8FG D CE048-01 - 0608 Engine

1-1
ENGINE
Page Page
ENGINE EXTERIOR VIEW ............. 1-2 V-BELT TENSION 0
ENGINE MAIN PARAMETERS ....... 1-6 ADJUSTMENT ............................ 1-39
ACCELERATOR PEDAL............... 1-40 1
ENGINE PERFORMANCE
CURVES........................................ 1-8 COMPONENTS ...............................1-40 2
ENGINE ASSY .............................. 1-12 INSPECTION·ADJUSTMENT ............1-41
REMOVAL·INSTALLATION DRIVE CONTROL DEVICE 3
(M/T VEHICLES) ........................... 1-12 (OPT) ...........................................1-43
REMOVAL·INSTALLATION COMPONENTS ...............................1-43
4
(T/C VEHICLES) ........................... 1-15 REMOVAL·INSTALLATION............... 1-44 5
AIR BLEEDING OF THE FUEL THROTTLE OPENING DEGREE
SYSTEM...................................... 1-18 ADJUSTMENT..............................1-46 6
ENGINE TROUBLESHOOTING ..................... 1-47
INSPECTION·ADJUSTMENT ..... 1-18 DPF-II SYSTEM (OPT) ..................1-49 7
4Y-M ENGINE (STD) ........................ 1-18 COMPONENTS ...............................1-49
8
4Y-E ENGINE (OPT) ........................ 1-22 CONNECTOR DIAGRAM .................1-52
1DZ-II·2Z ENGINE VEHICLE ............. 1-23 DPF MUFFLER 9
AIR CLEANER .............................. 1-25 REMOVAL·INSTALLATION ............1-54
SPECIFICATIONS ........................... 1-25

DPF MUFFLER DISASSEMBLY· 10
INSPECTION·REASSEMBLY .......... 1-55
COMPONENTS .............................. 1-25 CONTROLLER 11
AIR CLEANER REMOVAL·INSTALLATION ............1-57
CLEANING·INSPECTION............... 1-26 BLOWER 12
CLOGGING WARNING SYSTEM REMOVAL·INSTALLATION ............1-58
INSPECTION (OPT) ...................... 1-27 DPF VALVE 13
RADIATOR .................................... 1-28 REMOVAL·INSTALLATION ............1-59
COMPONENTS .............................. 1-28 DPF VALVE DISASSEMBLY· 14
INSPECTION·REASSEMBLY .......... 1-60
SPECIFICATIONS ........................... 1-31 15
INDIVIDUAL INSPECTION OF
COOLANT CAPACITY AND FUNCTIONAL PARTS ...................1-61
ANTIFREEZE TABLE .................... 1-31 16
CONTROLLER ERROR CODE
COOLANT INSPECTION .................. 1-31 CLEARING METHOD ....................1-65
MUFFLER & EXHAUST PIPE....... 1-33 DPF FILTER MEMORY 17
COMPONENTS .............................. 1-33 CLEARING METHOD ....................1-65
REGENERATION METHOD ..............1-65 18
REMOVAL·INSTALLATION .............. 1-35
DISPLAY OF PAST
MAINTENANCE OF CATALYTIC
ERROR CODES ............................ 1-66 19
MUFFLERS.................................. 1-35
BATTERY ...................................... 1-36 CLEARING OF PAST 20
ERROR CODES ............................ 1-67
COMPONENTS .............................. 1-36 TROUBLESHOOTING ..................... 1-68
SPECIFICATIONS ........................... 1-37
21
INSPECTION .................................. 1-38 E
1-2
ENGINE EXTERIOR VIEW

4Y-M Engine (STD)
1-3
4Y-E Engine (With Electronic Control: OPT)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
1-4
1DZ-II Engine
1-5
2Z Engine
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
1-6
ENGINE MAIN PARAMETERS

Gasoline Engine
Vehicle model 1·2·K2·K3 ton 1·2·K2·K3 ton
3·J3.5 ton series 3·J3.5 ton series
Item series series
Engine model 4Y-M ← 4Y-E (OPT) ←
Engine type Gasoline · 4 cycle ← ← ←
In-line 4 cylinder,
Number and arrangement of cylinders longitudinally ← ← ←
mounted
Combustion chamber type Wedge ← ← ←
Valve mechanism OHV·chain drive ← ← ←
91.0 × 86.0
Bore x stroke mm (in) ← ← ←
(3.583 × 3.386)
Total displacement cm3 (in3) 2237 (136.51) ← ← ←
Compression ratio 8.8 ← ← ←
Maximum output Gasoline exclusive 40 (54)/2400 43 (58)/2600 38 (51)/2570 44 (59)/2570
LPG convertible/
kW (PS)/rpm 35 (48)/2400 38 (52)/2600 38 (51)/2570 43 (58)/2570
Gasoline
LPG convertible/
35 (48)/2400 38 (52)/2600 38 (51)/2570 42 (57)/2570
LPG
LPG exclusive 37 (50)/2400 40 (54)/2600 38 (51)/2570 42 (57)/2570
Maximum torque Gasoline exclusive 162 (16.5)/1800 ← 160 (16.3)/2100 165 (16.8)/2570
LPG convertible/
N·m (kgf·m)/rpm 147 (15.0)/1600 ← 160 (16.3)/2100 ←
Gasoline
LPG convertible/
147 (15.0)/1600 ← 160 (16.3)/2100 ←
LPG
LPG exclusive 157 (16.0)/1800 ← 160 (16.3)/2100 ←
Minimum fuel
Gasoline exclusive 272 (200)/2300 ← 298 (219)/2000 310 (228)/1600
consumption
g/kW·h (g/PS·h)/ LPG convertible/
258 (190)/2400 ← 298 (219)/2000 310 (228)/1600
rpm Gasoline
LPG convertible/
258 (190)/2400 ← 233 (171)/2000 ←
LPG
LPG exclusive 252 (185)/2400 ← 233 (171)/2000 ←
Service weight kg (lb) 134 (295) ← ← ←
No-load maximum speedrpm 2600 2800 2570 ←
1-7
Diesel Engine
Vehicle model
1·K2·K3 ton series 2·3 ton series 2·3·J3.5 ton series
Item
Engine model 1DZ-II ← 2Z
Engine type Diesel · 4 cycle ← ←
In-line 4 cylinder,
Number and arrangement of cylinders ← ←
longitudinally mounted
Combustion chamber type Whirl chamber ← Direct injection
Valve mechanism OHV·gear drive ← ←
86.0 × 107.0 98.0 × 115.0
Bore x stroke mm (in) ←
(3.386 × 4.213) (3.858 × 4.528)
Total displacement cm3 (in3) 2486 (151.71) ← 3469 (211.69)
Compression ratio 21.5 ← 18.6
Maximum output kW (PS)/rpm 39 (53)/2400 42 (57)/2500 42 (57)/2200
Maximum torque N·m (kgf·m)/rpm 160 (16.3)/2300 160 (16.3)/2500 200 (20.3)/1600
Minimum fuel
g/kW·h (g/PS·h)/rpm 247 (181)/1400 ← 209 (153)/1000
conspumption
Service weight kg (lb) 162 (357) ← 212 (467)
No-load maximum speed rpm 2600 2800 2400
1-8
ENGINE PERFORMANCE CURVES

4Y-M Engine (STD) 1·2·K2·K3 Ton Series
Gasoline
LPG (Exclusive)
Torque LPG (Convertible)
Shaft torque
Fuel consumption ratio
4Y-M Engine (STD) 3·J3.5 Ton Series
Gasoline
Torque
LPG (Exclusive)
LPG (Convertible)
Shaft torque

1-9
4Y-E Engine (OPT) 1·2·K2·K3 Ton Series
Gasoline (Exclusive·Convertible)
LPG (Exclusive·Convertible)
Torque
Shaft torque
4Y-E Engine (OPT) 3·J3.5 Ton Series
Gasoline (Exclusive)
Gasoline (Convertible with LPG)
Torque
Gasoline (Exclusive)
Gasoline (Convertible with LPG)
Shaft torque
Fuel consumption ratio Gasoline (Exclusive·Convertible)

1-10
1DZ-II Engine 1·K2·K3 Ton Series
Torque
Shaft torque
1DZ-II Engine 2·3 Ton Series
Torque
Shaft torque

1-11
2Z Engine
Torque
Shaft torque

1-12
ENGINE ASSY
REMOVAL·INSTALLATION (M/T VEHICLES)
T = N·m (kgf·cm) [ft·lbf]
21
24
17 8
12
18
Engine mount set T = 53.2~98.0 (542~1000) [39.2~72.4]

