TOYOTA FORKLIFT Repairianual 2T75HL ENGINETOYOTA FORKLIFT REPAIR MANUAL TOYOTA MOTOR CORPORATIONFOREWORD This repair manual describes the description, construction, trouble shooting, removal, disassembly, inspection and repair, assembly, and installation of the various components of the 2T75HL model engine equipment on the TOYOTA SKID STEER LOADER 2SDK 4 model. You are encouraged to become thoroughly familiar with this manual so as to make the most of the outstanding performance and durability features of these loaders and to perform the proper servicing to maintain them in tip-top running condition. This repair manual contains the latest information available as of April, 1983. For any changes thereafter, you are asked to consult the Parts & Service News. Toyota reserves the right to make changes in specifications without incurring any obligation and without previous notice. TOYOTA MOTOR CORPORATIONSECTION INDEX _GENERAL ENGINE TUNE UP nce | FUEL SYSTEM me 3 pcoceneisiSiem Zz _ ENGINE ELECTRICAL EE TROUBLESHOOTING Ea MAINTENANCE STANDARDS [EMGENERAL ENGINE VIEW ...... ee eee seen TIPS ON OPERATION . ENGINE PERFORMANCE CURVES ENGINE SPECIFICATIONS .......0-2 ENGINE VIEW Fig.0-1 2T75HL EngineTIPS ON OPERATION 1. Before starting removal or disassembly, carefully observe the correct installation and assembly status (relative positions, securing methods, etc.) 2. When overhauling the engine and other mechanisms, arrange the disassembled parts orderly to prevent confusion at the time of reassemble, 3. Use liquid packing as required to prevent oil and water leak. Use specified bolts at specified places and tighten them to the specified torque as required with torque wrenches, 5. Gaskets, O-rings and rubber packings shall be replaced with new ones whenever they are disassembled. 6. Always use Toyota genuine parts for parts replacement at the time of overhaul or repair. Use of immitation parts not only accelerates functional degradation but is very dangerous in view of safe operation, 7. Special service tools (SSTs) are necessary depending on the repairing parts. Always use the specified SST for correct operation.0-4 aS ENGINE PERFORMANCE CURVES fandard Atmospheric Conditions Temperature: 20°C. Pressure: 760 mmHg Humidity: 65% Fan Gem Output shown is for when all parts fit properly. Torque: kom Ps Output: Specific Fuel Consumption gr/psh 1012 14 16 18 20 22 24 26 28 30 32 } ‘Speed of Crank shaft: rpm x 100 Fig. 0-2 2T75HL Engine Performance Curves ~8-ENGINE SPECIFICATIONS Model 2T75HL Manufacturer ‘Yanmar Diesel Engine Type Diesel engine Cooling method Water-cooling Engine proper Number of cylinders and arrangement In-line 2 cylinders Cycle 4 ‘Combustion chamber Special swirl chamber Valve location Overhead Cylinder liner Dry type Bore and stroke 9 75 x 85 mm (¢ 2.95 x 3.35 in.) Piston displacement 0.751 & (0.198 USgal) Compression ratio 23 ‘Compression pressure at 250 rpm 35 kg/cm? (497 psi) Maximum detonation pressure 65 kg/cm? (923 psi) Rated mean effective pressure 6.40 kg/cm? (91 psi) (3000 rpm} Rated output 14.5 PS/3000 rpm Maximum torque 4.3 kg-m (31.39 ft-lb)/2400 rpm Fuel comsumption at rated output 205 (0.441 Ibs}/PS-h (at full load) Engine dimensions (Lx W x H) prox. 442 x Approx.423 x Approx.617 mm (17x 166 x 24.3 in.) Dry engine weight 105 kg (231 Ibs} Piston material Aluminum alloy Compression ring 2 Number of piston rings Oil ring 1 Open At 20° BTDC Intake valve timing 7 Close At 50° ABOC Open At 0° BTDC Exhaust valve timing = Close At 20° ABDC Intake 0.2 mm (0.0079 in.) (Cold) Valve clearance Discharge 0.2 mm (0.0079 in.) (Cold) Starting system Overrunning clutch magnet No load minimum rpm 800 rpm Ignition ‘Compression ignition Fuel injection timing 21° (static) BYDC Order of fuel injection T=6 ee Type Bosch PFR 2K . Manufacturer Yanmar Disel Engine Injection pump Plunger diameter 6.5 mm ($0.26 in.) Cam lift 7.0 mm (0.276 in.) Name All-speed governor Governor Type Centrifugal Manufacturer ‘Yanmar Diesel Engine Nozzle holder type Screw-in Type Semi-throttle type Injection Noz. | Number of nozzle orifice 1 uz ze | Orifice diameter $1.0 mm (0.039 in.) Injection pressure 160 kg/cm? (2272 psi) Manufacturer Yanmar Diesel Engine Type Thermo start (intake preheating) Srepeating | Manufacturer Kokusan Electric Voltage-current 12v —14v Fuel Type Electromagnetic aoe Manufacturer Nippon Denso Type of lubrication Full force feed lubrication Oil pump type Trochoid sysene'"9 [Oil filter type Paper-element, full-flow filter About 2.3 & (0.61 USgal) Lubrication oif volume Effective volume: about 1.0 & (0.264 USgal) Water cooling by belt-driven water pump cool Be for recirculation ooling system Cooling system capacity About 1.52 (0.4 USgal) (for engine only) Water pump type Centrifugal type, belt-driven pump Type Alternator Manufacturer Nippon Denso Charging system Voltage 12v Maximum output 12V — 254 Type of regulator unit Tirrial type ; Type D.C. series wound (reduction type) Starting motor Manufacturer Nippon Denso Voltage-output 12V—1.4 KW =o)ENGINE TUNE-UP Page GENERAL 02.0.0 eee cece ee ee eee eee ee eee eeee 1-2 ENGINE OIL COOLING WATER .......0.0ceceeeeeeeee eee ee ee 1-3 VeBELT oe. 0e cece cece cece ceeeeee eee eeeeen es 4 FUEL FILTER ...ccccccccccesetceccsnscccsencees 1-4 AIR CLEANER ELEMENT ...........0..00.00000 es 1-5 BATTERY FUEL INJECTION TIMING . THERMO-START ........ 0.00 c cece cece eee eee 1-8 INJECTION NOZZLE .... 00.2. e cece eee e eee eee 1-9 INTAKE/EXHAUST VALVE CLEARANCE .......... 1-9 IDLING ADJUSTMENT ........ 00. c cece eee eee 1-10 NO-LOAD MAXIMUM RPM ADJUSTMENT ......... 1-10 INSPECTING COMPRESSION Soe enn rece ene reer 1-11 —ue2 Se GENERAL To always keep the engine in the best running condition and to obtain its full performance, periodic engine tune-up is necessary. If the engine becomes faulty, diagnose the engine through engine ture-up and take the necessary action. Engines in recent years use high compression ratios as well as many excellent electrical and other parts and mechanisms. On the other hand, these parts and mechnisms require accurate adjustment, Therefore, perfect engine tune-up is a must. Engine tune-up is classified into visual check and operations with testers. Since the check and adjustment operations described hereafter are mutually related, only parallel execu- tion of several or all items will bring about the tune-up effect. Operation considering the relationships between these items is necessary. ENGINE CHECK ITEMS © Check with the engine in stopped state 1. Engine oil check 2. Cooling water check 3. Vebelt check 4, Fuel filter cleaning 5. Air cleaner element check 6. Battery check 7. Fuel injection timing check 8. Thermo-start check 9. Injection nozzle check 0. Intake/exhaust valve clearance check ENGIN OIL OIL QUALITY CHECK Extract the level gauge. Check the oil adhered on the scale, The oi! quality is normal if there is no discoloration or degradation. The oil is gradually degraded and loses its viscosity through use. As a result, the lubrication effect is spoiled. If oil degradation or discoloration is excessive, exchange the oil even before the periodic ex- change timing OIL LEVEL CHECK AND OIL RE- PLENISHMENT The oil level is proper if it is near the upper limit scale on the level gauge, If the level is near the lower limit scale, supply the specified oil, API or CCI class oil, or the equivalent. © Carry out the following check during engine warming up for effieient operation, 11. Fuel pipe check © Check after engine warming up 12. Idling adjustment 13. Adjusting No-load maximum rpm 14, Compression check Estimated cause of oil discoloration Grayish color ...... Mixture of lead com- pound (metal particle, etc.) Mixture of water Mixture of carbon and dust through long use Milky while Blackish brown ... Caution: High-grade oil added with a large amount of purifying dispersant may be blackened in a short period, but this is not an abnormality aiaThe oil type shall be selected according to the season. Table 1 Oil viscosity and operating temperature SAE oil viscosity | Operating temperature SAE 20 =10°C ~10°C SAE 30 oc ~ 38°C SAE 40 more than 30°C SAE 10W - 30 -20°C ~ 15°C SAE 10W — 40 20°C ~ 30°C Total engine oil volume: About 2.3 {0.61 USgal) Caution: When the vehicle is kept horizontal, the oil level shall be at the upper limit of the level gauge. COOLING WATER CHECK AT EACH PART OF COOLING SYSTEM Fig. 1-2 Checking the Radiator Cap 1. Leak caused by damaged or age-hardened radiator hose or by insufficient tightening of the clamp. 2. Leak caused by corroded or damaged radia- tor core. 3. Leak caused by loosened cooling water drain cock. 4. Leak from water pump. 5. Leak from radiator cap If the cap is defective, water is likely to escape as steam. As a result, the cooling water flows excessively into the sub-tank to Caution: See page 4-4 for the check method. If antifreeze is mixed, supplying water alone cuases dilution to raise the freezing point. cause overflow in the sub-tank and ine sufficient cooling water level. Radiator cap, valve opening pressure 0.9 £0.16 kg/em? (12.79 psi} WATER QUALITY CHECK The water quality is normal if excessive scale accumulation exists near the radiator inlet hole and the cooling water is not contaminated with red rust or oil. Fig. 1-3 Checking the Cooling Water Level ~ 13 —1-4 WATER LEVEL CHECK AND RE- PLENISHMENT Remove the radiator cap and check the cooling water level. If it is insufficient, supply water to the specified level V-BELT VISUAL APPEARANCE CHECK 1. Crack, aged hardening, elongation and wear. Note: Inspect not only the outside but also the inside of the V-belt. 2. Oil adhesion Oil adhesion witl cause slipping and early wear, 3. Contact between each pulley and belt The belt is driven by the friction with pulley V-groove walls, If the belt is worn to contact with the pulley at the bottom of the V- groove, the friction decreases to cause pos sible slipping, 4. Check that the center of each pulley is correctly aligned. If not, the belt is stisted to cause abnormal wear. BLET TENSION CHECK AND ADJUST- MENT Push the belt with 10 kg force and check if the flexure is as specified, If not, move the alternator outward to adjust to the correct tension. Fan belt flexure: 10 — 15 mm (10 ka) 0.39 — 0.59 in. (22 Ibs) FUEL FILTER Wash the fuel filter with light oil. Replace the filter if itis extremely clogged or damaged. Caution: If antifreeze is mixed, supplying water alone causes dilution to raise the freezing point. Belt-inside Pulley Fig. 1-6 Cleaning the Fue! Filter 4AIR CLEANER ELEMENT Remove all dirt from inside the air leaner case. Clean out the air cleaner element by blowing compressed air through it from the inside. Caution: Use compressed air at a pressure of no great: er than 7 kg/cm? (99.4 psi). BATTERY EXTERNAL VISUAL INSPECTION Metal battery fittings: looseness or rust. 2. Battery case: cracking or damage. 3. Battery cable terminals: Conspicuous corrosion or damage Note: If the terminals or other parts are dirty, wash them with warm water and polish them with sandpaper. CHECKING AND ADDING FLUID 1, Plugs of all cells: ng, or air holes. 2. Fluid: if the fluid falls below the upper level, add more distilled water. Check for damage, crack- SPECIFIC GRAVITY After adding fluid, start the engine and measure the specific gravity of the fluid after the alter- nator has had a chance to charge the battery. Standard specific gravity: 1,280 (20°C) 1, Do not allow the float of the hydrometer to touch the inner surface of the outer tube. Read the specific gravity as shown in Fig 19 2. The difference between the specific gravities of all cells should not exceed 0.026. 3, The electrolyte should not be dirty. Battery fluid that has been used for a long time, and whose performance has fallen, becomes red, 4, Securely replace the caps of all cells. Fig. 1-9 Measuring Specific Gravity zg 28 50 3h oo 8 Saas ~~ a ot 304 5 67 No, of days battery can be used after cherging Fig. -15- |-10 Relationship Between Fluid Temperature and Selt-discharge16 VOLTAGE MEASUREMENT By battery tester Set the ammeter reading to 3 times the battery capacity (1804 for OAH battery, for example) by manipulating the resistor of the tester. Dis. charge for about 5 seconds in this state. If the voltage reading is about 9.6V or mor voltage is normal. Caution: The measurement shall be limited to 5 seconds (max.), and never repeat measure: ments. By boltmeter ‘After warming up the engine, place the regular handle at the stop position. Light the head lamp and start the engine by the starting motor. The voltage is proper if the voltmeter reading is about 9.6V or more Caution ‘The measurement shall be limited to 5 seconds (max.), and never repeat measure: ments. RECHARGING Carry out recharging when it is necessary as result of specific gravity and voltage measure- ment. At the time of recharging, especially pay attention to the following points Specific gravity of battery fluid and degree of discharge (at 20° C) Specific | Degree of Necessity of Gravity | discharge charging Over 1.23 |Less than 25%] Charging is unnecessary. ~ : Quick charging 1.23~1.25 | 25% | Quick ¢ 1.20 or less | Over 50% | Bench charging required Fig. 1-11 Measurement with battery tester Fig. 1-12 Recharging the battery — 16 —Caution: During battery recharging, pay attention to the following points for safe operation: © When recharging the battery, a high voltage may be applied to the alternator to cause breakdown of the diode. Be sure to remove both the positive @ and negative © battery cables. © During recharging, gases are generated, so remove the fluid plug of each cell. Since the gasses (hydrogen and oxygen) are likely to be ignited, be sure to keep a fire off, © If the battery fluid temperature rises to 45° C or above during recharging, suspend recharging and start recharging again after the fluid is cooled down. Excessive temperature may cause internal short- circuit leading to battery damage. o After recharging, polish battery terminals and lead terminals with a sandpaper and make sure connec tion. © Do not tap terminals with a hammer for terminal insertion. FUEL INJECTION TIMING Remove the injection pipe from the injection pump and check the timing according to the following procedure: 1. Set the engine regulator handle at the maximum rpm position by the accelerating lever. 2. Turn the crankshaft in the engine revolving direction by using the crankshaft V-pulley mounting nut. Stop the crankshaft when the il surface at the tip end of the delivery valve holder rises. 3. As the oil surface at the tip and of the delivery valve holder starts to rise, check if the punched mark on the circumference of the crankshaft V-pulley is aligned with the timing mark (21°BTDC) on the gear case. 4. If the injection timing is incorrect, adjust it by increasing or decreasing shims (fuel injec tion timing adjustment shims) between the injection pump and gear case. Increasing shims ...... Delays the injec- tion timing. Decreasing shims ...... Advances the injection timing, Fig. 1-14 Timing mark SweNotes: The standard shim thickness is 0.5 mm (0.0197 in). After adjustment, coat locktile 203M on both surface of shims. For injection pump installation or removal, see page 3-14. 1 mm of shim thickness changes about 1°. Shims are available in thickness of 0.1 mm (0.0039 in) and 0.2 mm (0.0079 in). THERMO-START Make sure that the header tank is charged with the fuel oil, Remove the intake pipe, and turn the starting switch to the GLOW position for about 18 seconds. When the starting motor is turned after lamp lighting, check that fuel oi! burns at the thermostat plug in the intake manifold. Also check that the flame extinguishes after engine starting. Carry out the following checks if the func- tion is abnormal. Heater coil and igniter check Check continuity between the terminal and thermo-start plug. If discontinuous, replace with a new part. Ball valve leak check Apply an air pressure of 1.4 kg/om? (19.8 psi) for 10 seconds from the fuel inlet and immerce tha ball valve in clean oil. Make sure that no air bubble appears from the joint between the nozzle body and valve stem, Check that there is no scar, crack, rust or any other damage. No fuel shall leak at the pipe joint after installation. Fig. 1-16 Checking continuity of the thermo start plug Fig. 1-17 Checking leak at the ball valve =eINJECTION NOZZLE Install the injection nozzle to the nozzle testet. Operate the handle at a rate of 50 to 60 times per minute and read the injection pressure. Injection pressure: 160 + 5 kg/cm? (2272 psi) Notes: The injection pressure shall be adjusted by the thickness of the adjustment shims. Shims are available in 4 kinds, 0.1, 0.2, 0.3 and 0.4 mm (0.0039, 0.0079, 0.018 and 0.0197 in) 0.1 mm (0.0039 in) increase or decrease varies the pressure by about 10 kg/cm? . oF Check that the injection angle in the above step is 5 ~ 10°. Notes: ° Placing a piede of white paper at about 30 cm from the nozzle an injection pattern which is almost round. Keep fingers off from the spray. Apply an ail pressure of 140 kg/cm? (1988 psi), and make sure that no oil leaks from the nozzle seat and case nut tightening por tion. Nozzle type: YDN-OSDYD1 Intake/exhaust valve clearance check Before adjustment, install the cylinder head bolts and nuts 2s well as. intake/exhaust valve rocker support mounting bolts and nuts as required, and tighten them to the specified torques. Cylinder head bolt and nut tightening torque Main bolt. M12. 1250 ~ 1350 kg-cm (9.125 ~ 9.855 ft-lb) Anxiliary bolt’ M 8 250 ~ 300 kg-cm (1.825 ~ 2.19 ft-lb) Support mounting nut tightening torque M10 450 ~ 500 ka-cm (32,85 ~ 36.5 ft-lb) Fig. 118 Nozzle test Thickness (t) | on ons a + i 03 05 Fig. 1-19 Nozzle spring adjustment shim Defective Defective Defective Good Fig. 1-20 Injection status Fig. 1-21, TD mark alignment —19-1-10 2. Set the adjustment cyliinder to the top dead center of compression. Notes: Align the TD mark on the outer circunference of the V-pulley with the gear case mark. Move the crankshaft pulley to the left and to the right to adjust the TD mark where the intake/discharge valve does not move 3. Inspect and adjsut the intake/exhaust valve clearance with the thickness gauge. Intake/exhaust valve clearance {in cold state for both intake and exhaust valves) 0.2 mm (0.0078 in) IDLING ADJUSTMENT Warm up the engine after it is started, Gradually decrease the speed and check if the minimum no toad rpm can be reduced to 800 rpm. MAXIMUM NO-LOAD RPM ADJUSTING After engine warming up, increase the speed and check the maximum no-load rpm, if incorrect, adjust the rpm by the adjustment bolt and seal the bolt. Maximum no-load rpm 3150 # 50 rpm. INSPECTING COMPRESSION 1. Carry out this inpsection after warming up before the cooling water temperature drops too much. 2. Remove the injection pipe and injection nozzle, Take of the combustion chamber (front and rear) except for the cylinder to be measured. Install the compression gauge via the SST (adaptor), 4. Turn down the regulator handle (to the stop position) Inspecting the intake/exhaust valve clearance Fig. 1-23. Setting the maximum no-load rpm ape chamber (rear) = — (Front) Fig. 1-24 Preparking for compression measurement — 20 —Rotating the engine by the starting motor conti- nuously until the speed is stabilized, and read the maximum valve, SST to be used: 09010-41840-71 and com- pression gauge for diesel, Caution: Since the engine speed decreases to cause a big difference in gauge readins as the battery is discharged, do not continue measurement more than it is necessary. Fig. 1-25 Measuring compression If the measured maximum valve or the difference between cylinders is different from the standard, repair the defective place and measure the com- pression again, ~ Standard compression | 35 kg/cm? (497 psi) pressure (250 rpm) Limit compression 30 kg/cm? (426 psi) pressure (250 rpm) Difference between 2 kg/cm? (28.4 psi) cylinder TRAVELING CHECK After end of engine parts inspection, let the machine travel and carry out overall inspection and check. The indications of charge, oil pressure and cooling water temperature shall be normal during traveling, The low speed, high speed acceleration and output shall be normal during Engine recheck traveling, and no abnormal sound shall be heard from each part of the engine. Meter inspection No engine oil, cooling water and fuel shall be leaking from any part after Leak check at each part traveling,MEMO 22ENGINE Page CEI | oossnoncmanesononnananenanonoopogooos 2-2 DISASSEMBLY ........0.0e0ceeeeeeee senses eee eee 2-4 INSPECTION AND REPAIR ........