Manual Servico TV Sony KDL 60W600B Chassis RB2G

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RM582E 2L, 2L-T, 3L & 5L Pages From Supplement

FOREWORD
TOYOTA MOTOR CORPORATION TO MODEL INDEX
This SUPPLEMENT has been prepared to provide information covering general service repairs for the
2L, 2L-T, 3L and 5L ENGINES equipped on the TOYOTA HILUX.
Applicable models: LN141, 145, 146, 147, 150, 152, 165, 166, 167, 170, 171, 172, 191 series
For the service specifications and repair procedures of the above model other than those listed in this supple-
ment, refer to the following manuals.
Manual Name Pub. No.
S 2L, 3L Engine Repair Manual RM520E
S HILUX Electrical Wiring Diagram EWD307F
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
1997 TOYOTA MOTOR CORPORATION
All rights reserved. This CD may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Aug. 8, 1997 01-- 970808-- 00
CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non--specialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.
S Must read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of ”IN” section.
S The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using non--specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.
S If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
BACK TO MAIN FOREWORD & Engine Index 2L, 2L-T, 3L & 5L Pages From Supplement
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MAIN INDEX: HILUX

SUPPLEMENT: 2L, 2L-T, 3L & 5L ENGINES
August 1997
INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
ENGINE MECHANICAL
TURBOCHARGER TC
ENGINE FUEL
COOLING
LUBRICATION
STARTING
CHARGING
ALPHABETICAL INDEX
BACK TO MAIN INDEX 2L, 2L-T, 3L & 5L Pages From Supplement
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INTRODUCTION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . IN-- 1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . IN -- 1
IDENTIFICATION INFORMATION . . . . . . . . . . IN-- 3
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . IN -- 3
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . IN-- 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . IN -- 4
FOR ALL OF VEHICLES . . . . . . . . . . . . . . . . . . IN-- 7
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN -- 7
TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-- 8
ABBREVIATIONS USED IN THIS MANUAL . . . . IN -- 8
CLICK HERE TO VIEW CHAPTER INDEX 2L, 2L-T, 3L & 5L Pages From Supplement
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IN--1
INTRODUCTION -- HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL

IN001--04
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the Section Title and major heading are given at the top of every
page.
2. GENERAL DESCRIPTION
At the beginning of each section, a General Description is given that pertains to all repair operations con-
tained in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
Intake Air Control Valve
14.5 (145, 10)
z Gasket
Bracket
Actuator Vacuum Hose

Check
Connector
Ground Strap
CONTINUED
Ground Cable
N∙m (kgf∙cm, ft∙lbf) : Specified torque

z Non--reusable part
S05108
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IN--2
INTRODUCTION -- HOW TO USE THIS MANUAL
The procedures are presented in a step--by--step format:

S The illustration shows what to do and where to do it.
S The task heading tells what to do.
S The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
Task heading : what to do
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a) Place SST and a dial indicator onto the overdrive brake
Piston as shown in the illustration.
SST 09350--30020 (09350--06120)
Illustration:
what to do and where Set part No. Component part No.
Detailed text : how to do task
(b) Measure the stroke applying and releasing the compressed
air (392 — 785 kPa, 4 — 8 kgf/cm2 or 57 — 114 psi) as shown
in the illustration.
Piston stroke: 1.40 — 1.70 mm (0.0551 — 0.0669 in.)
Specification
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section, for quick
reference.
8. CAUTIONS, NOTICES, HINTS:
S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
S NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
S HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N∙m (310 kgf∙cm, 22 ft∙lbf)
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IN--3
INTRODUCTION -- IDENTIFICATION INFORMATION
IDENTIFICATION INFORMATION IN00Q--03
ENGINE SERIAL NUMBER

The engine serial number is stamped on the engine block as
shown.
B01898
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IN--4
INTRODUCTION -- REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS IN003--04
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
P23717 (c) Observe the following:
(1) Before performing electrical work, disconnect the
negative (--) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the negative
(--) terminal cable which is grounded to the vehicle
body.
(3) To prevent damage to the battery terminal, loosen
the cable nut and raise the cable straight up without
twisting or prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals with
the nut loose, and tighten the nut after installation.
Do not use a hammer to tap the cable ends onto the
terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are secure and correct.
(e) Non--reusable parts
(1) Always replace cotter pins, gaskets, O--rings and oil
seals etc. with new ones.
(2) Non--reusable parts are indicated in the component
illustrations by the ”z” symbol.
(f) Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
(3) Precoated parts are indicated in the component il-
lustrations by the ”L” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
CONTINUED
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IN--5
(h) Carefully observe all specifications for bolt tightening

torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in the preparation part at the front
of each section in this manual.
(j) When replacing fuses, be sure the new fuse has the cor-
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
BE1367
Illustration Symbol Part Name Abbreviation
FUSE FUSE
MEDIUM CURRENT FUSE M--FUSE
HIGH CURRENT FUSE H--FUSE
FUSIBLE LINK FL
CIRCUIT BREAKER CB
V00076
(k) Care must be taken when jacking up and supporting the

vehicle. Be sure to lift and support the vehicle at the prop-
er locations.
(1) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels at the opposite
end in order to ensure safety.
(2) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on a vehicle raised on a jack alone, even for a small
job that can be finished quickly.
CONTINUED
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IN--6
(l) Observe the following precautions to avoid damage to the

following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull on the end, not

WRONG CORRECT the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
IN0253 tronic components, air filter and emissions--related
components from water.
(6) Never use an impact wrench to remove or install
WRONG CORRECT
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step--down
adapter instead. Once the hose has been
IN0252 stretched, it may leak.
Example (m) Tag hoses before disconnecting them:

(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20˚C (68˚F). Because the resis-
IN0002 tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurements should be made when the engine
has cooled down.
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IN--7
INTRODUCTION -- FOR ALL OF VEHICLES
FOR ALL OF VEHICLES

IN00R--02
PRECAUTION
IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two--way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle’s electronics systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Do not wind the antenna feeder together with the other wiring. As much as possible, also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Confirm that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
TO MODEL INDEX
IN--8
INTRODUCTION -- TERMS
TERMS
IN00S--03
ABBREVIATIONS USED IN THIS MANUAL

Abbreviations Meaning
A/C Air Conditioner
ACSD Automatic Cold Start Device
BTDC Before Top Dead Center
ECU Electronic Control Unit
HAC High Altitude Compensator
IG Ignition
LH Left--Hand
O/S Oversize
PCV Positive Crankcase Ventilation
RH Right--Hand
SSM Special Service Materials
SST Special Service Tools
TCV Timing Control Valve
TDC Top Dead Center
U/S Undersize
VSV Vacuum Switch Valve
w/ With
w/ o Without
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PREPARATION
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . PP-- 1

TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . PP-- 5
ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-- 7
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-- 11
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-- 14
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-- 15
REFER TO 2L, 3L ENGINE REPAIR MANUAL (Pub No.

RM520E)
NOTE: The above pages contain only the points which differ
from the above listed manual.
TO MODEL INDEX
PP--1
PREPARATION -- ENGINE MECHANICAL
ENGINE MECHANICAL
SST (Special Service Tools)
09222--54011 Connecting Rod Bushing Remover
& Replacer
(09222--03016) Remover & Replacer 2L--T, 3L, 5L
(09222--03021) Guide 2L--T, 3L, 5L
(09222--03026) Base 2L--T, 3L, 5L
09222--64012 Connecting Rod Bushing Remover

& Replacer
(09222--02022) Remover & Replacer 2L
(09222--02031) Guide 2L
(09222--02041) Base 2L
09275--54011 Plunger Stroke Measuring Tool
09275--54020 Maximum Speed Adjusting Screw 2L--T, w/ HAC

Lock Nut Wrench
09992--00025 Cylinder Compression Check Gauge

Set
(09992--00121) No. 4 Attachment
(09992--00211) Gauge Assy

TO MODEL INDEX
PP--3
Page PP-2 combined with PP-1 PREPARATION -- ENGINE MECHANICAL
PP0DH--01
RECOMMENDED TOOLS
09082--00040 TOYOTA Electrical Tester. VSV for intake sutter (5L)
09200--00010 Engine Adjust Kit .

TO MODEL INDEX
PP--4
PREPARATION -- ENGINE MECHANICAL
PP0DI--01
EQUIPMENT
Caliper gauge
Cylinder gauge
Dial indicator
Engine tune--up tester
Micrometer
Pin hole grinder
Piston ring expander
Plastigage
Round file
Torque wrench
Vacuum gauge
TO MODEL INDEX
PP--5
PREPARATION -- TURBOCHARGING
TURBOCHARGING
PP0DJ--01

09992--00242 Turbocharger Pressure Gauge
TO MODEL INDEX
PP--6
PREPARATION -- TURBOCHARGING
PP0DK--01
EQUIPMENT
Dial indicator
Torque wrench
TO MODEL INDEX
PP--7
PREPARATION -- ENGINE FUEL
ENGINE FUEL
PP0DL--01

09228--64030 Fuel Filter Wrench Europe
09228--64040 Fuel Filter Wrench Except Europe
09236--00101 Water Pump Overhaul Tool Set
(09237--00070) Shaft ”C” Governor sleeve plug
09260--54012 Injection Pump Tool Set
(09269--54020) Socket 14 mm
TO MODEL INDEX
PP--8
PP0DM--01
RECOMMENDED TOOLS
09040--00010 Hexagon Wrench Set .
09082--00040 TOYOTA Electrical Tester.

TO MODEL INDEX
PP--9
PP0DN--01
EQUIPMENT
Angle gauge
Brass brush Injection nozzle
Dial indicator with magnetic base
Graduated cylinder
Injection nozzle tester
Injection pump tester
Inner pressure gauge
Micrometer
Steel square
Timer measuring device
Torque wrench
Vernier calipers
TO MODEL INDEX
PP--10
PP0DO--01
SSM (Service Special Materials)

08833--00080 Adhesive 1344 Diaphragm push rod
THREE BOND 1344
LOCTITE 242 or equivalent
TO MODEL INDEX
PP--11
PREPARATION -- COOLING
COOLING
PP0DP--01

09230--01010 Radiator Service Tool Set
09231--14010 Punch
TO MODEL INDEX
PP--12
PP0DQ--01
EQUIPMENT
Radiator cap tester
Torque wrench
Vernier calipers
TO MODEL INDEX
PP--13
PP0DR--01
COOLANT
Item Capacity Classification
Engine coolant Ethylene--glycol base
2L, 3L, w/ Heater 9.5 liters (10.0 US qts, 8.4 lmp. qts)
w/o Heater 8.7 liters (9.2 US qts, 7.7 lmp. qts)
2L--T w/ Heater 9.7 liters (10.3 US qts, 8.5 lmp.qts)
5L w/ Heater 2WD 9.7 liters (10.3 US qts, 8.5 lmp. qts)
4WD 9.9 liters (10.5 US qts, 8.7 lmp. qts)
w/o Heater 2WD 8.9 liters (9.4 US qts, 7.8 lmp. qts)
4WD 9.1 liters (9.6 US qts, 8.0 lmp. qts)
TO MODEL INDEX
PP--14
PREPARATION -- LUBRICATION
LUBRICATION
PP0DS--01
LUBRICANT
Engine oil (2WD) API CF--4
Dry fill 6.5 liters (6.9 US qts, 5.7 lmp. qts) (You may also use API CF, CE or CD)
Drain and refill
w/ Oil filter change 5.8 liters (6.1 US qts, 5.1 lmp. qts)
w/o Oil filter change 5.3 liters (5.6 US qts, 4.7 lmp. qts)
Engine oil (4WD) API CF--4

Dry fill 7.2 liters (7.6 US qts, 6.3 lmp. qts) (You may also use API CF, CE or CD)
Drain and refill
w/ Oil filter change 6.5 liters (6.9 US qts, 5.7 lmp. qts)
w/o Oil filter change 6.0 liters (6.3 US qts, 5.3 lmp. qts)
TO MODEL INDEX
PP--15
PREPARATION -- STARTING
STARTING
PP0DT--01

09201--41020 Valve Stem Oil Seal Replacer Armature front bearing for 2.2 kW
09286--46011 Injection Pump Spline Shaft Armature rear bearing for 2.2 kW
Puller
09810--38140 Starter Magnet Switch Nut Wrench 2.2 kW

14
09950--00020 Bearing Remover Armature rear bearing for 2.2 kW

TO MODEL INDEX
PP--16
PP0DU--01
RECOMMENDED TOOLS
09082--00040 TOYOTA Electrical Tester.
TO MODEL INDEX
PP--17
PP0DV--01
EQUIPMENT
Dial indicator Commutator
Heater Water temperature sensor
Magnetic finger
Press
Pull scale Brush spring
Sandpaper Commutator
Thermometer Water temperature sensor
Torque wrench
V--block
Vernier calipers Commutator, Brush
TO MODEL INDEX
SERVICE SPECIFICATIONS
STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . SS-- 1

ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . SS-- 3
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . SS-- 9
ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-- 11
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-- 13
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-- 15
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-- 17
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-- 19
TO MODEL INDEX
SS--1
SERVICE SPECIFICATIONS -- STANDARD BOLT
STANDARD BOLT
SS00F--02
HOW TO DETERMINE BOLT STRENGTH
Mark Class Mark Class

Hexagon head 4-- 4T Hexagon
bolt flange bolt 4
Bolt 5-- 5T
Protruding 9T
head No. 6-- 6T w/ washer lines
7-- 7T hexagon bolt
8-- 8T Hexagon
9-- 9T flange bolt 5
10-- 10T Protruding 10T
w/ washer lines
11-- 11T
hexagon bolt
Hexagon
flange bolt 6
No mark 4T Protruding 11T
w/ washer lines
hexagon bolt
Hexagon Stud bolt No mark
flange bolt
No mark 4T
w/ washer
hexagon bolt 4T
Hexagon head
bolt 2
Protruding 5T
lines
Grooved
Hexagon
flange bolt 2
Protruding 6T 6T
w/ washer lines
hexagon bolt
Hexagon head
bolt 3
Protruding 7T Welded bolt
lines
Hexagon head
4T
bolt 4
Protruding 8T
lines
CONTINUED V06821
TO MODEL INDEX
SS--2
SERVICE SPECIFICATIONS -- STANDARD BOLT
SS00G--02
SPECIFIED TORQUE FOR STANDARD BOLTS
Diameter Pitch Specified torque

Class Hexagon head bolt Hexagon flange bolt
mm mm
N∙m kgf∙cm ft∙lbf N∙m kgf∙cm ft∙lbf
in.∙lbf in.∙lbf
in.∙lbf in.∙lbf
in.∙lbf in.∙lbf
V00079
TO MODEL INDEX
SS--3
SERVICE SPECIFICATIONS -- ENGINE MECHANICAL
ENGINE MECHANICAL
SS06N--01
SERVICE DATA
Compression at 250 rpm STD 2L--T 3,040 kPa (31.0 kgf/cm2, 441 psi) or more
pressure 2L, 3L, 5L 3,138 kPa (32.0 kgf/cm2, 455 psi) or more
Minimum 1,961 kPa (20.0 kgf/cm2, 284 psi)
Difference of pressure between each cylinder 490 kPa (5.0 kgf/cm2, 71 psi) or less
Valve clearance at cold Intake 0.20 -- 0.30 mm (0.008 -- 0.012 in.)

Exhaust 0.40 -- 0.50 mm (0.016 -- 0.020 in.)
Adjusting shim thickness (for repair part) No.01 2.50 mm (0.0984 in.)
No.42 2.55 mm (0.1004 in.)
No.06 2.60 mm (0.1024 in.)
No.43 2.65 mm (0.1043 in.)
No.11 2.70 mm (0.1063 in.)
No.44 2.75 mm (0.1083 in.)
No.16 2.80 mm (0.1102 in.)
No.45 2.85 mm (0.1122 in.)
No.21 2.90 mm (0.1142 in.)
No.46 2.95 mm (0.1161 in.)
No.26 3.00 mm (0.1181 in.)
No.47 3.05 mm (0.1201 in.)
No.31 3.10 mm (0.1220 in.)
No.48 3.15 mm (0.1240 in.)
No.36 3.20 mm (0.1260 in.)
No.49 3.25 mm (0.1280 in.)
No.41 3.30 mm (0.1299 in.)
Injection timing Plunger stroke 2L w/ ACSD 0.44 -- 0.56 mm (0.0173 -- 0.0220 in.)
w/o ACSD 0.84 -- 0.96 mm (0.0331 -- 0.0378 in.)
2L--T 0.54 -- 0.66 mm (0.0213 -- 0.0260 in.)
3L w/ ACSD 0.54 -- 0.66 mm (0.0213 -- 0.0260 in.)
w/o ACSD 0.84 -- 0.96 mm (0.0331 -- 0.0378 in.)
5L w/ ACSD 0.44 -- 0.56 mm (0.0173 -- 0.0220 in.)
w/o ACSD 0.64 -- 0.76 mm (0.0252 -- 0.0299 in.)
2L, 2L--T, 3L 650 -- 750 rpm
Idle speed
5L 750 -- 850 rpm
Maximum speed 2L Europe 5,020 -- 5,280 rpm
Others 4,770 -- 5,030 rpm
2L--T 4,670 -- 4,930 rpm
3L Malaysia 4,270 -- 4,530 rpm
others 4,470 -- 4,730 rpm
5L 4,470 -- 4,730 rpm
A/C idle--up speed -- 900 -- 1,000 rpm

VSV for intake at 20˚C (68˚F) 37 -- 44 Ω
shutter (5L)
Idler pulley Free length 44.4 -- 45.4 mm (1.748 -- 1.787 in.)

tension spring Installed load at 52.1 mm (2.051 in.) 53 -- 59 N (5.42 -- 5.98 kgf, 11.9 -- 13.2 lbf)
CONTINUED
TO MODEL INDEX
SS--4
Cylinder head Warpage Maximum 0.20 mm (0.0079 in.)

Valve seat
Refacing angle Intake 20˚, 45˚, 70˚
Exhaust 20˚, 45˚, 75˚
Contacting angle 45˚
Contacting width Intake 1.5 --- 1.9 mm (0.059 --- 0.075 in.)
Exhaust 1.8 --- 2.2 mm (0.071 --- 0.087 in.)
Cylinder head bolt thread inside diameter STD 11.800 --- 12.000 mm (0.4646 --- 0.4724 in.)
Minimum 11.60 mm (0.4567 in.)
Cylinder head gasket thickness Mark B 1.40 --- 1.50 mm (0.0551 --- 0.0591 in.)
Mark D 1.50 --- 1.60 mm (0.0591 --- 0.0630 in.)
Mark F 1.60 --- 1.70 mm (0.0630 --- 0.0669 in.)
Valve guide Inside diameter 8.010 -- 8.030 mm (0.3154 -- 0.3161 in.)
bushing Outside diameter for repair part STD 13.040 -- 13.051 mm (0.5134 -- 0.5138 in.)
O/S 0.05 13.090 -- 13.101 mm (0.5154 -- 0.5158 in.)
Valve Valve overall length STD Intake 2L, 2L--T, 3L 103.29 -- 103.69 mm (4.0665 -- 4.0823 in.)
5L 104.10 -- 104.50 mm (4.0984 -- 4.1142 in.)
Exhaust 2L, 2L--T, 3L 103.14 -- 103.54 mm (4.0606 -- 4.0764 in.)
5L 103.95 -- 104.35 mm (4.0925 -- 4.1083 in.)
Minimum Intake 2L, 2L--T, 3L 102.79 mm (4.0468 in.)
5L 103.60 mm (4.0787 in.)
Exhaust 2L, 2L--T, 3L 102.64 mm (4.0409 in.)
5L 103.45 mm (4.0728 in.)
Valve face angle 44.5˚
Stem diameter Intake 7.975 -- 7.990 mm (0.3140 -- 0.3146 in.)
Exhaust 7.960 -- 7.975 mm (0.3134 -- 0.3140 in.)
Stem oil clearance STD Intake 0.020 -- 0.055 mm (0.0008 -- 0.0022 in.)
Exhaust 0.035 -- 0.070 mm (0.0014 -- 0.0028 in.)
Maximum Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
Margin thickness STD Intake 1.6 mm (0.063 in.)
Exhaust 1.7 mm (0.067 in.)
Minimum Intake 1.1 mm (0.043 in.)
Exhaust 1.2 mm (0.047 in.)
Valve spring Deviation Maximum 2.0 mm (0.079 in.)
Free length Type A 46.20 mm (1.8189 in.)
Type B 48.54 mm (1.9110 in.)
Installed tension at 37.0 mm (1.457 in.) 301 -- 332 N (30.7 -- 33.9 kgf, 67.7 -- 74.7 lbf)
Valve lifter Valve lifter inside diameter 40.892 -- 40.902 mm (1.6099 -- 1.6103 in.)
Cylinder head lifter bore diameter 40.960 -- 40.980 mm (1.6126 -- 1.6134 in.)
Oil clearance STD 0.058 -- 0.088 mm (0.0023 -- 0.0035 in.)
Maximum 0.10 mm (0.0039 in.)
Manifold Warpage Maximum 0.40 mm (0.0157 in.)
CONTINUED
TO MODEL INDEX
SS--5
Camshaft Circle runout Maximum 0.10 mm (0.0039 in.)

Cam lobe height STD Intake 2L 53.850 -- 53.870 mm (2.1201 -- 2.1209 in.)
2L--T 53.450 -- 53.470 mm (2.1043 -- 2.1051 in.)
3L, 5L 54.290 -- 54.310 mm (2.1374 -- 2.1382 in.)
Exhaust 54.990 -- 55.010 mm (2.1650 -- 2.1657 in.)
Minimum Intake 2L 53.35 mm (2.1004 in.)
2L--T 52.49 mm (2.0665 in.)
3L, 5L 53.79 mm (2.1177 in.)
Exhaust 54.49 mm (2.1453 in.)
Journal diameter STD No.1 34.969 -- 34.985 mm (1.3767 -- 1.3774 in.)
Others 27.969 -- 27.985 mm (1.1011 -- 1.1018 in.)
U/S 0.125 No.1 34.844 -- 34.860 mm (1.3718 -- 1.3724 in.)
Others 27.844 -- 27.860 mm (1.0962 -- 1.0968 in.)
U/S 0.250 No.1 34.719 -- 34.735 mm (1.3669 -- 1.3675 in.)
Others 27.719 -- 27.735 mm (1.0913 -- 1.0919 in.)
Journal oil clearance STD 0.022 -- 0.074 mm (0.0009 -- 0.0029 in.)
Maximum 0.10 mm (0.0039 in.)
Thrust clearance STD 0.080 -- 0.280 mm (0.0031 -- 0.0110 in.)
Maximum 0.35 mm (0.0138 in.)
Combustion Protrusion ± 0.03 mm (0.0012 in.)
chamber Shim thickness 0.03 mm (0.0012 in.)
Connecting rod Thrust clearance STD 0.080 -- 0.300 mm (0.0031 -- 0.0118 in.)
Maximum 0.35 mm (0.0138 in.)
Connecting rod oil clearance STD STD 0.036 -- 0.064 mm (0.0014 -- 0.0025 in.)
U/S 0.25, U/S 0.50, 2L 0.023 -- 0.073 mm (0.0009 -- 0.0029 in.)
2L--T, 3L, 5L 0.033 -- 0.079 mm (0.0013 -- 0.0031 in.)
Maximum 0.10 mm (0.0039 in.)
Connecting rod bearing center wall thickness
Reference STD Mark 1 1.478 -- 1.482 mm (0.0582 -- 0.0583 in.)
Mark 2 1.482 -- 1.486 mm (0.0583 -- 0.0585 in.)
Mark 3 1.486 -- 1.490 mm (0.0585 -- 0.0587 in.)
Rod out--of alignment Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Rod twist Maximum per 100 mm (3.94 in.) 0.15 mm (0.0059 in.)
Bushing inside diameter 2L 27.008 -- 27.020 mm (1.0633 -- 1.0638 in.)
2L--T, 3L, 5L 29.008 -- 29.020 mm (1.1420 -- 1.1425 in.)
Piston pin diameter 2L 27.000 -- 27.012 mm (1.0630 -- 1.0635 in.)
2L--T, 3L, 5L 29.000 -- 29.012 mm (1.1417 -- 1.1422 in.)
Bushing oil clearance STD 0.004 -- 0.012 mm (0.0002 -- 0.0005 in.)
Maximum 0.05 mm (0.0020 in.)
Connecting rod bolt tension portion diameter STD 8.400 -- 8.600 mm (0.3307 -- 0.3386 in.)
Minimum 8.20 mm (0.3228 in.)
CONTINUED
TO MODEL INDEX
SS--6
Cylinder block Cylinder head surface warpage Maximum 0.20 mm (0.0079 in.)
Cylinder bore diameter STD 2L, 2L--T STD Mark 1 92.000 -- 92.010 mm (3.6220 -- 3.6224 in.)
Mark 2 92.010 -- 92.020 mm (3.6224 -- 3.6228 in.)
Mark 3 92.020 -- 92.030 mm (3.6228 -- 3.6232 in.)
3L STD Mark 1 96.000 -- 96.010 mm (3.7795 -- 3.7799 in.)
Mark 2 96.010 -- 96.020 mm (3.7799 -- 3.7803 in.)
Mark 3 96.020 -- 96.030 mm (3.7803 -- 3.7807 in.)
5L STD Mark 1 99.500 -- 95.010 mm (3.9173 -- 3.9177 in.)
Mark 2 99.510 -- 95.020 mm (3.9177 -- 3.9181 in.)
Mark 3 99.520 -- 95.030 mm (3.9181 -- 3.9185 in.)
Maximum 2L, 2L--T STD 92.23 mm (3.6311 in.)
O/S 0.50 92.73 mm (3.6508 in.)
O/S 0.75 92.98 mm (3.6606 in.)
O/S 1.00 93.23 mm (3.6705 in.)
3L STD 96.23 mm (3.7886 in.)
O/S 0.50 96.73 mm (3.8083 in.)
5L STD 99.73 mm (3.9264 in.)
O/S 0.50 100.23 mm (3.9461 in.)
Piston and piston Piston diameter 2L, 2L--T STD Mark 1 91.940 -- 91.950 mm (3.6197 -- 3.6201 in.)
ring Mark 2 91.950 -- 91.960 mm (3.6201 -- 3.6205 in.)
Mark 3 91.960 -- 91.970 mm (3.6205 -- 3.6209 in.)
O/S 0.50 92.440 -- 92.470 mm (3.6394 -- 3.6405 in.)
O/S 0.75 92.690 -- 92.720 mm (3.6492 -- 3.6504 in.)
O/S 1.00 92.940 -- 92.970 mm (3.6590 -- 3.6602 in.)
3L STD Mark 1 95.940 -- 95.950 mm (3.7772 -- 3.7776 in.)
Mark 2 95.950 -- 95.960 mm (3.7776 -- 3.7779 in.)
Mark 3 95.960 -- 95.970 mm (3.7779 -- 3.7783 in.)
O/S 0.50 96.440 -- 96.470 mm (3.7968 -- 3.7980 in.)
5L STD Mark 1 99.450 -- 99.460 mm (3.9153 -- 3.9157 in.)
Mark 2 99.460 -- 99.470 mm (3.9157 -- 3.9161 in.)
Mark 3 99.470 -- 99.480 mm (3.9161 -- 3.9165 in.)
O/S 0.50 99.950 -- 99.980 mm (3.9350 -- 3.9362 in.)
Piston oil clearance STD 2L, 2L--T, 3L 0.050 -- 0.070 mm (0.0020 -- 0.0028 in.)
5L 0.040 -- 0.060 mm (0.0016 -- 0.0024 in.)
Maximum 2L, 2L--T, 3L 0.14 mm (0.0055 in.)
5L 0.13 mm (0.0051 in.)
Piston ring groove clearance STD No.1 2L 0.031 -- 0.079 mm (0.0012 -- 0.0031 in.)
2L--T 0.061 -- 0.109 mm (0.0024 -- 0.0043 in.)
3L 0.031 -- 0.075 mm (0.0012 -- 0.0030 in.)
5L 0.057 -- 0.101 mm (0.0022 -- 0.0040 in.)
No.2 2L, 3L 0.060 -- 0.105 mm (0.0024 -- 0.0041 in.)
2L--T 0.070 -- 0.115 mm (0.0028 -- 0.0045 in.)
5L 0.060 -- 0.100 mm (0.0024 -- 0.0039 in.)
Oil 0.030 -- 0.070 mm (0.0012 -- 0.0028 in.)
Maximum 0.20 mm (0.0079 in.)
Piston ring end gap STD No.1 0.350 -- 0.590 mm (0.0138 -- 0.0232 in.)
No.2 2L, 2L--T 0.450 -- 0.720 mm (0.0177 -- 0.0283 in.)
3L 0.400 -- 0.670 mm (0.0157 -- 0.0264 in.)
5L 0.470 -- 0.720 mm (0.0185 -- 0.0283 in.)
Oil 0.200 -- 0.520 mm (0.0079 -- 0.0205 in.)
Maximum No.1 1.29 mm (0.0508 in.)
No.2 2L, 2L--T, 5L 1.42 mm (0.0559 in.)
3L 1.37 mm (0.0539 in.)
Oil 1.22 mm (0.0480 in.)
Piston protrusion from cylinder block 0.68 -- 0.97 mm (0.0268 -- 0.0382 in.)
CONTINUED
TO MODEL INDEX
SS--7
Crankshaft Thrust clearance STD 0.040 -- 0.250 mm (0.0016 -- 0.0098 in.)