Clutch housing set bolt T = 49.0~78.4 (500~800) [36.2~57.9]
1-13
Removal Procedure
1 Remove the engine hood. (See page 11-10.)
2 Remove the lower panel and toe board.
3 Drain coolant.
4 Remove the battery.
5 Remove the sedimenter bracket set bolt to free the bracket. (1DZ-II·2Z engine vehicle)
6 Disconnect the accelerator wire.
7 Disconnect the fuel hose.
8 Remove the relay block bracket set bolts to free the relay block.
9 Remove the battery set plate.
10 Remove the air cleaner and air inlet.
11 Remove the exhaust cover plate.
12 Disconnect the exhaust pipe.
13 Disconnect the water hose.
14 Remove the radiator and fan shroud.
15 Remove the under cover.
16 Remove the wiring and wire harness clamps around the engine.
17 Remove the oil pump set bolt and free it.
18 Remove the clutch housing cover, then remove the clutch cover, clutch disc, and flywheel. (See page 2-8.)
19 Remove the starter motor.
20 Remove the engine mount nuts.
21 Slightly hoist the engine. [Point 1]
22 Support the clutch housing with wooden blocks.
23 Separate the engine and clutch housing. [Point 2]
24 Remove the engine ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air from the fuel system after installing the engine ASSY. (1DZ-II·2Z engine vehicle) (See page 1-18.)
1-14
SST(1) Point Operations

[Point 1]
SST(2)
Removal•Installation:
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)
Removal:
Temporarily hoist up until the mount bolt completely comes out
of the hole in the frame.
[Point 2]
Removal:
Use a flat-head screwdriver for separation. If the fitting is too
tight, move the SST hook position to adjust the engine ASSY
angle for easier separation.
For the oil clutch vehicle, pay special attention so as not to
damage the crankshaft oil seal. If the oil seal is damaged,
replace it.
1-15
REMOVAL·INSTALLATION (T/C VEHICLES)

22
27
25
8
28
18 12
26
Engine mount nut T = 53.2~98.0 (542~1000) [39.2~72.4]

End plate set bolt T = 49.0~78.4 (500~800) [36.2~57.9]
1DZ-II·2Z: T = 125~186 (1275~1897) [92.2~137.2]
Drive plate set bolt (For connecting the engine crank shaft)
4Y: T = 78~98 (795~1000) [57.5~72.4]
Drive plate set bolt (For connecting the torque converter) T = 14.7~21.6 (150~220) [10.9~15.9]
Torque converter housing set bolt T = 29.4~44.1 (300~450) [21.7~32.6]
1-16
Removal Procedure
1 Remove the engine hood. (See page 11-10.)
2 Remove the lower panel and toe board.
3 Drain coolant.
5 Remove the sedimenter bracket set bolt to free the bracket. (1DZ-II·2Z engine vehicle)
6 Disconnect the accelerator wire.
7 Disconnect the fuel hose.
8 Remove the relay block bracket set bolt and free the relay block.
10 Remove the air cleaner and air inlet.
11 Remove the exhaust cover plate.
12 Disconnect the exhaust pipe.
13 Disconnect the water hose.
14 Disconnect the T/C cooler hose. [Point 1]
15 Remove the radiator and fan shroud.
16 Remove the under cover.
17 Remove the wiring and wire harness clamps around the engine.
18 Remove the oil pump set bolt and free it.
19 Remove the cover plate. [Point 2]
20 Remove the 6 drive plate set bolts. [Point 3]
21 Remove the engine mount nuts.
22 Slightly hoist the engine. [Point 4]
23 Support the torque converter housing with wooden blocks.
24 Separate the torque converter housing and engine. [Point 5]
25 Remove the engine ASSY.
26 Remove the drive plate.
27 Remove the torque converter end plate.
28 Remove the starting motor.
Note:
• Apply sealant (08833-76002-71 (08833-00080)) before tightening the drive plate set bolt (for connecting
engine and crankshaft).
• Bleed air from the fuel system after installation of the engine ASSY. (1DZ-II·2Z engine vehicle)
(See page 1-18.)
1-17
Point Operations
[Point 1]
Removal:
Put match marks on the radiator and torque converter cooler
hose.
Cover plate [Point 2]

Removal:
Remove the cover plate.
[Point 3]
Rotate the drive plate using the crank shaft pulley set bolt, and
remove the drive plate set bolt.
SST(1) [Point 4]
SST(2)
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)
Removal:
Temporarily hoist up until the mount bolt completely comes out
of the hole in the frame.
1-18
[Point 5]
Removal:
Use a flat-head screwdriver for separation.
If the fitting is too tight, change the SST hook position and
adjust the engine angle for easier separation.
AIR BLEEDING OF THE FUEL SYSTEM

1DZ-II·2Z Engine Vehicles Only
1. Perform air bleeding by moving the priming pump knob up and
down.
2. Once the pump operation becomes heavy, air bleeding is
completed.
ENGINE INSPECTION·ADJUSTMENT
Note:
• Warm up the engine beforehand, and proceed with inspection and adjustment when the vehicle is in the
following state:
• Coolant temperature: 75°C (167°F) or above, engine oil temperature: 60°C (140°F) or above, hydraulic oil
temperature: 50°C (122°F) or above
4Y-M ENGINE (STD)

Ignition Timing Inspection·Adjustment
1. Install the rev counter and timing light.
2. Inspect the idle speed.
Standard: 750 rpm
3. Inspect and adjust the ignition timing.

(1) Disconnect the distributor vacuum hose.
(2) Use the timing light to inspect the ignition timing.
Standard: BTDC 7°/750 rpm
(3) If the standard is not met, loosen the distributor set bolt
and rotate the distributor to adjust to standard value.
(4) Tighten the set bolt and inspect the ignition timing again.
(5) If the ignition timing has been adjusted, seal the
distributor set bolt with sealing tape.
1-19
Idle-up Speed Inspection·Adjustment

Idle up actuator
<Gasoline exclusive vehicles>
1. Install the rev counter. (Refer to 1-18)
2. Start the engine, and measure the engine speed with the
Vaccuum
vacuum hose removed from the idle-up actuator.
hose
Standard
M/T vehicle: 1100 ± 30 rpm
T/C vehicle: 1000 ± 30 rpm
If the standard is not met, adjust by turning the adjusting

screw.
Note:
Adjusting When the adjusting screw is turned clockwise, the engine
screw speed increases.
3. After adjustment, connect the vacuum hose.
<LPG or LPG/Gasoline Vehicle>

B
2. Start the engine, and measure the engine speed with the
vacuum hose removed from the idle-up actuator.
(The idle up actuator is not provided for the LPG vehicle.)
Actuator Standard
hose M/T vehicle: 1100 ± 30 rpm
T/C vehicle: 1000 ± 30 rpm
LPG/Gasoline vehicle
Actuator 3. If the standard is not met, adjust by turning adjusting screw B.

hose 4. Connect the idle up actuator.
LAA11-047
B
LPG vehicle
Idle Speed Inspection·Adjustment

<Gasoline exclusive vehicles>
1. Install the rev counter and vacuum gauge.
(1) Install the rev counter. (Refer to 1-18)
(2) Disconnect the vacuum hose from the vacuum advancer,
and connect the vacuum gauge.
Vacuum hose
1-20
2. Inspect and adjust the idle speed.

(1) Start the engine and alternately adjust the throttle
adjusting screw “1” and the idle adjusting screw “2”, so
that the vacuum is at a stable maximum at the specified
idle speed.
(2) If the idle speed does not decrease because the idle up
adjusting screw is in contact with the idle up actuator rod,
loosen the idle up adjusting screw.
1 Standard
2
Idle speed: 750 rpm
Vacuum: 400 mmHg or more
<LPG exclusive vehicles, Gasoline/LPG convertible vehicles>
A B
Standard: 750 rpm
3. If the standard is not met, make adjustment according to the
following procedure:
(1) Make adjustment by turning the adjusting screw B (LPG
Regulator LPG carburetor
vehicle) or C (LPG/gasoline vehicle).
(If less than the standard, turn the adjusting screw A
counterclockwise beforehand.)
(2) Slowly turn the adjusting screw A clockwise or
counterclockwise until the maximum speed is obtained.
(3) Determine the positions of adjusting screws B and C by
repeating steps (1) and (2) until the value obtained in step
(2) satisfies the standard.
(4) Slowly turn the adjusting screw A clockwise to the
position where the speed begins to drop, and then turn it
45 degrees counterclockwise.
Lock bolt No-load Maximum Speed Inspection·Adjustment

1. Install the rev counter.
2. Inspect and adjust the no-load maximum speed.
(1) Measure the speed when the accelerator pedal is fully
depressed.
Standard
1·2·K2·K3 ton series: 2600 ± 50 rpm
3·J3.5 ton series: 2800 ± 50 rpm
1-21
Bushing Adjusting screw (2) If the standard is not met, make adjustment as follows:
(a) Remove the seal and loosen the lock bolt.
(b) Fully depress the accelerator pedal.
(c) Turn the bushing while holding the adjusting screw of
the air governor with a flat-head screwdriver in order
to adjust the speed.
Hold
3. Check and adjust relief down.

(1) Operate the tilt lever fully backward with the engine
running at the maximum speed, and measure the
decrease in speed (relief down) upon full relief.
Standard: Within 300 rpm
(2) If the standard is not met, make adjustment according to

the following procedure:
(a) (a) Turn the adjusting screw counterclockwise to
decrease relief down.
(b) (b) Return the screw by 1/10 of a turn to eliminate
twisting of the spring in the air governor.
(c) Adjust the no-load maximum speed.
(d) Repeat steps (a), (b) and (c) until the measured
value satisfies the standard.
4. Check and adjust hunting.