-0.020e0eeee ees 2-4 ASSEMBLY AND INSTALLATION ..........000s0005 2-20 ra242 GENERAL (8 Fig. 2-1 Engine sectional view The 2T7SHL water cooled, inline 2-cylinder engine having 75 mm cylinder bore, 85 mm stroke, 751 co piston displacement and 14,5 PS rated output is a 4-cyicle 2-cylinder diesel engine developed for industrial vehicles and for general uses. It has been designed with stress laid on easy handling and maintenance as well as high durability, reliability and economy. Its unique fuel injection system and special swirl combution chamber promise excellent starting and silent operation, The governor using unique mechanism and optimal fuel injection control improve fuel consump- tion ratio and prevent black smoke exhaust by good coordination of the torque performance in the low to medium speed range and operation load performance, ‘The cast iron cylinder block is made compact by using dry cylinder liner, The clearance between the operating piston and cylinder liner is kept at an optimal level to reduce consumption of the lubricating o} ‘The deep skirt structure provides a very high rigidity. The cylinder head inserted with the unique special swirl combustion chamber adopts the cross flow type arrangement of the intake and exhaust ports on both sides of the engine in combination with large- diameter intake valves to enhance the intake efficiency. Excellent performance from low to high speeds is ensured. The piston made of LO-EX (ACBA-T6) has two compression rigns and one ring with coil expander. The crankshaft journal, thrust bearing and crank pink bearing use steel as the back metal casted with Kelmet, and overlay is added to provide better adaptation to the crankshaft. Forced feed by trochoid pump is used for lubrication, The coil through the oil filter lubricates the crank bearing, intake and exhaust valves at the cylinder head, and the camshaft, A cartridge type oil filter with built-in bypass valve is adopted, aDISASSEMBLY Caution: Before disassembly, make accurate judgement of the defect cause and do not remove or disassemble the parts other than the necessary parts. Disassembled parts shall be kept orderly for each cylinder No. Remove the radiator. Remove the silencer. Remove the air cleaner. Rocker arm housing, (1) Remove the over-flow pipe bolts. {2) Remove the fuel pipe (between the header tank and thermostart). (3) Remove the rocker arm housing. Caution: Carefully prevent dust entrance in the injec- tion nozzle. Rocker arm and push rods. (1) Remove the rocker arms for the intake and exhaust valves, (2) Remove push rods. (3) Remove valve retainers. Caution: © Loosen, the lock nuts and intake and suc- tion valve clearance adjustment screws before loosening the rocker arm supports. © Carefully prevent missing. Injection valves. (1) Remove the flanges. (2), Remove the injection pipes. (3) Remove the injection valves. Caution © Pay attention to the difference between the front and rear surfaces. © Carefully prevent dust entrance into the injection pump. © Distinguish between cylinder Nos. Fig. 23 Step 5, Removing the Rocker Arm Fig. 2-4 Step 6, Removing the Flanges ~ 2 -2-4 7. Water pump, (1) Remove the alternator. (2) Remove the fan (3) Remove the fan driving V-belt. (4) Loosen the hose clamp (on the pump side) (5) Remove the water pump. (6) Remove the water pump bracket Caution © Do not lose the collar. © Remove 4 bolts (M8) 8. Cylinder head (1) Remove the oil pipe. (2) Remove the cylinder head bolts and nuts, (3) Remove the cylinder head. (4) Remove the gasket and packing Caution: © Since the M8 union bolt has a small oil hole, check it. © Prevent excessive deformation. © Gradually loosen them in the sequence shown in Fig. 2-7 > Prevent damaging the combustion surface. 9. (1) Remove the gear case cover. (2) Remove fuel injection pump mounting nuts, (3) Put a finger through the gear case cover installation window, and remove the fuel injection pump while pushing governor lever No, 2 by about 10 ~ 15 mm (0.39 ~ 0.59 in) leftward (toward the cylinder} with the finger. Caution: © Pay attention to the bolt length and washer installation position. © Do not change the injection timing adjustment shims too much, © Carefully protect the removed injection Pump from dust. Fig. 2.8 Step 9, Removing the Injection Pump. 26 —10. u 12. Gear Case (1) Remove the crankshaft V-pulley with a pulley, (2), Remove the key for V-pulley. (3), Remove the gear case. (4) Remove the packings and O-rings. Caution © Insert an iron bar into the balance hole on the outer periphery of the flywheel to stop rotation © 2 O-rings Governor (1) Remove the governor sleeve. (2) Remove the crankshaft gear nut by using SST 09131-42160-71. {3) Remove the governor weight support. Caution © Do not damage the crankshaft Oil pump (1) Remove the pump mounting bolts and remove the oil pump. Oil pan (1) Lay the engine with the flywheel side down. (2) Remove the level gauge and level gauge guide, (3) Remove the oil pan mounting bolts and remove the oil, pump. (4) Remove the oil strainer. Caution: © Carefully prevent damaging the flywheel surface. © Pay attention to the O-ring at the fitting surface © Remove the cap nut outside the cylinder Fig. 2.9 Step 10, Removing the V-Pulley14. 15, Piston (1) Remove the rod bolt cylinder by cylinder, and extract pistons. (2) Disassembled connecting rod caps shall be arranged in combined status. Cauton: © When rotating the piston, hold the end of the cylinder liner down to prevent it from coming off from the cylinder block with the piston. © Piston shall be arranged for each cylinder No © Do not damage the piston bearing. Flywheel (1) Lay the engine with the starter facing the downward. (2) Remove the flywheel bolts. (3) Remove the flywheel, Caution © Support the cylinder block with wooden blocks, © Place a support between the crank arm and cylinder block to prevent rotation. . Crankshatt (1) Remove the side bearing (2) Remove 2 set bolts for the center bearing on the oil pan mounting side of the cylinder block {3] Remove the crankshaft and center bearing as a set, (4) Remove the upper and lower tightening bolts of the center bearing and remove the bearing Caution: © Do not damage the crankshaft oil seal. © Drive out the crankshaft by tapping the V-pulley mounting side with a plastic hammer. © Do not pinch the hand by the crank and bearing. © Do not damage the bearing surface of center bearing No. 1 (flanged thrust bearing). Fig. 2-16 Step 16, Drive Out the Crankshaft 28 -7 18. Camshaft and tappets (1) Remove the small cross recessed (+) head screw to find the camshaft ball bearing. (2) Extract the camshaft, (3) Remove the tappets. Caution: © Rotate the camshaft 2 to 3 turns to dis: place tappets. © Do not damage the cam gear and cam. © Tappets shall be arranged orderly by sort- ing according to cylinder Nos. and intake exhaust valves. Mounting flange (1) Remove the mounting flange with the starter. (2) Remove the oil pipe. INSPECTION & REPAIR Caution © Carefully clean each part before inspec: tion and repair to remove dirt, oil, carbon and fur, © Blow each oil hole with compressed air to remove adheared matter and check it is not clogged. © Carbon deposit on the cylinder head, intake valves and suction valves shall be removed carefully to prevent damaging. © Parts with determined combination shall be arranged orderly to prevent confusion. CYLINDER HEAD 1 Visually check and damage. Use a flow detecting agent as required. Repair or replace the cylinder head if defective. Use a straight edge and thickness gauge to measure deformation of the bottom surface of the cylinder head. If the deformation is beyond the limit, repair with a surface grinder or replace the cylinder head. Deformation limit: 0,03 mm (0.0012 in) Caution: © Deformation at the bottom surface of the cylinder head shall be measured at 4 sides and diagonal lines. © Clean the cylinder head surface before measurement. Fig.2-19 Nozzle spring adjustment shim Deformation limit 0.03 mm Fig. 2-20 Measuring cylinder head deformation 292-8 INTAKE AND EXHAUST VALVES 1. Inspect the viave heads and stems of intake and exhaust valves. Replace if excessive wear, damage or deformation is found. 2. If the valve head margin is smaller than the limit dimension shown below, replace the intake or exhaust valve. Limit on head margin: 0.7mm(0.0276 in} (for both intake and exhaust valves) 3, If the valve face (seating) or stem end face (contacting the rocker arm) is worn or damaged, repair with a valve refacer or re place with a new valve, Intake/exhaust valve seat angle: 45° Intake/exhaust valve seat with 1.77 mm (0.07 in) Repair limit on stem end. 0.3 mm (0.012 in) 4, As the valve seat is used for a long time and lapped repeatedly, the valve head sinks so much as to bring about adverse effect on valve performance. Replace the valve when ‘the limit is reached, Valve head sinking x mm (i (0.01 Limit sinking amount 125+ 0.3= 155 S=h+X mm fin} (0.049+0.012-0.08) Intake (0,040~0.085 Standard clearance _| 10.0016~0.0026) Limit Fig. 2-21 Measuring valve head thickness Fig. 2:22 Refacing valve Standard status [|| worn status between valve and | Exhaust | 0.045~0.070 guide (0.0018~0.0028) Cin clearance Drweentokeand | imate | 013 0.006) gue east | 019 (0058 zy [" VALVE GUIDE Check the clearance between the valve stem and guide. If the clearance exceeds the limit, replace the valve and valve guide. Caution: The clearance between the valve guide and stem shall be obtained as the difference between the measured guide bore dismeter and stem diameter. Fig. 2-24 Measuring valve quide to stem clearance — 30 -Valve guide replacement 1, Drive out the valve guide toward the bottom side of the cylinder head, Use the SST (09201-40010) to install the new valve guide. Drive the guide in the same direction (down- ward from the top of the cylinder head), and ream the bore as required. Protrusion of guide: 7 mm (0.276 in) (both intake and exhaust valves) Caution: © Insert until the bottom edge of the groove outside the valve guide aligns with the cylinder head top surface. © Carefully discriminate between intake exhaust valves. 2. Fit valve stem seal to the top of the valve guide. Caution: © Coat oil on the valve guide before fitting the valve stem seal. Carefully prevent deformation of the valve stem seal The valve stem seal shall he replaced with a new one once it is disassembled from the valve guide. VALVE SEATS Inspect each valve seat for any damage or defec: tive contact. Correct it if damaged or defective. Caution; ° If a valve seat required repair, check wear of the valve guide first. If it isworn, replace the valve guide before correcting the valve seat. Reface the seat surface witha seat cutter or grinder to the dimension shown in Fig. 2-29. After lapping the surface with a lapping compound, use red lead and make sure of full face contact of the valve. -31 on e WV ira ial Fig. 2-25 Replacing the valve guide valve guide Contacting width 1.77 mm, Fig. 2-28 Valve seat contacting width2-10 eee How to cut valve seat | The commoneast method for valve seat cut- ting with a valve seat cutter is as follows: 1, After refacing the valve face in contact with the seat, check the seat contact position as the guidline for seat cutting operation. Operate the cutter to obtain the 45° angle first as shown in Fig. 2-29, Then, cut the 15° angle, and finally the 75° angle to correct the contacting width, : . Fig. 2-29 Valve sest cutting sequence Seat contacting face width 1.77 mm (0.0697 in) (both intake and exhaust) 3. The seat should contact the valve in the center of the seat-contacting surface of the valve. To meet this requirement, the 15° and Upper: toners 75° cutting operations should be adjusted Lower: Outer accordingly. circumference Contacting position Note: | If the valve contacting position with seat is low, reface only with the 15° and 45° cut- as a i ters. If it is high, use only the 75° and 45° Fig. 2-30 Contacting position with seat cutters. Limit 122 mm VALVE SPRINGS 1. Check rectangularity of each spring by using @ square and a surface plate. Replace any spring that is inclined too much. Limit of spring departure from rectangularity: 1.22 mm (0.048 in) 2. Use a spring tester and check the spring ten sion. Replace any spring that does not meet the following standard Fig. 2-31 Inspecting spring rectangularity Free length | Installed length | Installed load 38.5mm | 29,.2mm 15.6 kg (1.52 in) (1.15 in) (34,32 Ibs) | Fig. 2-32 Measuring the installed loadVALVE ROCKER ARMS AND ROCKER SUPPORTS 1. Blow each oil hole with compressed air to make sure that it is not clogged. 2. Inspect the arms and shafts. Repair or replace if excessively damaged or worn, 3, Measure the clearance between each rocker arm bushing and rocker arm shaft. Replace them if the limit is exceeded. Rocker arm shatt | | iniy | #139 mm diameter (0.547 in) Rocker arm bush: ||. | 14.1 mm ing inside diameter| (0.555 in) Rocker arm shatt- {0.016~0.052mm to-bushing Standard] 16 ooo63~ clearance 0.002 in) TAPPETS Inspect each tappet, and replace it excessively oo cemedeg Fig. 224 Measuring tappet outside diameter Caution If uneven wear or damage exists of the tap- pet at the surface in contact with the cam, also inspect the camshaft. Limit of clearance bet- 0.08 mm| ween tappet and body | __ (0.00314 in) 0.005 ~ 0.035 mm Standard clearance (0.000197 ~ 0.00138 in) CAMSHAFT 1. Inspect the camshaft for straightness and the status of journals. If bent, excessively worn or damaged, repair or replace the camshaft, Note: For straightness measurement, use a dial gauge. Rotate the camshaft one full turn, and use 1/2 of the maximum difference in dial gauge readings. 2, Replace bearings whose balls, inner races, retainers or outer races are damaged or dent- ed, whose rotation is not smooth, or which are noisy, rickety or discolored by burning. — 33 - Fig. 2:36 Measuring the cam height2-12 Measure the cam height. Replacement is necessary If the height of any cam is less than the limit valve, Limit cam height (for 34.4 mm intake and exhaust) (1.354 in} Lim m height 44.5 mm (for fuel) (1.752 in) Caution: When assembling the fuel cam to the cam- shaft, set it so that the 0 mark on the side faces the tightening nut. CAM GEAR, CRANKSHAFT GEAR AND HYDRAULIC PUMP DRIVING GEAR 1. Inspect each gear. Replace any gear that is damaged or worn at the fitting area or tooth surface. 2. Measure the blacklash between gears. If the limit is exceeded, replace the meshing gears asa pair. Limit | 0.3 mm (0.012 ind Cam gear and crank: shaft gear Stand] 0.086 ~ 0.13 mm ard | {0.0034~0.0051 in} Limit | 0.3 mm (0.012 in) Backlash Hydraulic pump gear and crank: shaft gear Stand} 0.086 ~ 0.13 mm fard (0.0034 ~ 0.0051 in) GOBERNOR SLEEVE AND CRANK- SHAFT Repair or replace the governor sleeve if it does not slide smoothly on the governor sleeve quide Fig. 239 of the crankshaft, FLYWHEEL 1. Inspect the ring gear. Replace it if damaged, cracked or worn. Caution © Heat the ring gear and use a press for re- placement of the ring gear. © Pay attention to the direction of the ring gear at the time of installation. 2. Inspect the flywheel run-out by using a dial gauge. If the limit is exceeded, retighten the flywheel bolts. If still excessive, replace the Fa 240 Flywheel run-out flywheel, aaFace run- | 0.1 mmor less Flywhee [eit (0.0039 in) run-out [Radia 0.10 mm or less timit (0.0039 in) CRANKSHAFT OIL SEAL 1, Drive the oil seal outward for removal. 2. To install a new oil seal, use a backing plate and carefully operate to prevent Fig. 2-41 Oil Seal Markings inclination. Caution: Ke, © Coat oil slightly on the periphery of oil seal before driving it in. © Inspect if the crankshaft rotating direc- tion marked on the side of the oil seal is identical to the actual rotating direction of the crankshaft, Backing plate Housing Piston and piston rings 1. Inspect the piston skirt outside diameter and piston ring grooves. Replace the piston if Fig 2.42 Installing the oil seal worn, damaged or defective. Wear limit of piston skirt outside diameter: 74.80 mm (2.94 in) (Measure in the direction vertical to piston pin.) Caution: The fitting between the piston and piston shall be as follows: When the piston is headed to 50 to 60°C, the piston pin shall enter smoothly into the hole on the piston when it is pushed by the thumb. 2. Measure the piston ring end gaps and the clearance between rings and ring grooves. Replace any ring that is found defective. Caution: Measure the ring end gap after pushing it by the cylinder into the bootom part of the oylinder where the liner is not worn. (Refer to dimension L in Fig. 2-45.) Fig. 2-44 Measuring the ring end gap 35/ Measuring postion 125 mm (L) (4.92 in} = 15mm B | Not compression | 9 069 in) Piston Tee rs Nb Position E 2 | No. 2 compression Demension L 58 = Piston ring | Oil rin nm : (0.059 in} @ No. 1 compression 2mm oe $= | Not come (0.079 in) g= = Fig.2-48 End gop measuring postion BB | No.2compression | 02mm 2s (0.079 in) £8 0.15 mm Es i ae (0.059 in) Caution: When setting piston rings to the piston, direct the marked side toward the top of the piston. CONNECTING RODS 1. Install each connecting rod to its crankpin, Measure the thrust clearance. If the limit is excoaded or if either thrust surface is found to be damaged. Limit 0.5mm Connecting rod mi (0.0197 in) thrust clearance [S34] 0.2~04mm \(0.0079~0.0157 in) Use the connecting rod aligner to measure straightness and twist when the piston ring end gap has moved through operation or when uneven contact with the piston exists. If the limit is exceeded, repair or repaice the connecting rod. Limits of departure from straightness and twist 0.03 mm (0.00118 in) for each 100 mm (0.3.937 in) Fig. 2-48 Measuring the str ightness and twist — 36PISTON PIN BEARING REPLACEMENT or damaged. 1__ Press Use a press and SST for repalcement. SST: 09222-40011 0.11 mm (0.00433 in) oS) 0.025~6.047mm (0.0098~ 0.00185 in) lle Fig. 2-49 Replacing the piston pin bearing __ 09222-40011 Oil clearance between piston pin and piston pin bearing Caution: Carry out press fitting so that the oil hole of the piston pin bearing coincides with the oil hole at the small end of the connecting rod. 2, After press fitting of the piston pin bearing, finish the bearing bore with a reamer or pin honing machine according to the diameter of the piston pin to be used. Piston pin bearing bore: 23,025 ~ 23,038 mm (0.9066 ~ 0.907 in) Fig. 2-50 Finishing the piston pin bearing Note: ‘The fitting between the bearing and pin shall be as follows: The pin coated with engine oil shall enter the bearing at the room temperature when it is pushed with the thumb. CRANKSHAFT BEARING 1, Inspect each bearing for surface scaling fusion, burning or other surface defect. Re- place any bearing that is found defect. Use a press and a gauge to measure the oil clearance, Rod and bolt tightening torque: 550 ka-cm (40 ft-lb) Fig. 251 Crankshaft bearing Caution: Do not try adjustment by shims nor refinish the bearing surface, Always replace with a new bearing. Oil clearance 0.13 mm between each | E'™* | (0,005 in) crankshaft . |0,036~0.092 rer} journal and Stand TG Gorai~ | bearing il 0.00362 in) Fig. 252 Measuring the oil clearance ~37-2-16 CRANKSHAFT 1. Inspect each journal and pin of the crank- shaft for damage and uneven wear (departure from roundness or taper). If the limit is exceeded, correct by regrinding or replace, Limit departure from roundness (taper) 0.02 mm (0.00079 in) 2. Measure the outside diameter of each journat and pin of the crankshaft. Replace the crank- shaft. Replace the crankshaft if worn beyond, the limit, - Gear side and | Flywheel intermediate side 946.75 9 64.75, _. | Limit | (1.840 in) | (2.58 in} (@46.950~ | 66495~ | outside i 1 46.964 64.964 di te ‘a jameter | Standard] Gpaa~ | (2g671~ | 1,849 in)_| 2.5676 in) 94375 | a bin Limit | 999 iny | outside @ 47.950~ diameter Standard 47,964 | | (1.8878~ L 1.8883 in) | 3. Crankshaft side gap (1) Push the crank shaft toward one end, and measure the crankshatt thrust clear- ance with a dial gauge attached to the tip end of the crankshaft, or measure the clearance between the thrust bearing and crankshaft with a thickness gauge from below the cylinder, 0.30 mm Crankshaft |_“™"* (0.012 in) side gap 0.085~0.175mm Standers | (9 0035~0.0069 in) (2) If the side gap exceeds the limit, replace the cneter bearing so as to obtain the standard clearance, 4. Inspecting sliding contact area with governor sleeve Inspect the sliding contact surface of the crankshaft with the governor sieve for any surface defect. Make sure that the governor sleeve moves smoothly. VP ate Fig. 253 Measuring the deperture from roundness Fig. 2-55 Adjusting the side gap aoeMAIN BEARING 1 mediate 0.15 mm Oiletearance| "| (0.0059 in} between 0036~ bearing and | Stand- | 0.095 mm crankshaft [ard | (0,0142~ (0.0142~ | Jo.0037 ny | 0.00389 in} 3. Inspect each bearing for surface sealing, fusion, burning and together surface defect. Replace any bearing that is found defective. If burning is found, also inspect the cylinder block and center bearing in contact with the main bearing for damage and wear. Replace them if defective. Caution: Throughly clean each oil hole of the crank- shaft when surface scaling, fusion or burning is found Measure the main bearing inside diameter and crankshaft outside diameter to calculate the oil clearance, If the measured oil clearance exceeds the limit, use SST and replace the main bearing, SST: 09020-41840-71 Caution: © Always use the SST for replacement. © Let the chamfered side of the bearing face outward and surely align the oil holes. © Prevent the bearing from following flat. © After replacement, assemble the bearing to the crankshaft and make sure that the crankshaft rotates smoothly, CYLINDER BLOCK 1 Inspect the block for crank, damage or any other surface defect by visual inspection or color check. If any defect is found, repair or replace the block. Check the warpage at the top surface of the cylinder block. Repair or replace the block if the warpage exceeds the limit: Warpage limit: 0.03 mm (0,012 in) Fig. 256 Measuring the main bearing inside diameter Mgin metal 09020-41840-71 . 