHg, in.Hg)
strokes cc (cu in.) cc (cu in.)
13.6 -- 18.4 1.2
100 101 (760, 29.83) Volume during starting
(0.83 -- 1.12) (0.07)
10.92 -- 12.32 0.5
500 101 (760, 29.83) --
(0.67 -- 0.75) (0.03)
200 12.82 -- 13.14 0.4
Plus 23.5 -- 33.5˚ 101 (760, 29.83) Basic full load injection volume
(0.78 -- 0.80) (0.02)
1,600 11.10 -- 11.70
85.3 (640, 25.19) -- --
(0.68 -- 0.71)
12.30 -- 12.98 0.5
1,900 101 (760, 29.83) --
(0.75 -- 0.79) (0.03)
5L w/o HAC:
(Part No. 22100 -- 5B710)
No. of Injection volume Variation
Adjusting
Pump rpm measuring of each cylinder limit Remark
lever angle
strokes cc (cu in.) cc (cu in.)
13.6 -- 18.4 1.2
100 Volume during starting
(0.83 -- 1.12) (0.07)
10.36 -- 11.36 0.5
500 --
(0.63 -- 0.69) (0.03)
Plus 23.5 -- 33.5˚ 200
12.18 -- 12.50 0.4
1,200 Basic full load injection volume
(0.74 -- 0.76) (0.02)
11.01 -- 11.91 0.5
2,000 --
(0.67 -- 0.73) (0.03)
CONTINUED
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FU--32
ENGINE FUEL -- INJECTION PUMP
B00434
Bearing and
2 Bearing
Retainers
Stop Ring
New E--Ring
B00435
Bearing and
2 Bearing CONTINUED
Retainers
Stop Ring
New E--Ring
B00435
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FU--33
ENGINE FUEL -- INJECTION PUMP
2L--T 3 mm Hexagon (d) Using a 3 mm hexagon wrench, adjust by turning the timer
Wrench slide stopper.
15. 2L -- T:
ADJUST BOOST COMPENSATOR
Timer (a) Set the adjusting lever to maximum position.
Slide (b) Apply 13.3 kPa (0.14 kPa (0.14 kgf/cm2, 2.0 psi) of pres-
Stopper sure to boost compensator.
(c) Measure the injeciton volume.
B01356 (Part No. 22100--5B460, 5B670)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
10.76 -- 11.56
1,000 200
(0.66 -- 0.71)
2L--T Guide Bushing (d) Remove the rubber cap and overflow screw.
(e) Using a screwdriver, adjust the injection volume by the
guide bushing.
HINT:
When the guuide bushing is turned clockwise, as seen from
above, the injeciton volume will increase.
(f) Install the overflow screw.
Arrow
Mark Torque: 24.55 N∙m (250 kgf∙cm, 18 ft∙lbf)
B01357 (g) Install the rubber cap with the arrow mark facing down-
ward.
CONTINUED
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FU--34
ENGINE FUEL -- INJECTION PUMP
2L--T 16. 2L -- T:
c CHECK FOR CHARACTERISTIC TENDENCY
(a) Set the adjusting lever to maximum position.
a
(b) Apply 40.0 kPa (0.41 kgf/cm2, 5.8 psi) of pressure to
b boost compensator.
Injection Volume
d
b
Boost Pressure
B00473
B00472
B00904 17. 2L -- T:
CHECK HYSTERESIS
Compare the injection volume when the boost compensator
pressure is lowered from 107.0 kPa (1.09 kgf/cm2, 15.5 psi) to
13.3 kPa (0.14 khf/cm2, 2.0 psi), and conversely, when it is
raised from zero.
HINT:
Make measurements after moving the adjusting lever between
idle and maximum 3 times for each lowering of the pressure.
If not within standard value, check each sliding part of the boost
compensator and check whether or not there is any oil.