Maximum 0.30 mm (0.0118 in.)
Thrust washer thickness STD 2.430 -- 2.480 mm (0.0957 -- 0.0976 in.)
O/S 0.125 2.493 -- 2.543 mm (0.0981 -- 0.1001 in.)
O/S 0.250 2.555 -- 2.605 mm (0.1006 -- 0.1026 in.)
Main journal oil clearance STD STD 0.034 -- 0.065 mm (0.0013 -- 0.0026 in.)
U/S 0.25, 0.50 0.033 -- 0.079 mm (0.0013 -- 0.0031 in.)
Maximum 0.10 mm (0.0039 in.)
Main journal diameter STD 61.985 -- 62.000 mm (2.4403 -- 2.4409 in.)
U/S 0.25 61.475 -- 61.755 mm (2.4309 -- 2.4413 in.)
U/S 0.50 61.495 -- 61.505 mm (2.4211 -- 2.4215 in.)
Main bearing center wall thickness
Reference STD Mark 1 1.979 -- 1.983 mm (0.0779 -- 0.0781 in.)
Mark 2 1.983 -- 1.987 mm (0.0781 -- 0.0782 in.)
Mark 3 1.987 -- 1.991 mm (0.0782 -- 0.0784 in.)
Crank pin diameter 2L STD 52.988 -- 53.000 mm (2.0861 -- 2.0866 in.)
U/S 0.25 52.475 -- 52.755 mm (2.0766 -- 2.0770 in.)
U/S 0.50 52.495 -- 52.505 mm (2.0667 -- 2.0671 in.)
2L--T, 3L, 5L STD 54.988 -- 55.000 mm (2.1649 -- 2.1654 in.)
U/S 0.25 54.745 -- 54.755 mm (2.1553 -- 2.1557 in.)
U/S 0.50 54.495 -- 54.505 mm (2.1455 -- 2.1459 in.)
Circle runout Maximum 0.06 mm (0.0024 in.)
Main journal taper and out--of--round Maximum 0.02 mm (0.0008 in.)
Crank pin taper and out--of--round maximum 0.02 mm (0.0008 in.)
TO MODEL INDEX
SS--8
SS06O--01
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
Injection pump x Timing belt case 20.5 210 15
Injection pump x Injection pump stay 18 185 13
Injection pipe x Injection pump 24.5 250 18
Plug bolt x Distributive head plug on injection pump 17 170 13
Intake flange x Intake manifold 12 120 9
No.2 idler pulley x Cylinder block 33 340 24
Injection pump drive pulley x Injection pump 64 650 47
Camshaft timing pulley x Camshaft 98 1,000 72
No.1 idler pulley x Cylinder block 12 mm head 19 195 14
14 mm head 44 450 33
Cylinder head x Cylinder block 1st 78 800 58

2nd Turn 90˚ Turn 90˚ Turn 90˚
3rd Turn 90˚ Turn 90˚ Turn 90˚
Cylinder head cover x Cylinder head 12 120 9
No.2 cylinder head cover x Cylinder head cover 12 120 9
Exhaust manifold x Cylinder head 52 530 38
Exhaust manifold heat insulator x Exhaust manifold 12 120 9
Exhaust manifold heat insulator x Oil filter bracket 19 195 14
Intake manifold x Cylinder head 23.5 240 17
Engine hanger x Cylinder head LH 59 600 44
RH (Reference) 37 380 27
Water outlet housing x Cylinder head 19 195 14

No.2 timing belt cover x Cylinder head 18 185 13
Glow plug x Cylinder head 13 130 10
Glow plug connector x Glow plug 1.0 10 8.7 in.∙lbf
Camshaft oil seal retainer x Cylinder head 18 185 13
Camshaft bearing cap x Cylinder head 25 255 18
Crankshaft pulley x Crankshaft 235 2,400 173
Main bearing cap x Cylinder block 105 1,050 77
Connecting rod cap x Connecting rod 1st 54 550 40
2nd Turn 90˚ Turn 90˚ Turn 90˚
Rear oil seal retainer x Cylinder block 13 130 10

Union for alternator hose x Cylinder block 32 330 24
Fan belt adjusting bar x Cylinder block 45 460 33
Engine mounting bracket x Cylinder block 39 400 29
Alternator bracket x Cylinder block 39 400 29
Rear end plate x Cylinder block 18 185 13
Flywheel x Crankshaft 123 1,250 90
TO MODEL INDEX
SS--9
SERVICE SPECIFICATIONS -- TURBOCHARGING
TURBOCHARGING
SS06P--01
SERVICE DATA
Turbocharger Turbocharging pressure 60 -- 79 kPa (0.61 -- 0.81 kgf/cm2, 8.7 -- 11.5 psi)
Turbine wheel axial play Maximum 0.13 mm (0.0051 in.) or less
Turbine wheel radial play Maximum 0.18 mm (0.0071 in.) or less
Actuator push rod stroke 1.20 -- 1.70 mm (0.0472 -- 0.0669 in.)
Adjusting plate washer 0.5 mm (0.020 in.)
1.0 mm (0.039 in.)
2.0 mm (0.079 in.)
3.0 mm (0.118 in.)
TO MODEL INDEX
SS--10
SERVICE SPECIFICATIONS -- TURBOCHARGING
SS06Q--01
Turbocharger actuator x Compressor housing 19 195 14
Bearing housing side plate x Turbocharger 7.8 80 69 in.∙lbf
Turbo oil pipe x Turbocharger 19 195 14
Turbo water pipe x Turbocharger Nut 5.5 55 49 in.∙lbf
Bolt 12 120 9
Turbine outlet elbow x Turbocharger 26 260 19

Turbocharger x Exhaust manifold 52 530 38
Turbo oil pipe x Oil filter bracket 25.5 260 19
Exhaust manifold stay x Cylinder block 12 120 9
Exhaust manifold stay x Exhaust manifold 19 195 14
Intake flange x Intake manifold 12 120 9
TO MODEL INDEX
SS--11
SERVICE SPECIFICATIONS -- ENGINE FUEL
ENGINE FUEL
SS06R--01
SERVICE DATA
Fuel heater Resistance at 20˚C (68˚F) 0.5 -- 2.0 Ω
Injection nozzles Nozzle opening pressure New nozzle 2L, 2L--T, 3L 14,810 -- 15,590 kPa (151 -- 159 kgf/cm2, 2,148 -- 2,262 psi)
5L 15,790 -- 16,570 kPa (161 -- 169 kgf/cm2, 2,290 -- 2,404 psi)
Reused nozzle 2L, 2L--T, 3L 14,220 -- 15,200 kPa (145 -- 155 kgf/cm2, 2,062 -- 2,205 psi)
5L 15,200 -- 16,181 kPa (155 -- 165 kgf/cm2, 2,205 -- 2,347 psi)
Adjusting shim thickness 0.900 mm (0.0354 in.) 0.950 mm (0.0374 in.)
1.000 mm (0.0394 in.) 1.050 mm (0.0413 in.)
1.100 mm (0.0433 in.) 1.150 mm (0.0453 in.)
1.200 mm (0.0472 in.) 1.250 mm (0.0492 in.)
1.300 mm (0.0512 in.) 1.350 mm (0.0531 in.)
1.400 mm (0.0551 in.) 1.450 mm (0.0571 in.)
1.500 mm (0.0591 in.) 1.550 mm (0.0610 in.)
1.600 mm (0.0630 in.) 1.650 mm (0.0650 in.)
1.700 mm (0.0669 in.) 1.750 mm (0.0689 in.)
1.800 mm (0.0709 in.) 1.850 mm (0.0728 in.)
1.900 mm (0.0748 in.) 1.950 mm (0.0768 in.)
Injection pump Direction of rotation Clockwise as seen from drive side