2-87 Inserting the main bearing18 Make sure that the flanged portion of each: cylinder liner protrudes slightly from the top of the block. Standard cylinder liner protrusion 0.005 ~ 0,075 mm (0.000197 ~ 0,00296 in) Cautior Measure the protrusion especially after cylinder liner replacement. If it is excessive, clean impurities such as rust at the cylinder block, Measure that all oil holes are not obstructed or clogged. Inspect the cylinder block plug to see if water leakage is caused by loosening. If defective, coat liquid gasket and fit a new plug. CYLINDER LINER 1 - Cylinder bore measurement Use a cylinder gauge (inside dial gauge) and measure each cylinder bore (inside diameter of each cylinder liner). If it exceeds the limit, replace the cylinder liner. mm ED 75,000 ~ 75.035 23 75.135 Cylinder (2.96 in) Cylinder liner replacement If the inside surface of the cylinder liner is excessively damaged or worn, replace the cylinder liner. (1) Extract the cylinder liner, Use the SST and extract the cylinder liner so as not to damage the cylinder block. Fig. 260 Cylinder block and plug Cylinder liner Fig. 261 Cylinder liner Fig. 262 Measuring the cylinder liner bore — 40 —Caution: Never use any tool other than the specified SST for cylinder liner extraction because it may damage the surface of the cylinder block bore. {2} Carefully clean the cylinder block bore 80 as not to damage the surface. (3) Make sure that the outside surface of the new liner is free from any dust or damage, and insert the liner without hard driving. Do not use any tool for insertion, Note: The cylinder block bore and liner outside diameter are selectively combined. Check the combination mark to prevent combina- tion of A and C, As the spare liners, only those marked with B which fit any of A, B and C are shipped. However, always check the mark before fitting. Caution © Never drop or give hard striking to the cylinder liner to prevent deformation. © Apply clean engine oil slightly to the out- side surface of the new liner to facilitate insertion. (4) Inspect the following points after inspec- tion. End the operation if no abnormality is found, {a} Cylinder liner protrusion (See Fig. 269) (b) Departure from roundness of cylinder liner bore Limit departure from roundness: 0,08 mm (0.0024 in} Caution: If the protrusion or departure from round- ness exceeds the specified limit, extract the cylinder liner again and inspect the cylinder block | Fig. 266 Measuring the cylinder liner bore ale2-20 ASSEMBLY AND INSTALLATION REPLACEMENT FOR ASSEMBLY 1, Before assembling, prepare an overhaul kit (041 12-40020-71 Fig. 267 Overhaul Kit 2, See Standard Bolts Tightening Torques on page 8-2 for tightening torques of nuts and bolts © Coat new engine oil on sliding and rote- ting parts before installation. © Gasket, O-ring and similar parts shall al- ways be replaced with new ones whenever disassembled. © Use liquid packing wherever necessary to ensure oiltight and watertight joints. © During reassembly operation, always make sure that oil and thrust clearance are as specified. ASSEMBLY Caution: © Throughly clean all parts before re: © Always use correct types of nuts, bolts assembly. and washers. Be sure to observe the speci- fied tightening torques. Those studs and bolts run into or extending from aluminum alloy parts require special care to prevent excessive tightening, © Do not mistake combination of parts and sets, especially bearings and pistons. Always check clearances, match marks and other identification marks during re- assembly. * The unit of the tightening torque given for each bolt in the assembly procedure is kg-cm. (Ex) T = 300 ~ 360 means 300 ~ 350 kg-cm which equals 3.0 ~ 3.5 kg-m (21,9 ~ 25.5 ft-lb) —42-Mounting flange (1) Install the mounting flange with the starter. ‘T = 560 ~ 600 (40 ~ 43.81) (2) Check the face run-out of the mounting flange. Limit = 0.3 mm (0.012 in) Caution © If the run-out limit is exceeded, retighten the bolts. Replacement is necessary, if the measured run-out is still beyond the limit. Tappets and camshaft (1) Install the tapers. (2) Install the comshaft. (3) Install the small (+) bind screw to hold the cam shaft ball bearing. Caution: © Carefully discriminate between the cylin- der Nos., intake and exhaust © Do not directly strike the top end hard. Fig. 2-69 Step 2-(2), Installing the Camshaft Crankshaft (1) Assemble the crankshaft center bearing * Install the bearing for the center bearing integrated with thrust bearing (1) between No. 1 and No. 2 cylinders * Tighten bolts to fasten the center bearing upper and lower. T= 450 ~ 500 (32.9 ~ 36.5) * Moke sure that the bearing rotates smoothly (2) Lay the engine with the gear side down. (3) Insert the crankshaft into the cylinder block, and lower. * Suspending with the V-belt will facil tate the operation. Caution © Assemble the center bearing with the bottm mark on the side of the center bearing facing the flywheel side. © Align the arrow and chambering on one side of the center bearing for assembly. Fig. 2-71 Center bearing marks ~ 43 —2-22 © Alternately tighten teamer bolts gradually for uniform tightening, © Place 16 ~ 19 om (6.3 ~ 6.7 in) thick wooden base under the cylinder block to keep the engine off from the floor. © V-belt shall be centered with the crank- shaft. 3. * Temporarily fit the center bearing set bolts. Insert the center bearing in alignment with bolt holes, and remove the set bolts. (4) Screw in the center bearing set bolts. Caution: © The V-belt shall be centered with the crankshaft. © Tighten the set bolts naturally without compulsion. T = 700 ~ 750 (51.1 ~ 54.8) 4, Side bearing sub-assy (1) Inspect the metal O-ring. (2) Install the side bearing. T=250~270 — (18.3~19,7) Check the crankshaft side clearance, Standard: 0.085 ~ 0.175 mm (0.00335 ~ 0.069 in) Caution: © Always replace O-rings if damaged. © Coat oil on the oil seal. Flywheel (1) Install the flywheel. T = 650 ~ 700 (47.3 ~ 51.1) (2) Check the face run-out of the flywheal. Limit — 0.1 mm (0,0039 in) Caution © Alternately tighten the reamer bolts for uniform tightening. © If the measured run-out (face or radial) is beyond the limit, check the bolt tighten- ing torque and joint surface. Fig. 2-75 Step 6, Check the Face Run-Out — 442-23 6, Piston (1) Lay the engine with the flywheel side down. (2) Piston ring positions Caution: © Do not damage the flywheel surface. © Fit piston rings with the mark facing up- ward (toward the piston head). © When fitting piston rings with expansion, do not apply an excessive force. Torsion D shall be within 1B. (3) Insert the piston, (4) Fit the cap and tighten the rod bolt, T = 450 ~ 500 (32.9 ~ 36.5) (5) After installation to 3 cylinders, check if movernent is smoot Caution: © End gap opening (A) shall be within 8T. (See 2-76) © Position each eing end gap with displace. ment as shown in Fig. The end gap of the No. 1 compression ring shall not be on the exhaust side. Use the correct rings for each cylinder No. Coat oil on the metal surface. The identification No. on the rod large end shall be identical to the cap No. Always hold the cylinder liner with a hand if it comes out. ° ° ° ° ° 8 € ZL ~ eo ] End gap opening Fig, 2-76 Caution for Ring Fitting Fig. 2-77 Inserting the Piston Fig, 2-78 Step 6-(4), Tightening the Rod Bolt af2-24 7, Oil strainer (1) Install the oil strainer and fit the cap nut outside the cylinder block. Caution © Fit itso that the inlet comes to the center. © Do not tighten the nut excessively Oil pan (1) Install the oil pan. T =80~ 100 (5.84 ~ 7.3) (2) Install the level gauge. T=80~ 100 (5.84~7.3) Caution: © Install the oil pan with the drain plug facing downward. © Check the o-ring at the joint Crankshaft gear and governor (1) Install the crankshaft gear with timing mark alignment. (2). Install the governor weight support. (3) Tighten the crankshaft gear nut. T = 1100 ~ 1150 (80 ~ 84) (4) Install the governor sleeve. Caution: © Do not strike governor support pin when, striking gear. © SST: 09131-42160-71 © check the direction (front and rear) of the gear nut. © Do not damage the crankshaft. Fig. 2-81 Step 9, Timing Mark Alignment 4610. 11. 12. il pump (1) Install the oil pump. T= 100~ 120 (7.3~ 8.76) Caution: © 6T bolts... 3 pieces Gear case and V-pulley (1) Set the gear case packing and 2 oil rings at oil pipe joints. (2) Tighten the gear case set bolts. T = 250 ~ 270 (18.3 ~ 19.7) (3) Insert the key to the crankshaft, and install the V-pultey. (4) tighten the V-pulley lock nut. T= 600 ~ 700 (43.8 ~ 51.1) (6) Insert camshaft bearing housing and tighten the lock nut. (6) Erect the engine, Injection pump (1) Install injection timing adjusting shims at the pump mounting position of the gear case (2) While moving the gear case redulator handle to the left and to the right, nstall the pump with fitting between the governor lever No. 2 and rack pin. (3) Tighten the pump mounting nuts. T = 250 ~ 270 (18.3 ~ 18.7) (4) Install fuel pipes, Caution © Coat liquid packing on both faces of the shim, © The rack pin shall perfectly fit inot governor lever No. 2. 2-25 Fig. 283 Steps 11-(2), (4), (5), Install and V-Pulley Fig. 285. Step 122), Installing the Injection Pump -47-2-26 13. 14, Cylinder head (1) Set the gasket packing. (2) Install the cylinder head. T for stud bolt = 50 ~ 560 (36.5 ~ 48) T for M12 bolts = 1300 ~ 1400 (95 ~ 102) T for M8 bolts = 200 ~ 300 (18.3~ 21.9) (3) fit the oil pipe and clamp. (4) Fix the level gauge by the nut. (5) Install the stay to the stud bolt on the flywheel side. Caution: © The TOP mark shall face the head cover side. © See Fig. 2-88 for the tightening sequence. © The tightening sequence and torques shall be as specified, © Coat lubrication or oil on the tightening bolt thread. © The oil hole diameter of the M8 pipe joint bolt shall be small. Water pump end fan (1). Install the water pump body. (2), Install the water pump. T= 250 ~ 270 (18.3 ~ 19.7) (3) Tighten the hose clamp. (4) Install the cooling fan and oulley. T =80~ 100 (5.8 ~7.3) (5) Temporarily install the alternator. (6) Fit the fan belt and adjust the belt ten sion. Fan belt flexure: 10~ 15 mm at 10 kg (0.39 ~ 0.59 in/22 Ib} Caution: © One hexagon recessed head bolt is used Fig. 2-86 Step 13-(2), Installing the Cylinder Head Fig. 2.88 Step 14, Adjusting the Fan Belt — 48 -15, Push rods and valves rocker arms (1) Install the push rods. (2) Fit valve caps to intake and exhaust valves. (3) Install valve rocker arm supports. T = 450 ~ 500 (32.9 ~ 36.5) (4) Adjust the valve clearance, 0.2 mm {in cold state) (0.0079 in) Caution: © Discriminate between cylinder No., take and exhaust. © Do not push into the cylinder. Fig. 289 Step 14-6), Installing the Valve Rocker Arms 16. Injection valve (1) Check precombustion chamber installa- tion. (2) Preassemble the injection valves. (3). Install the fuel injection pipes. {4} Install the fuel injection clamps. {5) Install the fuel injection valve fianges. 260 ~ 270 (18.7 ~ 19.7) (6) Install the nozzte leakage pipe. {7} Install the rocker arm housing. (8) Carry out piping to head tank and thermostat. Caution © The protruded side shall be on the injec- tion valve side. 8 Avoid uneven tightening. [Se-Nozzle assy © The oit hole diameter of the MB pipe Insulator joint bolt shall be large. Rear precombustion chamber Packing }— Front precombustion chamber Packing Oil hole 1.0 17. After checking the governor link function from the gear case cover opening, install the cover. Fig. 2-91 Step 17, Installing the Cover, 49-2-28 18. Fill engine oil. Total engine oil volume 2.3 £ (0.6 USgal) INSPECTION AFTER ENGINE INSTALLATION After remounting the engine in place, proceed as follows. 1, Fill coolant. 2. Fuel injection timing check. (1) Remove the cap nut on the injection pump side of the fuel injection pipe. (2) Bleed the air up to the fuel injection pump. (3) Fix the regulator handle at the maxi- mum rpm position, (4) Crank the engine and measure the deli- very timing from delivery valves of the fuel injection pumo. Caution © Turn on the engine switch, loosen the air plug on the injection pump side, and bleed out all air. (5) Inspect for both the No, 1 and No. 2 cylinders If any abnormality is found, carry out readjustment according to the explana- tion in gage 11 Fuel injection timing: 21° BTDC (stalled) Fig. 2.93 Step 2-(4), Checking the Injection Timing 3. Bleed the air from the fuel system. — 504, Turn the starting switch to the GLOW posi- tion, and check if the pilot clamp lights and ‘the ignition coil in the intake pipe gets red hot. When the pilot lamp goes off, turn the switch to the START position to see if the fuel is combusted in the thermostat plug. Caution : © Pour a small amount of light oil in the head tank. © If defective, inspect the piping and wiring. If still defective, inspect the thermostat as explained in page Start the engine and make sure that each guage and meter operates mormally. While idling the engine for warm-up, make sure that no oil or water is leaking, Check the engine speed (1) No-load maximum speed. 3.150 rpm (2) Idling speed (max.): 800 rom (3) Smooth contro! shall be possible for the whole speed range. Caution: © Seal each part after proper adjustment. 61 -MEMO 52 -FUEL SYSTEM Page FUEL INJECTION MECHANISM .........-0++0+e000+ 3-2 INJECTION PUMP ......-6 sec ee ener eee reer eeeee 3-12 INJECTION NOZZLE 3-24 GOVERNOR LINK ......... 00 eee e cece eee e eee eee 3-29 eee ee rea 3-33 ios3-2 FUEL INJECTION MECHANISM Fig. 3-1 Fuel Injection Mechanism INTRODUCTION The fuel injection system in a diesel engine is finely machined mechanism operating under high pressures. At these high operating pressures, even the slightest contamination by dirt or moisture can greatly shorten the service life of the injection nozzles, the most critical components of the engine. Therefore, all fuel especially light oil - - - must be throughly purified and filtered. This means that not only must the fuel go- ing into the fuel tank be as pure as possible, but also that the engine contain a highly effective fuel filter. The feed pump (1) forces fuel from the fuel tank through the elements, the fuel is then pressurized by the injection pump (2) and sent, in rhythm with the engine's firing order, through the fuel pipes to the injec: tion nozzles, In the special vortex combustion chambers, it mixes with air and starts to burn, Joined to therack on the injection pump through the governor link is equipment which adjusts the engine's output and torque characteristics to match the operating conditions. Excess fuel from the injection nozzles flows through the overflow pipe (4) to the header tank (5) in the THERMOSTAT equipment for use in boosting cold weather starts. Any excess from the header tank flows back to the fuel tank. Fig. 3-2 Injection Pump Fig. 3-3 Injection Pump3-3 The Model 2T7SHL engine uses a YANMAR Model YPFR2K Bosch injection pump. This simple, compact pump delivers the proper amount of fuel under all conditions from engine starting to high engine loads The amount is regulated by the interaction of the tension in the regular spring and the centrifugal force generated by the governor weights which spin as the engine turns. Inside the injection pump is a plunger which reciprocates with a fixed stroke to pump the fuel Since this plunger is precisely lapped to fit the plunger barrel, the two can only be changed as a set. In the cylindrical surface of the plunger and at an angle is a cut, called the “lead”, which is connected to the head of the plunger with a longitudinal groove. in the barrel is a suction hole through which the fuel enters the pump. The pressure of the plunger opens the delivery valve, sending the fuel through the injection pipe to the injection nozzles for injection into the special vortex combustion chambers. Fitted over the plunger is a pinion with a logitu dinal slot cut in its lower part. The plunger re ciprocastes within this slot, but rotates as the rack turns the pinion through a cetain range. It is this rotation which provides continuous variation of the amount of fuel injected from 0 to the maximum. — 55 Delivery valve Plunger Suction hole 1 Lead Plunger barrel INS Pinion Fig. 3-4 Injection Purnp Structure Delivery spring ~ < Valve seat Delivery valve Plunger control plate Pinion Plunger spring Plunger guide Roller pin — Fig. 3-5 Injection Pump Structure3-4 FUEL REGULATION At the plunger's bottom dead center, fuel from the suction hole fills the deilvery chamber above the plunger. As the plunger rises, it closes the suction hole and applies pressure to the fuel in the delivery chamber. This pressure opens the delivery valve, sending the fuel into the injection pipe. When the upward pressure of the plunger guide has raised the pressure even further to 160 kg/cm?, the nozzle opens, spraying the fuel into the special vortex combustion chamber. However, when the rising plunger brings the lead opposite the suction hole, the pressurized fuel in the del very chamber flows through the longitudial groove in the plunger and the lead back into the suction chamber, cutting off the fuel injection. Moving the rack rotates the plunger, changing the effective stroke according to the rotation angle and, thus, the amount of fuel discharged, For example, when the rack positions the longtudinal groove opposite the suction hole, the suction hole never closes even if the plunger rises so no fuel is discharged. This occurs when most of the rack is on the cylinder side of the pinion, Moving the rack to the other extreme produces the maximum fuel discharge. However, in actual engines, the fuel limiter prevents the tuel dis- charge from reaching this maximum, Fig. 3-6 No Injection Effective stroke Fig. 3-7 Half Injection — —_ Effective stroke t Fig. 3-8 Full Injection — 56 —DELIVERY VALVE MOVEMENTS The delivery valve at the top of the plunger barrel, in addition to keeping the fuel from flow- ing back out of the injection pipe, provides suc- tion to eliminate dripping from the nozzle valve. This suction arises because, when the lead meets the suction hole in the plunger barrel and the pressure drops, the suction collar first blocks all flow between the delivery chamber and the injec- tion pipe before the delivery valve spring brings the valve all the way down to the valve seat. This difference in timing increases the volume of the injection pipe, thus quickly reducing inside. As a result, the nozzle valve closes more quickly and there is less fuel that can drip. These effects increase nozzle life and improve comustion effi- ciency, 57 Closed Fig. 3-9 Delivery Valve Movements ‘This increase in volume produces a corresponding decrease in pressure. Injection ends and suetion begins. Suetion ends Fig. 3-10 Delivery Valve Movements3-6 GOVERNOR MECHANISM Rack ferme __ Regulator lever = Regulator handle Return spring | Governor sleeve limiter | Rugulator spring ie Lever | (G— Governor lever shatt Governor lever No, 2 Governor lever | pa) nea | Parallel pin / Governor weight | Governor lever No. 2 Lo Parallel pi a Fig. 3-11 Governor Mechanise Among the many demands placed on the use of Cr ~ an engine is the one that it runs at one particular | speed regardless of the load or at least within a | certain speed range, The model 2T7SHL engine contains a simple, but highly stable, mechanical governor which uses the interaction between the Rack tension in the regulator spring and the centrifugal eae Y — ey force generated by the governor weights to stabi- litize the position of the governor lever and thus control the amount of fuel injected, This mechanism incorporates the foliowing addi- tional features: + a governor on the crankshaft and needle bear- ings on the governor lever shaft to improve speed regulation, a return spring on the governor lever shaft and Regulator lever Lys Regulator handle FO limiter Governor lever No. 2 [Governor lever shaft CEE Return spring a parallel pin between the lever and governor orleans o, - lever No. 2 to provide the increased fuel injec- | Governor weisht_j- 28] Governor lever No. 1 tion appropriate for better starting, Crank gear ICT and ~p | an FO limiter whose spring tension can be se to yield the best torque characterisctics for the engine application. Fig. 3-12 Governor Mechanism — 68 —SS GOVERNOR OPERATION 1 To Start the Engine (1) Mormal Starting Caution: Governor levers Nos. 1 & 2 are fixed to the governor lever shaft while the lever turns freely, To start the engine, it is necessary to shift the regulator handle to “START” and improve the starting capability by increasing the amount of fuel injected. The low speed of the starting motor driving the engine produces only a minimal centrifugal force on the governor sleeve so the tension from the return spring shifts governor lever No. 1 Transmitted to governor lever No. 2, this shift automatically sets the amount of fuel injected to the maximum and thus improves starting Minimal force fon the governor sleeve Governor lever No. 1 Governor lever No. 2 Fig. 313 Normal Starting3-8 (2) Cold Weather Starts No.2 Governor lever Sy Over: _during starting ‘Over-injection Over-injection lever \ during starting Operating position during starting | Over-injection mechanism Fig. 3-14 Cold Weather Starts When the temperature is below freezing, the balancing torque increases and the engine requires additional fuel to build up the necessary speed to start, Therefore the Model 2T75HL engine contains an overinjection mechanism to boost the amount of fuel injected when starting, OPERATION STEPS (a) Pull the over-injection lever all the way back. (This turns the shaft of the enrich- ment lever when the engine is started, moving lever No. 2 of the governor, and moves the injection pump rack so that i —_____ the amount of fuel that is injected is increased.) (b) Set the regulator handle to the 1/2 ~ 3/4 position. (this fuel injected so that the engine can be started easily even | Over.injection mae y Pes when it is cold.) ‘normal operating (c}_ After starting the engine, always return eames om (Lever must | the overinjection lever and the regu: | Reprox. 