CONTINUED
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FU--35
ENGINE FUEL -- INJECTION PUMP
w/o HAC (2L, 3L), 2L--T, 5L 18. w/o HAC (2L, 3L), 2L -- T, 5L:
5 mm ADJUST LOAD SENSING TIMER
Hexagon (a) Using a 5 mm hexagon wrench, adjust the starting and
Wrench end points of the load sensing timer by turning the gover-
nor shaft.
(b) Set the adjusting lever to maximum position.
(c) Measure the injection volume.
2L, 3L, 5L:
Governor Shaft Adjusting lever
Pump rpm
No, of measuring
position strokes
2L -- T:
Inner Pressure
w/o HAC (2L, 3L), 2L--T, 5L (d) Slowly move the adjusting lever from the maximum speed
side to the idle speed side, and secure it at the point
where the pump inner pressure begins to drop.
(e) Measure the injection volume at the drop point (starting
kg/cm2
point).
2L, 3L, 5L:
Slowly
Move Injection volume of
No of measuring
Pump rpm each cylinder
strokes
B00438 cc (cu in.)
Measured value
1,200 200 at step (d) minus
1.0 (0.06) ± 0.4 (0.02)
2L -- T:
Injection volume of
No of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
Measured value
1,000 200 at step (d) minus
0.6 (0.04) ± 0.4 (0.02)
w/o HAC (2L, 3L), 2L--T, 5L (f) Using a 5 mm hexagon wrench, adjust the load sensing
5 mm
timer by turning the governor shaft, and perform the mea-
Hexagon
surement again as specified.
Wrench
HINT:
The injection volume will increase approx. 3 cc (0.2 cu in.) with
each 1/2 turn of the governor shaft.
w/o HAC (2L, 3L), 2L--T, 5L (g) Check the end point injection volume by slowly moving
the adjusting lever from the maximum speed side to the
Stop idle speed side, and secure it at the point where the pump
inner pressure stops dropping.
kg/cm2
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
Slowly
Move Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
B00437 cc (cu in.)
9.0 -- 9.4
1,200 200
(0.55 -- 0.57)
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
8.38 -- 8.78
1,200 200
(0.51 -- 0.54)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
8.0 -- 8.4
1,000 200
(0.49 -- 0.51)
3L:
(Part No. 22100 -- 54710, 5B510)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
8.12 -- 8.52
1,200 200
(0.50 -- 0.52)
3L:
(Part No. 22100 -- 54850, 54860)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
8.72 -- 9.12
1,200 200
(0.53 -- 0.56)
5L w/ ACSD:
(Part No. 22100 -- 5B710)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
9.5 -- 9.9
1,200 200
(0.58 -- 0.60)
CONTINUED
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FU--37
ENGINE FUEL -- INJECTION PUMP
5L w/o ACSD:
(Part No. 22100 -- 5B720)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
9.58 -- 9.98
1,200 200
(0.58 -- 0.61)
w/o HAC (2L, 3L), 2L--T, 5L (h) Check the timer piston fluctuation when the adjusting le-
ver is moved from the maximum speed side to the idle
speed side.
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
Pump rpm Timer piston fluctuation mm (in.)
Move w/ TCV OFF
1,200
1.80 -- 2.60 (0.0709 -- 0.1024)
B00424 2L w/o ACSD:
(Part No. 22100 -- 54770, 54780)
Pump rpm Timer piston fluctuation mm (in.)
1,200 0.62 -- 1.02 (0.0244 -- 0.0402)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Pump rpm Timer piston fluctuation mm (in.)
1,000 1.40 -- 1.80 (0.0551 -- 0.0709)
3L w/ ACSD:
(Part No. 22100 -- 5B510)
Pump rpm Timer piston fluctuation mm (in.)
1,200 1.44 -- 1.84 (0.0567 -- 0.0724)
3L w/o ACSD:
(Part No. 22100 -- 54710, 54850, 54860)
Pump rpm Timer piston fluctuation mm (in.)