Injection order 1 -- 3 -- 4 -- 2 (A -- B -- C -- D)
Plunger spring deviation 2.0 mm (0.079 in.)
Spring free length
Delivery valve spring 24.4 mm (0.961 in.)
Plunger spring 30.0 mm (1.181 in.)
Coupling spring 16.6 mm (0.654 in.)
Pneumatic bellows spring w/ HAC 30.0 mm (1.181 in.)
Boost compensator spring 2L--T 19.4 mm (0.764 in.)
Roller height variation 0.02 mm (0.0008 in.)
Fuel cut solenoid resistance at 20˚C (68˚F) 9.5 -- 11.9 Ω
Pickup sensor resistance at 20˚C (68˚F) 650 -- 970 Ω
Timer adjusting screw protrusion pre--setting 5.0 -- 6.0 mm (0.197 -- 0.236 in.)
Plunger spring shim thickness 0.5 mm (0.020 in.) 0.8 mm (0.031 in.)
1.0 mm (0.039 in.) 1.2 mm (0.047 in.)
1.5 mm (0.059 in.) 1.8 mm (0.071 in.)
2.0 mm (0.079 in.)
Plunger adjusting shim thickness 1.9 mm (0.075 in.) 2.0 mm (0.079 in.)
2.1 mm (0.083 in.) 2.2 mm (0.087 in.)
2.3 mm (0.091 in.) 2.4 mm (0.094 in.)
2.5 mm (0.098 in.) 2.6 mm (0.102 in.)
2.7 mm (0.106 in.) 2.8 mm (0.110 in.)
2.9 mm (0.114 in.)
Flyweight holder thrust clearance 0.15 -- 0.35 mm (0.0059 -- 0.0138 in.)
Governor gear adjusting washer thickness 1.05 mm (0.0413 in.) 1.25 mm (0.0492 in.)
1.45 mm (0.0571 in.) 1.65 mm (0.0650 in.)
1.85 mm (0.0728 in.)
Governor shaft protrusion 0.5 -- 2.0 mm (0.020 -- 0.079 in.)
Governor sleeve plug head thickness 3.0 mm (0.118 in.) 3.1 mm (0.122 in.)
3.2 mm (0.126 in.) 3.3 mm (0.130 in.)
3.4 mm (0.134 in.) 3.5 mm (0.138 in.)
3.6 mm (0.142 in.) 3.7 mm (0.146 in.)
3.8 mm (0.150 in.) 3.9 mm (0.154 in.)
4.0 mm (0.157 in.) 4.1 mm (0.161 in.)
4.2 mm (0.165 in.)
TO MODEL INDEX
SS--12
SERVICE SPECIFICATIONS -- ENGINE FUEL
SS06S--01
Fuel heater x Fuel filter cap 3.19 32.5 28 in.∙lbf
Nozzle holder body x Nozzle holder retaining nut 46.58 475 42
Injection nozzle x Cylinder head 64 650 47
Nozzle leakage pipe x Injection nozzle 29.5 300 22
Injection pipe x Injection nozzle, Injection pump 24.5 250 18
Fuel inlet hollow screw x Injection pump body 36.8 375 27
Regulator valve x Injection pump body 8.85 90 78 in.∙lbf
Feed pump cover x Injection pump body 2.45 25 22 in.∙lbf
Timer cover, Governor cover x Injection pump body 8.35 85 74 in.∙lbf
Timer adjusting screw x Timer cover 14.2 145 10
Governor link support bolt x Injection pump body 13.75 140 10
Connector bracket (w/ TCV), Distributive head x Injection pump body 11.75 120 9
Delivery valve holder x Distributive head 58.85 600 43
Distributive head plug x Distributive head 68.65 700 51
Bolt for control lever x Governor cover 2L--T, w/ HAC 6.85 70 61 in.∙lbf
Diaphragm cover x Governor cover 2L--T 7.35 75 65 in.∙lbf
Pneumatic bellows cover x Governor cover w/ HAC 7.35 75 65 in.∙lbf
Bolt for lever control spring x Governor cover 2L--T, w/ HAC 11.3 115 8
Overflow screw x Governor cover 2L--T 24.55 250 18
No.2 adjusting lever x Governor adjusting shaft 8.35 85 74 in.∙lbf
No.2 adjusting lever x No.1 adjusting lever 6.05 62 54 in.∙lbf
Fuel cut solenoid x Distributive head 22.1 225 16
Lead wire x Fuel cut solenoid 1.7 17.5 15 in.∙lbf
Connector bracket x Distributive head w/o TCV 20.1 205 15
Pickup sensor x Injection pump body 20.6 210 15
Timing control valve x Injection pump body w/ TCV 8.35 85 74 in.∙lbf
Lead wire x Timing control valve w/ TCV 1.7 17.5 15 in.∙lbf
Overflow pipe x Injection pump body w/ TCV Upper union bolt 14.2 145 10
Lower union bolt 19.6 200 14
Overflow pipe clamp x Injection pump body, Connector bracket w/ TCV 8.35 85 74 in.∙lbf
Thermo wax x Injection pump body 8.35 85 74 in.∙lbf
Idle--up lever x Governor cover, Injection pump body w/ ACSD 8.35 85 74 in.∙lbf
Idle--up actuator x Governor cover w/o ACSD for w/ A/C 8.35 85 74 in.∙lbf
Fuel inlet pipe, Fuel return pipe x Injection pump 24.55 250 18
Injection pump x Timing belt case 20.5 210 15
Injection pump stay x Injection pump, Cylinder block 18 185 13
TO MODEL INDEX
SS--13
SERVICE SPECIFICATIONS -- COOLING
COOLING
SS06T--01
SERVICE DATA
Thermostat Valve opening temperature 86 -- 90˚C (187 -- 194˚F)
Valve lift at 100˚C (212˚F) 8 mm (0.31 in.) or more
Radiator cap Relief valve opening pressure STD 93 -- 123 kPa (0.95 -- 1.25 kgf/cm2, 13.5 -- 17.1 psi)
Minimum 59 kPa (0.6 kgf/cm2, 8.5 psi)
CONTINUED
TO MODEL INDEX
SS--14
SERVICE SPECIFICATIONS -- COOLING
SS06U--01
Engine coolant drain plug x Cylinder block 29 300 21
Water pump x Cylinder block 23 230 17
Fan x Fluid coupling 6.5 65 58 in.∙lbf
Fluid coupling x Water pump pulley 18.5 185 14
Water outlet x Water outlet housing 19 195 14
Support x Tank on radiator 13 130 10
TO MODEL INDEX
SS--15
SERVICE SPECIFICATIONS -- LUBRICATION
LUBRICATION
SS06V--01
SERVICE DATA
Oil pressure at idle speed 29 kPa (0.3 kgf/cm2, 43 psi) or more
at 3,000 rpm 294 -- 539 kPa (3.0 -- 5.5 kgf/cm2, 43 -- 78 psi)
Oil pump Tip clearance STD 0.110 -- 0.240 mm (0.0043 -- 0.0094 in.)
Maximum 0.30 mm (0.0118 in.)
Body clearance STD 0.114 -- 0.219 mm (0.0057 -- 0.0086 in.)
Maximum 0.40 mm (0.0157 in.)
Side clearance STD 0.035 -- 0.085 mm (0.0014 -- 0.0033 in.)
Maximum 0.15 mm (0.0059 in.)
TO MODEL INDEX
SS--16
SERVICE SPECIFICATIONS -- LUBRICATION
SS06W--01
Drain plug x Oil pan 34.5 350 25
Oil pump cover x Oil pump 10 105 7
Plug x Oil pump 37 375 27
Oil pump (Timing belt case) x Cylinder block 22.5 230 17
Oil pump (Timing belt case) x Injection pump 20.5 210 15
Oil strainer x Cylinder block Bolt 18 180 13
Nut 21 210 15
Oil pan x Cylinder block 18 180 13

Oil pan x Oil pump (Timing belt case) 18 180 13
Oil pan x Rear oil seal retainer 18 180 13
Union for oil filter x Oil filter bracket 49 500 36
Use SST 42 430 31
Oil filter bracket x Oil cooler 15.5 160 11

Oil filter bracket x Relief valve plug 36 370 27
Oil filter bracket x Union bolt 20 200 15
Oil filter bracket x Cylinder block 29.5 300 22
TO MODEL INDEX
SS--17
SERVICE SPECIFICATIONS -- STARTING
STARTING
SS06Z--01
SERVICE DATA
Pre--heating Light lighting time
system Super glow type Approx. 2.2 seconds
Variable delay type Approx. 5 seconds
Starter (2.0 kW) Rated voltage and output power 12 V 2.0 kW
No-- load characteristics Current 100 A or less at 11.5 V
rpm 4,000 rpm or more
Brush length STD 15.0 mm (0.591 in.)
Minimum 9.0 mm (0.354 in.)
Brush spring installed load STD 21.5 -- 27.5 N (2.2 -- 2.8 kgf, 4.9 -- 6.2 lbf)
Minimum 12.7 N (1.3 kgf, 2.9 lbf)
Commutator
Diameter STD 35.0 mm (1.378 in.)
Undercut depth STD 0.7 mm (0.028 in.)
Field frame
Shunt coil resistance at 20˚C (68˚F) 1.5 -- 1.9 Ω
Magnetic switch
Contact plate for wear Maximum 0.9 mm (0.035 in.)

No--load characteristics Current 120 A or less at 11.5 V
Commutator
Magnetic switch

No--load characteristics Current 180 A or less at 11.0 V
Commutator
Magnetic switch
TO MODEL INDEX
SS--18
SERVICE SPECIFICATIONS -- STARTING
SS070--01
Glow plug resistor x Intake manifold 34 350 25
Water temperature sensor x Cylinder block 17.5 178 13
Glow plug x Cylinder head 13 130 10
Terminal 30 nut, Terminal C nut x Terminal bolt 2.0 kW, 2.2 kW 17 173 13
2.7 kW 30 306 22
End cover x Magnetic switch housing 3.6 37 32 in.∙lbf

End cover x Brush holder 2.0 kW 3.8 39 34 in.∙lbf
2.7 kW 3.6 37 32 in.∙lbf
Starter housing x Magnetic switch 9.3 95 82 in.∙lbf

Starter housing x Filed frame 2.2 kW 12.7 130 9
End cover x Starter housing 2.0 kW, 2.7 kW 9.3 95 82 in.∙lbf
Lead wire of field frame x Terminal C 2.0 kW, 2.2 kW 5.9 60 52 in.∙lbf
2.7 kW 24 245 18
Lead wire x Terminal 50 of magnetic switch 3.6 37 32 in.∙lbf

TO MODEL INDEX
SS--19
SERVICE SPECIFICATIONS -- CHARGING
CHARGING
SS06X--01
SERVICE DATA
Battery Specific gravity at 20˚C (68˚F) 1.25 -- 1.29
Voltage at 20˚C (68˚F) 12.5 -- 12.9 V
Drive belt Deflection New belt 7 -- 10 mm (0.28 -- 0.39 in.)

Used belt 10 -- 14 mm (0.39 -- 0.55 in.)
Tension New belt 440 -- 540 N (45 -- 55 kgf)
Used belt 200 -- 340 N (20 -- 35 kgf)
Alternator Rated output 12 V 55 A, 12 V 70A

Rotor coil resistance at 20˚C (68˚F) 2.7 -- 3.1 Ω
Slip ring diameter STD 14.2 -- 14.4 mm (0.559 -- 0.567 in.)
Brush exposed length STD 10.5 mm (0.413 in.)
IC regulator Regulator voltage 13.2 -- 14.8 V
CONTINUED
TO MODEL INDEX
SS--20
SERVICE SPECIFICATIONS -- CHARGING
SS06Y--01
Bearing retainer x Drive end frame 2.6 26.5 23 in.∙lbf
Rectifier end frame x Rectifier holder 3.9 40 35 in.∙lbf
Rectifier end frame x Drive end frame 5.9 60 52 in.∙lbf
Rectifier holder x Coil lead on rectifier end frame 2.0 20 18 in.∙lbf
IC regulator x Rectifier end frame 2.0 20 18 in.∙lbf
IC regulator x Rectifier holder 2.0 20 18 in.∙lbf
Brush holder x Rectifier holder 2.0 20 18 in.∙lbf
Brush holder x IC regulator 2.0 20 18 in.∙lbf
Rear end cover x Rectifier holder 4.5 46 40 in.∙lbf
Terminal insulator x Rectifier holder 4.1 41.5 36 in.∙lbf
Vacuum Pump x Rectifier end frame 7.8 80 69 in.∙lbf
TO MODEL INDEX
ENGINE MECHANICAL
COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 1
INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . EM-- 3
IDLE SPEED AND MAXIMUM SPEED . . . . . . EM-- 5
INTAKE SHUTTER (5L) . . . . . . . . . . . . . . . . . . . EM-- 7
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . EM-- 9
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . EM-- 12

RM520E)
TO MODEL INDEX
EM--1
ENGINE MECHANICAL -- COMPRESSION
COMPRESSION EM058--01
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE GLOW PLUGS
3. DISCONNECT INJECTION PUMP (FUEL CUT SOLE-
NOID) CONNECTOR
SST (Attachment) 4. CHECK CYLINDER COMPRESSION PRESSURE

HINT:
Turn the starter before measuring the compression and dis-
charge the foreign objects.
(a) Install SST (attachment) to the glow plug hole.
SST 09992 -- 00025 (09992 -- 00121)
A01001
SST (Compression) (b) Connect SST (compression gauge ) to the SST (attach-
ment).
SST 09992 -- 00025 (09992 -- 00211)
(c) Fully open the throttle valve, and start the engine.
(d) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine revolution
A01002 of 250 rpm or more.
(e) Repeat steps (a) through (d) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
2L--T 3,040 kPa (31.0 kgf/cm2, 441 psi) or more
2L, 3L, 5L 3,138 kPa (32.0 kgf/cm2, 455 psi) or more
Minimum pressure: 1,961 kPa (20.0 kgf/cm2, 284 psi)
Difference between each cylinder:
490 kPa (5.0 kgf/cm2, 71 psi) or less
CONTINUED
TO MODEL INDEX
EM--2
ENGINE MECHANICAL -- COMPRESSION
(f) If the cylinder compression in one or more cylinders is low,

pour a small amount of engine oil into the cylinder through
the glow plug hole and repeat steps (a) through (d) for the
cylinder with low compression.
S If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damaged.
S If pressure stays low, a valve may be sticking or
seating improperly, or there may be leakage past
the gasket.
(g) Remove the SST.
SST 09992 -- 00025 (09992 -- 00121, 09992 -- 00211)
5. RECONNECT INJECTION PUMP (FUEL CUT SOLE-
NOID) CONNECTOR
6. REINSTALL GLOW PLUGS
7. START ENGINE AND CHECK FOR LEAKS
TO MODEL INDEX
EM--3
ENGINE MECHANICAL -- INJECTION TIMING
INJECTION TIMING EM059--01
INSPECTION
HINT:
Inspect and adjust the injection timing when the engine cold.
1. INSTALL SST AND DIAL INDICATOR