20° Approx. 20° always lator handle to their original positions | Qveriniection position) | and allow the engine to warm up. starting Fig. 3-15 Position for Overinjection Lever — 60Idling " Less fuel Governor force Small centrifugal force Fig. 3-16 tating When the engine is idling, the reduced tension in the accelerator cable reduces tension in the regulator spring. As a result, the greater governor force shifts both governor leaves (No, 1 & 2) in the directions indicated by arrows until the two forces balance each other out, This shift moves the injection pump. rack in the “less fuel’ direction, decreasing the amount of fuel injected and hence stabilizing the engine speed. 3. At Maximum Rated Speed Governor lever No. 2 A___ sri A 28 near the He. Regulator spring (Large tension) \ Lever Large centrifugal force Fi 17 At Maximum Rated Speed Pulling the regulator handle to its maximum position increases the tension in the regulator spring. The parallel pin on the lever pushes the governor lever No. 2 to increase the amount of fuel injected. As the engine speeds up, the centrifugal force from the governor weights increases and acts on the governor leaves to opposite the force from the regulator spring, These two forces reach equilibrium somewhere in the vivinity of the lever position marked on the rack. At equilibrium, there is very little gap between the FO limiter and the lever. (Governor force = Regulator spring tension) - 613-10 4, Overloading ‘The tension in the regulator spring moves the lever and compresses the torque spring in the x FO timiter. Oy™N Lever Centrifugal force Fig. 3-18 Overloading When the load on the engine increases, the engine speed drops, reducing the centrifugal force generated by ‘the governor weights. However, if the tension in the regulator spring is at its maximum and exceeds the load setting of the torque spring in the FO Limiter, this tension moves the lever further and compresses the torque spring. The parallel pin on the lever pushes the governor lever No. 2 to increase the amount of fuel discharged by the injection pump, thus increasing engine torque, generating more power, and prevent- ing stalling, ‘The torque spring inside the FO limiter and the positioning of the FO limiter itself are adjusted to match the optimum operating condition of the vehicle. Caution: The role of the FO limiter is to increase the amount of fuel injected during an overload situation. - 62 -3-11 5. Stopping Governor lever No. 2 No fuel injection ~: [7 Reguator lever Regulator spring > Governor sleeve Fig. 319 Stopping Pushing the regulator handle beyond the low speed position releases all tension in the regulator spring. The centrifugal force generated by the governor weights presses the governor sleeve against governor lever No, 1 and decreases the amount of fuel injected. If the accelerator lever forces the regulator handle in the direction indicated by the arrow, the regulator lever mounted on the same axle as the regulator handle moves governor lever No, 2 to the “no fuel’’ end of the rack and the engine dies. ~ 63 -3-12 ee INJECTION PUMP Since the injection pump and the injection nozzles are precision parts machined to high tolerances and since they represent the heart of the engine, they require extremely carefully handling, 1 ¢ 2 8 3 : 5 6S 7 eB dpeoF ERS 202 q * 7 ote Se BR VBee® a \ 25 26 12 3-9 “8 ' 18 16m va | wos 19 9 Fig.3.20 Injection Pump Fig. 3-21 Injection Pump Components Delivery holder O-ring Delivery spring Delivery vaive (set with 6) Packing Delivery vaive seat Plunger barrel (set with 11) Barrel packing Pump body Rack + Plunger Pinion Spring retainer A Plunger spring Spring retainer 8 st Plunger guide Roller pin Seis 19, 20. 21. 22. 23. 24. 26. 26. Roller, lnner/outer Plunger control plate Adjusting screw Plate washer Spring washer Screw Guide piece Stopping pinINJECTION PUMP SPECIFICATIONS Cam lift 7.0 mm (0.276 in) lesen : Outer diameter 6.5 mm (0.256 in) Plunger Shape Starting booster Injection sequence 1-2 Maximum rack sliding friction (with the pump at rest) 60 gor less Plunger head clearance/pump installation dimension T mm (0,039 in)[for 8 7 mm (0.0276 in}]/ 76 mm (2,992 in) (from flange face to] roller point 0 ‘Thicknesses of shims for adjusting plunger position 0.1 mm (0.0089 in), 0.2 mm {0.0079 in) (two thicknesses) Free length 35.5 mm (1.398 in) Plunger spring installed length 29.50 mm (1.16 in) Load when installed 11,59 mm (0,456 in) Free length 21.00 mm (0.827 in) Delivery valve spring Installed length 17.25 mim (0.68 in) Load when installed 2.40 kg (5.28 Ibs} INJECTION PUMP REMOVAL Length Outer diameter 680 mm (26.78 in} Inner diameter Injection pump end Injection nozzle end #3 wiaxis Fig. 3-22 Injection Pipe oot3-14 INJECTION PUMP REMOVAL 1, Removal the injection and fuel pipes. Caution: Do not let any dirt get inside the pump. 2. Remove the cover. 3. Remove the injection pump. Caution: © Make sure that the rack does not catch on the gear case. © Be careful not to damage the injection timing shims. Fig. 3-23 Removing the Injection Pump INJECTION PUMP DISASSEMBLY Before you begin: © Number the plungers from the right as you face the nameplate. © Wash with clean fuel before disassembling. Keep the parts from the different plungers separate. Do not touch screws holding contro! lates or adjusting screws unless you have access to pump tester. ° 1, Remove the stopping pin and the guide piece. Caut It is easy to remove the guide piece if the pump body is pressed during this procedure. 2. Remove the plunger guide. Caution: © Do not misplace any plunger positioning shims which may be inside the plunger guide, © Record the numbers and thicknesses of the positioning shims for each plunger. Fig. 3-25 Disassembling the Injection Pump, Step 2 Seo3. Remove the plunger with its spring. Caution: © Be careful not to damage or soil the plunger. © Keep the parts from the different plungers separates. 4, Remove the plunger spring retainer and Pinion. Caution: ‘© Remove by tapping with the palm of the hand. © Keep the parts from the different plungers separates. 5. Remove the rack. 6. Remove the delivery valve. (1) Remove the delivery valve holder. (2) Remove the delivery valve spring. (8) Remove the delivery valve packing, the valve, and the valve seat. Caution: © Do not change the delviery valve seat combination. © Keep the parts from the different plungers separate. 7. Push th plunger barrel toward the delivery valve end to remove, Caution: © Store the plunger barrel with the plunger inside. © Soak the delivery valve and the plunger in clean light oil and store with the parts for that plunger. © After disassembly, do not loosen the control plates, adjusting screws, or the serews holding the control plates. If these are loosened, reassembly is impossible without a pump tester. INJECTION PUMP INSPECTION Rinse all parts with clean light oil before inspecting, Caution: When handling the plunger and delivery valve, be careful not to touch the face. fbn rane Fig. 3-29 Step 7, Disassembling the Injection Pump. ~67 -3-16 ees PLUNGER Inspect. the sliding surface, If they are damaged or discolored or the action is not smooth, replace the entire plunger as a set. Check the sliding resistance, Holding the barrel at an angle of approxima- tely 60°. pull out the plunger and release. It should slide back smoothly. Rotate the plunger and check for various positons. If the plunger slides too quickly or sticks partway, replace the plunger as a set, DELIVERY VALVE 2 Replace the delivery valve if the suction collar or valve seat is damaged or dented. Pull up the valve and release, It should sink back immediately. Otherwise, replace the valve asa set. Close the hole at the bottom of the valve seat with a finger, insert the valve, and press down, The valve should spring back to the original position, Otherwise, replace the valve asa set. Remove the finger from the hole, The valve should completely close under its own weight. Otherwise, replace the valve as a set, Caution: Before using a new valve set, remove the rust- proofing with light oil or gasoline and check according to the preceding procedure. Fig. 3-30 Inspecting the Plunger Lead Fig. 3-31 Checking the Sliding Resistance Fig. 3-33 Steps 3 & 4, Inspecting the Delivery Valve 68 —RACK AND PINION 1, Inspect the tooth and sliding surface of the rack. Replace if damaged. Caution: After replacing the rack or pinion, measure the pump discharge with a pump tester and mark the rack. 2, Replace the pinion if the teeth are worn or damaged. PLUNGER GUIDE Inspect the inner and outer plunger guide rollers for damage and wear. Replace if defective. Measure the overall clearance of the assembled plunger guide, Replace if the clearance exceeds the limit, Overall clearance limit: 0.3 mm (0.012 in) PLUNGER AND DELIVERY VALVES SPRINGS Inspect the springs for damage and rust, measure their lengths, and replace if defective. 36.50 mm Free length (1.398 in) Re _— 29.50 mm BB inst rth (1.16 in} 23 11.59 kg Load when installed (285 Ibs) 21.00 mm gre leat (0.83 in) 2s 17.25 mm 2 | Installed length (0.68 in) 33 2.49 ka Load when installed eaeiea Aligning marks Aligning marks Fig. 3-34 Inspecting the lack and Pinion Fig. 3-35 Inspecting the Plunger Guide Fig. 3-36 Inspecting the Springs — 69 —3-18 INJECTION PUMP ASSEMBLY Before you begin: © Divide the parts into those to be replaced and those to be reused, clean, and ar- range. © When replacing parts without a pump tester, replace the corresponding parts in both individual pumps. © Replace all packing. 1. Assemble the plunger with the leads over the stopping pin and control plate pin for No. 2 and No. 1, respectively. Caution: © Check the plunger barrel packing. © Firmly position the leads over the pins, but do not force. 2. Assemble Une delivery valves. Caution: © Assembly is incorrect if the tips of the delivery valves protrude much beyond the upper surface of the pump body. 3. Assemble the delivery valves holders. (1) Delviery packing. (2) Delivery valve springs (3) Temporarily fasten the delivery valve holders. Caution: When tightening the delivery valve holders with a torque wrench, first secure the pump body and examine the rack’s sliding resist- ance as you proceed. T=40~4.5 kg-m (29.2 ~ 32.9 ftlb) Fig. 3-39 Step 3, Assembling the Injection Pump 70 -Racks and pinions (1) Assemble the rack with the match-mark facing the pump body. (2) Assemble the pinion with its mark op- posite the rack mark Caution: © The rack should move smoothly over its entire length. © After assembly, move the rack to check its mesh with the pinion and confirm that the marks match. Assemble the plunger spring retainers and plungers. (1). Spring retainers. (2) Plunger springs. Caution: © The plunger spring retainers should face the bottom of the pump body. Assemble the plungers (1) Plungers (2), Plunger spring lower retainers Caution: © Match the marks on the pi plunger collar. © Do not mix up the plungers. © Clean the plungers with light oil. n Fig. 3-41 Step 5 ) > Matchmarks Step 63-20 7, Assemble the plunger guide: (1) Place the plunger positioning shims on the lower retainers, (2) Rotate the plunger guide until the anti- rotation hole is in the correct direction and then gently press in. (3) When the hole matches the one for the guide piece. (4) Insert the plunger guide stopping pin. Caution: © After assembling with the same number of shims and the same thicknesses, measure the clearance at the head of the plunger. © If it deviates from the standard, adjust. See page 3-21 for the adjustment proce- dure. After assembly, tighten the delivery valve holders with a torque wrench. T=4~45 kg-m (29.2 ~ 32.9 ftlb) Caution: After each turn, move the rack to check the sliding resistance. Check the rack’s sliding resistance, After assembly, rinse with clean light oil. Place the pump on its side, hold the rack ver- tical, and release, It should slide smoothly under its own weight over its entire length. Turn the pump over, repeat the rest, and check for abnormalties. Maximum rack sliding resistance: 60 g or less (0.132 Ibs or less) Caution © Too great a resistance and the engine wit run unevenly or race. The main causes of increased resistance are excessive tightening of the delivery valve holders mistaken plunger assembly dirt or marks on the sliding surfaces. — — Fig, 3-43 Clearance at the Plunger Head Fig. 3-86 Step 9, Assembling the Injection Pump 72 -INJECTION PUMP TEST Preparation 1. Measure the injection initiation pressure of the test nozzle. Injection initiation pressure: 160 kg/cm? (2272 psi) Caution: © Test nozzle part number: YDN-OSDYD1 Adjust the injection pressure after appro- ximately every year of use. ° Use an injection pipe with the following dimensions: Outer diameter x inner diameter x length 9 6x 15 x 680 mm ($ 0.236 x $ 0,059 x 26.8 in) Minimum radius of sharpest hard 25 mm or more (9.84 in or more} Supply fuel to the pump at a pressure of 0.5 kg/cm? {7.1 psi) Measure the amount of fuel injected into each cylinder with the soecified graduated cylinder. Important: Incline the graduated cylinder and collect the fuel for approximately 30 sec. Return the cylinder to the vertical and read immedi- ately. Inspect and correct the tachometer approxi- mately every two months. Precision at 2000 rpm: + 1% Attach the injection pump drive unit to the pump tester. Inspect the oil level in the injection pump drive unit and make up any deficiencies. Attach the fuel pump to the pump drive unit. Install the fuel and injection pipes. Attach @ dial gage to the rack with a magne- tic base or other means. Caution: Place the dial gauge so that it reads “0” when the rack is pushed all the way to the No. 2 pump side. Fig. 3.47 Pump Tester Caution Use of a non-conforming pipe may make adjust- ment to the standard injection amount impossible. Fig. 3-48 Pump Drive Unit Fig, 3-49 Ataching the Dial Gauge 73 =3-22 10. Bleed the air from the pump and the pipes. TEST Measure the Rack’s Sliding Resistance. Measure the rack’s sliding resistance with a spring balance. Pump speed: 0 rpm Maximum sliding resistance: 60 g (0.132 Ibs) Caution: Disassemble and repair if defective Adjust the Clearance at the Head of the Plunger. 1, Turn the drive unit cam shaft until the Plunger is at the top dead center (i.e, lifted 7 mm (0.276 in) 2. Remove the delivery valve holder and the delivery valve, Set the dial gauge to "0" at the end face of the plunger barrel and then shift to head of the plunger measure the difference, the clearance at the head of the plunger. 76 mm (2.99 in} Instaltation (from the bottom of the length plunger to the edge of the roller ‘Amount of plunger hf 7mm (0.276 in} Clearance at head | 1. mm (0.039 in) for 7 mm of plunger (0.276 in) lift * The installation length is the distance from the flange surface on the pump bady to the edge of the roller. * The lift is the amount of fuel cam lift, 4. If the clearance exceeds the standard, remove the plunger guide and add shims. Fig. 3-51 Measuring the Rack’s Sliding Resistance ~ Plunger barrel ~ Plunger | I With the plunger lifted 7 mm. Fig, 3-52 Clearance at the Head of the Plunger Fig. 3-53 Measuring the Clearance at the Head of the Plunger3-23 Important: © There are two shim thicknesses, 0.1 mm. (0.039 in) and 0.2 mm (0.079 in). © Adjust the clearances until they meet the standard common to all cylinders. After checking and adjusting the clearance, reassembly the delivery valve holders and delivery valves. Delivery valve tightening torque: T=4~45 kgm (29.2 ~ 32.9 ft-lb) Adjust Unbalanced Injection. 1 Measured stroke | 1000/1500 rpm Set the rack at the pump’s reference mark and measure the amount of fuel injected. If the amount injected into cylinder No. 1 does not fall within the range specified below, disassemble once again and check for mis- takes in assembly. Amount of ~ fuel injected Ce Measure the amount injected into cylinder No, 2 and adjust with the adjusting screw on the control plate so that the amounts injected, into both cylinders fall with the range speci- fied below. Cam Measured) Amount | Amount _injec- shaft stroke | injected | ted at a posi- speed | atthe | tion 2mm from rack | the rack mark mark po-| sition | | [LyMark 1600 | 1000 fo~220e| pty rom 2 ram\ aoepns euepuers 226 IThe difference | between cylinders should be within 1 ce/1000 strokes (or 0.5 ec/500 strokes). Fig. 3-54 Plunger Positioning Shims Fig. 3-56 Adjusting the Amount Injected Nozzle used! YDN OSDYD1 Nozzle injection pressure: 160 kg/cm? Fuel used: JIS No. 2 light oil Fuel pressure: 0.5 kg/cm? Injection pipe used $6xo15x 680 mm Rack mark size’ 0.5~90.7 mm] 75 -324 PLUNGERS AND DELIVERY VALVES 1, Plunger test (1) Attach a pressure gauge to the delivery valve holder on the pump to be tested. Caution: Pressure gauge full-scale reading: 1000 kg/em? (14200 psi) Approximate length of high pressure tube: 100 mm (3.94 in) (2) Place the rack in the “NO INJECTION” position, With the pump running at 300 rpm, shift the rack, The pressure should exceed 300 kg/cm? (4260 psi) in the vicinity of the rack mark with no sharp drops, (3) When the pressure has reached 300 kg/m? (4260 psi) , move the rack in the “less fuel” direction and shut the pump tester. Caution: The delivery valve must be good. 2. Delivery valve test. (1) Proceed as in the plunger test, stopping the pump and returning the rack to the "0" position when the pressure reaches 120 kg/om? (1704 psi). (2) Measure the time the delivery valve holder pressure takes to drop the 10 kg/ om? (142 psi) from 100 kg/cm? (1420 psi) to 90 kg/cm? (1278 psi). It should take at least 5 sec for the pressure to drop 10 kg/ern® (142 psi) (3) If the delivery valve fails the test, re place both it and the plunger. — 76 Fig. 3-57 Testing the Plungers Reference: © Presure gauge designation Pressure gauge AVT1/2 x 10 1000 kg/cm? (14200 psi) © Do not let the pressure drop suddenly after use. Fig. 3-58 Testing the Delviery Valves3-25 _— INJECTION NOZZLE INTRODUCTION The case nut holds the valve needle in the injection nozzle body. The injection nozzle, disperses, distri butes, and provides penetration power to the high pressure fuel from the injection pump. It must also inject the fuel into the comustion chamber with the correct timing. The model 2T75HL engine contains semi-throttle nozzles suitable for its special vortex combustion chambers and shims for adjusting the nozzle valve opening pressure. Fuel from the injection pump flows through the lateral oil channel and the three oil holes arranged about the circumference of the valve body into the pressure chamber at the bottom. When the pressure builds up to between 165 ~ 165 kg/cm? (2201 ~ 2343 psi), it forces the nozzle valve upwards, starting the injec- tion. When the plunger stops pressurizing the fuel, the suction action of the delivery valve produces a sharp pressure drop. The nozzle spring then forces the nozzle valve downwards, sealing the needle seat and stopping the injec- tion, The high pressure on the fuel in the pressure chamber forces a small amount between the nozzle valve and the vaive body. This fuel lubricates and cools the valve and eventually flows back to the fuel tank through the overflow pipe. Spring retainer Nozzle spring I D> Injection nozzle (sav 4 — Serraretiner | | POR torte vae || ott ports ee a IN Fig. $59 Injection Nozzle Components Fig. 360 Nozzle Valve Componenets We3-26 — Injection Nozzle Specifications Nozzle valve model number YDN~OSDYD 1 Type Throttle Opening pressure 160 £6 kg/cm? (2272 £71 psi) Nozzle valve Diameter of opening #1 mm 10,0039 in) Injection angle oe 7 Free length 30,0 mm (1.18 in} Nozzle spring Installed length 28.7 mm (1.13 in) Load when installed 14.1 kg (31,02 Ibs) I - | Thicknesses of shims for adjusting the needle valve's |_ opening pressure | t= 0.1, 0.2, 0.3, 0,5 mm (Four thicknesses) (0,009 in) (0.0079 in} (0.012 in){0.0197 in) INJECTION NOZZLE COMPONENTS Nozzle spring holder Spring adjustment shim Nozzle spring Spring retainer Interspindle Injection nozzle body Nozzle valve Case nut avoaaaenas Fig. 3-61 Injection Nozzle Components INJECTION NOZZLE REMOVAL 1, Remove the injection pipe and overflow pipe. Caution: Seal the openings so that dirt cannot get into the fuel system. 