1,200 0.62 -- 1.02 (0.0244 -- 0.0402)
5L w/ ACSD:
(Part No. 22100 -- 5B710)
Pump rpm Timer piston fluctuation mm (in.)
1,200 1.03 -- 1.43 (0.0406 -- 0.0563)
5L w/o ACSD:
(Part No. 22100 -- 5B720)
Pump rpm Timer piston fluctuation mm (in.)
1,200 0.82 -- 1.22 (0.0323 -- 0.0480)
CONTINUED
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FU--38
ENGINE FUEL -- INJECTION PUMP
w/o HAC Hole Diameter If the timer stroke is not as specified when the load sensing is
(2L, 3L), at maximum retard angle, select a new governor sleeve.
2L--T, HINT:
5L A large hole diameter decreases the timer stroke and a smaller
hole diameter increases the timer stroke.
Governor Sleeve
B00056
w/o HAC (2L, 3L), 2L--T, 5L (i) Check the protrusion of the governor shaft.
0.5 -- 2.0 mm Protrusion: 0.5 -- 2.0 mm (0.020 -- 0.079 in.)
Governor Shaft
B00049 B00055 B00423
2L:
(Part No. 22100 -- 54770, 54780, 54800, 54810, 5B320, 5B360)
No. of
Adjusting Injection volume of each cylinder Variation limit
Pump rpm measuring Remark
lever angle cc (cu in.) cc (cu in.)
strokes
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
No. of
Adjusting Injection volume of each cylinder Variation limit
Pump rpm measuring Remark
lever angle cc (cu in.) cc (cu in.)
strokes
Minus 9.5 -- 19.5˚ 350 200 3.18 -- 4.18 (0.19 -- 0.26) 0.34 (0.02) Adjust
3L:
(Part No. 22100 -- 54710, 54850, 54860, 54870, 54880, 5B510)
No. of
Adjusting Injection volume of each cylinder Variation limit
Pump rpm measuring Remark
lever angle cc (cu in.) cc (cu in.)
strokes
CONTINUED
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FU--39
ENGINE FUEL -- INJECTION PUMP
5L:
(Part No. 22100 -- 5B710, 5B720)
No. of
Adjusting Injection volume of each cylinder Variation limit
Pump rpm measuring Remark
lever angle cc (cu in.) cc (cu in.)
strokes
Idle Speed (b) Adjust injection volume by turning the idle speed adjust-
Adjusting ing screw.
Screw
S04647
S03373
w/ ACSD Metal Plate (d) Check the adjusting lever opening angle and consider
Turn this angle as zero.
(e) Remove the metal plate between the cold starting lever
and thermo wax plunger.
S03761
w/ ACSD (f) Torque the cold starting lever clockwise to approx. 4.9
N∙m (50 kgf∙cm, 43 in.∙lbf) and keep the lever tightened
for about 10 seconds. Then release the torque.
(g) Measure the timer piston stroke.
4.9 N∙m
CONTINUED
S03390
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FU--40
ENGINE FUEL -- INJECTION PUMP
2L:
(Part No. 22100 -- 5B320, 5B360)
Fuel temperature Piston stroke
Pump rpm
C (˚F) mm (in.)
1.50 -- 1.90
25 (77) 350
(0.0591 -- 0.0748)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Fuel temperature Piston stroke
Pump rpm
C (˚F) mm (in.)
1.70 -- 1.90
25 (77) 350
(0.0669 -- 0.0748)
3L:
(Part No. 22100 -- 5B510)
Fuel temperature Piston stroke
Pump rpm
C (˚F) mm (in.)
0.85 -- 1.05
25 (77) 350
(0.0335 -- 0.0413)
5L:
(Part No. 22100 -- 5B710)
Fuel temperature Piston stroke
Pump rpm
C (˚F) mm (in.)