(c) (1) Check for hunting upon tilt relief at the no-load maximum
(b)
speed.
(a) (2) If hunting occurs a few times or more, make adjustment
according to the following procedure:
(a) Turn the adjusting screw clockwise by 1/2 of a turn or
more.
(b) Return the screw counterclockwise by 1/4 of a turn.
(c) Finally, turn it clockwise by 1/10 of a turn to eliminate
twisting of the spring in the air governor.
(d) Adjust the no-load maximum speed.
(e) Repeat steps (a) through (d) until hunting close not
occur.
5. Repeat adjustments in steps 2 to 4 until respective standards
are satisfied.
6. Seal the lock bolt.
1-22
4Y-E ENGINE (OPT)

1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
Standard: 750 ± 30 rpm (For both gasoline and LPG)
Rev terminal
3. If the standard is not met, adjust by the following procedure.

(1) Connect the plug-in analyzer.
SST 09240-26600-71
Note:
• Vehicles equipped with the multifunction display (OPT)
have the same functions as the analyzer, so the plug-in
analyzer is not necessary.
• For an explanation on using the multifunction display and
plug-in analyzer, refer to the multifunction display section.
(2) Set the idle speed to within standard values on the idle
adjustment screen.
No-load Maximum Speed Inpsection

2. Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator is fully pressed down.
Standard: 2570 ± 30 rpm (For both gasoline and LPG)
Rev terminal
1-23
3. Inspect the relief down amount.

Operate the tilt lever fully backward at the maximum engine
speed, and measure the engine speed upon full relief.
Measure the decrease (relief down) in the engine rpm.
Ignition Timing Inspection·Adjustment

Standard: 750 ± 30 rpm
3. Install the timing light.
Diagnostic connector
4. Use the SST to short circuit terminals 10 and 16 of the

diagnostic connector.
SST 09843-76001-71
(09843-18040)
Caution:
If the short circuit positions are incorrect, this will cause a
fault. Make sure to short circuit the correct terminals.
Diagnostic connector
5. Inspect the ignition timing.

If the standard is not met, loosen the distributor set bolt and
rotate the distributor to adjust the ignition timing to the
standard value.
Standard: 7° (BTDC) (For both gasoline and LPG)
1DZ-II·2Z ENGINE VEHICLE

Rev counter
1-24
Idle adjusting screw 2. Check the return of the accelerator wire, and also check that
the injection pump idle adjusting screw is in contact with the
accelerator lever.
Standard
1DZ-II: 750 ± 25 rpm
2Z: 775 ± 25 rpm
4. If the standard is not met, loosen the lock nut and adjust with
Accelerator lever the idle adjusting screw.
5. Tighten the lock nut, and inspect the idle speed again.
Maximum adjusting screw No-load Maximum Speed Inspection·Adjustment

2. Inspect the no-load maximum speed.
(1) While the engine is at standstill, press down the
accelerator fully, and check that the adjusting lever is
touching the maximum adjusting screw.
(2) Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator pedal is fully
Accelerator lever pressed down.
Standard
2Z: 2400 ± 50 rpm
1DZ-II:
1·K2·K3 ton series: 2600 ± 50 rpm
2·3 ton series: 2800 ± 50 rpm
In the case of vehicles equipped with drive control, the rpm
tolerance is .
3. Adjust the no-load maximum speed.
Remove the sealing of the maximum adjusting screw, and
adjust by turning it.
4. Inspect the relief down amount.

(1) Operate the tilt lever to fully backward at the maximum
engine speed, and measure the engine speed upon full
relief. Measure the decrease (relief down) in the engine
rpm.
5. Seal the set screw.
1-25
AIR CLEANER
SPECIFICATIONS
Single (STD) Double (OPT)
Type Cyclone type ←
Size 7-inch ←
Intake type Fresh air introduction type ←
Outer 18600 (2883)
Filtering area cm2 (in2) 18600 (2883)
Inner 510 (79.1)
Others With evacuator valve ←
COMPONENTS
1703
1-26
AIR CLEANER CLEANING·INSPECTION

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

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

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

Hold the tip end of the evacuator valve and discharge dust and
dirt from the inside of the valve.
5. Inspect the element.
After cleaning, place an electric bulb in the element to inspect
any damage in the element. If any pinhole, tear or damage is
found, replace it with a new element.
6. Element replacement
Replace the element after it is washed six times or generally at
intervals of 12 months.
1-27
7. Install the element.

Install the evacuator valve in the illustrated direction.
25°
CLOGGING WARNING SYSTEM

INSPECTION (OPT)
1. Warning lamp inspection
(1) Check that the air cleaner warning lamp comes on when
the ignition key switch is turned ON and goes out when
the engine starts.
2. Individual inspection
(1) Use a mity vac to apply a negative pressure to the
vacuum switch, and inspect for continuity.
Standard
4Y engine vehicle
2630~3218 Pa (270~330 mmAq) (19.9~24.3 mmHg):
continuity exists
1DZ-II·2Z engine vehicles
6904~8042 Pa (704~820 mmAq) (51.7~60.3 mmHg):
continuity exists
1-28
RADIATOR
COMPONENTS
4Y (M/T Vehicle)
1603
4Y (T/C Vehicle)
1603
1-29
1DZ-II (M/T Vehicle)
1603
1DZ-II (T/C Vehicle)
1603
1-30
2Z (M/T Vehicle)
1603
2Z (T/C Vehicle)
1603
1-31
SPECIFICATIONS
Type Crossflow
Fin type Corrugated fin
Coolant capacity (in radiator) See the table below
Cap opening pressure kPa (kgf/cm2) [psi] 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1]
Others Built in torque converter cooler (torque converter vehicle)
COOLANT CAPACITY AND ANTIFREEZE TABLE

Unit: l (US gal)
30% Antifreeze 50% Antifreeze
Total coolant Antirust mixture
Radiator capacity mixture mixture
capacity 5%
(down to -15°C) (down to -35°C)
M/T 2.2 (0.58) 7.0 (1.85) 2.1 (0.55) 3.5 (0.92) 0.4 (0.11)
4Y
1 ton T/C 2.0 (0.53) 7.8 (2.06) 2.3 (0.61) 3.9 (1.03) 0.4 (0.11)
series M/T 2.2 (0.58) 6.7 (1.77) 2.0 (0.53) 3.4 (0.90) 0.3 (0.08)
1DZ-II
T/C 2.0 (0.53) 6.5 (1.72) 2.0 (0.53) 3.3 (0.69) 0.3 (0.08)
M/T 2.2 (0.58) 8.0 (2.11) 2.4 (0.63) 4.0 (1.07) 0.4 (0.11)
K2·K3 4Y
T/C 2.0 (0.53) 7.8 (2.06) 2.3 (0.61) 3.9 (1.03) 0.4 (0.11)
ton
series M/T 2.2 (0.58) 6.7 (1.77) 2.0 (0.53) 3.4 (0.90) 0.3 (0.08)
1DZ-II
T/C 2.0 (0.53) 6.5 (1.72) 2.0 (0.53) 3.3 (0.69) 0.3 (0.08)
M/T 2.3 (0.61) 8.1 (2.14) 2.4 (0.63) 4.1 (1.08) 0.4 (0.11)
2·3 ton series:
T/C 8.1 (2.14) 2.4 (0.63) 4.1 (1.08) 0.4 (0.11)
4Y 2.25 (0.59)
J3.5 ton series:
T/C 9.5 (2.51) 2.9 (0.77) 4.8 (1.27) 0.5 (0.13)
3.7 (0.98)
2·3·J3.5 M/T 2.3 (0.61) 6.8 (1.80) 2.0 (0.53) 3.4 (0.90) 0.3 (0.08)
ton 1DZ-II
series T/C 3.7 (0.98) 8.2 (2.16) 2.5 (0.66) 4.1 (1.08) 0.4 (0.11)
M/T 2.3 (0.61) 7.8 (2.06) 2.3 (0.61) 3.9 (1.03) 0.4 (0.11)
2 ton series:
T/C 7.8 (2.06) 2.3 (0.61) 3.9 (1.03) 0.4 (0.11)
2Z 2.25 (0.59)
3·J3.5 ton series:
T/C 9.2 (2.43) 2.8 (0.74) 4.6 (1.21) 0.5 (0.13)
3.7 (0.98)
Note:
• The total coolant capacity does not include the capacity of the reservoir tank.
• Reservoir tank capacity: 0.47 l (0.124 US gal) (at FULL mark position)
COOLANT INSPECTION
1. Inspect the coolant level.
Check that the coolant level is between FULL and LOW in the
radiator reservoir tank.
1-32
2. Measure the coolant concentration. (LLC)