2. Remove the valve retainer and the injection nozzle. Caution: © Do not let any dirt into the antechamber. © Remove any carbonization built up in the antechamber. Fig. 362 Removing the Injection Nozzle - 78 -INJECTION NOZZLE DISASSEMBLY Caution: ‘As was the case with the injection pump, disassemble the injection in a clean enviro- ment. 1. Remove the case nut and the spring holder, 2. Disassemble into (1) Spring holder, (2) spring shim, (3) nozzle spring, (4) spring retainer, (5) interspindle, (6) injection nozzle, (7} nozzle valve, and (8) case nut. Fig. 3-63 Disassembling the Injection Nozzle Caution: Be vareful not to drop any of the parts inside! NOZZLE CLEANING 1, After cleaning the injection nozzle parts, always rinse them with fresh light oil 2. Use a commercially available nozzle cleaning kit and clean the nozzle valve in light oil Remove any carbonization of the nozzle needle tip. 4. Clean the valve seat in the nozzle body with Fig. 8.65 Nozzle Cleaning Kit a scraper - Caution When using a polishing agent such as _ chromium oxide, apply only a small amount fe at a time and rinse thoroughly after each application. ay 5. Use a cleaning needle for the valve opening. ty 6. Remove all carbonization (except on the lapped surfaces) from the exterior of the ee Fig. 3.66 Cleaning the Needle Valve Body 79 —3-28 NOZZLE VALVE ACTION TEST After cleaning the nozzle valve and valve body in clean light oil, pull the nozzle valve about halt- way out of the body and release. It should slide back very smoothly under its own weight. Repeat several times, rotating the nozzle valve slightly each time, If the nozzle valve sticks at any point, replace the nozzle valve as a set. INJECTION NOZZLE ASSEMBLY 1. Insert the nozzle (7) in the case nut and attach to the injection nozzle (6). Insert the interspindle (5) into the upper part of the injection nozzle. Insert into the spring holder (1), the shim (2), nozzle spring (3), and spring retainer (4) and attach to the injection nozzle. Caution: Be careful not to reverse the spring retainer. 2. Clamp the injection nozzle in a vise and tighten the case nut and the spring holder. Tightening torques (kg-m) Case nut: 10 kg-m (73 ft-lb) Spring holder: 7 — 8 kg-m (51.1 ~58.4 felb) 3. Spray test (1) Use a nozzle tester for testing and ad- justing Fuel injection pressure: 160 + 5 kg/cm? (2272 £71 psi) Fig. 369 Tightening the Case Nut (2) Adjust the fuel injection pressure by changing shims. Caution: © Make sure that fuel in the tester is clean. © There are four shim thicknesses available (0.1, 0.2, 0.3, and 0.5 mm). Changing the thickness by 0.1 mm (0.0039 in) changes the pressure by approximately 10 kg/cm? (142 psi). Fig. 370. Testing the Nozzle — 80 —(3) (4) Ca ° ° Gently work the lever on the tester when measuring the injection pressure. Inspect the spray pattern {a} The spray should be a cone sym- metrical about the valve axis and with an apex angle between 5 and 1s (b). The spray should produce a perfect circle on a white sheet of paper placed approximately 30 om (11.8 in.) below the nozzle. (c) Check for leakage. Holding the lever on the tester down should not produced dripping {d) Applying a pressure of 120 kg/cm? (1704 psi) from the tester should not produce leakage from the noz- zle seat ution: Never stick your hand into the high pres- sure spray. If cleaning the nozzle valve with fuel does not eliminate dripping, replace the noz- zle valve. Alter the test, when removing the nozzle from the high pressure pipe connecting it to the tester, first loosen the connection only slightly and gradually release any pressure remaining inside. Install the injection nozzle. a (2) Inspect the antichamber. Install in the reverse order to removal. (3) After installation, bleed any air inside. Ca ° ° ution: Above all, check the antichamber pro- tector (heat insulation) for damage. The convex side of the valve retainer should face the nozzle. | Thickness (t) oo | | orns-| | 02 | ' Pe fl Fig. 3:71 Shirms Defective Defective Defective Good Fig. $72 Spray Patterns Fig. 273 Installing the Injection Nozzle — B813-30 GOVERNOR LINK The governor is set to provide the output and torque characteristics best matching the operating condi: tions. When the engine is running, the centrifugal force generated by the governor weights and the tension in the regulator spring balance each other to stablize the governor lever and hence the amount of fuel injected. The Mode! 2T7SHL engine is notable for its compact link arrangement with governor weights and a governor sleeve on the crank gear and its unique injection booster link. Rack ‘ey Mote fuel . Regulator lever Regulator handle Do Maximum speed limiting bolt Return spring Governor sleeve FO limiter Accelerator cable Regulator spring } Lever — Governor lever shaft \ : d Governor weight Governor lever No. 2 A Parallel pin Governor lever No. 2 Fig. 3-74 Governor Components — 82 -3-31 FO LIMITER AND THE RETURN SPRING 499 The FO limiter mounted in the gear case limits the movement of the lever and is set to provide t the rated engine output. !t contains a mecha- i nism, the FO limiter spring, to remove the I limitation when a sudden overload threatens to ff Vf j\e FO tine spring stall the engine. It is also set to give the engine | \y\ the torque characteristics best suited to the \ vehicle's operations, The return spring has been attached to the Tt governer lever shaft to increase the amount in- jected during starting and improve the starting characteristics — especially at lower tempera tures Lever Return spring Fig. 3-75 FO Limiter GOVERNOR LINK ADJUSTMENT There is usually no need to ever adjust the governor link in the field. In fact, attempting to adjust it after replacing an injection pump, for example, is more liable to decrease engine performance. We therefore advise careful study of the explanation below before such an attempt. Rack / More fuel _-Regulator lever /Jo=— Regulator handle Maximum speed Return spring Governor sleeve \ fovernor lever shaft Governor lever No. 2 Governor ‘T lever No. 1 Governor weight Governor lever No. 2 \ Parallel pin Parallel pin Fig. 3-76 Governor Link Components 53-32 When Injection Pump Replacement When only replacing the injection pump, never touch the FO limiter; it is factory-set with a dynamometer. 1. Replace the injection pump. (see Injection Pump Removal on P. 3-14.) Caution: Make sure that the injection pump is secure- ly meshed with governor lever No. 2. 2. Check that governor lever No. 2 moves easi ly. Install the cover. 3. Bleed all air from the fuel circuits. Start a test run, (1) Gradually raise the speed to the maxi- mum. If the maximum differs from the standard for the unloaded engine, break the seal on the adjuster and correct. (2) Gradually decrease the speed to check the engine idling speed. Caution: © Maximum unloaded engine speed: 3150 + 50 rpm © Never break the seal unless it is necessary! © Maximum idling speed: 800 rpm When Replacement of parts of the governor link or gear case. (This is the procedure to follow when the FO limiter itself must be recalibrated.) Inspect and assemble all parts. 1. Remove the FO limiter from the gear case. 2. Remove the gear case cover. Shift the regulator handle to confirm that the governor link operates smoothly. Fig. 3-80 Step 2, Adjusting the FO Limiter ~84—3-33 Insert a spacer between the lock nut and the body of the FO limiter Install the FO limiter in the gear case. Caution The spacer must be between 0.5 and 1.0 mm (0.0197 ~ 0.039 in.) thick! Remove the gear case cover. Wedge the blade of a screwdriver between the lever and governor lever No. 2 to eliminate the play. Maintaining this position, push the FO limiter in until the rack mark on the injec- tion pump faces the standard surface. Remove the screwdriver and the spacer on the FO limiter. Turn the FO limiter between 55 and 60° counterclockwise and pull out. (1) Look the FO limiter in this position. (2) Install the cap nut. {3) Install the side plate. Cautior Do not overtighten the lock nut! 85 p_—— Spacer rime tat Fig. 3-81 Step 3, Adjusting the FO Limiter Governor Fig. 3-82 Steps 4 & 6, Adjusting the FO Limiter Fig. 3-84 Step 7, Adjusting the FO Limiter3.34 8. Bleed all air from the fuel circuits. Start circuits. (1) Gradually raise the speed to the maxi- mum to check the maximum unloaded engine speed (2) Gradually decrease the speed to check ‘the engine idling speed. (3), If either speed differs from the standard, repeat the adjustment. (4) After adjustment, always seal Caution: © Maximum unloaded engine speed: 3150 + 50 rpm © Maximum idling speed: 800 rpm Fig. 385 Adjuster and Seal FUEL PUMP ‘A magnetic fuel pump (transistorized) is used in the 2T75HL engine to pump fuel from the fuel tank to the injection pump. The fuel pump begins pumping up fuel from the tank when the engine switch is turned on, t our 7 Fig. 3:86 Fuel Pump ; SPECIFICATIONS Rated voltage - 12v Amperage 1.5 A or less Pumping capacity _____ 300 ce/min. or greater Weight 2 0.45 kg (0.99 Ib) Direction of installation Vertical (QUT facing up) or horizontal ce3-35 ——— INSPECTION AND CLEANING If the fuel pump does not operate, or its capacity falls, the pump assembly should be removed and compressed air (at a pressure of 5 kg/cm? (71 psi) or less) should be blown into the pump from the IN side. The pump should be cleaned at the same time, and its operation then checked. It should then be re-installed on the vehicle. If the pump still does not operate, or if its capacity is still low, it should be replaced Caution: 1. @ and © leads should never be connected backwards. 2. The pump should never be installed with the IN and OUT pipes reversed. 3. Never allow the pump to operate dry for long periods of time. Fig. 3-87 Fuel Pump Inspection — 87 —MEMO - 88GENERAL COOLING SYSTEM INSPECTION .... 22.0.0 eee cece eee eee eee eee 89 —4-2 GENERAL [TERE Te radiator Figure 4-1 Cooling System Circuits The Model 2T75HL engine features a forced ——— circulation cooling system with a readiator and ‘thermostatic valve The water pump forces the cooling water to circulate, drawing water cooled by the radiator from the lower tank of the radiator, pressurizing it, and sending it to the cylinder block. Flowing around the cylinders (through what are called “water jackets"), the water cools them and flows if up into the cylinder head where it cools the combustion chambers, intake and exhaust valves, and the guides for the intake and exhaust valves. _ The water accumulates in the pump housing and Fig. 4.2 Water Pump in the vicinity of the cooling water outlet in the cylinder head. At low temperatures, the thermostatic valve keeps the outlet closed to force the cooling water to heat up; the only flow is through the bypass. At higher temperatures, the thermostatic valve opens to allow the water to flow back to the radiator to give up its heat, cool, and be recirculated. When the internal pressure exceeds the design limit, the radiator release valve opens to release water into a separate reserve tank for storage. When there is a vacuum inside the radiator, however, the vacuum draws some of this water back, This arrangement assures a lasting supply of cooling water and makes mainte- mamee ic] easoer; WATER PUMP ‘The water pump itself is cast from an aluminum alloy while the impeller and housing are cast iron. In the upper part of the housing is a thermostatic valve. 90 -COOLING SYSTEM SPECIFICATIONS Pump type Centrifugal , Water temperature B0°C Perform. | eee Pump speed 3250 rpm ance — Td Minimum discharge rate | ____more than 258/min (6.6USgal/min} | Total lift 2m Aq mes Impelier diameter 55 mm (2.165 in.) } Pume Number of blades 8 Watertight seal type Mechanical | | Bearing type Double ball bearings Pulley diameter 88 mm (3.46 in.) Minimum discharge rate 34° Type Wax pellet Thermo. |” = static Valve-opening temperature 77°C valve - : Valve-opening lift 8 mm (0.31 in.) V-belt size “A (34.5 inches) Total cooling water volume 2.858 (0.766 USgal} (Engine + Radiator) RADIATOR The radiator fins are wave-shaped sheet metal pieces welded at equal distances along large flat brass pipes arranged vertically. This arrangement provides good air flow and reduces the risk of clogging due to air- borne dust. The waves in the fins increase the heat dispersion RADIATOR CAP Exposing the water inside the radiator to the air would limit the temperature to the boiling point (100°C) and thus decrease the temperature difference between the cooling water and the atmosphere, The radiator cap increases this, temperature difference — and, by extension, the cooling efficiency — by sealing the radiator and letting the expansion due to heating pressurize the water and raise its boiling point. The pressurized radiator cap contains a pressure relief valve and a vacuum relief valve. When the pressure inside the cooling system exceeds a certain limit, the former opens to relieve the exces’ pressure by releasing water through the overflow pipe into the reserve tank. The latter opens when the engine stops and cooling reduces the internal pressure to below that of the surrounding atmosphere. The greater pressure outside forces the condensed water in the reserve ‘Vacuum relief valve open Fig. 4-4 Radiator Cap Function (2) —91- I To reserve tank is Pressure relief valve open Fig. 4-3 Radiator Cap Function (1) From reserve tank4-4 —————————— tank back into the radiator to equalize the pres- sure, INSPECTION V-BELT Since the V-belt transmits power through friction with the pulley, its tension greatly influences the transmission efficiency. If the V-belt is too slack, not enough power is transmitted and the engine overheats or fails to generate enough electricity. On the other hand, overtightening decreases the service life of not only the pulley itself, but also of the bearings in the fan and the alternator. Therefore, it is necessary to periodically inspect and adjust the V-belt tension, Caution: © Lack of clearance with the bottom of the pulley groove and shininess indicate excessive wear. Replace the V-belt! © Be especially watchful for deterioration, cracking, wear, and oil stains. Measure the “give’” mid-way between the fan and dynamo pulleys. Standard “give’’ for a 10 kg force: 10 — 15 mm (0,39 ~ 0.59 in.) (22 Ibs) RADIATOR Check the radiator core for blockages and defor- mation. Clean the radiator to improve air circula- tion, Caution: The radiator core and fins bend and crush easily so do not allow them to contact other parts. Fig. 4-5 Inspecting the V-belt Water Pump ‘Alternator Crankshaft pulley Fig. 4.6 Checking the V-belt Tension 92 -RADIATOR CAP 1, Measure the spring tensions and examine seal tightness for the pressure relief and vacuum relief valves. Replace the cap if there are any faults, 2. Attach to the radiator cap tester as shown in, Figure 48 and apply a pressure which exceeds the imiit. The pressure relief valve should withstand this pressure for at least 6 06 Without on pressure os

opening temperature: Temperature temperature: 71°C 85°C Fig. 4-13 Testing the Thermostatic Valve 9 Teapropvi | Starting switch Sterter Fig. 63 Starter Circuit Diagram ~ 105 —6-4 FUNCTION When the starting switch is turned ON 1. Turning the starting switch on causes the curtent to flow to the holding coil (HC) and through the holding coil. (The holding coil and pull-in coil generate magnetic force in the same direction.) 2. The magnetic force of the pull-in coil and holding coil attract. the magnet switch Plunger leftward to bring the pinion gear into mesh with the ring gear. 3. As the pinion meshes with the ring gear, the plunger contact plate closes the main contact and a large current flows to the filled and armature coils because of direct connection to the battery. 4. As a result, the armature revolves at a high speed, which is then reduced to about 1/3 through the drive pinion, idle gear and clutch gear. The pull-in coil is short-circuited and the plunger is held only by the holding coil Upon engine start-up When the engine starts, the armature is driven reversely by the ring gear, so the clutch rotates without engagement to protect the armature from revolving at an abnormally high speed. The clutch is of the roller type. When the starting switch is turned off 1, Turning off the starting switch cuts off the urrent supply to the holding coil to elemin- ate the plunger attracting force. The pinion gear is returned to the stationary position by the return spring. 2. The main contact is opened to cut off current supply to the armature to stop armature revolution, = | Gear — | \E 1] \ Shaft =—— Field : coil apes me J Contact) icf plate \ x | J suertingt Pinion gear Clutch gear j | twitch + Plunger | Fig. 64 Upon Turning on the Starting Switch oe Srmeture ste Fiets coil Contact [ache niate 2. tt Starting + een Ring geer Clutch gear | owh / | Prunger Fig 6-5 Upon Magnetic Switch Actuation | High apeed ie not because of the clutch Ring gear Clutch gear Plunger Fig 66 For High Engine Speed Gear | \ | ‘Armature = Fiold coil Shaft Contact UT plate | ER Main | [RCPS] Flywheel spring j Starting ring gear Clutch gear / | Stich = ! ohn Plunger Fig 6-7 Upon Turning Off the Starting Switch — 106 -COMPONENTS 1. Yoke 12. Roller 2. Armature 13, Retainer 3. Brush 14, Magnet switch 4, Ball bearing 15. Coll spring 8. Felt washer 16. Steet ball 6. Brush holder 17. Clutch 7. Brush spring 18. Housing 8. Rubber packing 19. Spring 9. Pinion gear 20. Pinion stop nut 10. Idle gear 21. Snap ring 11. Reduction gear Fig. 6-8 Starter Components 107 -SPECIFICATIONS Motor type Direct current, series wound (reduction type) Nominal voltage 12V Nominal output - - 1.4 KW Time rating : 30 seconds Revolving direction Clockwise as viewed from the pinion side Number of poles 4 Number of pinion teeth 9 Overall tength 224 mm (8.8 in.) Yoke outside diameter 76 mm (3 in.) Weight About 5.2 kg (11.44 Ibs) Voltage 11.5V No load characteristics [Current 90 A max Speed 3600 rpm min. Voltage ; 24V Locked characteristics Current 400 A max. Torque 1.1 kgem (8 ftlb) min OUTPUT CHARACTERISTICS Voltage Torque gas goF ae e&s soa. N 5000] 2.0) 10} \ “PT som}.2| ol anifos] 4 rfo. dd Fig. 69 Starter Output Characteristics = 108 -INSPECTION AND REPAIR Commutator Inspect the following items, and replace or repair the commutator if defective: 1. Check the surface for dirt or burning, Clean’ with sandpaper if defective. 2. Check the outside diameter for wear. If the outside diameter is smaller than the wear limit, replace the armature. Wear limit: 29mm (1.142in.) Standard outside diameter: 30 mm (1.18 in.) 3. Check uneven wear. If exessive, correct with alathe, Caution: If the difference between the maximum and minimum diameter exceeds 0.4 mm (0.016 in), correct it to 0.05 mm (0.00197 in) or less. When cutting the commutator on a lathe, the finished outside diameter shall be greater than the original diameter minus 2 mm (0.079 in). Limit 0.2 mm 4. Inspect the radial run-out, and repair on a lathe if it is excessive. Tolerance: 0.02 mm (0.00079 in) 4 Inspect the depth of mica between segments. eo Limit: 0.2 mm (0.00079 in.) en Standard: 0.5 ~ 0.9 mm (0.0197 ~ 0.036 in.) - -—— segment Fig. 6-11. Inspecting the Mica Depth Armature bearing Inspect the following items, and replace the bearing if defective: 1. Smocth revolution shall be obtained when. rotated by applying a force with fingers. 2, No abnormal sound shall be heard when rotated rapidly. Fig. 6-12 Inspecting the Bearing — 109 -6-8 Armature Coil 1 Coil open-circuit test {1} Inspect continuity between segments by using the resistance range (x19) of a multimeter. (2) If no continuity is found, repair or re- place the armature coil 2. Armature coil ground test (1) Check continuity between the com- mutator and armature coil core by using the resistance range (k2) of a multi- meter. (2) If continuity is found, repair or replace the armature because there is @ short- circuit Field Coil 1. Coil open-circuit test (1) Check continuity between the C ter- minal lead wire, field coil and brush by Using the resistance range (x12) of a multimeter (2) If no continuity is found, discontinuity in the armature coil is the reason Repair or replace the armature coil 2. Coil ground test (1) Check continuity between one terminal of the field coil and the yoke (2) If there is continuity, remove the pole core sequentially to find the grounded area. Repair or replace the defective part. Brush 1. The brush surface shall not be roughened. 2. Measure the brush length. If it is less than the limit, replace the brush. Wear limit: 10 mm (0.39 in.) Standard length: 14 mm (0.56 in.) 3. When using a new brush, wind sandpaper ( # 300 or above) on the commutator and correct the contact surface. Fig. 6-16 Messuring the Brush Length — 10 -Use @ spring scale and measure the brush spring installed load. (1) Read the scale indication when the brush spring leaves the brush. (2) If the reading is below the limit, replace the spring Limit: 850 9(1.87 Ibs) Standard: 1700g(3.74llbs}(new brush) Brush Holder Carry out the insulation test between the 1 © side brush holder/ side brush holder and the end frame by measuring the resistance with a multimeter set to the resistance range (x19) 2. If there is continuity, repair or replace the brush holder. 