Gasket
(a) Remove the plug bolt and gasket from the distributive
Plug Bolt
head plug of the injection pump.
(b) Install SST (plunger stroke measuring tool) and a dial indi-
cator to the plug bolt hole of distributive head plug.
SST 09275 -- 54011
Dial
Indicator SST A01003
w/ ACSD Metal Plate 2. w/ ACSD:

RELEASE ACSD ADVANCE
(a) Using a screwdriver, turn the cold starting lever counter-
clockwise approx. 20˚.
Turn (b) Put a metal plate (thickness of 8.5 -- 10.0 mm (0.335 --
0.394 in.)) between the cold starting lever and thermo
wax plunger.
A01004
3. SET NO.1 OR NO.4 CYLINDER TO 25 -- 30˚ BTDC/

25 -- 30˚ COMPRESSION
Turn the crankshaft pulley clockwise so the pulley groove is
25 -- 30˚ from the timing pointer.
NOTICE:
Do not turn the crankshaft pulley counterclockwise.
Turn
A01005
4. INSPECT AND ADJUST INJECTION TIMING

(a) Set the dial indicator at 0 mm (0 in.).
(b) Slowly rotate the crankshaft pulley clockwise until its
groove is aligned with the timing pointer.
Turn CONTINUED
A01006
TO MODEL INDEX
EM--4
ENGINE MECHANICAL -- INJECTION TIMING
(c) Measure the plunger stroke.

Plunger stroke:
2L w/ ACSD 0.44 -- 0.56 mm (0.0173 -- 0.0220 in.)
w/o ACSD 0.84 -- 0.96 mm (0.0331 -- 0.0378 in.)
2L--T 0.54 -- 0.66 mm (0.0213 -- 0.0260 in.)

3L w/ ACSD 0.54 -- 0.66 mm (0.0213 -- 0.0260 in.)
w/o ACSD 0.84 -- 0.96 mm (0.0331 -- 0.0378 in.)
5L w/ ACSD 0.44 -- 0.56 mm (0.0173 -- 0.0220 in.)

w/o ACSD 0.64 -- 0.76 mm (0.0252 -- 0.0299 in.)
(3) (d) Loosen these nuts and bolts:

(2) (1) 4 union nuts holding injection pipes to injection
(1) pump
(2) Bolt (2L--T) or 2 bolts (2L, 3L, 5L) holding injection
pump to injection pump stay
(3) 2 nuts holding injection pump to timing belt case
(3) NOTICE:
(2) Do not turn the nuts more than 90˚.
2L, 3L, 5L (1) A01007
Greater than (e) Adjust plunger stroke by slightly tilting the injection pump
Specification body.
If the stroke is less than specification, tilt the pump toward the
engine.
If the stroke is greater than specification, tilt the pump away
Less than from the engine.
Specification (f) Tighten these nuts and bolts:
S 2 nuts holding injection pump to timing belt case
A01008 Torque: 20.5 N∙m (210 kgf∙cm, 15 ft∙lbf)
S Bolt (2L--T) or 2 bolts (2L, 3L, 5L) holding injection
pump to injection pump stay
S 4 nuts holding injection pipes to injection pump
Torque: 24.5 N∙m (250 kgf∙cm, 18 ft∙lbf)
(g) Recheck the plunger stroke.
5. REMOVE SST AND DIAL INDICATOR
6. w/ ACSD:
REMOVE METAL PLATE
(a) Remove the SST and dial indicator.
SST 09275 -- 54011
(b) Install a new gasket and the plug bolt of the distributive
head plug.
7. START ENGINE AND CHECK FOR FUEL LEAKS
TO MODEL INDEX
EM--5
ENGINE MECHANICAL -- IDLE SPEED AND MAXIMUM SPEED
IDLE SPEED AND MAXIMUM

SPEED EM05A--01
INSPECTION
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All accessories switched OFF
(d) All vacuum lines properly connected
(e) Valve clearance set correctly
(f) Injection timing set correctly
(g) Transmission in neutral position
(h) w/ PS:
Steering wheel at straight--ahead position
2. CONNECT TACHOMETER
Idle Speed Adjusting Screw 3. INSPECT AND ADJUST IDLE SPEED

(a) Check that the adjusting lever touches the idle speed ad-
Touch
justing screw when the accelerator pedal is released.
If not, adjust the accelerator linkage.
(b) Start the engine.
(c) Check the idle speed.
Release
Idle speed:
Adjusting 2L, 2L--T, 3L 650 -- 750 rpm
Lever S03722
5L 750 -- 850 rpm
(d) Adjust the idle speed.

(1) Disconnect the accelerator linkage.
(2) Loosen the lock nut of the idle speed adjusting
screw.
(3) Adjust the idle speed by turning the idle speed ad-
justing screw.
(4) Securely tighten the lock nut, and recheck the idle
speed.
(5) Reconnect the accelerator linkage.
(6) After adjustment, adjust the accelerator linkage.
Maximum Speed Adjusting Screw 4. INSPECT AND ADJUST MAXIMUM SPEED

(a) Check that the adjusting lever touches the maximum
Touch speed adjusting screw when the accelerator pedal is de-
pressed all the way.
Adjusting Lever If not, adjust the accelerator linkage.
(b) Start the engine.
Depress (c) Depress the accelerator pedal all the way.
S03723 CONTINUED
TO MODEL INDEX
EM--6
ENGINE MECHANICAL -- IDLE SPEED AND MAXIMUM SPEED
(d) Check the maximum speed.

Maximum speed:
2L Europe 5,020 -- 5,280 rpm
Others 4,770 -- 5,030 rpm
2L--T 4,670 -- 4,930 rpm

3L Malaysia 4,270 -- 4,530 rpm
Others 4,470 -- 4,730 rpm
5L 4,470 -- 4,730 rpm
2L--T, w/ HAC (e) Adjust the maximum speed.

SST (1) Disconnect the accelerator linkage.
(2) Cut off the seal wire of the maximum speed adjust-
ing screw.
(3) 2L--T, w/ HAC:
Using SST, loosen the lock nut of the maximum
speed adjusting screw.
SST 09275 -- 54020
S03724 (4) w/o HAC:
Loosen the lock nut of the maximum speed adjust-
ing screw.
(5) Adjust the maximum speed by turning the maximum
speed adjusting screw.
HINT:
Adjust at idle speed. Then, raise engine speed and recheck the
maximum speed.
(6) 2L--T, w/ HAC:
Using SST, securely tighten the lock nut.
SST 09275 -- 54020
(7) w/o HAC:
Securely tighten the lock nut.
(8) Recheck the maximum speed.
(9) Reconnect the accelerator linkage.
(10) After adjustment, adjust the accelerator linkage.
(11) Seal the maximum speed adjusting screw with a

new seal wire.
Seal
Wire
A01009
TO MODEL INDEX
EM--7
ENGINE MECHANICAL -- INTAKE SHUTTER (5L)
INTAKE SHUTTER (5L) EM05B--01
INSPECTION
1. INSPECT INTAKE SHUTTER OPERATION
(a) Start the engine.
(b) When running the engine, check the diaphragm rod is ful-
Closed
Open ly open position.
(c) When the engine stops (IG OFF), check that the dia-
B01342
phragm rod is fully closed position.
(d) A few seconds after the engine stops (IG OFF), check that
the diaphragm rod is fully open position.
Disconnect
2. INSPECT VENTURI
(a) Start the engine.
(b) Disconnect the vacuum hose from the actuator.
(c) Apply vacuum directly to the actuator with the engine id-
ling.
(d) Check that the engine runs rough or dies.
(e) Reconnect the vacuum hoses to the proper locations.
Connect B01343
3. INSPECT THROTTLE VALVE

(a) Remove the 3 nut, intake flange and gasket.
(b) Fully close the throttle valve, and check that it return
smoothly.
(c) Apply at least 29.3 kPa (220 mmHg, 8.66 in.Hg) of vacu-
um to the actuator.
(d) Check that the vacuum does not drop immediately.
Vacuum (e) Install a new gasket and the intake flange with the 3 nuts.
B01344
Ohmmeter Continuity 4. INSPECT VSV

(a) Remove the VSV.
(b) Inspect the VSV for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the terminals.
Resistance: 37 -- 44 Ω at 20˚C (68˚F)
If there is no continuity, replace the VSV.
B01338
CONTINUED
TO MODEL INDEX
EM--8
ENGINE MECHANICAL -- INTAKE SHUTTER (5L)
(c) Inspect the VSV for ground.

Ohmmeter No Continuity
Using an ohmmeter, check that there is no continuity be-
tween each terminal and the body.
If there is continuity, replace the VSV.
B01339
Air (d) Inspect the VSV operation.

(1) Check that air flows from ports E to G.
E
B01340
Air (2) Apply battery voltage across the terminals.

(3) Check that air flows from port E to the filter.
E If operation is not as specified, replace the VSV.
Battery
Filter
B01341
TO MODEL INDEX
EM--9
ENGINE MECHANICAL -- CYLINDER HEAD
CYLINDER HEAD EM05C--01
INSPECTION
1. INSPECT VALVES
Overall Length Check the valve overall length.
Standard overall length:
Intake
2L, 2L--T, 3L 103.29 -- 103.69 mm (4.0665 -- 4.0823 in.)
EM2534 5L 104.10 -- 104.50 mm (4.0984 -- 4.1142 in.)
Exhaust
2L, 2L--T, 3L 103.14 -- 103.54 mm (4.0606 -- 4.0764 in.)
5L 103.95 -- 104.35 mm (4.0925 -- 4.1083 in.)
Minimum overall length:
Intake
2L, 2L--T, 3L 102.79 mm (4.0468 in.)
5L 103.60 mm (4.0787 in.)
Exhaust
2L, 2L--T, 3L 102.64 mm (4.0409 in.)
5L 103.45 mm (4.0728 in.)
If the overall length is less than minimum, replace the valve.
2. INSPECT CAMSHAFT
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
2L 53.850 -- 53.870 mm (2.1201 -- 2.1209 in.)
2L--T 53.450 -- 53.470 mm (2.1043 -- 2.1051 in.)
3L, 5L 54.290 -- 54.310 mm (2.1374 -- 2.1382 in.)
Exhaust 54.990 -- 55.010 mm (2.1650 -- 2.1657 in.)
EM2011
Minimum cam lobe height:
Intake
2L 53.35 mm (2.1004 in.)
2L--T 52.49 mm (2.0665 in.)
3L, 5L 53.79 mm (2.1177 in.)
Exhaust 54.49 mm (2.1453 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
TO MODEL INDEX
EM--10
EM05D--01
INSTALLATION
1. CHECK PISTON PROTRUSIONS FOR EACH CYL-
INDER
(a) Clean the cylinder block with solvent.
(b) Set the piston of the cylinder to be measured to slightly
before TDC.
(c) Place a dial indicator on the cylinder block, set the mea-
25 mm
suring tip as shown in the illustration.
(0.98 in.) A00998
(d) Set the dial indicator at 0 mm (0 in.).
HINT:
S Use a dial indicator measuring tip as shown in the illustra-
tion.
S Make sure that the measuring tip is square to the cylinder
block gasket surface and piston head when taking the
measurements.
Measuring Tip (e) Find where the piston head protrudes most by slowly turn-
ing the crankshaft clockwise and counterclockwise.
Protrusion
A00999
Front (f) Measure each cylinder at 2 places as shown in the il-

lustration, making a total of 8 measurements.
25 mm
(g) For the piston protrusion value of each cylinder, use the
(0.98 in.)
average of the 2 measurements of each cylinder.
Piston protrusion: 0.68 -- 0.97 mm (0.0268 -- 0.0382 in.)
When removing piston and connecting rod assembly:
25 mm If the protrusion is not as specified, remove the piston and con-
(0.98 in.) necting rod assembly and reinstall it.
Measuring Point A01000
2. SELECT NEW CYLINDER HEAD GASKET