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

3. Check that there is no oil etc. mixed in with the coolant.
Measured temperature (°C)

1-33
MUFFLER & EXHAUST PIPE

COMPONENTS
4Y
1702
1DZ-II (1·K2·K3 Ton Series)
1702
1-34
1DZ-II (2·3 Ton Series)·2Z
1702
1-35
REMOVAL·INSTALLATION
Note:
The muffler can be removed by either of the two methods shown below.
(1)Remove the muffler after removing the counterweight.
(2)Remove the muffler after removing the radiator W/ counterweight.
Here, method (1) is explained.
3
4
2
Removal Procedure
1 Remove the counterweight. (See page 11-11.)
2 Separate the union between the exhaust pipe and muffler.
3 Remove the exhaust pipe fixation bolts.
4 Remove the muffler.
5 Disconnect the tail pipe from the muffler.
Note:
Use a new gasket.
MAINTENANCE OF CATALYTIC MUFFLERS

For diesel vehicles, replace the muffler ASSY every year or every 2000 hours.
For gasoline vehicles, replace the 3-way catalytic muffler ASSY every 5 years or every 3500 hours.
1-36
BATTERY
COMPONENTS
4Y
1901
1DZ-II
1901
1-37
2Z
1901
SPECIFICATIONS
List of battery types (different batteries are used depending on which engine they are mounted).
Engine 2Z
4Y 1DZ-II 2Z (Specifications for cold
Specifications areas)
STD 34B 19L(S) 80D 26L 95D 31L 75D 23L × 2
OPT
55D 23L 95D 31L 55D 23L × 2 —
(High capacity battery)
Battery model
34B 19L 55D 23L 75D 23L 80D 26L 95D 31L
Item
Voltage V 12 ← ← ← ←
5 hour rated capacity Ah 27 48 52 55 64
Specific gravity of electrolyte in use
1.280 ← ← ← ←
(at 20°C (68°F))
Cold cranking current A 272 356 550 582 622
Cell weight kg (lb) 9.1 (20.1) 14.7 (32.4) 16.3 (35.9) 17.2 (37.9) 21.5 (47.4)
1-38
INSPECTION
1. Inspect the battery fluid level.
Inspect that the battery fluid level is between the UPPER and
LOWER lines. Add distilled water if insufficient. Do not overfill
UPPER
above the upper fluid limit.
LOWER
2. Inspect the specific gravity of the battery fluid.

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

If battery terminals are contaminated to white, clean then and
apply a thin coat of MP grease on terminals.
4. Inspect the battery terminals and the harness connecting
portions for loosening.
Retighten the battery terminals and the harness connecting
portions.
Battery Removal
1. Disconnect battery terminals.
Note:
Disconnect the negative terminal first.
2. Remove the battery stopper.
3. Remove the battery.
Battery Installation
1-39
V-BELT TENSION ADJUSTMENT

1. Inspect the V-belt tension.
Standard
[amount of delfection when pressed with 98 N (10 kgf)]
4Y: 8~13 mm (0.31~0.51 in)
1DZ-II·2Z: 8~13 mm (0.31~0.51 in)
Standard
[When using a tension gauge (SST)]
SST 09216-76002-71 (09216-00021)
4Y: 294~490 N (30~50 kgf) [66~110 lbf]
1DZ-II·2Z: 324~559 N (33~57 kgf) [73~126 lbf]
Set bolt 2. V-belt deflection adjustment

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

Adjustment bolt
(1) Loosen the fixing bolt and adjusting bolt.
(2) Stretch the V-belt using a pry bar with the length of 300 to
400 mm (11.8 to 15.7 in), and tighten the alternator
adjustment bolt.
(3) Tighten the fixing bolt then recheck the belt tension.
Note:
Adjustment of the tension using a pry bar gives rise to
Fixing bolt considerable individual differences, and tends to result in
excessive or insufficent tension. Therefore, be sure to inspect
the deflection amount.
1-40
ACCELERATOR PEDAL
COMPONENTS
2601
4Y-M (STD) 4Y-E (OPT)
1DZ-II·2Z
2601
1-41
INSPECTION·ADJUSTMENT
B 1. Inspect the angle of the accelerator pedal.
4Y 1DZ-II 2Z
A
A: When the accelerator is OFF 45° 45° 45°
Rod B: At full throttle (reference) 17° 20° 15°
Adjust by adjusting the length of the rod.
Stopper bolt
2. 4Y-M (STD) engine vehicle

1DZ-II·2Z Stopper bolt
Adjust the height of the stopper bolt on the floor side so that
engine vehicles
the throttle lever of the carburetor comes to a position just
Link
before full open when the pedal is depressed.
3. 1DZ-II·2Z engine vehicles
Adjust the height of the stopper bolt on the floor side so that
the link contacts the stopper bolt on the engine side when the
pedal is depressed.
4. Adjust the accelerator wire so that there is about 2° of play in

the pedal.
4Y-E (OPT)·Diesel Vehicle with Drive Control (OPT)

1. Inspect the angle of the accelerator pedal.
B
A: When the accelerator is OFF 45°
A
m)
B: At full throttle (Reference) 16°

2m
Rod Adjust by adjusting the length of the rod.

(5
2. Temporarily set the pedal stopper bolt height to 52 mm

(2.05 in).
Stopper bolt Accelerator
sensor
3. Adjust the accelerator sensor.

(1) Connect the plug-in analyzer.
SST 09240-26600-71
For diesel vehicles with drive control (OPT) use the
multifunction display.
Note:
For an explanation on using the display, refer to the
multifunction display section.
1-42
(2) Adjust the sensor voltage when the accelerator is OFF.

Display the I/O ENGINE CTRL 4/10 screen on the display.
Adjust the installation position of the accelerator sensor
so that the VPA1 output (V) comes to the value below,
and fix it with a the set screw.
VPA1: 0.85 ± 0.1 V
(3) Adjust the height of the stopper bolt so that the difference
between the VPA1 output (V) in the full throttle position
and the initial VPA1 output (V) is 2.4 V or greater, and the
VPA2 output (V) in the full throttle position is less than 4.6
V.
(Note: the change in output per single turn of the stopper
bolt is 0.06 V)
(4) After adjustment, apply thread tightener (08833-76002-71
(08833-00080)) to the threaded section of the stopper bolt
lock nut and reassemble it.
(5) Clear the learned values.
For the 4Y-E:
Remove the battery plug for more than 10 seconds, then
reconnect it.
For diesel vehicles with drive control:
Turn the key ON with the accelerator sensor connector
disconnected. (An accelerator sensor error will be
detected.)
Then, turn the key OFF and reconnect the accelerator
sensor connector.
(6) Check that the VPA1 and VPA2 values displayed with the
accelerator OFF are within a range specified below of the
values displayed inside the brackets.
Standard: Within ± 0.1 V
1-43
DRIVE CONTROL DEVICE (OPT)

1DZ-II·2Z Engine Vehicle
COMPONENTS
2607
1-44
REMOVAL·INSTALLATION
LBA26-006
Removal Procedure
1 Open the engine hood and disconnect the negative terminal of the battery.
3 Remove the relay block bracket set bolt and free the relay block.
4 Remove the sedimenter.
6 Disconnect the injection pump side link.
7 Remove the actuator. [Point 1]
Note:
• After installation, adjust the throttle opening degree. (Refer to 1-46)
• After installation, operate the accelerator pedal and check that the links are working normally.
1-45
[Point 1]
Inspection:
Inspect the actuator.
1. Check that the actuator shaft can be manually turned smoothly
without sticking.
2. Check the resistance of the actuator.
Tester range: Ω × 1 range
Standard
Between (1) and (3): Approx. 2.5~3.7 Ω
Inspection:
Measure the insulation resistance between each actuator
terminal and body.
Tester range: Ω × 1 M range
Standard: 100 MΩ or more
[Point 2]
Inspection:
Inspect the continuity of the limit switch.
Standard
Free position: ∞ Ω
When pushed 2.3 mm (0.091 in) or more: 0 Ω
1-46
Idle set THROTTLE OPENING DEGREE

screw Thickness ADJUSTMENT
gauge
Idle Switch (Injection Pump Lever Completely Closed)
Adjustment
LBA26-010 1. Fix the injection pump lever in completely closed state with a
thickness gauge (1.3 mm (0.051 in) thickness) placed between
the lever and the idle set screw.
2. Tighten the adjustment bolt on the idle switch side from the
state where the switch and bolt are not in contact (switch OFF)
and adjust the bolt to the point where the switch switches
(OFF→ON). (It is possible to tighten up to 1/4 turn from the
Idle switch switching point)
3. Fix the adjustment bolt with the lock nut.
Lock nut
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.
Adjustment bolt
NMR Switch (Injection Pump Lever Completely Open)