3, The brush shall move smoothly in the brush holder. Clutch 1. The gear shall not be worn or damaged, 2. Clutch function Make sure that the clutch is locked when the gear is rotated in the driving direction, and rotates smoothly when the gear is rotated in the reverse direction Magnetic Switch Caution: Carry out each test in a very short time (3 ~5 seconds) and at 1/2 the rated voltage. Pull-in coil test Connect the battery negative © terminal to the magnetic switch body and C terminal Next, connect the battery positive © terminal to the 50 terminal The pinion gear shall jump out. r Brush| xa ~ 1d. Fig. 6-17 Testing the Brush Spring Force Ka fl Fig. 6-18 Brush Holder Insul 30 terminal Fig. 6-20 Pull-in Coil Test i6-10 2. Holding coil retention test The pinion gear shall remain in the jumped out state when the wiring to the C terminal is disconnected from the state in the pull-in test. Greasing Coat Denso No. 50 cable grease to the following areas before starting assembly’ Armature spline Pinion gear teeth surface and spline Idle gear teeth surface Roller and retainer . Coil spring and steel ball . Clutch gear teeth surface oosene Performance Test Caution: © If no lock+test device is available, carry out only the noload test. © The specified voltage is @ voltage gained from the following tests using a full changed 45 AH battery. Nosoad test Check the maximum rpm and current at no load. The revolution shall be smooth and stabilized at 5000 mm or more with the voltage at 11.5 V and current at 90A or less in the circuit configuration as shown in Fig, 6.24 Lock test Check the torque and current at overload when the rpm is zero. With the specified voltage (2.4 V), the armature in the locked state, and the current at less than 400A, the generated torque shall be 0.77 kg-m or more. 50 terminal Ammeter | Variable resistor Voltmeter, Sbarter Battery Ammeter Starter a LJ oma S Bottery UL Fig. 6-24 No-Load Starter Test (Simplified Method) — 112 -PREHEATING SYSTEM (THERMO-START PLUG & HEADER TANK) OPERATION The thermo-start plug structure is roughly classified into the following parts: © Heater unit to operate the thermo-start plug and light the pilot lamp to indicate the heater preheating status © Nozzle body housing the plunger and solenoid to contro! the fuel flow into the plug © Heater coil to evaporate the incoming fuel, ignition heater to ignite the vaporized fuel © Outer cover and shield to house these parts. © Terminals for connection to the battery. Thermo-Start Operation 1. Operating the starting switch to the TS position lights the pilot lamp and starts power supply to the termo-start plug heater to start preheating. * The starting switch shall be kept at the TS position until the pilot lamp goes off. The pilot lamp goes off when the specified time elapses after unit operation. Turning the starting switch to the ST position after pilot lamp extinction starts the starting motor and supplies current to the solenoid at the thermosstart plug heater. The plunger is attracted to open the valve and the fuel oil from the header tank flows to the heater section. 4. The fuel flowing out to the heater section is vaporized by the preheater and ignited by the ignition heater. The air supply from the manifold continues combustion to heat the air in the manifold. 5. In 10 seconds after starting motor start-up, the current supply to the solenoid at the thermosstart plug heater is automatically cut off by the heater unit. The fuel supply is stopped for easy engine starting 6. Turning off the starting switch after engine start-up stops the starting motor. The power supply to the heater at the thermosstart plug is cut off to cease combustion at the heater. oN Starting switch From injection nozzle Header tank. Lip Battery| | werning lamp | Intake munifold] Valve Plunger Solenoid Fig. rating System Operational Diagram - 13 —6-12 THERMO-START GENERAL DESCRIPTION The thermo-start plug installed by screwing to the intake manifold causes the fuel from the header tank to burn in the intake manifold by the operation of the starting switch and heater unit for preheating of the intake air to facilitate engine starting in cold weather. Since the thermostart is different from the glow plug in that it is nct exposed to the engine combustion heat, it has excellent durability. Furthermore, the one used in the 2T75HL adopts the solenoid system to open and close the valve, so power loss and soot generation resulting from excessive use Fig. 6-26 Thermosstart System “Temp to which ter heats of the air in the manifold are least possible. The Pagine resulting little battery load and the enhanced Starter | starting starting performance are big merits of this ‘anion | eperating [ system, Fo Ewtromagraie [SownlSane ents Fated voltage BV (eee Current consumption 14 oT 7 on | Om] ont or Fuel flow rate = onl ral Thermo : (ambiont tempera. eee wm aa get | reader | 121.700! 100 mm) Fig. 6:27 Operation Status Chart Ignition time Until engine — He tir 9.5 sec Carel (D.C 12V at 20°C) Contr | Feet weply mening rotor unit cut-off thme start-up Solenoid Source worRege 7 Green iead fluctuation range Peat J Pilot lamp capacity _| _12V = 3W |e u Terminal _Vaive a [— INSPECTION 1. Thermo-start plug (1) Preheater and ignition heater inspection Check continuity between the thermo- start plug body and the terminal. If there is no continuity, replace with a new part. {2} Solenoid inspection Check continuity between the thermo- start plug body and the green lead. If there is no continuity, replace with a new part. A _Thermo- [7 start plug t Prehoater ZZ — gnitionnester Fig. 6-28 Plug Structure = 14 -(3). Plunger and valve check Apply an air pressure of 1.4 kg/cm? (20 psi) from the fuel inlet, Immerse the plunger and valve in clean oil and make sure no air bubble appear from the heater side or joint. Caution Do not immerse the green lead and rubber seal at the top of the plug. (4) Make sure that there is no scar, crack, rust or any other damage. Fig, 6-29 Inspecting the Thermo-start Plug (1) (5) After installation and piping, check that there is no oil leak. 2. Frame heater unit The frame heater unit consists of the timer circuit, amplifier circuit, lamp drive circuit and starter detection circuit. The timer circuit sets the heating time for the heater, the amplifier circuit amplifies the signal from the timer circuit, and the lamp drive circuit drives the lamp. The starter detecting circuit opens the solenoid to supply fuel to the heater when the starting switch is turned Fig, 630 Frame Heater Unit to the ST position and holds the lamp drive circuit. Inspection a mm To 1. Pilot lamp off time ] (E—siack If the actual time is not within the standard, | replace the frame heater unit. (Ei reatwnite Standard lamp-off set time | 12v Dc Wve 9.5 seconds (at 12 Yellow oe) EU Uy 20°C ce 2. Remove cables from the frame heater unit- carry out continuity test with a multimeter. The unit is normal if continuity is as speci: Fig, 631 Connector and Lead Color Coding fied in the following table. It inconsistent at Caution: any one place, the frame heater unit is faulty, Since this unit has no protection circuit for Even if the following table is satisfied, the erroneous operation such as incorrect bat- frame heater may be defective because of tery connection or incorrect battery discon- egradation, necting operation, careful handling in Check lst (normall_necessary, ME mina Cable color Muttimeter negative ————____| white | Reaswnite | Green Yellow | Black White FF OFF | OFF on Rea/Wnite ON ON ‘OFF OW Cable color Green ‘ON [oF F ON Yellow OFF OFF ofr | ———__|_orF Black ‘on | OFF ore | OFF — + Set the multimeter at as high a resistance range as possibie. * ON means pointer deflection, and OFF means no deflection. = 115 =6-14 CHARGING SYSTEM Fuse Starting switeh Voltage regulator. ZBartery I [Reteeor lary ‘Alternator 7 : p Charge relay ‘iternator regulator Fig. 6-32 Alternator Operation Diagram ma Charge warning | GENERAL DESCRIPTION In an alternator, unlike a DC dynamo, the magnetic pole excited by the current from the battery is rot ed to induce 3-phase alternating current in the surrounding stator coil. The induced 3-phase current is subject to full wave rectification by 6 rectifiers (silicon diodes) built in the end frame to output a DC current, Since the alternator is capable of controlling the maximum current by itself, no current limiter is required. It is also unnecessary to provide a cut-out relay because of the cha: racteristics of the silicon diodes used as rectifiers. The above figure (Fig. 6-32) shows the operations of the alternator, generator and regulator. Turning on the starting switch causes a current to flow from the battery, through the fuse, charge lamp and points Pg and P, of the charge relay, to the ground to light the charge warning lamp. At the same time, the current from the battery flows through the fuse and points Ps and P4 of the voltage regulator to the rotor coi! of the alternator to excite the rotor. When the engine is started in this state, the rotor rotates to induce a 3-phase alternating current in the stator coil, which is then rectified by 6 rectifiers to provide a DC voltage output between terminal B and E. At the same time, the potential at the neutral point of the stator coil rises to apply a voltage to the charge relay voltage coil to attract point Py to point P, so as to turn off the charge warning lamp. When the voltage generated by the alternator rises beyond the battery voltage, a current flows to the load ‘or battery. The reverse current from the battery to the stator coil is checked by the rectifiers and the stator coil does not allow flowing of a current beyond a given level in the coil when the revolving speed increases. Therefore, a regulator having a cut-out relay and current limiter required in a DC dynamo is unnecessary, and only the voltage shall be controlled Since the voltage generated by the alternator varies with the revolving speed, proper charging to the battery requires control of the A terminal voltage within the specified level. The voltage regulator takes care of this control. As the voltage at terminal A increases, the voltage applied to terminal 1G of the regulator rises. As a result, the attraction force of the regulator voltage coil increases to depart point Py from pcint Ps (low-speed side contact) This causes the current to the rotor coil of the alternator to pass through control resistor (Ry). As a result, ‘the current to the rotor coil decreases to weaken the magnetic force and reduce the voltage at terminal A. High speed revolution from reduced load will connect point Ps with point Px (high-speed side contact) to further reduce the rotor coil current for regulation of voltage at terminal A. — 116 -ALTERNATOR Drive end frame Fan Jf Brush holder Tul Fig. 6-33 Alternator Sectional View \ FEY seator | REar end frame COMPONENTS | | | 1. Pulley 9. Retainer plate 17. Brush holder 2. Fan 10. Spacer ring 18. Rear end cover | 3. End frame 19. Insulation terminal 4, Felt 20. Insulation ternimal 5. Shim 21. Bushing 6. Spacer 14. Rear end frame 22. End frame 7. Drive end frame 15. Brush 8. Bearing 16. Brush spring Fig. 6-34 Alternator Components leSPECIFICATIONS Nominal voltage 12V Maximum output (14V, hot state) 2A Polarity " Negative side connected to ground Revolving direction 7 : Clockwise as viewed from pulley side Armature winding phase, Y connection Rectification - Full-wave rectification by 6 silicon diodes. Pulley outside diameter - 7 9 67 (2.64 in.) No-load rpm (14V, hot state) - 1250 rpm | Regulator control voltage = 138~148V Weight i About 3.4 kg (7.48 Ibs) | taling speed (cold) 7 14V, 0A 1200 * 150 rpm | Load-carrying speed (cold) 7 “4000 rpm max. (14V, 25) OUTPUT CHARACTERISTICS Constant voltage at 14V al T | Cold 30 +. Hot 5 20 6 10 1000-2000~«—«3000 «4000 ~—~—«S000 Alternator speed (rom) Fig. 6-35 Alternator Output Characteristics 118 -CHARGING SYSTEM INSPECTION Charging system troubles come under any of the three following symptoms (1) Battery over-discharge (2) Battery over-charge (3) Faulty indication by charge warning lamp A battery over discharge state can be detected by failure of starting motor revolution or dim light of the head lamp. However, overcharged battery is hardly detected. Special attention must be paid because over-charging may cause insufficient battery fluid or deterioration of call plates. If the charging system is suspected to be faulty, check if the cause is in the battery, regulator, alternator or use of vehicle not involving functional fault, BATTERY OVER-DISCHARGE V-belt tension check Standard V-belt flexure: 10 ~ 15 mm (at 10 kg) (0.39 ~ 0.59 in.) (22 Ibs) Check mounting status of terminals and couplers as well 4s contact status of battery terminals. Disconnect the cable from the positive & terminal of the battery, and carry out con tinuity test between the cable and ground to see that a permanent battery circuit is not formed. Charge the battery and check the battery uatity on the basis of the charging status. Measure the charging time, specific gravity of the battery fluid in each cell and the difference of specific gravities in different cells. Cheek the vehicle operation status Pay attention to load increase, starter use frequency and night operation status. 6-17 Fig. 6-36 Multimeter Characteristics of multimeter In continuity test with a multimeter, the built-in battery in the multimeter causes @ current to flow from the negative © terminal of the multimeter to the positive ©® terminal. The negative © terminal and positive © terminal of the multimeter havepositive © and negative © polarities, respectively. This polarity reversal does not ‘occur in voltage or current measurement. If the circuit to be tested contains semi- conductor elements, a current flows when the semiconductor polarities are the same and no current flows if they are reverse. It is necessary to pay attention to this point when testing the rectifier circuit. Fig. 6-37 V-belt Flexure — 119 =18 REGULATED VOLTAGE AND CURRENT CHECK 1. Use the regulator tester and check the func ions of the regulator and alternator. 2. Gradually increase the engine speed and measure the voltage at terminal A. Because of hysteresis, read the voltage when the pointer stops. Standard voltage: 13.8 ~ 14.8 Vat 20°C 3. When the voltmeter indication is instable. (1) Check contamination or sign of fusion at regulator points. (2) Check imperfect contact at terminal F. 4. When the voltmeter indication is not within the standard voltage range: (1) If the indication is too high or too low for both the high and low speeds, adjust by turing the adjusting screw of the voltage regulator as follows: Open the regulator cover and 2 similar relays are seen, The voltage regulator is the one having a relatively narrow point gap and larger point diameter. Turn the adjustment and lock the adjusting screw. To increase voltage: turn clockwise To decrease voltage:turn counterclockwise (2) If the required voltage adjustment values are greatly different for the high and low speeds, fine adjustment of the regulator is necessary. (3) Other causes are as follows * High point contact resistance or point fusion © Discontinuity in relay coil on | regltr tener CH | eae F - 0 [Peas || Fig. 6-38 Regulator Tester Wiring [Standard voltage 138 ~ 148 V n 6 810lay, Fig. 6-40 Regulator u 3 1 7 ri | < Adjustment |} adjustment | ( for low w 11 for high spre | | ! Fig. 6-41 Adjusting Voltage Characteristic for 2-Contact Type 120 ~‘© Discontinuity in regulator N or A terminal circuit ‘* Regulator grounding error To measure the voltage between E and F, stop the engine, extract the alternator terminal connector and turns the starting switch at the ON position. If the voltmeter indication is 0 or very low: (1) Check discontinuity in or imperfect contact of the 1G or F terminal lead of the fuse and regulator. (2) Check fusion of the high-speed side point CHECKING RESISTANCE BETWEEN TERMINALS 1 Inspect the regulator connector and measure the resistance between terminals IG and F with a multimeter. If the resistance indication is over 0, the contact resistance of the low speed side point is too high. Measure the resistance between terminals F and € (rotor coil) of the alternator. Standard rotor coil resistance: About 4.20 at 20°C If the resistance indication is too low, check shortcircuit in the rotor coil or wiring, If the indicated resistance between terminals F and E is higher than about 4.22 (1) Check discontinuity in the rotor coil (2) Burning or improper contact of rotor brush or slip ring. — Adjusting arm Fig. Fig, (low speed side. Armature gas Angle gap Point Poi (high speed side) Point gap, 6-42 Regulator Components _ Regulator tester AT-3 (Standard vorege] he | &))) | £ | MS | (Ss si ie oq F Alternator | tie 6-43 Checking the Voltage between Terminals E and F of the regulator Fig Multimeter 6-44 Resistance between IG-F of Regulator Regulator terminals ‘Standard resistance: 00] Standard resistance: 6 — 991 Fig, — 121 - 6-45. Checking Resistance between Terminals F and E of AC Generator6-20 LOAD TEST 1, Remove the alternator and carry out the performance test specified in page 115. 2. Possible causes for ammeter indication below the standard current (1) Open-circuit in rectifier (2) Short-circuit in rectifier (3) Discontinuity or short-circuit in stator coil 3. Shortcircuit test by multimeter Disconnect the cable from alternator ter- minal A and the connector. Reversing the tester probes for the following terminals will almost eleminate continuity © side diodes (between terminals N and A) © side diodes (between terminals N and E) — 122 | Alternator Regulator Fig. 6-46 Measuring the Load Current Alternator Neutral PointDISASSEMBLY 1. Remove 3 through bolts. Insert a screw: driver in the notched portion of the drive end frame. Tap the end frame lightly with a wooden hammer while prying with the screwdriver to separate the rear end from the drive end, i Caution Do not insert the screwdriver too far into the end frame notch to prevent damage to the stator coil. 6-48 Step 1, Separating the Rear End 2. Fix the rotor core with a vise and loosen the pulley lock nut with a box-end wrench Caution: When fixing the rotor core with the vise, do not tighten too much to prevent deforma- tion. Fig, 6-49 Step 2, Removing the Pulley 3. Remove the pulley and fan, and take the drive end frame off from the rotor shaft, Fig. 6-50 Step 3, Removing the Rotor Shaft 4, Remove 4 nuts on the rear side of the rear end frame, and remove the stator and recti fier. Caution: Insulation terminal is used for the + side rectifier for insulation. Fig. 6-51 Step 4, Removing the Stator = 123 —6-22 5. For separation of the rectifier from the stator, use @ soldering iron and quickly melt the soldered place, Fig. 6-52 Step 5, Separating the Rectifier = 124INSPECTION Brushes 1. Brush length Limit length: 5.5 mm (0.22 in.) Standard legth: 12.5 mm (0.49 in.) Caution: Since the brush tip end is inclined, measure the length at the center, 2, Brushes shall move smoothly in bursh holders. Stator Coil 1. Stator coil open-circuit test (1) Check a pair out of 3 leads by using the resistance range (x19) of a multimeter. (2) If there is no continuity, repair or re- place discontinuity in the stator coil 2. Stator coil grounding test (1) Check continuity between one lead and the core by using the resistance range of the multimeter. (2) If there is continuity, repair or replace the stator coil because it is short circuited, Caution: Disconnect the rectifier before testing the stator coil. Rectifier (diodes) Recifier defects are categorized into open-circuit and short-circuit. Open-circuit_ means no con- tinuity and short-circuit means current conduc- tion in both the foreard and reverse directions. Fig. 6-53 Brush Wear Fig. 6-54 Testing Open-Circuit in Stator Coit Fig. 6-55 Testing Grounding of Stator Coil () side| (+) side B ry Stator coil : Fig. 6-56 Diode Circuit = 125 -6-24 Se Use a multimeter for these test. Touch the re- ctifier lead with the negative © probe of the multimeter and the holder fin with the positive @® red probe for each diode on the @ side, If there is no continuity, there is open-circuit in the diode. If there is continuity when the multi- meter probes are reversed, the diode is short- circuited, Carry out the same test for all three diodes. When testing a diode on the © side, reverse the multimeter probes for each test, If any defect is found, replace the diodes as an assembly. Rotor Coil 1. Rotor coil open-circuit test (1) Measure the resistance between slip rings with a multimeter set to resistance range (x19) (2) The rotor coil is normal if the measured resistance is about 4.22. Repair or replace the rotor coil if there is no continuity, (3) Rotor coil ground test Standard resistance: About 4.20 at 20°C 2. Rotor coil ground test (1) Measure the resistance between the slip ring and core with a multimeter set to the resistance range. (2) Repair or replace the rotor coil if there is continuity. Slip Rings 1, Slip ring outside diameter Slip ring outside diameter Limit: $32.1 mm (1.26 in.) Standard: @ 32.5 mm (1.28 in.) 2. Slip ring surface inspection Slip ring surface is normal if it is smooth without staining, If stained, wipe it clean with a cloth soaked with alcohol. roughened, correct by polishing with #600 ~ 600 sandpaper. Rotor Ball Bearing Inspect the following items, and replace the bearing if found defective 1. The rotation shall be smooth when it is rotated by fingers 2, No abnormal sound shall be heard when it is rotated rapidly. Fig. 6-57 Inspecting the Diode — Fig. 6-68 Rotor Coil Open-Circuit Test Fig. 6-60 Measuring the Outside iameter of Slip Ring — 126 -6-25 ASSEMBLY The assembly procedure is the reverse of the disassembly procedure. Pay special attention to the following points 1. Brushes and slip rings shall be assembled after removing oil, grease and dirt. 2. When assembling the rectifier and end frame, hold two brushes with fingers and pass wires through the holes as shown in Fig, 6-62 to prevent them from coing doen, After assembling the alternator, be sure to remove wires lifting the brushes up. 3. Firmly tighten the pulley lock nut, Tightening torque: 8 ~ 10 kg-m (58.4 ~73 ft-lb} 4, Charge Denso No. 50 grease in the bearing. PERFORMANCE TEST To inspect the alternator, remove it from the engine. Carry out wiring as shown in Fig. 6-63 and drive the alternator by a voriable-speed motor. 