1.10 -- 1.30
25 (77) 400
(0.0433 -- 0.0512)
Timer Adjusting
Screw S03388
2L:
(Part No. 22100 -- 5B320, 5B360)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
q = 1.7 -- 2.7
350 200
(0.10 -- 0.16)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
q = 3.18 -- 4.18
350 200
(0.19 -- 0.26)
3L:
(Part No. 22100 -- 5B510)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
q = 1.8 -- 2.8
350 200
(0.11 -- 0.17)
5L:
(Part No. 22100 -- 5B710)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
q = 2.54 -- 3.54
400 200
(0.16 -- 0.22)
(d) Remove the metal plate between the cold starting lever
and thermo wax plunger.
w/ ACSD (e) Torque the cold starting lever clockwise to approx. 4.9
N∙m (50 kgf∙cm, 43 in.∙lbf) and keep the lever tightened
for about 10 seconds. Then release the torque.
(f) Measure the injection volume.
2L, 3L:
Injection volume of
4.9 N∙m Pump rpm
No. of measuring
each cylinder
strokes
cc (cu in.)
2L -- T:
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
q plus 0.22 -- 0.42
350 200
(0.01 -- 0.03)
CONTINUED
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TO MODEL INDEX
FU--42
ENGINE FUEL -- INJECTION PUMP
5L:
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
q plus 1.24 -- 1.44
400 200
(0.08 -- 0.09)
w/ ACSD (g) Adjust the injection volume by turning the fast idle adjust-
First Idle ing screw.
Adjusting 22. POST ADJUSTMENT CHECK
Screw (a) Check the injection stops when the fuel cut solenoid har-
ness is removed.
Pump revolution: 100 rpm
S04646
S03761
(d) w/ ACSD:
Remove the metal plate between the cold starting lever
and thermo wax plunger.
23. REMOVE INJECTION PUMP FROM PUMP TESTER
Move B00450
S04649
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FU--43
ENGINE FUEL -- INJECTION PUMP
FU00K--01
REASSEMBLY
1. ASSEMBLE BOOST COMPENSATOR
(a) Install the control lever.
(1) Insert the connecting pin into the governor cover.
B01353
B01351
4 mm
Hexagon
Wrench
B01350
Gui
S03343
B01346
B01382 B01381
B01349
Spring
B01348
5 mm
Hexagon
Wrench CONTINUED
B01347
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FU--45
ENGINE FUEL -- INJECTION PUMP
2L--T
w/ HAC
Plug
Bolt
w/o HAC
Bolt
B01358
B01389
B01390 B01380
S04636
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TO MODEL INDEX
COOLING
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . CO -- 1
..............................
COMPONENTS CO-- 1
RADIATOR ....................... CO-- 2
.......................
ON-VEHICLE INSPECTION CO-- 2/3
COMPONENTS ....................... CO-- 4
DISASSEMBLY ....................... CO-- 5
REASSEMBLY ....................... CO-- 6/5
THERMOSTAT
CO047--01
COMPONENTS
2L--T
Radiator Cap
Check Connector
Water Outlet
Water Outlet (2L, 3L, 5L)
zGasket
Thermostat
RADIATOR CO048--01
ON -- VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
Remove the radiator cap from the water outlet (2L--T) or radia-
tor (2L, 3L, 5L).
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2L--T 2. 2L -- T:
INSPECT RADIATOR CAP
Radiator Cap Tester NOTICE:
S If the radiator cap has contaminations, always rinse
it with water.
S Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.
Using a radiator cap tester, pump the tester and measure the
Radiator Cap
CO0034 relief valve opening pressure.