Thickness gauge Adjustment
NMR set 1. Fix the injection pump lever in completely open state with a
screw thickness gauge (0.3 mm (0.051 in) thickness) placed between
the lever and the NMR set screw.
2. Tighten the adjustment bolt on the NMR switch side from the
state where the switch and bolt are not in contact (switch OFF)
and adjust the bolt to the point where the switch switches
Adjustment (OFF→ON). (It is possible to tighten up to 1/4 turn from the
NMR switch bolt switching point)
3. Fix the adjustment bolt with the lock nut.
Lock nut 4. Unlock the injection pump lever from fully open state.
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.
1-47
TROUBLESHOOTING
This page contains troubleshooting advice for the mechanical system of the drive control device. In the case of an
error code being recieved, or trouble with the electrical system, refer to the troubleshooting section.
● Idle switch open error
Check the injection pump
Check that the injection pump return spring is Not broken A defect in the mechanical system of the drive control
not broken. device.
Check the components of the drive control device.
Broken
Replace the return spring
Checking the components

of the drive control device
There is
Move the link by hand, and check that there is interference
no interference with surrounding parts. Remove the interference.
There is no interference
There is
looseness or
Check that there is no looseness or rattling in the rattling
motor bracket. Retighten the installation bolts.
There is no looseness
or rattling
There is
Check that there is no bending in the connecting bending
rod or bracket. Replace defective components.
There is no bending
There is
Check that there is no catching on the sliding catching
portion of the ball joint. Clean and grease the joint section.
There is no catching
90°C (194°F )
Check that the temperature around the motor in or more
use is 90°C (194°F) or less. Outside the range of the motor operation warranty.
90°C (194°F) or less
Mechanically no cause can be found, therefore

refer to the drive control device electrical system
troubleshooting.
1-48
● The idle speed deviates from the specified value

specified A defect in the mechanical system of the drive control

Hold pump lever completely closed with your speed device.
hand, then start the engine and check whether Check the components of the drive control device (refer
the engine idles at the specified speed. to 1-47).
Not-specified speed
Adjust the idle set screw
● The idle up speed does not rise

There is no A defect in the mechanical system of the drive control

Move the pump lever with your hand to check catching device.
that there is no catching in the sliding
Check the components of the drive control device (refer
movement.
to 1-47).
There is catching
Service the injection pump (apply grease, etc.)
● No NMR
Check that there is NMR when starting the A defect in the mechanical system of the drive control
There is NMR device.
engine and turning the pump lever to the fully-
open position with your hand. Check the components of the drive control device (refer
to 1-47).
There is no NMR
Adjust the maximum set screw
● The engine does not respond to operation of the accelerator pedal

A defect in the mechanical system of the drive control

With the engine running, move the pump lever Engine revs up
device.
with your hand and check the rev-up response.
Check the components of the drive control device (refer
Engine doesn't rev up to 1-47).
Service or replace the injection pump

1-49
DPF-II SYSTEM (OPT)

COMPONENTS
5701
5701
1-50
1DZ-II
1702
1702
1-51
2Z
1702
1-52
CONNECTOR DIAGRAM
1-53
1-54
DPF MUFFLER REMOVAL·INSTALLATION
3
1
Removal Procedure
1 Remove the radiator cover.
2 Remove the weight.
3 Open the engine hood, and disconnect the heater and temperature sensor connector.
4 Cut the tie-wrap and pull the heater and temperature sensor harness out toward the rear of the vehicle.
5 Disconnect the back pressure sensor connecting hose.
6 Disconnect the exhaust pipe from the muffler.
7 Remove the DPF muffler ASSY.
Note:
• Replace the gasket between the muffler and exhaust pipe with a new one.
• When the muffler ASSY is replaced, clear the memory. (See page 1-65.)
1-55
DPF MUFFLER DISASSEMBLY·INSPECTION·REASSEMBLY

T = 11.76~14.70 3
(120~150)
[8.68~10.9] 2
Disassembly Procedure
1 Remove the outlet pipe.
2 Remove the 16 bolts. [Point 1]
3 Remove the DPF heater ASSY.
4 Remove the DPF jacket ASSY. [Point 2]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Replace the DPF jacket ASSY gasket with a new one.
• When the DPF jacket ASSY is replaced, clear the memory. (See page 1-65.)
1 Point Operations
5 8 [Point 1]
Reassembly:
Install the bolts, nuts and washers in the illustrated order.
3 4 Note:
Use the specified bolts, nuts and washers. Use of general
items may cause malfunctions.
7 6
2
1-56
[Point 2]
Inspection:
Replace the DPF jacket ASSY if its center or inside wall is
blackened with soot when seen from the outlet side.
1-57
CONTROLLER REMOVAL·INSTALLATION
Note:
Since the two wires from the controller to the outlet are both black, put tags showing the connecting
positions.
6 3
T = 1.18~1.76
(12~18)
[0.87~1.30]
Removal Procedure
1 Open the engine hood, and disconnect the battery negative terminal.
2 Remove the step.
3 Remove the bracket set bolts.
4 Disconnect the wiring from the controller to the outlet.
5 Disconnect the controller connector.
6 Remove the controller ASSY.
Note:
When the controller is replaced, turn the ignition key switch ON and check no error is present.
1-58
BLOWER REMOVAL·INSTALLATION
Note:
Since the blower is to be removed from under the frame, operate in a pit.
View A
5
3
7
Removal Procedure
1 Open the engine hood, and disconnect the battery negative terminal.
2 Remove the toe board.
3 Remove under cover from the vehicle.
4 Disconnect the connector.
5 Disconnect the blower hose from the blower.
6 Remove the blower set bolts, and remove the blower W/ bracket from under the vehicle.
7 Remove the blower ASSY.
Note:
When the blower wiring clamp is removed, replace it with a new one.
1-59
DPF VALVE REMOVAL·INSTALLATION
6
2
2 5
3 5
4
7
Removal Procedure
1 Disconnect the battery negative terminal.
2 Disconnect the DPF air cleaner hose (air cleaner side) and blower hose (flow rate sensor side).
3 Disconnect the back pressure sensor connector and back pressure sensor hose, and remove the back pressure
sensor.
4 Disconnect the DPF valve hose.
5 Disconnect the DPF valve connector and blower sensor connector.
6 Remove the base & bracket W/ DPF parts ASSY from the vehicle. Disconnect the wire harness clamps from the
base & bracket.
7 Remove the DPF valve W/ fitting. [Point 1]
Point Operations
[Point 1]
Installation:
Install the DPF valve in the correct direction.
The arrow marked on the valve body must be pointing the front
of the vehicle.
The connector of the core must be facing the front of the
vehicle as well. (The core can be turned by hand.)
Front
(Blower side)
1-60
DPF VALVE DISASSEMBLY·INSPECTION·REASSEMBLY

1
T = 20.6~30.4 (210~310) [15.2~22.4]
Disassembly Procedure
1 Fix the valve body in a vise, and loosen the lock nut.
2 Separate the valve body and core, and remove the plunger and spring. [Point 1]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Inspection:
Clean off soot accumulated in the valve body, plunger, and
core with compressed air.
Replace the valve ASSY if any damage or wear is seen on the
plunger seat.
Plunger seat
Reassembly:
Core Install the spring in the correct direction.
Face the minor diameter side of the spring to the valve body
side.
Spring
Body
1-61
INDIVIDUAL INSPECTION OF FUNCTIONAL PARTS
Starter relay
Display
Main relay
Back pressure sensor

For the flow sensor
For the valve
For the heater Heater relay
Blower
Buzzer
For the temperature sensor Controller
Heater
Connector for heater
Inspect the heater coil resistance.
Inspection method: Measure the resistance between both
terminals of wiring from the heater
Standard: Approx. 17 Ω
Temperature Sensor
Connector for temperature sensor Inspect the temperature sensor continuity.
terminals of the temperature sensor
connector.
Note:
Do not scratch gold plating on the connector pins at the time
of inspection.
1-62
DPF Blower
Inspect the DPF blower for continuity.
terminals of the DPF blower.
Standard: Approx. 2.2 Ω
Note:
Do not scratch gold plating on the connector pins at the time
of inspection.
Inline Filter
Muffler side
Inspect the outlet on the back pressure sensor side for soot
accumulation. If soot is seen, replace the sensor.
Back pressure sensor side
Note:
Back pressure Muffler Regarding the direction of the inline filter. Do not install in the
sensor side side reverse direction after inspection. Check the direction by the
Soot "DENSO" mark direction. Although no direction is specified
for installation of a new filter, it is recommended to install with
the "DENSO" mark facing the back pressure sensor side.
A
View A Mark
DPF Valve
Measure the resistance between both terminals of the DPF valve
wiring.
Inspection method: Between both terminals of the valve
connector
Note:
The part has a direction, so take care not to reassemble it in
the opposite direction.
Main Relay
Remove the main relay and inspect the function.
Inspection method: Inspect continuity between terminals C
and D, with the battery voltage applied to
terminals A and B.
Standard: 0Ω
Main relay
1-63
Starting Motor Relay

Remove the starting motor relay and inspect the function.
Starting motor relay
terminals A and B.
Standard: 0Ω
Heater Relay
C A Inspect the function.
terminals A and B.
Standard: 0Ω
D B
Buzzer
Inspect the buzzer for continuity.
Display
1. Disconnect the controller connector, and measure the applied
battery voltage on the wiring side.
BATT Inspection method: Between BATT terminal ⊕ of the
controller connector (wiring side)
and body ground
Tester range: DC 50 V range
Standard: 10~14 V
2. Inspect the controller connector for continuity (on the controller

side).
Inspection method: E01-E1
E02-E1
E01
E1-E2
E02 E2 E1 Standard: There is continuity.
1-64
3. Inspect if any LED is burnt out.