B Cutout
D Mark
HINT:
There are 3 sizes of new cylinder head gaskets, marked ”B”, ”D”
Mark
F or ”F” accordingly.
B, D or F
New installed cylinder head gasket thickness:
Mark B 1.40 -- 1.50 mm (0.0551 -- 0.0591 in.)
Mark D 1.50 -- 1.60 mm (0.0591 -- 0.0630 in.)
Mark F 1.60 -- 1.70 mm (0.0630 -- 0.0669 in.)
Front A03113
CONTINUED
TO MODEL INDEX
EM--11
Select the largest piston protrusion value from the measure-

ments made, then select a new appropriate gasket according
to the table below.
Piston protrusion Gasket size
0.68 -- 0.77 mm (0.0268 -- 0.0303 in.) Use B
0.78 -- 0.87 mm (0.0307 -- 0.0343 in.) Use D
0.88 -- 0.97 mm (0.0346 -- 0.0382 in.) Use F
TO MODEL INDEX
EM--12
ENGINE MECHANICAL -- CYLINDER BLOCK
CYLINDER BLOCK EM05E--01
DISASSEMBLY
RE MO V E CO NNE CTI NG RO D CAP S AND CHE CK O I L
CLEARANCE
Measure the Plastigage at its widest point.
Standard oil clearance:
STD 0.036 -- 0.064 mm (0.0014 -- 0.0025 in.)
A03116 U/S 0.25, U/S 0.50
2L 0.023 -- 0.073 mm (0.0009 -- 0.0029 in.)
2L--T, 3L, 5L 0.033 -- 0.079 mm (0.0013 -- 0.0031 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
Link Continues
TO MODEL INDEX
EM--13
EM05F--01
Mark INSPECTION
1, 2 or 3 1. INSPECT CYLINDER BORE DIAMETER
No.4 HINT:
No.3
No.2 There are 3 sizes of the standard cylinder bore diameter,
No.1 marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the
top or under of the cylinder block.
No.2 No.3 No.4

No.1
Mark
1, 2 or 3
Front
A00981
A03117 A00985
Using a cylinder gauge, measure the cylinder bore diameter at

positions A, B and C in the thrust and axial directions.
Standard diameter:
2L, 2L--T
Mark 1 92.000 -- 92.010 mm (3.6220 -- 3.6224 in.)
Mark 2 92.010 -- 92.020 mm (3.6224 -- 3.6228 in.)
Mark 3 92.020 -- 92.030 mm (3.6228 -- 3.6232 in.)
3L
Mark 1 96.000 -- 96.010 mm (3.7795 -- 3.7799 in.)
Thrust
1 Mark 2 96.010 -- 96.020 mm (3.7799 -- 3.7803 in.)
1 Direction
Front 2 Mark 3 96.020 -- 96.030 mm (3.7803 -- 3.7807 in.)
Axial
2 5L
Direction
10 mm Mark 1 99.500 -- 99.510 mm (3.9173 -- 3.9177 in.)
A (0.39 in.) Mark 2 99.510 -- 99.520 mm (3.9177 -- 3.9181 in.)
B Mark 3 99.520 -- 99.530 mm (3.9181 -- 3.9185 in.)
C 10 mm Maximum diameter:
A03118 (0.39 in.) 2L, 2L--T
A03086 A00984
STD 92.23 mm (3.6311 in.)
O/S 0.50 92.73 mm (3.6508 in.)
O/S 0.75 92.98 mm (3.6606 in.)
O/S 1.00 93.23 mm (3.6705 in.)
3L
STD 96.23 mm (3.7886 in.)
O/S 0.50 96.73 mm (3.8083 in.)
CONTINUED
TO MODEL INDEX
EM--14
5L
STD 99.73 mm (3.9264 in.)
O/S 0.50 100.23 mm (3.9461 in.)
2L, 2L--T, 3L Front Mark Size Mark 2. INSPECT PISTON

(Arrow) (2L) HINT:
Size There are 3 sizes of the standard piston diameter, marked ”1”,
Mark ”2” and ”3” accordingly. The mark is stamped on the piston top.
(2L--T, 3L) (a) Using a micrometer, measure the piston diameter at right
angles to the piston center line, the indicated distance
Distance from the piston head.
Distance
Front Mark 2L, 2L--T 58.27 -- 58.33 mm (2.2941 -- 2.2965 in.)
Size
5L (Arrow) 3L 56.27 -- 56.33 mm (2.2153 -- 2.2177 in.)
Mark
5L 61.27 -- 61.33 mm (2.4122 -- 2.4146 in.)
Piston diameter:
2L, 2L -- T
STD Mark 1 91.940 -- 91.950 mm (3.6197 -- 3.6201 in.)
Distance Mark 2 91.950 -- 91.960 mm (3.6201 -- 3.6205 in.)
Mark 3 91.960 -- 91.970 mm (3.6205 -- 3.6209 in.)
O/S 0.50 92.440 -- 92.470 mm (3.6394 -- 3.6405 in.)
A00994 O/S 0.75 92.690 -- 92.720 mm (3.6492 -- 3.6504 in.)

A00995 A03324
O/S 1.00 92.940 -- 92.970 mm (3.6590 -- 3.6602 in.)
3L
STD Mark 1 95.940 -- 95.950 mm (3.7772 -- 3.7776 in.)
Mark 2 95.950 -- 95.960 mm (3.7776 -- 3.7779 in.)
Mark 3 95.960 -- 95.970 mm (3.7779 -- 3.7783 in.)
O/S 0.50 96.440 -- 96.470 mm (3.7968 -- 3.7980 in.)
5L
STD Mark 1 99.450 -- 99.460 mm (3.9153 -- 3.9157 in.)
Mark 2 99.460 -- 99.470 mm (3.9157 -- 3.9161 in.)
Mark 3 99.470 -- 99.480 mm (3.9161 -- 3.9165 in.)
O/S 0.50 99.950 -- 99.980 mm (3.9350 -- 3.9362 in.)
(b) Measure the cylinder bore diameter in the thrust direc-

tions. (See step 1)
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
CONTINUED
TO MODEL INDEX
EM--15

2L, 2L--T, 3L 0.050 -- 0.070 mm (0.0020 -- 0.0028 in.)
5L 0.040 -- 0.060 mm (0.0016 -- 0.0024 in.)
Maximum oil clearance:

2L, 2L--T, 3L 0.14 mm (0.0055 in.)
5L 0.13 mm (0.0051 in.)
If the oil clearance is greater than maximum, replace all the 4

pistons and rebore all the 4 cylinders. If necessary, replace the
cylinder block.
HINT:
Use new cylinder block: Use a piston with the same number
mark as the cylinder bore diameter marked on the cylinder
block.
Mark 2L--, 2L--T, 3L Size Mark
1, 2 or 3 Front Mark (2L)
(Arrow)
No.4 Size Mark
No.3
No.2 (2L--T, 3L)
No.1 No.2 No.4
No.3 Front Mark
No.1 (Arrow)
Mark 5L Size
1, 2 or 3 Mark
Front
A00981 A03117 A00997 A00996 A00983
No.1 Ring 3. INSPECT PISTON RING GROOVE CLEARANCE

(a) No.1 Ring:
Install a new piston ring to the piston. Using a feeler
gauge, measure the clearance between the piston ring
and the wall of the ring groove.
Standard groove clearance:
2L 0.031 -- 0.079 mm (0.0012 -- 0.0031 in.)
2L--T 0.061 -- 0.109 mm (0.0024 -- 0.0043 in.)
A03087
3L 0.031 -- 0.075 mm (0.0012 -- 0.0030 in.)
5L 0.057 -- 0.101 mm (0.0022 -- 0.0040 in.)
Maximum groove clearance: 0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the piston.
CONTINUED
TO MODEL INDEX
EM--16
No.2 and Oil Rings (b) No.2 and Oil Rings:

Using a feeler gauge, measure the clearance between a
new piston ring and the wall of the ring groove.
Standard groove clearance:
No.2 2L, 3L 0.060 -- 0.105 mm (0.0024 -- 0.0041 in.)
2L--T 0.070 -- 0.115 mm (0.0028 -- 0.0045 in.)
5L 0.060 -- 0.100 mm (0.0024 -- 0.0039 in.)
Oil 0.030 -- 0.070 mm (0.0012 -- 0.0028 in.)
A03119 Maximum groove clearance: 0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the piston.
4. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 140 mm (5.51 in.) from the top of the
cylinder block.
140 mm
S04423
(c) Using a feeler gauge, measure the end gap.

Standard end gap:
No.1 0.350 -- 0.590 mm (0.0138 -- 0.0232 in.)
No.2 2L, 2L--T 0.450 -- 0.720 mm (0.0177 -- 0.0283 in.)
3L 0.400 -- 0.670 mm (0.0157 -- 0.0264 in.)
5L 0.470 -- 0.720 mm (0.0185 -- 0.0283 in.)
Oil 0.200 -- 0.520 mm (0.0079 -- 0.0205 in.)
Maximum end gap:

EM7639
No.1 1.29 mm (0.0508 in.)
No.2 2L, 2L--T, 5L 1.42 mm (0.0559 in.)
3L 1.37 mm (0.0539 in.)
Oil 1.22 mm (0.0480 in.)

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

(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
2L 27.008 -- 27.020 mm (1.0633 -- 1.0638 in.)
2L--T, 3L, 5L 29.008 -- 29.020 mm (1.1420 -- 1.1425 in.)
A03120 CONTINUED
TO MODEL INDEX
EM--17
(b) Using a micrometer, measure the piston pin diameter.

Piston pin diameter;
2L 27.000 -- 27.012 mm (1.0630 -- 1.0635 in.)
2L--T, 3L, 5L 29.000 -- 29.012 mm (1.1417 -- 1.1422 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
0.004 -- 0.012 mm (0.0002 -- 0.0005 in.)
EM0227
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bus-
ing. If necessary, replace the piston and piston pin as a set.
6. INSPECT CRANK PINS

Using a micrometer, measure the diameter of each crank pin.
Crank pin diameter:
2L
STD 52.988 -- 53.000 mm (2.0861 -- 2.0866 in.)
U/S 0.25 52.745 -- 52.755 mm (2.0766 -- 2.0770 in.)
U/S 0.50 52.495 -- 52.505 mm (2.0667 -- 2.0671 in.)
2L -- T, 3L, 5L
A03121 A03122 A03115
STD 54.988 -- 55.000 mm (2.1649 -- 2.1654 in.)
U/S 0.25 54.745 -- 54.755 mm (2.1553 -- 2.1557 in.)
U/S 0.50 54.495 -- 54.505 mm (2.1455 -- 2.1459 in.)
If the diameter is not as specified, check the oil clearance. If
necessary, grind or replace the crankshaft.
TO MODEL INDEX
EM--18
EM05G--01
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHINGS
SST (a) Using SST and a press, press out the bushing.
SST 2L
09222 -- 64012 (09222 -- 02022, 09222 -- 02041)
2L -- T, 3L, 5L
SST 09222 -- 54011 (09222 -- 03016, 09222 -- 03026)
A03127 A03128 A03126
(b) Using a round file, lightly file off any roughness from the
small end of the connecting rod.
A03129
(c) Attach the bushing to SST with the ball of SST inside the
oil hole of the bushing.
Oil Hole SST 2L
09222 -- 64012 (09222 -- 02031)
2L -- T, 3L, 5L
Ball 09222 -- 54011 (09222 -- 03021)
SST
A03130
(d) Align the oil holes of a new bushing and the connecting
rod.
Oil
Hole
A03131
(e) Using SST and a press, press in the bushing.

SST SST 2L
09222 -- 64012 (09222 -- 02022, 09222 -- 02031,
Bushing 09222 -- 02041)
SST
2L -- T, 3L, 5L
09222 -- 54011 (09222 -- 03016, 09222 -- 03021,
09222 -- 03026)
SST
A03132 A03133 A03125

CONTINUED
TO MODEL INDEX
EM--19
(f) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page) between the
bushing and piston pin.
A03134
(g) Check the piston pin fit at normal room temperature.