Standard opening pressure:
93 -- 123 kPa (0.95 -- 1.25 kgf/cm2, 13.5 -- 17.1 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
CONTINUED
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CO--3
COOLING -- RADIATOR
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
93 -- 123 kPa (0.95 -- 1.25 kgf/cm2, 13.5 -- 17.1 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
4. REINSTALL RADIATOR CAP
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CO--4
COOLING -- RADIATOR
CO049--01
COMPONENTS
Bushing
Radiator Cap (2L, 3L, 5L)
Collar
Radiator
Bracket z O--Ring
Core
Collar
Bushing
Bushing
Collar
z O--Ring
Bushing Radiator
Bracket
Lower Tank
Collar
Drain Plug
z O--Ring
DISASSEMBLY
1. REMOVE RADIATOR BRACKETS
Remove the 4 bolts, 4 collars, 2 brackets and 4 bushings.
2. 2L, 3L, 5L:
REMOVE RADIATOR CAP
3. REMOVE DRAIN PLUG
(a) Remove the drain plug.
(b) Remove the O--ring.
4. ASSEMBLE SST
Part A
SST 09230 -- 01010
(a) Install the claw to the overhaul handle, inserting it in the
hole in part A as shown in the diagram.
Dimension B (b) While gripping the handle, adjust the stopper bolt so that
SST Stopper Bolt
dimension B is as shown in the illustration.
Dimension B: 0.2 -- 0.3 mm (0.008 -- 0.012 in.)
NOTICE:
Claw Overhaul Handle CO1205 If this adjustment is not done the claw may be damaged.
Stopper
Bolt
B00469
Tap
B00013
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CO--6
COOLING -- RADIATOR
CO04B--01
REASSEMBLY
Lock Plate Lock Plate 1. INSPECT LOCK PLATE FOR DAMAGE
HINT:
S If the sides of the lock plate groove are deformed, reas-
sembly of the tank will be impossible.
S Therefore, first correct any deformation with pliers or simi-
lar object. Water leakage will result if the bottom of the
Core lock plate groove is damaged or dented.
CO1267
NOTICE:
The radiator can only be recaulked 2 times. After the 2nd
time, the radiator core must be replaced.
X Twisted
O--Ring
CO0317
WRONG
Tap
Tank
Lock
Plate B00466
3. ASSEMBLE SST
Part SST 09230 -- 01010, 09231 -- 14010
(a) Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part A as shown in the illustration.
Dimension B (b) While gripping the handle, adjust the stopper bolt so that
SST Stopper Bolt dimension B is as shown in the illustration.
Dimension B: 8.4 mm (0.331 in.)
Tank
Stopper
Bolt
Lock
SST Plate
B00011
B00467 B00907
HINT:
(2)
S Do not stake the areas protruding around the ports (1),
flange (2) and bracket (3).
(1)
(3)
(1)
B00905
B00012
B00014 B00996
(b) Check the lock plate height (H) after completing the caulk-
ing.
Plate height (H): 7.40 -- 7.80 mm (0.2913 -- 0.3071 in.)
H
If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
5. INSTALL DRAIN PLUG
(a) Install a new O--ring to the drain plug.
(b) Install the drain plug.
B00468 6. 2L, 3L, 5L:
INSTALL RADIATOR CAP CONTINUED
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CO--8
COOLING -- RADIATOR
B00015
LUBRICATION
Others
15W--40
10W--30
5W--30
40
30
P23182
B01366 B01379
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STARTING
Pre--Heating Timer
S--REL
PRE -- HEATING SYSTEM (Super
Glow Type) ST027--01
INSPECTION
1. INSPECT LIGHTING TIME OF GLOW INDICATOR
LIGHT
Sec. Sec. Turn the ignition switch ON, and measure the lighting time.
6.0 120
Light lighting time (T1): Refer to the chart graph
Light Lighting Time (T1)
S--REL
EG
TCV
STA
in these chart:
B01391
Continuity
S03356
Battery S03357
--20 0 20 40 60 80 100
(--4) (32) (68) (104) (140) (176) (212)
S01196
S01699 Temperature ˚C (˚F) Z17274
B01383
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ST--3
STARTING -- PRE--HEATING SYSTEM (Super Glow Type)
NOTICE:
S Be careful not to damage the glow plug pipes as it
could cause an open circuit or shorten life of the glow
plugs.