Turn the ignition key switch ON and check if all LEDs are lit for
1 second.
The buzzer sounds for 0.5 seconds.
Note:
Regarding cleaning of the DPF filter
When the amount of soot reaches the limit, a buzzer sounds and 6 LEDs on the display flash. In this state, it
is necessary to perform regeneration process immediately. If the machine continues to be used in this
condition, a warning LED will light up and an error code "5-1" is generated. When the vehicle has reached
this condition, it is necessary to replace or to clean the filter.
If you feel that "We are carrying out regeneration process periodically, but the movement time is getting
shorter", it is recommended that you clean the filter.
Cleaning the filter
• Clean the filter when it is cold (when you feel no heat on touching it with your hand).
• Face the IN side of the filter downwards and apply high pressure water from above the OUT side. (The
filter is designed to withstand high pressure water to 5 MPa.)
• When no more white residual ash comes out under high pressure water, cleaning is finished.
After cleaning, always perform a "DPF filter memory clear".
1-65
CONTROLLER ERROR CODE CLEARING

METHOD
1. Turn the ignition key switch ON.
2. Press the RESET switch until the buzzer sounds.
3. Turn the ignition key switch OFF after the warning LED goes
out.
Note:
• Do not turn the ignition key switch ON until all LEDs on
Press
the display go out.
• Do not perform this operation before reading the error
code.
• If the buzzer does not sound when the RESET switch is
pressed, an internal switch defect may be the cause.
4. After LEDs go out, turn the ignition key switch ON and check
that the warning LED is not blinking.
DPF FILTER MEMORY CLEARING METHOD

1. Turn the ignition key switch ON.
2. Press the FILTER switch until the buzzer sounds.
3. Turn the ignition key switch OFF.
Note:
• Do not turn the ignition key switch ON until all LEDs on
the display go out.
• Perform this operation only when the filter is replaced.
Press • If the buzzer does not sound when the FILTER switch is
pressed, an internal switch defect may be the cause.
REGENERATION METHOD
1. Connect the external power cord (AC 200 V).
2. Press the regeneration switch until the buzzer sounds.
Note:
• The regeneration process ends in about 50 minutes
(about 70 minutes in case of high collection). One soot
soot amount indicating LED goes out every ten minutes,
and the process ends when all LEDs go out.
Press • If the buzzer does not sound when the regeneration
switch is pressed, an internal switch defect may be the
cause.
3. Disconnect the external power cord (AC 200 V).
Note:
• During the regeneration process, the engine does not start even though the ignition key switch is turned
to the START position. In this case the buzzer sounds to warn the operator.
• If the external power supply (AC 200 V power) is cut off for more than one minute during the
regeneration process, the buzzer will sound and the regenerating LED will blinks to warn the operator.
• While the power cord is kept connected after the end of regeneration, the engine does not start even
though the ignition key switch is turned to the START position. In this case, the buzzer sounds and the
warning LED blinks to warn the operator.
1-66
DISPLAY OF PAST ERROR CODES

Note:
• If any switch is operated incorrectly, turn the ignition key switch OFF once before retrying switch
operation.
• Check that no error code is displayed.
Operation Procedure
1. Turn the ignition key switch ON (engine in stopped state).
2. Press the FILTER, MODE and RESET switches at a time until
the buzzer sounds.
Press
3. Press the MODE switch until the buzzer sounds.
Press within 10 seconds

âüÇ²
Soot amount indicationg LED 4. Press the FILTER and MODE switches at a time until the
buzzer sounds.
5. The display becomes as follows:
When there is no past error code:
All LEDs are kept off for 5 seconds.
When there are any past error codes:
After the soot quantity display LEDs are kept off for one
second, the error codes are displayed one by one for five
seconds each from the oldest one. The buzzer sounds each
time the error code is switched over. The display is repeated
Press within 10 âüÇ²
seconds after all codes are displayed.
10ïbà»ì‡Ç
6. After checking the display, turn the ignition key switch OFF.
1-67
CLEARING OF PAST ERROR CODES

Note:
• Operate with a past error code being displayed.
• If any switch is operated incorrectly, turn the ignition key switch OFF once and display the past error
code again before retrying switch operation.
Operation Procedure
1. Turn the ignition key switch ON (engine in stopped state).
2. Press the FILTER, MODE, and RESET switches at a time until
the buzzer sounds.
Press
3. Press the MODE switch until the buzzer sounds.
4. Press the MODE and RESET switches at a time until the

buzzer sounds.
5. Past error codes are cleared.
6. Turn the ignition key switch OFF.

1-68
TROUBLESHOOTING
How to Approach Diagnosis
On detecting an abnormal area the controller lights a warning LED on the display and sounds a buzzer. The detected
abnormal area is then displayed as an error code using the soot amount indicating LEDs. When the warning LED
lights, pressing and holding the MODE switch for about one second will display the error code using the soot amount
indicating LEDs.
When the regenerating LED flashes with the ignition key switch ON, this indicates that the previous regeneration was
aborted partway due to a drop in voltage of the external power supply (AC 200 V), and the error code is 7-2. In this
case performing regeneration again will reset the error code without clearing the error code.
The connector numbers (A to M) specified in troubleshooting are the same as those shown on the connector diagram
on page 1-52.
Error Code Indicating Method

Turn the ignition key switch ON, and remove the communication switch cover. The error code is displayed by the
lighting LED positions while the buzzer sounds.
No. Error code Abnormal portion
During regeneration, the heater temperature does not rise to the specified level within the
1 1-1
specified time.
2 1-2 The heater temperature drops abnormally during regeneration.
3 1-3 The exhaust temperature rises abnormally while the engine is running.
4 1-4 The temperature sensor outputs an abnormally high temperature.
5 2-1 The back pressure sensor output is above or below the upper or lower limit.
The back pressure sensor output remains unchanged when the engine speed varies beyond
6 2-2
the given level.
7 3-1 The alternator L signal becomes abnormal upon starting the engine.
8 3-2 The rpm sensor output becomes abnormal after starting the engine.
9 3-3 The alternator L signal becomes abnormal after starting the engine.
10 4-1 The flow rate sensor output value is abnormal.
11 4-2 The blower flow rate is apart from the target level.
12 4-3 The flow rate sensor output deviates though the blower is not operated.
13 5-1 The amount of soot accumulated in the DPF filter is above the level that can be regenerated.
14 6-1 The controller memory is abnormal.
15 7-1 The vehicle battery voltage dropped abnormally.
16 7-2* The external power voltage (AC 200 V) dropped for 1 minute or more during regeneration.
*: For error code 7-2, the regenerating LED flashes instead of the warning LED.
1-69
Explanation on Error Code

The abnormal system portion is indicated by the soot amount indicating LEDs. When multiple system abnormalities
are detected at a time, they are indicated alternately at intervals of 5 seconds.
c : On ● : Off
Example : Error code 3-1
Code Soot amount indicating LEDs
No.1
Green 1 Green 2 Green 3 No.2 display
display No.1 display
No.2
Green 4 Green 5 Yellow
display
1 ● ● c
2 ● c ●
3 ● c c
4 c ● ●
5 c ● c
6 c c ●
7 c c c
Before Troubleshooting
1. Check that there was no interruption during regeneration such as the plug being accidentally pulled from the
power socket or some other circumstance.
If there has been an interruption during regeneration, the regenerating LED will flash when the ignition key
switch is turned ON. Carry out regeneration again. In this case it is not necessary to perform an error code clear
operation. If a regeneration interruption reoccurs, carry out the troubleshooting for error code 7-2.
2. Check that the battery voltage is the specified voltage (10~14 V).
If it deviates from the specified voltage, charge or replace the battery.
3. Check that the bulbs for the display are not blown. (Refer to 1-64)
If the LEDs on the display do not light when the ignition key switch is turned ON, replace the display.
4. Check that the display does not always light.
Repair or replace the display wiring.
1-70
Troubleshooting
Error Code 1-1 or 1-2
Inspection 1: NG
Inspect the heater resistance. Defective heater ASSY.
OK
NG
Inspection 2:
Defective temperature sensor.
Inspect the temperature sensor for continuity.
OK
Inspection 3: NG
Inspect continuity between the temperature sensor and Repair or replace the wiring.
controller.
OK
Inspection 4: NG
Inspect continuity between the heater relay and controller. Repair or replace the wiring.
OK
DPF system in normal state.
Inspection 1:
Heater resistance inspection
Disconnect the heater connector.
Tester range: Ω × 1
Measurement terminals Both terminals of heater connector: E-1 - E-2
Standard Approx. 17 Ω
Heater connector
(E) Heater connector
ÉCÉâÉXÉgë“Çø 2 1
OK → To inspection 2
NG → Defective heater ASSY
1-71
Inspection 2:
Temperature sensor continuity inspection
Disconnect the temperature sensor connector.
Measurement terminals Both terminals of temperature sensor connector: I-1 - I-2
Standard Approx. 1 Ω
(I) Temperature sensor connector
2 1
Temperature sensor connector
NG → Defective temperature sensor
Inspection 3:
Temperature sensor wiring continuity inspection
Disconnect the temperature sensor and controller connector.
Controller connector B-8 - Temperature sensor connector I-1
Measurement terminals
Controller connector B-21 - Temperature sensor connector I-2
Standard 0Ω
(B) Controller connector (I) Temperature sensor

connector
2 1
1 2
Temperature sensor
Controller connector connector
NG → Repair or replace the wiring
1-72
Inspection 4:
Heater relay wiring continuity check
Disconnect the heater relay and controller connectors.
Measurement terminals Controller connector B-10 ~ Heater relay 3
Standard 0Ω
Heater relay 3
(B) Controller connector
Heater relay 3
Controller connector
OK → DPF system in normal state