1. First, close switch (S1) to supply the field current from the battery to the alternator. Gradually raise the alternator revolving speed, and open switch (S1) when the ammeter reading becomes 0 to provide the selfexcitation st Increase the revolution speed further until the voltmeter indicates 14V, The revolving speed for this voltage output shall be within a range of 1200 # 150 rpm. 2. Then close switch (S2) and further increase the revolving speed. Since the voltmeter indication varies, keep it always at 14V by manipulating the variable resistor. The alternator speed shall be 4000 rpm or less when the ammeter indication is 254. If satisfactory performance is not obtained in the above test, the alternator is detective. Inspect each part of the alternator. Fig. 6-62 Lifting the Brush Up ‘Ammeter (50A) Al s, \S aces Voltmeter Nos | tov = 88 ee | é i Veroble speed 33 drive motor 7 3s Fig 6-63 Inspection by Test Bench Ta constantly fel 30) Output current (A) 7000 2000 3000 4000 6000 Alternator speed (FEM) Fig. 6-64 Alternator Output Characteristic — 127 =6-26 REGULATOR SPECIFICATIONS Regulated voltage ci Sutin volt: Polarity @ ground ELECTRICAL ADJUSTMENTS 1. Check the voltage regulator function, and make necessary adjustment if defective, Adjustment shall be made by bending the adjusting arm, Regulated voltage: 13.8~ 14.8 V Note: Bending the adjusting arm upward increases the regulated voltage, 2. Check the charge relay function, and make necessary adjustment if defective. Make sure that point P3 is open when the engine is in stop state and is closed when the engine is idled. Cutin voltage: 4.0~5.8V MEASURING RESISTANCE BETWEEN TERMINALS if satisfactory values are not obtained by elec- trical adjustment, use a multimeter and inspect the regulator internal status, Fig 6-65 Regulator ‘Armature gap Point P1 (low speed side) + ] [ Angle gap Adjusting arm Point P2 (high-speed side Point gap | Adjusting arm Point Pa (low-speed side) Fig 6-67 Charge Relay Terminal IG (white/red) Terminal & (white/black) Terminal N (white/biue) Terminal L (white/yeliow) ‘Angle gap Point P3 (high-speed side} Point gap Terminal F (white/green) | Terminal 8 (white) Fig 6-68 Regulator Terminal Arrangement = 128 —6-27 Voltage regulator Low-speed side About 11 Fig 669 Internal Wiring and Mein Velues (at 20°C) Resistance between regulator terminals Charge | Voltage | Resistance Measuring | relay | regulator | value in Inducation in abnormal state and possible cause terminals | state | state. _|normal state | If the indication is about 09, detective contact at a ~ Stationary | 02 | low-speed points (py and pa) of voltage regulator. 1 : ; lastroction |e If as is indicated, discontinuity the resistor inserted [Attraction about 119 | in the resistor inserted in the rotor a If the indication is about OM, defective contact bet | oe Stationary ~ 02 | ween pg and ps of charge relay Atiraction§ | about _| If the indication is other than °°, fusion of pé6 and 1002 | Ps If 0 is indicated, short circuit in charge relay voltage ee = = about | coil 232 _ | If e»is indicated, discontinuity in charge relay volta iv ge relay voltage coil a 7 Ifother than © is indicated, fusion of Pa and ps in A-E [Stationary — 2 | ene talan ao Stationary] Attraction om | If the indication is above OM, defective contact bet- ween high-speed points p and p3 of voltage regulator. Caution: ° Attraction means the state where the armature point is brought into contact with the high-speed side point or point Py by pressing the cor- responding armature with a finger. Stationary means the state where the armature point is in contact with the low-speed side point or point Px. — 129 -6-28 MECHANICAL ADJUSTMENTS Armature gap Armature gap / ‘Angle gap Adjusting rm s ° I Adjusting arm ! Point (P,) Point (P,) (high-speed side) Point gop Point (P,) = Point gon Voltage regulator Voltage relay Fig. 6-70 Measuring Gaps Fig. 6-70 Measuring Gap The following adjustments shall be made only when satisfactory results are not obtained by electrical adjustments explained above. Caution: © Always disconnect the regulator connector at the time of inspection and adjustment. © Refrain from dimensional adjustment, unless it is absolutely necessary. 1. Voltage regulator Check item Standard value About 0.3 mm or Armature gap more (0,012 in or more) Point gap 0.3~ 0.45 mm (0.012 ~ 0.018 in) (Atattraction) Contact spring fiexure | 0.2~0.6 mm (0.0079 ~ 0.024 in} (At attraction) Angle gap About 0.2 mm or | more (0.0079 in or more} Contact point About80 9 or more | Fig. 6-71 Voltage Regulator pressure (0.176 lbs} 7 aes 2. Charge relay Check item ‘Standard value 0.4~1.2mm Point gap (0.016 ~ 0.047 in) Contacting | etre enue) (0,0079 ~ 0,024 in) Contact point 60 ~ 140g or more pressure (0.132 ~ 0.31 Ibs) Fig. 6-72 Charge Relay - 130 -WARNING LAMP The 2T76HL engine has the following warning lamp which monitor functions of engine mechanism during operation and issue alarms for abnormalities: (1) Oil pressure warning lamp (2) Charge warning lamp OIL PRESSURE WARNING LAMP This system monitors the pressure of the engine oil sent by the oil pump during engine operation. The pilot lamp lights when the starting switch is turned on, and goes off when the pressure rises to the specified level. Oil pressure switch Operating pressure: 0,6 + 0.2 kg/cm? Oil pressure lamp Starting switch Fuse Oil pressure switch t Oil pressure Fig. 6-73 Oil Pressure Warning Lamp Fig. 6-74 Oil Pressure Switch (7.1 £2.84 psi) Pilot lamp capacity: 12 V — SW INSPECTION Sympton Check point Remedial action 1, Blown fuse © Replace the fuse The lamp does not light when the starting switch is turned on, terminal. 2-1 The lamp lights. 2. Ground the oil pressure switch 3-2 The does not light. © Replace the oil pressure (© Repair the lamp and wiring. Low oil pressure The lamp lights during 4, Low engine oil level © Check the oil pressure and make necessary repair, © Supply the oil engine operation 5. >. Defective oil pressure switch © Replace the switch and pressure switch 6. Grounding between the lamp. © Repair the wire harness.MEMO 132TROUBLESHOOTING Page TROUBLESHOOTING ..........0..0eceee eee eee eens 7-2 JUDGEMENT AND TREATMENT ACCORD- DING TO EXHAUST GAS OBSERVATION ......... 7-6 INJECTION NOZZLE... 0... 0ceseseee esse esse eran 7-8 INJECTION PUMP .........0ccsececeeeee seen neers 7-9 ENGINE ELECTRICAL .......... beeen eee 7-13 133 —7-2 TROUBLESHOOTING The following list shows causes of common troubles experienced in the engine and remedial actions, When a sign of trouble is encountered, take the proper action immediately before the trouble develops to a serious accident, Symptoms and possible causes Insufficient Power 1, Low compression (1) Incorrect valve clearance (2) Compression leak from valve seat (3), Valve stem sticking (4) Weak or broken valve spring (5) Compression leak from cylinder head gasket (6) Piston ring sticking or broken (7) Worn piston ring or cylinder 2. Defective fuel injection system (1) Incorrect injection timing (2) Defective nozzlets) (3) Carbon deposit in cylinder head antichamber 3. Defective fuel system (1) Clogged fuel filter element | (2) Air mixing in fuel system (3) Dirty fuel tank (4) Oil leak from fuel pipe (5) Degraded fuel pump performance (6). Incorrect injection pump discharge (7) Lack of discharge because of incorrect governor adjustment 4, Insufficient intake (1) Clogged air cleaner (2) Excessive valve clearance Remedial actions Adjust value clearance (0.2 mm){0.0079 in} Remove cylinder head and lap valves and seats, Correct or replace. Replace valve spring. Replace gasket. Replace piston rings. Overhaul or repair engine, Adjust injection timing. (B.T.D.C. 21° dwell) Adjust or repair nozzle(s). Remove carbon. Replace fuel filter element. Bleed air from piping Clean inside of tank Tighten or replace fuel pipe. Overhaul or repair fuel pump. Adjust injection pump on test bench. Readjust governor link. Clean or replace air cleaner element Adjust valve clearance (0.2 mm) (0.0079 in} ~ 134 ~Symptoms and possible causes Remedial actions 5. Overheating a (2) (3) (4) co) (6) a” (8) (9) (10) Replace with specified oil Lack of cooling water Worn or defective V-belt Defective water pump Clogged or leaky radiator Defective nozzle(s) Incorrect valve Excessive resistance in exhaust system Incorrect injection timing Defective radiator function earance Replace with specified oil Replenish cooling water Adjust or replace V-belt Replace water pump Clean, repair or replace radiator. Adjust or replace nozzle(s) Adjust valve clearance. (0.2 mm)(0.0079 in) Clean or replace exhaust system | Inspect and adjust injection timing Replace radiator Excessive Oil Consumption ay (2) (3) (4) (6) 6) a) (8) @) (10) ay (12) (13) (14) Loose oil pan drain plug Loose oil pan mounting bolts Loose gear case mounting bolts Defecti Defective cylinder head gasket Loose oil pump mounting bolts Loose oil pump joint bolts Defective oil filter body packing Worn valve stem guide or damaged stem oil seal Broken piston ring Defective positions of piston ring gaps Worn or sticky piston rings Remove mounting of piston rings Worn piston and cylinder liner crank oil seal [Difficult Starting 1. Slow cranking speed ay (2) (3) (4) Tooheavy engine oil Battery discharged or degraded per- formance, Defective connections of starter cables and ground strap Defective starter Retighten plug or replace packing Retighten mounting bolts Retighten mounting bolts Replace oil seal Replace gasket | Retighten mounting bolts Retighten joint bolts. Replace packing Replace valve stem guide or stem seal. Replace rings Replace or correct rings or replace connecting rod. Replace piston rings or piston. Correct ring mounting Replace piston or cylinder liner. | Replace with specified oil. Charge or replace battery. Clean and retrighten terminals, or replace cables. Repair or replace, — 135 —7-4 —————————— eee ‘Symptoms and possible causes Remedial actions 2. Defective fuel injection system (1) Fuel leak in fuel system Retighten or replace pipes. (2) Defective nozzles) Correct or replace nozzle(s). (3) Air mixing in fuel system Bleed air from fuel system. (4) Retarded injection timing Adjust injection timing, (5) Improper control rack operation Clean or repair. 3. Insufficient compression (1) Burnt valves or defective contact Lap or replace, | (2) Worn cylinder, piston and rings | Overhaul or repair engine, (3) Damaged cylinder head gasket Replace gasket (4) Defective antichamber packing Replace packing. (5) Defective installation of injection | Retighten or correct nozzle(s) nozzle(s) Engine Knocking 1. Diesel knock (1) Defective fuel injection from nozzles | Celan, adjsut or replace or insufficient injection pressure (2) Improper fuel (low cetane number) Replace fuel. (3) Incorrect nozzle installation Replace with correct nozzles (YDN—-OSDYD1) (4) Excessive injection pressure Adjust pressure (6) Insufficient compression pressure Overhaul or repair engine, (6) Incorrect injection timing (too fast) (7) Excessive cold or hot engine (8) Unbalanced fuel delviery Correct injection timing, Warm up engine or replace coolant Adjust injecion volume from injection pump (9) Incorrect valve clearance Adjust viave clearance {0.2 mm){0,0079 in} (10) Stick valves) Overhaul, repair or replace (11) Weak vaive spring(s) Replace springls) (12) Defective cylinder head gasket Replace gasket 2, Improper engine idling (1) Unbalanced fuel delivery for each Adjust injection pump injection volume cylinder (2) Improper control rack operation Clean, overhaul or repair (3) Improper governor link operation Repair or replace (4) Unbalanced spray or injection Adjust or repair pressure from nossles (5) Incorrect valve clearance Adjust valve clearance, (0.2 mm} (0.0079 in) (6) Defective contact of valve seat Lap valves. (7) Too low engine speed Adjust idling speed (to 800 rpm} {8) Too cold engine Warm up engine, — 136 —‘Symptoms and possible causes Remedial actions Engine Noises Since engine noises consits of various noises from |the rotating and sliding parts in addition to com- bustion noise, it is necessary to discharge each lsound by stopping injection by loosening the jection pipe retaining nut. 1. Crankshaft and main bearings (1) Excessive oil clearance because of worn bearings (2) Uneven wear of crankshaft journals (3) Burnt or flaked crankshaft bearings 2. Connecting rod and crank pin bearings (1) Worn crank pin bearings (2) Worn crank pin (3) Bent connecting rod (4) Burnt crank pin bearings 3. Piston, piston pin and piston rings (1), Excessive clearance because of worn cylinder liner. (2) Worn pistonts) or piston pin(s) (3) Secored piston(s) (4) Damaged piston rings 4, Others (1), Worn timing gear (2) Worn tappets {3) Excessive valve clearance Replace, Correct or replace. Replace Replace, Replace, Replace, Replace. Overhaul or repair engine. Replace piston and pins. Replace piston and piston rings Replace piston rings. Replace gears. Replace tappets, | Adjust valve clearance (0.2mm)(0.0079in) = 137 =7-6 SNe JUDGEMENT AND TREATMENT ACCORDING TO EXHAUST GAS OBSERVATION Symptoms and possible causes Difficult Starting tarting cranks engine, but no gas is exhausted, 1. No fuel to injection pump (1) Air in fuel pipe (2) Clogged fuel filter and fuel line (3) Degraded fuel pump performance 2. No pressurized fuel to nozzies | (1) Loose of cracked injection pipe(s) (2) Injection pipe rack not at injection position | (3) Failure of injection pump delivery Slight Gas Exhaust, but Failure in Starting 1, Lack of fuel injection volume (1) Lack of fuel pump delivery (2) Improper adjustment of governor link lExcessive Exhaust Gas, but Failure in Starting 1. Incorrect injection timing (1) Retarded injection timing 2. Poor spray status {1) Burnt nozzle(s) (2) Carbon deposit on nozzle needie Too low compressed air temperature (1) Incorrect valve clearance 3. (2) Improper valve seating (3) Lack of starter speed (4) Defective thermo-start function Improper fuel (1) Low cetane number (2) Water mixed in fuel Remedial a Bleed air, Clean or replace fuel filter and fuel line, Repair or replace. | Retighten or replace, Clean or overhaul. Replace valve. Repair or replace. Adjust or replace, Adjust injection timing Clean or replace. Clean, Adjust valve clearance (0.2 mm) (0.0079 in) Lap valves Repair or repalce battery or starter. Repair or repalce, Replace with special fuel. Replace with clean fuel. — 138 -Symptoms and possible causes Remedial actions Engine Starts but Lacks Power 1. Insufficient compression temperature 100 low compression pressure (1) Worn pistons, piston rings and cylinder lines (2) Improper valve seating (3) Incorrect vaive clearance (4) Insufficient tightening of injection nozzle(s) (6) Defective antichamber packing 2. Improper fuel grade or mixture of impurities in fuel (1) Low cetane number and high viscosity (2) Water mixture in fuel 3. Clogged muffler Black and Excessive Exhaust Gas at Starting 1. Too fast injection timing (1) Incorrect shim adjustment 2. Poor injection spray (1) Burnt nozzle valves) (2) Carbon deposit on nozzle vaivels) 3. Insufficient air intake (1) Clogged air cleaner (2) Excessive valve clearance 4, Unbalanced fuel injection volume (1) Improper adjustment of injection pump (2) Defective delivery valve operation (3) Broken delivery valve spring Overhaul or repair engine, Lap valves. | Adjust valve clearance (0.2 mm) (0.0079 in) Correct tightening, Replace, Replace with specified fuel. Replace fuel Clear. Add shims, inpsect and adjust. Replace nozzle valve(s} Clean or replace nozzle(s) Clean or replace element. ‘Adjust valve clearance (0.2 mm) {0.0079 in). Adjust injection volume by pump tester Replace, Replace. [Excessive Exhaust Gas during Driving 1. Excessive white exhaust ay (2) (3) (4) Excessively retarded injection timing Compression teak Water mixed in oil Excessive or insufficient engine oil (sometimes blush white or blackish grey) (5) Engine overcooling Inspect and adjust injection timing. Overhaul or repair engine Replace fuel. Inspect oil level. Overhaul or repair engine. Install radiator cover. = 139 -Symptoms and possible causes Remedial actions 2. Excessive black exhaust (1) Excessive injection volume (2) Unbalanced injection delivery (3) Insufficient intake air | (4) Improper fuel (5) Advanced injection timing (6) Excessive or insufficient oil Overload 7) Adjust injection pump Adjust injection pump, Clean or replace air cleaner element. Replace with specified fuel. Inspect and adjust injection timing, Inspect oil level. Overhaul or repair engine | Fleduce load, The engine troubles and remedial actions have been correct representation of the symptom is essential for INJECTION NOZZLE diagnosis is first possible through experience. It is important to correctly judge the symptom because cor explained by using various examples. Actually, the determination of correct remedial action, Symptoms and possible causes Remedial actions 1. Fuel leak (1) Loose injection nozzle spring retainer (2) Defective spring retainer packing (3) Loose overflow pipe bolt (4) Cracked overflow pipe Poor spraying (1) Defective nozzle seat contact (2) Foreign matter on nozzle seat (3) Damaged or dformed nozzle office (4) Nozzle needle and deformed Incorrect injection pressure (1) Incorrect injection pressure adjustment (2) Weak nozzle spring (3) Worn nozzle valve (4) (5) Deformed pressure adjustment shims Poor movement at sliding contact Portion (6) Fuel leakage 6) Retighten. Replace, Retighten, Replace, Replace Clean or replace. Replace. Replace. Adjust injection pressure: (160 + 5 kg/cm?) (2272 £71 psi) Adjust shims or replace. Replace, Adjust shims or replace, Correct or replace. Retighten or replace, = 140 -7-9 SS INJECTION PUMP Before inspecting the injection pump, it is necessary to make sure that other conditions besides the pump are normal. (1) Engine coolant temperature (2) Air bleeding from each pipe in fuel system (3) Operating conditions of injection nozzles (4) 5) (6) Inspection and cleaning of fuel filter No fuel leak from injection pipe (no crack) Air cleaner cleanliness (10) (4) (7) Fuel inspection (entrance of moisture and dirt, low cetane value) (8) (9) Compression pressure and difference between cylinders. Operating conditions of thermo-start Operating conditions of governor link Valve clearance inspection Symptoms and possible causes Remedial actions Engine !s Cranked But Not Started. 