S Avoid getting oil and gasoline on the glow plug when
cleaning.
S During inspection, be sure to wipe any oil of the termi-
nal and bakelite washer with a dry cloth.
S Be careful no to apply more than 11 V to the glow plug
as it could cause an open circuit.
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ST--4
STARTING -- PRE--HEATING SYSTEM (Variable Delay Type)
INSPECTION
1. INSPECT LIGHTING TIME OF GLOW INDICATOR
LIGHT
Turn the ignition switch ON, and measure the lighting time.
Light lighting time: Approx. 5 seconds
P08103
CHG
IG
in these chart:
B01367
STARTER(2.2 kW)
ST029--01
COMPONENTS
Starter Housing
Starter Clutch Assembly
Steel Ball
Return Spring
Lead Wire z O--Ring
z Front Bearing
z Dust Protector
Armature
z Rear Bearing
z O--Ring
Field Frame
B00441
Terminal Bolt
Lead Terminal
Plunger
z Gasket z Terminal C Kit Part
End Cover
O--Ring
Terminal Insulator
Terminal
Bolt Wave Washer
Lead Clamp 17 (173, 13) Terminal Bolt
Contact Plate
Terminal Insulator
B00442
Dust DISASSEMBLY
Protector 1. REMOVE LEAD WIRE
Remove the screw and lead wire.
P05488
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ST--8
STARTING -- STARTER (2.2 kW)
ST02B--01
INSPECTION
1. INSPECT ARMATURE COIL
Ohmmeter (a) Check the commutator for open circuit.
Using an ohmmeter, check that there is continuity be-
Continuity tween the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
ST1098
S04640
ST1100
(d) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.7 mm (0.028 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.
CONTINUED
ST0040
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ST--9
STARTING -- STARTER (2.2 kW)
B00453
B00454
Length
ST1103
B00455 B00900
Continuity B00451
Switch
Body (b) Check the hold--in coil for open circuit.
Ohmmeter
Using an ohmmeter, check that there is continuity be-
Terminal tween terminal 50 and the switch body.
50 If there is no continuity, replace the magnetic switch.
Continuity B00452
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ST--11
STARTING -- STARTER (2.2 kW)
ST02C--01
REPLACEMENT
1. REPLACE FRONT BEARING
(a) Using SST and a press, press out the bearing.
SST SST 09950 -- 00020
ST1110
ST1126
ST1107
Upward (b) Using a 10 mm (for thread diameter) nut and press, press
10 mm in a new bearing.
Nut NOTICE:
Be careful of the installation direction.
Downward
ST1108 ST0605 ST0606 B00901
Punch
CONTINUED
ST0607
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ST--12
STARTING -- STARTER (2.2 kW)
B00443
Wear
B00444
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(7) Wave washer
(8) Terminal nit
NOTICE:
Be careful to install the insulation paper, terminal insulator
(inside) and wave washer in the correct direction.
S03785
B00448
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ST--15
STARTING -- STARTER (2.2 kW)
ST02D--01
REASSEMBLY
HINT:
Use high--temperature grease to lubricate the bearings and
gears when assembling the starter.
1. PLACE ARMATURE INTO FIELD FRAME
(a) Apply grease to the armature bearings.
(b) Using a press, press in armature.
P04699
ST0096
(c) Using a screwdriver, hold the brush spring back, and con-
nect the brush into the brush holder. Connect the 4
brushes.
NOTICE:
Check that the positive (+) lead wires are not grounded.
(d) Install a new O--ring to the groove of the field frame.
N00562
P24191
CONTINUED
B00456
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ST--16
STARTING -- STARTER (2.2 kW)
(3)
(d) Install the starter housing to the magnetic switch with the
2 screws.
Torque: 9.3 N∙m (95 kgf∙cm, 82 in.∙lbf)
B00462
B00463
Terminal C
Terminal 50 TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid during out the coil.