1-73
Error Code 1-3
NG
Inspection 1:
Temperature sensor defect.
OK
Inspection 2: NG
Inspect continuity of the wiring between the temperature Repair or replace the wiring.
sensor and controller.
OK
Controller defect.
Inspection 1:
See inspection 2 of error code 1-1.
NG → Temperature sensor defect
Inspection 2:
OK → Controller defect
1-74
Error Code 1-4
NG
Inspection 1:
Temperature sensor defect.
OK
Inspection 2: NG
Inspect continuity of the wiring between the temperature Repair or replace the wiring.
OK
NG
Inspection 3:
Repair or replace the power cord.
Measure the power supply voltage (AC 190~220 V).
OK
Inspection 4: NG
Inspect continuity of the wiring between the heater relay Repair or replace the wiring.
and controller.
OK
NG
Inspection 5:
Heater ASSY defect.
Inspect the heater resistance.
OK
Controller defect.
Inspection 1:
NG → Temperature sensor defect
Inspection 2:
1-75
Inspection 3:
Power supply voltage inspection
Connect the power cord to the power outlet.
Tester range: AC 500 V
Measurement terminals Power cord terminals
Standard AC 190~220 V
NG → Repair or replace the power cord
Inspection 4:
Heater relay wiring continuity inspection
Inspection 5:
Heater resistance inspection
NG → Heater ASSY defect
1-76
Error Code 2-1
OK
Inspection 1:
Controller defect
Inspect the back pressure sensor input.
NG
Inspection 2: OK
Inspect continuity of the wiring between the back pressure Back pressure sensor defect
sensor and the controller.
NG
Repair or replace the wiring.
Inspection 1:
Back pressure sensor input check
Voltage measurement between terminals
Controller connector: Back pressure sensor connector in connected state
Stop the engine and turn the ignition key switch ON.
B3 ~ B16
Measurement terminals Controller connector Controller connector
B4 ~ B16
Standard B3 ~ B16 : 5 ± 0.25 V, B4 ~ B16 : 1.5 ± 0.5 V
NG → To inspection 2
Inspection 2:
Back pressure sensor wiring continuity inspection
Disconnect the back pressure sensor and controller connector.
B4 ~ J1
Measurement terminals Controller connector B16 ~ Back pressure sensor connector J2
B3 ~ J3
Standard 0Ω
Back pressure sensor connector

(J) Back pressure
(B) Controller connector sensor connector
1 2 3
OK → Back pressure sensor defect

1-77
Error Code 2-2

Check the exhaust pipe and DPF muffler for exhaust gas leakage from each part or joint.
Inspection 1: NG
Check the pipes and hoses connecting functional parts of Repair or replacement
the DPF-II system for leakage or clogging.
OK
Inspection 2: NG
After leaving in idle state for about 30
Check the pipes connecting functional parts of the DPF-II
minutes, conduct inspection 3.
system for freezing.
OK
Inspection 3: NG
Check the in-line filter for clogging. Replace the in-line filter.
OK
NG Replace the valve, flow rate sensor,

Inspection 4:
blower, controller and DPF air cleaner,
Check the valve outlet for soot leakage.
and clean or replace the piping.
OK
OK
Inspection 5:
Controller defect
Check the back pressure sensor input.
NG
Inspection 6: OK
Inspect continuity of the wiring between the back pressure Back pressure sensor defect
sensor and the controller.
NG
Inspection 1:
DPF-II system gas leakage inspection
Check the pipes and hoses that connect parts for leakage or clogging.
NG → Repair or replacement
Inspection 2:
Pipe freezing check
Check the pipes and hoses that connect parts for freezing.
NG → To inspection 3 after defrosting.
Inspection 3:
In-line filter clogging check
NG → Replacement
1-78
Inspection 4:
Valve outlet soot leakage check
Back pressure sensor Air cleaner
Valve
Valve outlet Blower
Flow rate sensor
To exhaust manifold
NG → Replace the valve, flow rate sensor, blower and DPF air cleaner, and clean or replace the piping.
Inspection 5:
Back pressure sensor input check
Controller connector: Back pressure sensor connector in connected state
(1) Stop the engine and turn the ignition key switch ON.
B3 ~ B16
B4 ~ B16
Standard B3 ~ B16 : 5 ± 0.25 V, B4 ~ B16 : 1.5 ± 0.5 V
(2) Start the engine and keep the NMR running. (*)
Measurement terminals Controller connector B4 ~ Controller connector B16
Standard B4 ~ B16 : Value measured between B4 and B16 in (1) above + 0.2 V or more
(*) Perform this inspection only when three or more soot amount indicating LEDs are lit.
Inspection 6:
Back pressure sensor wiring continuity check
NG → Repair or replace the wiring.
1-79
Error Code 3-1 or 3-3
Inspection 1:
Check that the charge lamp on the combination meter NG Inspect the alternator by referring to the
comes on upon turning the ignition key switch ON and alternator section in the engine repair
goes out upon turning it to the START position. manual.
OK
Inspection 2: NG
Inspect continuity of the L signal wiring between the Repair or replace the wiring.
alternator and controller.
OK
Controller defect.
Inspection 1:
Charge lamp lighting inspection
Charge lamp
NG → To alternator inspection in the engine repair manual
Inspection 2:
Alternator L signal wiring continuity inspection
Disconnect the alternator and controller connectors.
Measurement terminals Controller connector B19 ~ Alternator terminal 1
Standard 0Ω
Alternator connector
(B) Controller connector Alternator
1 2 3
1-80
Error Code 3-2 (For Vehicles without Drive Control)
Inspection 1:
Inspect the engine rpm sensor installed on the injection NG
pump. Replace the injection pump ASSY.
OK
Inspection 2: NG
Inspect continuity of the wiring between the engine rpm Repair or replace the wiring.
OK
Controller defect.
Inspection 1:
Engine rpm sensor individual inspection
Disconnect the engine rpm sensor connector.
Tester range: Ω × 1 k
Measurement terminals Between both terminals M-1 and M-2 of rpm sensor
Standard Approx. 1 kΩ
Rpm sensor (M) Rpm sensor connector

connector
2 1
3
NG → Replace the injection pump ASSY.
1-81
Inspection 2:
Engine rpm sensor wiring continuity inspection
Disconnect the engine rpm sensor and controller connectors.
B7 ~ M2
Measurement terminals Controller connector Engine rpm sensor connector
B20 ~ M1
Standard 0Ω
Engine rpm sensor connector

(M) Engine rpm
(B) Controller connector
sensor connector
1 2
3
1-82
Error Code3-2 (For Vehicles with Drive Control)
Inspection 1: NG
Carry out the relevant troubleshooting.
Check the error display of the meter.
OK
Inspection 2: NG
Inspect for continuity between the ASC controller and the Wiring repair or replacement.
DPF controller.
OK
Inspection 3:
NG
Remove the ASC controller, directly connect the engine
rpm sensor and the DPF controller and check for any DPF controller defective.
errors.
OK
ASC controller defective.
Inspection 1:
Check for errors in the vehicle
NG → To relevant troubleshooting
1-83
Inspection 2:
Continuity check of harness between ASC controller and DPF controller
Disconnect the ASC controller connector and DPF controller connector.
25 ~ B7
Measurement terminals ASC controller connector DPF controller connector
38 ~ B20
Standard 0Ω
(B) DPF controller connector ASC controller connector
17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39 40 41 42
DPF controller connector ASC controller connector
Inspection 3:
Engine rpm sensor operation check when directly connected to the DPF controller
After clearing the error code disconnect the ASC controller connector, short circuit 25 to 36, and 24 to 38 of the
connector and start the engine. Check that an error reoccurs by the lighting of the warning LED (this time the
meter displays error 18-2).
ASC controller connector
17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39 40 41 42
ASC controller connector
No light → ASC controller defective