Coat the piston pin with engine oil, and push it into the
connecting rod with your thumb.
A03135
2. REPLACE OVERSIZED (O/S) PISTONS FOR

CYLINDER BORING
HINT:
S Bore all the 4 cylinders to the oversized piston outside di-
ameter.
S Replace all the piston rings with ones to match the over-
sized pistons.
(a) Keep 4 new O/S pistons.
O/S piston diameter:
2L, 2L--T
O/S 0.50 92.440 -- 92.470 mm (3.6394 -- 3.6405 in.)
O/S 0.75 92.690 -- 92.720 mm (3.6492 -- 3.6504 in.)
O/S 1.00 92.940 -- 92.970 mm (3.6590 -- 3.6602 in.)
3L
O/S 0.50 96.440 -- 96.470 mm (3.7968 -- 3.7980 in.)
5L
O/S 0.50 99.950 -- 99.980 mm (3.9350 -- 3.9362 in.)
CONTINUED
TO MODEL INDEX
EM--20
2L, 2L--T, 3L Front Mark Size Mark (b) Using a micrometer, measure the piston diameter at right
(Arrow) (2L) angles to the piston pin center line, the indicated distance
Size from the piston head.
Mark Distance:
(2L--T, 3L) 2L, 2L--T 58.27 -- 58.33 mm (2.2941 -- 2.2965 in.)
3L 56.27 -- 56.33 mm (2.2153 -- 2.2177 in.)
Distance 5L 61.27 -- 61.33 mm (2.4122 -- 2.4146 in.)
(c) Calculate the amount each cylinder is to be rebored as fol-

Front Mark lows:
Size
5L (Arrow) Size to be rebored = P + C -- H
Mark
P = Piston diameter
C = Piston clearance:
2L, 2L--T, 3L 0.050 -- 0.070 mm (0.0020 -- 0.0028 in.)
5L 0.040 -- 0.060 mm (0.0016 -- 0.0024 in.)
Distance H = Allowance for honing: 0.02 mm (0.0008 in.) or less
(d) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)
A00994
A00995 A03324 NOTICE:
Excess honing will destroy the finished roundness.
TO MODEL INDEX
EM--21
EM05H--01
REASSEMBLY
No.1
INSTALL PISTON RINGS
Using a piston ring expander, install the No.1 and No.2 piston
rings with the code mark facing upward.
Code
Code mark:
No.2 Mark
No.1 2L, 2L--T T1 or 1N
3L T1 or N1
5L 1N
A03124 A03123 A03114
No.2 2L, 2L--T 2T or 2N
3L T or 2N
5L 2N
TO MODEL INDEX
TURBO CHARGING
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . TC- 1
PRECAUTION ....................... TC-- 1/2
TROUBLESHOOTING ....................... TC-- 3/4
ON-VEHICLE INSPECTION . . . . . . . . . . . . . TC-- 5
COMPONENTS ....................... TC-- 6/7
REMOVAL ....................... TC -- 8
INSPECTION ....................... TC -- 9
REPLACEMENT ....................... TC -- 10/11
INSTALLATION ....................... TC -- 12/13
TO MODEL INDEX
TC--1
TURBOCHARGING -- TURBOCHARGER
TURBOCHARGER TC001--01
PRECAUTION
1. DO NOT STOP ENGINE IMMEDIATELY AFTER PULL-
ING TRAILER OR AFTER HIGH SPEED OR UPHILL
DRIVING
IDLE ENGINE FOR 20 -- 120 SECONDS, DEPENDING
ON HOW HARD VEHICLE HAS BEEN DRIVEN
2. AVOID SUDDEN ACCELERATION OR RACING IM-
MEDIATELY AFTER STARTING COLD ENGINE
3. IF TURBOCHARGER IS FOUND TO BE DEFECTIVE
AND MUST BE REPLACED, CHECK FOR CAUSE, AND
REPAIR OR REPLACE THESE ITEMS AS NEC-
ESSARY:
S Engine oil level and quality
S Conditions under which turbocharger was used
S Oil lines leading to turbocharger
4. USE CAUTION WHEN REMOVING AND REINSTAL-

NO! LING TURBOCHARGER ASSEMBLY
DO NOT DROP IT OR BANG IT AGAINST ANYTHING
OR GRASP IT BY EASILY -- DEFORMED PARTS, SUCH
AS ACTUATOR OR PUSH ROD, WHEN MOVING IT
5. BEFORE REMOVING TURBOCHARGER, PLUG IN-
TAKE AND EXHAUST PORTS AND OIL INLET TO PRE-
VENT ENTRY OF DIRT OR OTHER FOREIGN MATERI-
B00932 AL
6. IF REPLACING TURBOCHARGER, CHECK FOR AC-

CUMULATION OF SLUDGE PARTICLES IN OIL PIPE,
AND IF NECESSARY, REPLACE OIL PIPE
7. COMPLETELY REMOVE GASKET ADHERED TO LU-
BRICATION OIL PIPE FLANGE AND TURBOCHAR-
GER OIL FLANGE
8. WHEN REPLACING BOLT OR NUTS, USE ONLY AU-
THORIZED REPLACEMENT PARTS TO PREVENT
B00927 BREAKAGE OR DEFORMATION
9. IF REPLACING TURBOCHARGER, PUT APPROX. 20

cm3 (1.2 cu in.) OF FRESH OIL INTO TURBOCHAR-
GER OIL INLET HOLE AND TURN TURBINE WHEEL
BY HAND TO SPREAD OIL TO BEARING
10. IF OVERHAULING OR REPLACING ENGINE, CUT
FUEL SUPPLY AFTER REASSEMBLY AND CRANK
E NG I NE F O R 3 0 S E CO NDS TO DI S T RI BUTE O I L
THROUGHOUT ENGINE
B00933 THEN ALLOW ENGINE TO IDLE FOR 60 SECONDS.
CONTINUED
TO MODEL INDEX
TC--2
11. IF ENGINE IS RUNNING WITHOUT AIR CLEANER,

CASE COVER AND HOSE, ENTRY OF FOREIGN PAR-
TICLES WILL DAMAGE WHEELS WHICH RUN AT EX-
TREMELY HIGH SPEED
B00926
TO MODEL INDEX
TC--3
TC002--01
TROUBLESHOOTING
HINT:
Before troubleshooting the turbocharger, first check the engine itself. (valve clearance, engine compression,
injection timing etc.)
1. INSUFFICIENT ACCELERATION, LACK OF POWER OR EXCESSIVE FUEL CONSUMPTION
Possible Cause Check Procedure and Correction Method
1. TURBOCHARGING PRESSURE Check turbocharging pressure. (See page TC -- 5)
TOO LOW Turbocharging pressure:
60 -- 79 kPa (0.61 -- 0.81 kgf/cm2, 8.7 -- 11.5 psi)
If pressure is below specifications, begin diagnosis
from item 2.
2. RESTRICTED INTAKE SYSTEM Check intake air system, and repair or replace parts as
necessary. (See page TC -- 8)
3. LEAK IN INTAKE AIR SYSTEM Check intake air system, and repair or replace parts as
4. RESTRICTED EXHAUST SYSTEM Check exhaust system, and repair or replace parts as
5. LEAK IN EXHAUST SYSTEM Check exhaust system, and repair or replace parts as
necessary. (See -- page TC -- 8)
6. ERRATIC TURBOCHARGER Check rotation of impeller wheel.

OPERATION If it does not turn or turns with heavy drag, replace
turbochager.
Check axial and radial plays of turbine shaft.
(See page TC -- 9)
Maximum axial play: 0.13 mm (0.0051 in.) or less
Maximm radial play: 0.18 mm (0.0071 in.) or less
If play is greater than maximum, replace turbocharger.
2. ABNORMAL NOISE
Possible cause Check Procedure and Correction Method
1. TURBOCHARGING HEAT Check for loose, improperly installed or deformed Insu-
INSULATOR RESONANCE lator nut and bolts, and repair or replace as necessary.
2. EXHAUST PIPE LEAKING OR Check for deformed exhaust pipe, loose bolts or dam-
VIBRATING aged gasket, and repair or replace as necessary.
3. ERRATIC TURBOCHARGER Refer to item 6 of INSUFFICIENT ACCELERATION,

OPERATION LACK OF POWER OR EXCESSIVE FUEL CON-
SUMPTION.
CONTINUED
TO MODEL INDEX
TC--4
3. EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST
Possible Cause Check Procedure and Correction Method

FAULTY TURBOCHARGER OIL SEAL Check for oil leakage in exhaust system.
S Remove turbine outlet elbow from turbocharger,
and check for excessive carbon deposits on tur-
bine wheel. Excessive carbon deposits indicate a
faulty turbocharger.
Check for oil leakage in exhaust system.
S Check for axial and radial plays of turbine shaft,
and replace turbocharger if necessary.
(See page TC -- 9)
Maximum axial play: 0.13 mm (0.0051 in.) or less
Maximum radial play: 0.18 mm (0.0071 in.) or less
NOTICE:
Some oil mist in blowby from PCV is normal. Do not
mistake it for oil leak from turbocharger.
TO MODEL INDEX
TC--5
TC003--01
ON -- VEHICLE INSPECTION
1. INSPECT INTAKE AIR SYSTEM
Check for leakage or clogging between the air cleaner housing
and turbocharger inlet and between the turbocharger outlet and
cylinder head.
S Clogged air cleaner .... Clean or replace element
S Hoses collapsed or deformed ....Repair or replace
S Leakage from connections .... Check each
connection and repair
S Cracks in components .... Check and replace
2. INSPECT EXHAUST SYSTEM
Check for leakage or clogging between the cylinder head and
turbocharger inlet and between the turbochager outlet and ex-
haust pipe.
S Deformed components .... Repair or replace
S Foreign material in passages .... Remove
S Leakage from components .... Repair or replace
S Cracks in components .... Check and replace
3. CHECK TURBOCHARGING PRESSURE

(a) Warm up engine.
(b) Using a 3--way connector, connect SST (turbocharger
SST
pressure gauge) to the hose leading to the intake man-
ifold.
SST 09992 -- 00242
(c) Press in the clutch pedal, then press the accelerator ped-
al down as far as it will go. Measure the turbocharging
B00928 pressure at maximum speed (5,100 -- 5,200 rpm).
Standard pressure:
60 -- 79 kPa (0.61 -- 0.81 kgf/cm2, 8.7 -- 11.5 psi)
If the pressure is less than specified, check the intake air and
exhaust systems for leakage.
If there is no leakage, replace the turbocharger.
If the pressure is above specification, check if the actuator hose
is disconnected or cracked. If not, replace the turbocharger.
4. INSPECT IMPELLER WHEEL ROTATION
(See page TC -- 9)
5. INSPECT ACTUATOR OPERATION
(See page TC -- 9)
TO MODEL INDEX
TC--6
TC004--01
COMPONENTS
PCV Hose
Wire Clamp
Clamp
No.1 Turbo Insulator
No.2 Turbo Intake Pipe

Insulator and Intake Gas Filter
Flange Assembly
z z z Gasket
z 52 (530, 38)
z
z z No.3 Turbo
Insulator
Exhaust
Manifold Turbocharger
Stay Assembly
25.5 (260, 19)
z Gasket
z Gasket
Turbo Water Hose
Oil Hose
N∙m (kgf∙cm, ft∙lbf) : Specified torque CONTINUED

z Non--reusable part B00944
TO MODEL INDEX
TC--7
Turbocharger
Bearing Housing
Side Plate
z Gasket
z Actuator Kit Part
z
Actuator 26 (260, 19)
Hose z Gasket
E--Ring
Actuator z z
Plate Washer Turbine Outlet Elbow
z Gasket
z Gasket
Turbo Water Pipe
z z
19 (195, 14)
Turbo Oil Pipe

TO MODEL INDEX
TC--8
TC005--01
REMOVAL
(1) (2)
1. DRAIN ENGINE COOLANT
2. REMOVE INTAKE PIPE AND INTAKE FLANGE AS-
(3) SEMBLY
(a) Disconnect these parts:
(1) PCV hose from intake pipe
(2) Wire clamp from bracket
(3) Gas filter from clamp
B00945
(b) Remove the 3 nuts, and disconnect the intake flange from
the intake manifold. Remove the gasket.
(c) Loosen the hose clamp, and disconnect the air hose from
the turbocharger. Remove the intake pipe and intake
flange assembly.
3. REMOVE TURBO HEAT INSULATORS
(a) Remove the bolt, nut and No.1 turbo heat insulator.
(b) Remove the bolt and No.2 turbo heat insulator.
(c) Remove the 2 bolts and No.3 turbo heat insulator.
4. DISCONNECT TURBO WATER HOSES FROM TURBO
WATER PIPE
5. DISCONNECT OIL HOSE FROM TURBO OIL PIPE

6. REMOVE EXHAUST MANIFOLD STAY
Remove the 2 bolts, 2 nuts and manifold stay.
Oil
Hose
B00946
7. REMOVE TURBOCHARGER ASSEMBLY

(a) Remove the union bolt holding the turbo oil pipe to the oil
filter bracket. Remove the 2 gaskets.
(b) Remove the 4 nuts, the turbocharger assembly and gas-
ket.
8. REMOVE TURBO OIL PIPE FROM TURBOCHARGER
Remove the 2 nuts, oil pipe and gasket.
9. REMOVE TURBO WATER PIPE FROM TURBOCHAR-
Turbo Oil Pipe B00947 GER
Remove the 2 nuts, bolt, water pipe and gasket.
10. REMOVE TURBINE OUTLET ELBOW FROM TURBO-
CHARGER
Remove the 4 nuts, outlet elbow and gasket.
11. REMOVE BEARING HOUSING SIDE PLATE FROM
TURBOCHARGER
Remove the 2 bolts, side plate and gasket.
TO MODEL INDEX
TC--9
TC006--01
INSPECTION
1. INSPECT TURBINE SHAFT ROTATION
Grasp the edge of the turbine shaft, and turn it. Check that the
turbine shaft turns smoothly.
Turn If the turbine shaft does not turn or if it turns with a heavy drag,
replace the turbocharger.
B00929
2. INSPECT AXIAL PLAY OF TURBINE SHAFT

(a) Using a dial indicator, insert the needle of the dial indicator
into the exhaust side.
(b) Move the turbine shaft in an axial direction, measure the
axial play of the turbine shaft.
Maximum oil clearance: 0.13 mm (0.0051 in.) or less
Move
If the axial play is greater than maximum, replace the turbochar-
ger.
B00930
Needle of Dial Indicator 3. INSPECT RADIAL PLAY OF TURBINE SHAFT

(a) Using a dial indicator, insert the needle of the dial indicator
into the oil outlet hole, and set it in the center of the turbine
shaft.
Move (b) Move the turbine shaft in a radial direction, measure the
radial play of the turbine shaft.
Maximum oil clearance: 0.18 mm (0.0071 in.) or less
If the radial play is greater than maximum, replace the turbo-
B00931 charger.
4. INSPECT ACTUATOR AND WASTE GATE VALVE OP-

ERATION
Open (a) Disconnect the actuator air hose from the compressor
SST
housing.
(b) Using SST, apply approx. 83 kPa (0.85 kgf/cm2, 12.0 psi)
Move of pressure to the actuator.
SST 09992 -- 00242
Disconnect (c) Move the actuator push rod, and check that the waste
B00934 gate valve is open.
If operation is not as specified, replace the turbocharger.
NOTICE:
Never apply more than 94 kPa (0.95 kgf/cm2, 13.5 psi) of
pressure to the actuator.
(d) Reconnect the actuator air hose to the compressor hous-
ing.
TO MODEL INDEX
TC--10
TC007--01
REPLACEMENT
REPLACE ACTUAOR
(a) Remove the actuator.
(1) Remove the actuator hose.
(2) Remove the 2 bolts holding the actuator to the com-
pressor housing.
(3) Remove the E--ring holding the actuator push rod to
the waste gate valve link, and remove the actuator.
B00937
SST (b) Install the actuator.