1. PERFORM 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.
B00457
B00458
B00459
INSPECTION
1. REMOVE STARTER RELAY
LOCATION: See relay locations in Electrical Wiring Diagram.
4 3 Battery
S00421
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CHARGING
COMPONENTS
Drive End Frame (Stator) Bearing Cover
Rotor
Bearing Retainer
z Front Bearing
z Oil Seal
Alternator Washer
Vacuum Pump
z Rear Bearing
Terminal Insulator
Brush Holder Cover
(Black Colored Screw)
Brush Holder
Cord Clamp Rubber
Insulator
Rear End Cover
Spring
Brush
IC Regulator
Rectifier End Frame
Rectifier Holder
z Non--reusable part B01364
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ALPHABETICAL INDEX
TO MODEL INDEX
ID -- 1
ALPHABETICAL INDEX (A - T)
A R
Page Page
ABBREVIATIONS USED IN THIS MANUAL RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO -- 2
(TERMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN -- 8 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . IN -- 4
ALTERNATOR (Hi-- Speed Compact Type) . . . . . . . . . . . CH -- 1
S
C
STANDARD BOLT (SERVICE SPECIFICATIONS) . . . . SS -- 1
CHARGING (SERVICE SPECIFICATIONS) . . . . . . . . . . SS-- 19 STARTER (2.2 kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-- 5
COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 1 STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-- 18
COOLING (PREPARATION) . . . . . . . . . . . . . . . . . . . . . . . PP -- 11 STARTING (PREPARATION) . . . . . . . . . . . . . . . . . . . . . . PP -- 15
COOLING (SERVICE SPECIFICATIONS) . . . . . . . . . . . SS-- 13 STARTING (SERVICE SPECIFICATIONS) . . . . . . . . . . . SS-- 17
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 12
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 9
T
E TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN -- 8
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO -- 1
ENGINE FUEL (PREPARATION) . . . . . . . . . . . . . . . . . . . PP-- 7 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC -- 1
ENGINE FUEL (SERVICE SPECIFICATIONS) . . . . . . . SS-- 11 TURBOCHARGING (PREPARATION) . . . . . . . . . . . . . . PP -- 5
ENGINE MECHANICAL (PREPARATION) . . . . . . . . . . . PP-- 1 TURBOCHARGING
ENGINE MECHANICAL (SERVICE SPECIFICATIONS) . . . . . . . . . . . . . . . . . . SS-- 9
(SERVICE SPECIFICATIONS) . . . . . . . . . . . . . . . . . . SS-- 3
ENGINE SERIAL NUMBER
(IDENTIFICATION INFORMATION) . . . . . . . . . . . . . . IN -- 3
F
FOR ALL OF VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . IN -- 7
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU -- 1
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU -- 2
G
GENERAL INFORMATION
(HOW TO USE THIS MANUAL) . . . . . . . . . . . . . . . . . IN -- 1
GENERAL INFORMATION
(REPAIR INSTRUCTIONS) . . . . . . . . . . . . . . . . . . . . . IN -- 4
H
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . IN -- 1
I
IDENTIFICATION INFORMATION . . . . . . . . . . . . . . . . . . IN -- 3
IDLE SPEED AND MAXIMUM SPEED . . . . . . . . . . . . . . EM-- 5
INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU -- 3
INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU -- 4
INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 3
INTAKE SHUTTER (5L) . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 7
L
LUBRICATION (PREPARATION) . . . . . . . . . . . . . . . . . . . PP -- 14
LUBRICATION (SERVICE SPECIFICATIONS) . . . . . . . SS-- 15
O
OIL AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU -- 1
P
PRE -- HEATING SYSTEM (Super Glow Type) . . . . . . . . ST-- 1
PRE -- HEATING SYSTEM (Variable Delay Type) . . . . . . ST-- 4
PRECAUTION (FOR ALL OF VEHICLES) . . . . . . . . . . . IN -- 7