Light → DPF controller defective
1-84
Error Code 4-1
Inspection 1:
Inspect the blower air cleaner for gas leakage during NG Replace the valve, flow rate sensor,
engine running. blower and/or DPF air cleaner, and
clean or replace the piping.
OK
Inspection 2: OK
Controller defect
Inspect the flow rate sensor input.
NG
Inspection 3: OK
Inspect continuity of the wiring between the flow rate Flow rate sensor defect
NG
Controller defect
Inspection 1:
Air cleaner gas leakage inspection
Check that there is no exhaust gas leakage from the blower air cleaner outlet.
Air cleaner
Outlet of air cleaner

for blower
NG → Replace the valve, flow rate sensor, blower and/or DPF air cleaner, and clean or replace the piping.
1-85
Inspection 2:
Flow rate sensor input check
Controller connector: Flow rate sensor connector in connected state
Stop the engine and turn the ignition key switch ON.
B1 ~ B15
B5 ~ B15
Standard B1 ~ B15 : Battery voltage, B5 ~ B15 : 2.0 V or less
Inspection 3:
Flow rate sensor wiring cointinuity inspection
Disconnect the flow rate sensor and controller connector.
Tester range: Ω×1
B1 ~ K3
Measurement terminals Controller connector B15 ~ Forw rate sensor connector K2
B5 ~ K1
Standard 0Ω
Flow rate sensor

connector (K) Flow rate
(B) Controller connector sensor connector
1 2 3

1-86
Error Code 4-2
Inspection 1: NG
Inspect the air cleaner for clogging. Clean or replace the air cleaner.
OK
Inspection 2: NG
Inspect the piping between the air cleaner and blower Clean or replace the piping.
sensor for clogging or leakage.
OK
Inspection 3: NG
Inspect continuity of the wiring between the blower and Repair or replace the piping.
controller.
OK
Inspection 4: NG
Inspect the blower. Blower defect.
OK
NG
Inspection 5:
DPF valve defect.
Inspect the DPF valve.
OK
NG
Inspection 6:
Inspect the wiring between the DPF valve and controller. Repair or replace the wiring.
OK
To the next page.

1-87
From the previous page.
OK
Inspection 7: OK
Inspect the flow rate sensor input. Controller defect
NG
Inspection 8: NG
Inspect continuity between the flow rate sensor and Reapair or replace the wiring.
controller.
OK
Disassemble and inspect the DPF muffler.

Repair or replace if defective.
Inspection 9: OK
Inspect the piping between the blower sensor and muffler Flow rate sensor defect
for clogging.
NG
Clean or replace the piping.
Inspection 1:
Air cleaner clogging inspection
Check that the blower air cleaner is not clogged.
Air cleaner
OK → To inspaection 2
NG → Clean or replace the air cleaner
1-88
Inspection 2:
Gas leakage inspection
Check that no exhaust gas is leaking from the piping that connects the blower air cleaner and flow rate sensor.
Air cleaner
Flow rate sensor Blower
NG → Clean or replace the piping
Inspection 3:
Blower wiring continuity inspection
Disconnect the blower and controller connectors.
B1 ~ F2
Measurement terminals Controller connector Blower connector
B12 ~ F1
Standard 0Ω
(F) Blower
(B) Controller connector connector
Blower
connector
1 2
Inspection 4:
Blower individual inspection
See page 1-61.
NG → Blower defect
1-89
Inspection 5:
DPF valve individual inspection
See page 1-61.
NG → DPF valve defect
Inspection 6:
DPF valve wiring continuity inspection
Disconnect the DPF valve and controller connectors.
B1 ~ D2
Measurement terminals Controller connector DPF valve connector
B11 ~ D1
Standard 0Ω
DPF valve
connector
(D) DPF valve
(B) Controller connector connector
Inspection 7:
Inspection 8:
Flow rate sensor wiring continuity inspection
OK → To inspection 9 after DPF muffler individual inspection
Inspection 9:
Clogged piping inspection
Check that the piping between the blower sensor and muffler is not clogged.
Valve
Flow rate sensor
To muffler
OK → Flow rate sensor defect

NG → Clean or replace the piping
1-90
Error Code 4-3
OK
Inspection 1:
Controller defect
Inspect the flow rate sensor input.
NG
Inspection 2: OK
Inspect continuity of the wiring between the flow rate Flow rate sensor defect
NG
Inspection 1:
NG → To inspectinon 2
Inspection 2:
Flow rate sensor wiring continuity check
OK → Flow rate sensor defect
Error Code 5-1
Replace the DPF filter.
Error Code 6-1
Replace the controller.
1-91
Error Code 7-1
Inspection 1: NG
Charge or replace the battery.
Inspect the battery voltage (10~14 V).
OK
Inspection 2: NG
Inspect the wiring defect between the battery and controller. Repair or replace the wiring.
OK
Controller defect.
Inspection 1:
Battery voltage inspection
Check that the battery voltage is between 10 and 14 V.
NG → Charge or replace the battery
Inspection 2:
Wiring inspection
Inspect the wiring between the battery and controller for continuity.
Error Code 7-2
Check that the buzzer and display LED

Inspection 1: NG
are functioning normally when the
Check that the power breaker is not open and that the
ignition key switch is tuned ON with the
cord is securely connected to the outlet.
power cord connected.
OK
NG
Inspection 2:
Power code defect.
Inspect continuity of the power cord.
OK
Inspection 3: NG
Check that the AC wiring for the controller is correctly Correct wiring connection.
connected to the external power receptacle.
OK
Inspection 4:
Connect the power cord and check that the voltage at NG
cord terminals is AC 200 V. Connect the cord to the Controller defect.
vehicle and check for correct functioning when the
regeneration switch on the display is pressed.
OK
DPF system in normal state.

1-92
Inspection 1:
Power supply inspection
Check that the power breaker is not opened and the power cord is securely connected.
NG → Check for correct functioning of LEDs after the correction
Inspection 2:
Power cord continuity inspection
Inspect continuity between the terminals at both ends of the power cord.
NG → Power cord defect
Inspection 3: ]
Controller AC wiring inspection
Check that the wiring between the controller and outlet is securely connected.
NG → Correct wiring connection
Inspection 4:
Power supply voltage inspection
Connect the power cord.
Tester range: AC 500 V
Measurement terminals Power cord terminals
Standard AC 190~220 V
OK → DPF system in normal state

NG → Controller defect

8FG D CE048-01 - 0608 Engine

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

8FG D CE048-01 - 0608 Engine

Uploaded by

Copyright:

Available Formats

1-1

SPECIFICATIONS ........................... 1-25

ENGINE EXTERIOR VIEW

4Y-E Engine (With Electronic Control: OPT)

ENGINE MAIN PARAMETERS

ENGINE PERFORMANCE CURVES

Fuel consumption ratio

4Y-M Engine (STD) 3·J3.5 Ton Series

Fuel consumption ratio

4Y-E Engine (OPT) 1·2·K2·K3 Ton Series

Fuel consumption ratio

4Y-E Engine (OPT) 3·J3.5 Ton Series

Fuel consumption ratio Gasoline (Exclusive·Convertible)

1DZ-II Engine 1·K2·K3 Ton Series

Fuel consumption ratio

1DZ-II Engine 2·3 Ton Series

Fuel consumption ratio

Fuel consumption ratio

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

SST(1) Point Operations

REMOVAL·INSTALLATION (T/C VEHICLES)

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

Cover plate [Point 2]

AIR BLEEDING OF THE FUEL SYSTEM

4Y-M ENGINE (STD)

3. Inspect and adjust the ignition timing.

Idle-up Speed Inspection·Adjustment

If the standard is not met, adjust by turning the adjusting

<LPG or LPG/Gasoline Vehicle>

Actuator 3. If the standard is not met, adjust by turning adjusting screw B.

Idle Speed Inspection·Adjustment

2. Inspect and adjust the idle speed.

Lock bolt No-load Maximum Speed Inspection·Adjustment

3. Check and adjust relief down.

(2) If the standard is not met, make adjustment according to

4. Check and adjust hunting.

4Y-E ENGINE (OPT)

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

No-load Maximum Speed Inpsection

3. Inspect the relief down amount.

Ignition Timing Inspection·Adjustment

4. Use the SST to short circuit terminals 10 and 16 of the

5. Inspect the ignition timing.

1DZ-II·2Z ENGINE VEHICLE

Maximum adjusting screw No-load Maximum Speed Inspection·Adjustment

4. Inspect the relief down amount.

AIR CLEANER CLEANING·INSPECTION

3. Clean the element.

(2) Element washing method

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

7. Install the element.

CLOGGING WARNING SYSTEM

1DZ-II (M/T Vehicle)

1DZ-II (T/C Vehicle)

COOLANT CAPACITY AND ANTIFREEZE TABLE

2. Measure the coolant concentration. (LLC)

words, the concentration is approximately 35%.

Measured temperature (°C)

MUFFLER & EXHAUST PIPE

1DZ-II (1·K2·K3 Ton Series)

1DZ-II (2·3 Ton Series)·2Z

MAINTENANCE OF CATALYTIC MUFFLERS

2. Inspect the specific gravity of the battery fluid.