1. No exhaust (1) Control rack stops at non-injection position. (2) Air mixed in fuel pump 2. Will exhaust (1). Retarded injection timing Caution: Other than injection pump (1): Engine too cold (2): Small air entrance (3): Detective nozzle injection (7): Defective fue! Clean if foreign matters are trapped. In other cases, remove and repair the pump. Bloed air. Inspect and adjust injection timing. Drain coolant and use hot water. Bleed air. Adjust or replace nozzle Clean fuel or replace with fuel having high cetane number. (1) Incorrect injection timing (2) Excessive unbalance of fuel injection (3) Heavy sliding of control rack | (4) Defective function of delivery valve Caution Other than pump {1}: Engine too cold (2): Oil leak from injection pipe (3): Defective injection nozzle function (4): Air entrance in injection pipe (7): Excessive water or dirt in fuel (9): Insufficient compression Overhaul or repair engine. pressure (10): insufficient function of thermo- | Repair or replace start Difficult Idling 1. Hunting Inspect and adjust injection timing, Remove and adjust pump. Remove and adjust pump. Replace delivery valve, Warm up engine. Tighten or replace pipe. Adjust or replace nozzle, Bleed air. Replace with clean fuel. = 1412. Symptoms and possible causes (8): Incorrect valve clearance (9): Excessive difference in compres- sion pressure between cylinders (11): Defective contact or function of of governor link Low engine speed is not maintained (1) Heavy sliding of injection pump control rack Caution If the cause is other than injection pump, defective setting of accelarator rod or wire, Remedial actions Adjust valve clearance (0.2 mm){0,0079 in) Overhaul or repair engine. Correct. Remove, disassernble and repair pump. Correct. Will Not Reach Maximum Revolution 1 No-load condition (1) Retarded injection timing (2) Defective function of plunger (broken spring, etc.) Caution Other than inje: ion pump, (2): Air mixed in fuel system (3): Defective injection nozzle function (4): Leak from injection pipe (5): Defective air cleaner (6): Clogged fuel filter (7); Defective fuel (11): Defective governor link function At full load or during travel (1) Insufficient injection volume (rack resetting) (2) Defective plunger operation (3) Retarded injection timing (4). Defective injection pump function Caution Other than injection pump. (1): Engine too cold (2): Air mixed in fuel system (3): Defective injection nozzle function (4): Leak from injection pipe (5): Clogged air cleaner (6): Clogged fuel filter (7): Defective fuel (8): Insufficient valve clearance (11): Defective governor link function Inspect and adjust injection timing, Remove, disassemble and repair pump. Bleed air. Adjust or replace nozzle Retighten or replace injection pipe. Clean or replace filter element. Clean or replace filter element. Replace with clean fuel, Correct or replace governor link Readjust governor link Disassemble and repair pump. Inspect and adjust injection timing, Disassemble and repair pump. Cover radiator and warm up engine, Bleed air Adjust or replace nozzle Retighten or replace pipe. Clean or replace filter element. Clean or replace filter element. Replace fuel oil. Adjust valve clearance, Correct — 142 -7-11 ee ‘Symptoms and possible causes Remedial actions Insufficient Power (1) Insufficient injection volume (rack setting) (2) Incorrect injection timing (3) Defective injection pump function (4) Defective plunger function (broken spring, etc.) Caution Other than injection pump. (1): Engine too cold (2): Air mixed in fuel system (3): Defective injection nozzle function (4): Leak from injection pipe (6): Clogged air cleaner (6): Clogged oil filter (7): Defective fuel (8): Insufficient valve clearance (9): Insufficient compression pressure (11): Defective governor fink adjustment Readjust governor link, Inspect and adjust injection timing. Disassemble and repair pump, Disassemble and repair pump. Cover radiator and warm up. Bleed air. Adjust or replace nozzle Retighten or replace pipe. Clean or replace filter element, Clean or replace filter element, Replace fuel Adjust valve clearance. Disaasemble and repair engine. Readjust governor link. Excessive Black Exhaust (1) Incorrect injection timing (2) Unbalanced injection volume Caution: Other than injection pump (3): Defective injection pump function (incorrect spraying) (6): Clogged air cleaner (7): Defective fuel (9): Insufficient compression pressure (excessive oil) [Excessive White Exhaust (1), Retarded injection timing Caution: Other than injection pump (1): Engine too cold (7): Moisture mixed in fuel (9): Low compression pressure (worm rings and cylinder) Adjust injection timing Remove pump and adjust injection volume. Adjust or replace nozzle(s). Clean or replace filter element. Replace with clean fuel Disassemble and repair engine Inspect and adjust injection timing Cover radiator and warm up engine. Replace with aclean fuel, Disassemble and repair engine. 143 —Symptoms and possible causes Remedial actions Diesel Knock | (1) Advanced injection timing (2) Unbalanced injection volume Caution: Other than injection pump (1): Engine too cold (3): Defective nozzle spraying (excessive injection pressure} (7): Low cetane number (9}: Low compression pressure il Pressure Warming Lamp Does Not Go ff During Engine Operation. (1) Insufficient engine oil (2) Defective oil pressure switch (3) Grounded between lamp and pressure switch (4) Too low oil pressure (excessive oil clearance) (5) Defective oil pump relief valve. ing | Inspect and adjust iniection timing, Remove and adjust pump. Cover radiator and warm up engine. Adjust or replace nozzle Replace with fuel having high cetane number. Dis issemble and repair engine, Replenish oil. Replenish switch Repair Inspect oil pressure and repair, Inspect and repair relief valve. (6) Excessive bearing oil clearance Replace. |Too Low Oil Discharge Pressure (1) Loose oil pump cover installation Retighten. (2) Defective oil pump O-ring Replace. (3) Excessive clearance between pump outer | Replace. rotor and body (4) Excessive clearance between outer and Replace. inner rotors. (5) Excessive pump side clearance, Replace. Overheating (1) Insufficient coolant (2) Loose V-belt (3) Oil adhesion on V-belt, (4) Clogged coolant passage (5) Incorrect injection timing {6) Brake dragging Replenish coolant, or inspect and repair leak. Adjsut V-belt tension, Replace V-belt, Clean radiator and coolant passage. Adjust injection timing. Adjust brakes. - 144 —7-13 (7), Defective water pump function (8) Defective radiator function Symptoms and possible causes Remedial actions Repair pump. Replace. lOvercooling (Coolant Temperature Does _ Not Rise.) (1) Extremely cold atmospheric temperature Decrease exposed area of radiator. Loss of Coolant {1} Leak from radiator (2) Loose or damaged radiator connections (3) Leak from water pump (4) Leak trom cylinder head gasket (5) Cracked cylinder head or block (6) Defective radiator cap (continuous valve opening) Noisy Coolant System (1) Defective water pump bearing (2) Loose of deformed fan (3) Loose or damaged V-belt (4) Damaged water pump seal WL ENGINE ELECTRICAL Symptoms and possible causes ‘Starter Does Not Rotate Or Rotates Too Slowly, Failing To Start Engine | 1, Battery (1) Defective batterterminal contact. (2) Defective battery cable grounding (3) Too low voltage by overdischarge (4) Insufficient voltage by battery defect Starting switch (1) Defective contact of starting switch points. (2) Defective switch connector Repair on replace radiator | Retighten hose clamps or replace hose(s). Replace water pump. Retighten cylinder head bolts or replace gasket. Replace head or block. Replace radiator cap. | Replace bearing, Retighten or replace fan. Adiust or replace V-belt, Replace seal Remedial actions Clean contact surface and retighten. Clean and correct. Charge battery. Replace battery. Replace switch. Correct.7-14 Symptoms and possible causes Remedial actions 3. Magent switch (1) Defective terminal wire and connection (2) Burnt or faulty contact of switch contact plate (3) Opened pull-in coil circuit (4) Opened holding coil circuit | 4. Starter aSSY (1) Faulty brush contact (2) Weak brush spring(s) (3) Grounded field coil (4) Defective soldering of field coil connection (5) Burnt commutator (6) High commutator mica (7) Grounded armature Correct Replace switch Replace switch. Replace switch, Dress or replace. Replace spring(s) Replace field coil Correct Correct Under-cut mica, Replace armature. (8) Other worn parts Replace. IStarter keeps Rotating or Hardly Stops 1. Starting switch (1) Switchreturning failure Replace. (2) Short circuit in switch Replace. \ 2. Magent switch (1) Contact plate fusion Replace. (2) Shorted coil layers Replace. [Starter Rotates but Engine Does Not Start 1. Starter ASSY (1) Clutch slipping (2) Worn pinion end (3). Defective spline sliding (4) Worn bushing (5) Worn or missing starter driver lever (6) Damaged clutch gear. (7) Worn or damaged ring gear Replace clutch, Replace clutch, Correct or replace. Replace, Correct or replace. Replace. Replace.‘Symptoms and possible causes | 2. Magent switch | (1) Opened holding coil circuit 3, Non-ignition despite current conduction to thermo-start (1) Faulty switch contact ! (2) Open-circuit of preheating or ignition | coil | (3) Open-circuit of solenoid coil (4) Faulty contact at wiring terminals(s) (5) Clogged fuel pipe (6) Defective plunger function (7) Fuel leak at fuel pipe joint Charging System 1, Battery overdischarge (1) Loose V-belt (2) Grounding or open-circuit of stator coil (3) Open-circuit in rotor coil | (4) Defective contact at brush and slip ring (5) Defective alternator rectifier (8) Too low regulated voltage (7) Defective contact at regulator low speed point (8) Fusion at regulator high speed point | (9) Insufficient or improper battery fluid (10) Defective battery electrode (internal shorting) (11) Defective battery terminal contact (12) Open-circuit or defective contact between starting switch and regulator 1G terminal (13) Open-circuit or defective contact between alternator F terminal and regulator F terminal (14) Open-circuit or defective contact between N terminal and regulator N terminal (15) Excessive electrical load 2. Battery overcharge (1) Defective battery € terminal (2) Open-circuit of voltage regulator pressure coil Remedial actions Replace, Replace, Replace, Replace. Inspect and correct Inspect and correct. Replace, Retighten or correct. Adjust V-belt tension Replace stator. Replace rotor. Repalce brushes and clean brush holder Replace rectifier Adjust regulator. Dress the point. Replace regulator. Replenish distilled water and adjust specific gravity Replace battery. Clean and retighten. Correct Correct Correct Check current capacity, Correct Replace regulator. — 147 -7-16 Symptoms and possible causes Remedial actions 3. (3) Fusion of regulator low-speed point (4) Faulty contact of regulator high-speed point (5) Too high setting of regulated voltage Charge warning lamp indication error (1) Loose V-belt (2) Loose wire harness connection (3). Defective regulator point function Abnormal noise generation from alternator (1). Defective bearing (2). Defective rectifier function (3) Grounding or layer shorting of stator coil Replace regulator Dress point. Adjust regulator. Adjust V-belt tension. Correct Replace regulator. Replace bearing. Replace rectifier. Replace stator. = 148 -MAINTENANCE STANDARDS MAIN COMPONENTS TIGHTENING TORQUES ........:csseeeeeeeeneee 8-2 LUBRICANT AND CAPACITY . ENGINE ADJUSTMENT STANDARDS ..........----+ 8-3 ENGINE ASSY FUEL SYSTEM LUBRICATING OIL SYSTEM..........0seeeeeeeenee 8-8 COOLING SYSTEM ....... 6... cece cece ee eee eee 8-8 ELECTRIC EQUIPMENT a8 SPECIAL SERVICE TOOLS (SST) .....-...-+ see eeeee 8-11 — 149 —8-2 _—_——— MAIN COMPONENTS TIGHTENING TORQUES Tightening location Nominal size | Tightening torque{K9iem = Tightening location 12 500 ~ 550 (36.5~40) Cylinder head tightening Bolts and ruts | Main bolt 12 1300 ~ 1400 (95~102) Auxiliary bolt 8 250 ~ 300 (18.3~21.9) Rod bolt 9 450 ~ 500 (32.9~36.5) Center bearing upper and lower tightening bolt 10 450 ~_500 (32.9~36.5) Center bearing set bolt 12 700 ~ 750 (51.1~54.8) Bearing set bolt 8 250 ~ 270 (18.3~19.7} Flywheel bolt 10 650 ~ 700 (47.3~651.1) Rocker arm support lock nut 10 450 ~ 500 (32.9~36.5} 18 600 ~ 700 (43.8~51.1) 18 600 ~ 700 (43.8~51.1) 8 250 ~ 270 (18.3~19.7) 8 250 ~_270 (18.3~19.7) 28 1100 ~ 1150 (80~84) 0 450 ~ 500 (32.9~36.5) 6 80 ~ 100 (5.84~7.3) 6 100 ~ 120 (7.3~8.76) 8 150 ~~ 1/0 (1i~12.4) 8 250 ~ 270 (18.3~19.7) 0. 4 6 8 Crankshaft V-pulley lock nut Fuel cam and cam gear tightening nut Gear case set bolt Injection pump set bolt and nut Crankshaft gear tightening nut Starter set nut Oil pan set bolt Oil pump set bolt Camshaft bearing hulding cross recessed head screw Water pump housing set bolt Mounting flange set bolt 550 ~ 600 (40~51.1) 20~ 35 11.46~2.56) 80 ~ 100 (5.84~7.3) =/=/=|=/=|=]=|=]=|=]2)=/=)z]z/z)e/ele/elelelelel/slsl=e Other bolts 250 ~ 270 (18.3~19.7) 10 450 ~ 500 (29.2~36.5) 12 700 ~ 750 (51.1~54.8) 8 120 ~ 170 (8.8~12.4) Union bolts, 10 200 ~ 300 (14.6~21.9) 12 250 ~ 350 (18.3~25.6) Caution: © Coat oil on threaded parts and seats, and make sure no foreign matter adhesion or damage exists on threaded parts before tightening bolts and nuts. © When tightening 2 or more nuts and bolts, gradually and alternately tighten them to prevent uneven tightening. = 150 —LUBRICANT & CAPACITY Location Capacity ‘Type of lubricant Engine 2.3 2 (0.61 USgal) Toyota genuine oil, API CD class or above ENGINE ADJUSTMENT STANDARDS Fluid level 10 ~ 20 mm (0,39 ~ 0.79 in.) (above electrodes) Battery Specific gravity —_ 1,280 (20°C) (Change if below 1.20 or if the “| difference between calls is over 0.025.) a | Oitpan capacity 1.0.8 (0.264 USgall (effective capacity) Overall capacity About 2.32 (0.61 USgal) = Capacity "| About 1.5 liters (0.4 USgal) (engine ASSY) | Coolant Radigtor cap vane | Limit | OS kglom? (7.1 psi) opening pressure | Standard 0.9 kg/cm? (12.8 psi) V-belt fiexirure 1 10~15 mm (0.39 ~ 0.59 in.) (10 kg) (22 lbs) | Fuel injection timing (degreed BTDC)/as installed 21° (start of discharge from delivery valve) Idling rpm 800 rpm Limit - 30 kg/em? (426 psi) (250 rpm) Compression | Standard ~_35 kg/em? (497 psi) (250 rpm) Difference between cylinders ‘Average # 5% (250 rpm) Valve clearance (cold), both intake and suction "0.2mm (0.0079 in.) _ Engine oil pressure (at idling rpm with oil 3 ; Engine of presse) 1.5 kg/cm? (21.3 psi) or more | Maximum no-load rpm 3150 £50 rpm Note: Engine oil pressure shall be measured at oil pressure switch: ENGINE ASSY Warpage limit at bottom surface of cylinder head 0.03 mm (0.0012 in.) Contact width 1.77 mm {0.00697 in.) Valve seat Contact angle 45° L Surface correction angles ieweanToH VALVE GUIDES [Outside diameter 7 12mm (0.47 in.) Protrusion above head (from valve spring installing surface) 7mm (0.275 in.) —— — Limit (both intake and exhaust) 0.13 mm (0.005 in.) stem and guide: Stendard Intake 7 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in.) Exhaust 0.050 ~ 0.075 mm (0.0018 ~ 0.028 in.) — 191 -84 a VALVES Intake 32 mm (1.26 in.) Head diameter Exhaust 27 mm (1,063 in.) Intake 94.75 mm (3.73 in.) Overall length Exhaust 94.75 mm (3.73 in.) Intake 97 mm (0.276 in.) Steam diameter Exhaust 7 mm (0.276 in.) Valve contact angle 45° Stem and grinding limit 0.3 mm (0.012in.) Head thickness limit 0.7 mm (0.07 in.) VALVE SPRINGS Free length 38.5 mm (1.52 in.) installed length 28.2 mm (1.15 in.) Installed load limit 15.6 kg (34.32 Ibs) Installed load 16.2 kg (35.6 Ibs) Rectangularity limit 1.22 mm (0,048 in. CYLINDER BLOCK Cylinder block top surface warpage limit 0.03 mm (0.0012 in.) Tappet hole inside diameter 10 mm (0.39 in.) Cylinder bore 76.000 ~ 75.035 mm (2.953 ~ 2.954 in.) Cylinder bore Maximum wear limit 0.1 mm (0.0039 in.) Cylinder bore difference 0.08 mn (0.00718 in.) Cylinder liner protrusion 0,005 ~ 0.075 mm (0.000197 ~ 0.00298 in.) CONNECTING ROD Bend limit 0.03 mm (0.00118 in.) Twist fimit 0.08 mm (0.00118 in.) Large end thrust clearance Limit csoae am Standard 0.2~0.4 mm (0.0079 ~ 0.0187 in.) en an ree een smal on pinion 0.025 ~ 0.047 mm (0.0098 ~ 0.00185 in.) Connecting rod bearing oll Limit 0.13 mm (0.005 in.} leerance Standard 0.036 ~ 0,092 mm (0.00142 ~ 0.00362 in.) — 152 -8-5 PISTON AND PISTON RINGS Piston Piston diameter 74.913 ~ 74.943 mm (2.949 ~ 2.950 in.) Clearance between piston and cylinder fat dkict) 0.057 ~ 0.117 mm (0.0022 ~ 0.0046 in.) Piston pin bore $ 22.995 ~ 23.008 mm (0.9053 ~ 0.9058 in.) Piston pin diameter ¢ 22.995 ~ 23.000 mm (0.9053 ~ 0.9056 in.) Fittingallowance between pin bore and pin +0.017~=0.005 mm (+0.00067~—0,.0002in.) Pin fitting temperature BOC ~ 60°C Piston ring Compression |No. 1 0.2~ 0.4 mm (0.0079 ~ 0.016 in.) End gap ring No.2 0.2~ 0.4 mm (0.0079 ~ 0.016 in} Oil ring 0.2~ 0.4 mm (0.0079 ~ 0.076 in.) a Spmoresion [No.1 10,065 ~ 0.100 mm (0.00256 ~ 0.0039 in.) ‘tween ring and No.2 0,035 ~ 0.070 mm (0.0014 ~ 0.0028 in.) oad Oil ring (0,020 ~ 0.055 mm (0.00079 ~ 0.0022 in.) TIMING GEAR Crankshaft gear and camshaft gear_| 0.086 ~ 0.13 mm (0.0034 ~0.0051 in.) Gear backlash Crankshaft gear and oi! pump gear 0.086 ~ 0.13 mm (0.0034 ~ 0.051 in.) VALVE ROCKER ARM AND SUPPORT Rocker arm shaft diameter limit, @ 13.9 mm (0.547 in.) Rocker arm bushing bore limit 9 14.1 mm (0.555 in.) Clearance between rocker arm |_Limit DiS amnl(O.008 i bushing and shaft Standard 0.016 ~ 0,052 mm (0.00063 ~ 0,0020 in.} TAPPET AND PUSH ROD Tappet diameter 10 mm (0.39 in.) Clearance between cylinder block |_Limit 0.08 mm {0.00314 in.) ‘tappet hole and tappet Standard 0.005 ~ 0.035 mm (0.000197 ~ 0.00138 in.) Push rod bend limit 0.3 mm {0.012 in.) — 153 —8-6 es CRANK SHAFT Limit 0:30 mn (0.012 in.) Thrust clearance Standard (0.085 ~ 0.175 mm (0.0035 ~ 0.0069 in.) Center main bearing standard width 30 mm (1.18 in.) Gear side and intermediate @ 47 mm (7.85 in.) uma Flywheel side 9 65 mm (2.56 in.) Seema ps Timit 0.18 mm (0.0059 in.) Oil clearance Standard 0.036 ~ 0.092 mm (0.0014 ~ 0,0036 in.) Journal and crak pin: Taparand out-ofround limit 0.02 mm (0.00079 in.) Standard outside diameter 9 44 mm {1.73 in.) area Limit 0.13 mm (0.006 in.) Oil clearance Standard 0.036 ~ 0.092 mm (0.00742 ~ 0.00362 in.) FLY WHEEL Flun-out limit 0.1 mm (0.0039 in.) CAM SHAFT Bend limit (0.02 mm (0.00079 in.) Flywheel side 30. mm (1.18 in.) Cam shaft i Gear Case side 42.5 mm (67 im] eed oenaed | Mueeroenena Flywheel side 41.5 mm (7.63 in.) Fh ~ S Oil clearance lywheel side 0.040 ~ 0.085 mm (0.0016 ~ 0.0033 in.) Intermediate 0.050 ~ 0.100 mm (0.00197 ~ 0.0039 in.) M 4 1A: 5 Cam height limit ntake/exhaust valve cam 34.4 mm (1.35 in.) Fuel cam 44.5 mm (1.76 in.) andr am Intake/exhaust valve cam 36.0 mm (1.38 in.) ae Fuel cam 45.0 mm (1.77 in.) FUEL SYSTEM INJECTION PUMP Cam lift 7.0 mm (0.276 in.) Plunger diameter 6.5 mm (0.266 in.) Injection order 1-2 Control rack sliding resistance (pump stalled) Less than 60g (0.132 Ibs) Plunger top clearance 1.0 + 0.05 mm (0.039 + 0.00197 mm} Plunger position adjusting shim thickness 0.1 mm (0.0039 me of mm (0.0079 in.) inds Free length 35.50 mm (1.398 in.) Plunger spring Installed length 29.50 mm (1.16 in.) Installed load 11.59 kg (0.456 in.) Free lengih 21.00 mm (0.827 in.) Detivery valve | Installed length 17.25 mm (0.68 in.) Installed load 2.40 kg (5.28 Ibs) - 18487 —— INJECTION PUMP PRESSURE ADJUSTMENT AND TEST Plunger pressure (Pump at 200 rpm and rack at rack ‘mark position) Over 300 kg {4260 psi)/cm? Delivery valve pressure (Raised to 120 ka/em?, and 10 kg/cm? drop from 100 kg/cm?) Over 5 seconds for deliyery retainer internal to drop 10kg (142 psifem (rack at 0 mm position) INJECTION VOLUME ADJUSTMENT Rack position Pack at rack mark Rack at 2mm short of mark Remark Pump speed (rom) 1500 1500 Number of strokes 1000 1000 Variation limit 1 1 Conditions Nozzle YON-OSDYD1 Nozzle opening pressure 160 kg (2272 psi) ‘em? High pressure pipe 96x 91.5 x 680 mm (0.236 x 0.059 x 26.8 in.) Fuel pressure 0.5 kg {7.1 psi)/cm? INJECTION PIPE Overall length x Outside diameter x Inside diameter 680 mm x ¢6 mm x 9 1.5 mm (26.8 in. x 0.236 in. x 0.059 in.) INJECTION NOZZLE Model YDN-OSDYD1 Nozle Type. Throitle Valve opening pressure 160+ 5 kg/cm? (2272 + 71 psil Injection angle 18° Injection pressure adjustment shim thickness 0.1 mm (0.0039 in.}, 0.2 mm (0.0079 in.), 0.3 mm (0.012 in.}, 0.5 mm (0.0197 in.) (4 kinds) LUBRICATING OIL SYSTEM OIL PUMP AND OIL FILTER Pump type Trochoid Discharge rate 13.2/ min (3.43 USgai/min) Fi , Oil temperature 100°C aa aan Discharge pressure B kg/cm? (42.6 psi) Revolving speed 2600 rpm Clearance between Limit 0.25 mm (0.0098 in.) Suier rotor Standard 0:70 ~ 0.16 mm (0.0039 ~ 0.0063 in.] Clearance between. Limit 0.25 mm (0.098 in.) outer and inner rotors |” Standard 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.) Bods iter rot id iinet rotor side oP |_Limit 0.18 mm (0.0089 in.) clearance Standard 0.03 ~ 0,09 mm (0.0012 ~ 0.0035 in.) Relief valve opening pressure 4.0 £ 0.6 kg/cm? (56.8 + 7.1 psi) Filtration type Full-flow filtering paper type Filter valve opening pressure 1.0 #0.2 kg/cm? (14.2 + 2.8 psi) = 155 ~8. COOLING SYSTEM RADIATOR Overall coolant capacity 2.9 2 (0.766 USgal) Coolant capacity (engine ASSY) 1.35 2 (0.36 USgal) Limit 0.5 kg/cm? (7.1 psi) Radiator cap valve opening pressure Standard 0.9 + 0.15 kg/cm? (12.8 £ 2.13 psi) WATER PUMP Discharge rate 25 &Imin or more (6.6 USgal/min or more) Pump performance Revolving speed Water temperature 3250 rpm THERMOSTAT Valve opening Initial openingtemperature | mC eee Full opening temperature 85°C Valve stroke 7 8 mm (0.31 in.) ELECTRIC EQUIPMENT STARTER Rated output - 1.4 KW lees 7 | Voltage BV No-load characteristics Current 90A Perfor- Revolving speed | 3600 rpm or more mance Vottage 24V Locked characteristics Current 400 A or less. Torque il 1.1 kam (8 ftlb) ALTERNATOR Rated output —__28A (at 14 V, in hot state) ‘| No-load rpm 1250 rpm (at 14 V, in hot state) Output speed 4000 rpm or less (at 14 V, 25 A in cold state) | } — 156 ~REGULATOR Regulated voltage 13.5~ 145V Cutin voltage 4~58Vv Armature gap more 0.3 mm (0.012 in.) Point gap 0.30 ~ 0.45 mm (0.012 ~ 0.018 in.) Voltage regulator Contact spring flexure 0.2~0.6 mm (0.0079 ~ 0.024 in.) Angle gap more than 0.2 mm Point gap 0.4 ~ 1.2 mm (0.016 ~ 0.047 in.) Charge relay Contact spring flexure 0.2~ 0.6 mm (0.0079 ~ 0.024 in.) THERMO-START Rated voltage 12V Thermo. | Current consumption 14A start Fuel flow rate (at 20° C ambient plu¢ 1.2~ 1.7 celmin a temperature, fuel head: 100 mm) Ignition timing Within 9.5 seconds (—20°C) Lamp off time 9.5 seconds (DC 12 V at 20°C) Control | Fuel cutoff time 10 seconds unit Source voltage vari 6~13V Pilot lamp capacity 12V-3W Header tank Approx. 50 cc BATTERY Rated voltage 12V Capacity 45 AH Battery fluid specific gravity (at 12°C) 1.280 Limit specific gravity difference between cells 0.025 max. — 187 —10 SPECIAL SERVICE TOOLS (SST) Part No. Name Use ry | Remarks| ec aw Crankshaft gear nut removal 1 Oe inaaauad (naeencans nut wrench and installation 1 Crank main bearing 2 | 08020-41840.71 Main bearing replcer | Sta cnt 1 set 3 09201-40010 Valve guide replacer Valve guide replacement 1 Piston pin bushing 4 09222-40011 Piston pin bushing replacer replacement 1 | | 5 |09010-41840-71 | Compression gauge adapter | FOr compression pressure | 4 1 2 3 — 158 —Prepared by TOYOTA MOTOR CORPORATION No. 23-22 Izumi 1-chome, Higashi-ku Nagoya, Japan April 1983 No. 95689 Printed in Japan