(1) Using SST, apply approx. 83 kPa (0.85 kgf/cm2,
12.0 psi) of pressure to a new actuator.
SST 09992 -- 00242
(2) Connect the actuator push rod to the waste gate
valve link with a new E--ring.
(3) Install the actuator to the compressor housing with
the 2 bolts.
B00938 Torque: 19 N∙m (195 kgf∙cm, 14 ft∙lbf)
(4) Remove the SST.
NOTICE:
S Never apply more than 94 kPa (0.95 kgf/cm2, 13.5 psi)
of pressure to the actuaor.
S Do not use a hammer, etc. to force the actuator push
rod onto the waste gate valve link.
SST (c) Adjust the actuator rod stroke.

NOTICE:
Never apply more than 125 kPa (1.27 kgf/cm2, 11.3 psi) of
pressure to the actuator.
(1) Using a dial indicator, set the dial indicator in a
straight line with the actuator push rod.
Stroke (2) Using SST, apply 83 kPa (0.85 kgf/cm2, 12.0 psi) of
pressure to the actuator, and measure the actuator
B00936 push rod stroke.
SST 09992 -- 00242
(3) From the table below select the plate washer thick-
ness to match the stroke measured in (b) above.
Stroke measurement Requires plate washer thickness
mm (in.) mm (in.)
1.20 -- 1.70 (0.0472 -- 0.0670) None required

1.71 -- 2.20 (0.0673 -- 0.0866) 0.5 (0.020)
2.21 -- 2.70 (0.0870 -- 0.1063) 1.0 (0.039)
2.71 -- 3.20 (0.1067 -- 0.1260) 1.5 (0.059)
3.21 -- 3.70 (0.1264 -- 0.1457) 2.0 (0.079)
CONTINUED
TO MODEL INDEX
TC--11
3.71 -- 4.20 (0.1461 -- 0.1654) 2.5 (0.098)

4.21 -- 4.70 (0.1657 -- 0.1850) 3.0 (0.118)
4.71 -- 5.20 (0.1854 -- 0.2047) 3.5 (0.138)
5.21 -- 5.70 (0.2051 -- 0.2244) 4.0 (0.157)
5.71 -- 6.20 (0.2248 -- 0.2441) 4.5 (0.177)
6.21 -- 6.70 (0.2445 -- 0.2638) 5.0 (0.197)
6.71 -- 7.20 (0.2642 -- 0.2827) 5.5 (0.217)
7.21 -- 7.70 (0.2839 -- 0.3031) 6.0 (0.236)
7.71 -- 8.20 (0.3035 -- 0.3228) 6.5 (0.256)
NOTICE:
S Use a combination of plate washers of 0.5 mm (0.020
in.), 1.0 mm (0.039 in.), 2.0 mm (0.079 in.) and 3.0 mm
(0.118 in.) thickness to achieve the required thick-
ness.
S Use the same thickness of plate washer for the 2 loca-
tions between the actuator and compressor housing.
S If the plate washer thickness exceeds 3.5 mm (0.138
in.), replace the actuator installation bolts with the
bolts from the kit part.
(4) Using SST, apply approx. 83 kPa (0.85 kgf/cm2,
Selected 12.0 psi) of pressure to the actuator, and install the
Plate selected plate washers between the actuator and
SST
Washer compressor housing with the 2 bolts.
SST 09992 -- 00242
B00935
SST (5) Using SST, apply 83 kPa (0.85 kgf/cm2, 12.0 psi) of
pressure to the actuator, and measure the actuator
push rod stroke.
SST 09992 -- 00242
Standard stroke: 1.20 -- 1.70 mm (0.0472 -- 0.0669 in.)
If the stroke is outside specifications, reselect the plate wash-
Stroke ers.
(d) Install the actuator hose.
B00936 (e) Apply yellow paint from the actuator bolts to the actuator
bracket to indicate that they have been correctly installed.
(f) Check the turbocharging pressure. (See page TC -- 5)
TO MODEL INDEX
TC--12
TC008--01
INSTALLATION
NOTICE:
After replacing the turbocharger assembly, pour approx.
20 cm3 (1.2 cu in.) of fresh oil into the oil inlet hole and turn
the turbine wheel by hand to splash oil on the bearing.
1. I NS TALL BE ARI NG HO US I NG S I DE P LATE TO
TURBOCHARGER
Install a new gasket and the side plate with the 2 bolts.
B00933
Torque: 7.8 N∙m (80 kgf∙cm, 69 in.∙lbf)
2. INSTALL TURBINE OUTLET BLBOW TO TURBO-
CHARGER
Install a new gasket and the outlet elbow with 4 new nuts.
New 3. INSTALL TURBO OIL PIPE TO TURBOCHARGER

Gasket Install a new gasket and the oil pipe with 2 new nuts.
Small Torque: 19 N∙m (195 kgf∙cm, 14 ft∙lbf)
Oil NOTICE:
Hose Be careful of the gasket installation direction. Align the
small oil holes of the gasket and turbocharger.
4. INSTALL TURBO WATER PIPE TO TURBOCHARGER
Install a new gasket and the water pipe with the 2 nuts and bolt.
B00949 Torque:
5.5 N∙m (55 kgf∙cm, 49 in.∙lbf) for nut
12 N∙m (120 kgf∙cm, 9 ft∙lbf) for bolt
5. INSTALL TURBOCHARGER ASSEMBLY

Protrusion
(a) Place a new gasket on the exhaust manifold.
NOTICE:
Be careful of the installation direction.
CONTINUED
Front
B00948
TO MODEL INDEX
TC--13
(b) Install the turbocharger assembly with the 4 nuts.

Torque: 52 N∙m (530 kgf/cm2, 38 ft∙lbf)
(c) Connect the turbo oil pipe to the oil filter bracket with 2
new gaskets and the union bolt.
Turbo Oil Pipe B00947
6. INSTALL EXHAUST MANIFOLD STAY

Install the manifold stay with 2 new nuts and the 2 bolts.
Torque:
19 N∙m (195 kgf/cm2, 14 ft∙lbf) for nut
12 N∙m (120 kgf/cm2, 9 ft∙lbf) for bolt
7. CONNECT OIL HOSE TO TURBO OIL PIPE
8. CONNECT TURBO WATER HOSES TO TURBO WA-
TER PIPE
B00946 9. INSTALL TURBO INSULATORS
(a) Install the No.3 turbo heat insulator with the 2 bolts.
(b) Install the No.2 and No.3 turbo heat insulators with the 2
bolts and nut.
10. INSTALL INTAKE PIPE AND INTAKE FLANGE AS-

(1) (2) SEMBLY
(a) Connect the air hose to the turbocharger.
(b) Install a new gasket and the intake flange with the 3 nuts.
(3) Torque: 12 N∙m (120 kgf∙cm, 9 ft∙lbf)
(c) Connect these parts:
(1) PCV hose to intake pipe
(2) Wire clamp to bracket
B00945 (3) Gas filter to clamp
11. FILL WITH ENGINE COOLANT
12. START ENGINE AND CHECK FOR LEAKS
13. CHECK ENGINE OIL LEVEL
TO MODEL INDEX
ENGINE FUEL
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-- 1

FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . FU-- 2
INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . FU-- 3
INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . FU-- 4

RM520E)
TO MODEL INDEX
FU--1
ENGINE FUEL -- FUEL FILTER
FUEL FILTER FU00D--01
REPLACEMENT
1. REMOVE FUEL FILTER ASSEMBLY FROM FUEL
FILTER SUPPORT
2. REPLACE FUEL FILTER
(a) Loosen the drain plug, and drain the fuel from the fuel fil-
ter.
(b) Mount the fuel filter cap in a soft jaw vise.

(c) Using pliers, remove the fuel filter warning switch and O--
ring.
NOTICE:
Be careful not to damage the warning switch.
B00940
(d) Using SST, remove the fuel filter.

SST
SST 09228 -- 64030 for Europe
09228 -- 64040 for Except Europe
B00941
(e) Install a new fuel filter.

(1) Check and clean the fuel filter installation surface.
(2) Apply fuel to the gasket of a new fuel filter.
(3) Lightly screw the fuel filter into place, and tighten it
until the gasket comes into contact with the seat.
(4) Tighten it additional 3/4 turn by hand.
(f) Install the fuel filter warning switch to the fuel filter.
(1) Install a new O--ring to the warning switch.
B00942 (2) Apply fuel to the O--ring of the warning switch.
(3) Install the warning switch to the fuel filter by hand.
3. REINSTALL FUEL FILTER ASSEMBLY TO FUEL
FILTER SUPPORT
Operate
4. REFILL FUEL FILTER WITH FUEL
Operate the hand pump until you feel more resistance.
5. START ENGINE AND CHECK FOR FUEL LEAKS
B00943
TO MODEL INDEX
FU--2
ENGINE FUEL -- FUEL HEATER
FUEL HEATER FU00E--01
INSPECTION
1. REMOVE FUEL HEATER
B00910
2. INSPECT FUEL HEATER

0.5 -- 2.0 Ω (a) Apply vacuum of 34.7 ± 5.3 kPa (260 ± 40 mmHg,10.24
Ohmmeter ± 1.57 in.Hg) or more to the vacuum switch port.
(b) Using an ohmmeter, measure the resistance between ter-
minal 2 and the switch body.
Resistance: 0.5 -- 2.0 Ω at 20˚C (68˚F)
Vacuum
If the resistance is not as specified, replace the fuel heater and
vacuum switch assembly.
2 B00908
3. INSPECT VACUUM SWITCH

No Continuity (a) Inspect the switch continuity
Ohmmeter Using an ohmmeter, check that there is no continuity be-
tween terminal 2 and the switch body.
If there is continuity, replace the fuel heater and vacuum switch
assembly.
2 B00909
(b) Inspect the switch operation

Continuity (1) Apply vacuum of 34.7 ± 5.3 kPa (260 ± 40
Ohmmeter mmHg,10.24 ± 1.57 in.Hg) or more to the vacuum
switch port.
(2) Using an ohmmeter, check that there is continuity
between terminal 2 and the switch body.
Vacuum
If there is no continuity, replace the fuel heater and vacuum
switch assembly.
2 B00908 4. REINSTALL FUEL HEATER
TO MODEL INDEX
FU--3
ENGINE FUEL -- INJECTION NOZZLE
INJECTION NOZZLE FU00F--01
TEST
INJECTION PRESSURE TEST
Opening pressure:
2L, 2L--T, 3L
New nozzle 14,810 -- 15,590 kPa (151 -- 159 kgf/cm2, 2,148 -- 2,262 psi)
Reused nozzle 14,220 -- 15,200 kPa (145 -- 155 kgf/cm2, 2,062 -- 2,205 psi)
B01388 5L
New nozzle 15,790 -- 16,570 kPa (161 -- 169 kgf/cm2, 2,290 -- 2,404 psi)
Reused nozzle 15,200 -- 16,181 kPa (155 -- 165 kgf/cm2, 2,205 -- 2,347 psi)
TO MODEL INDEX
ENGINE FUEL – INJECTION PUMP
PAGE 1 of 3
INJECTION PUMP – COMPONENTS FU-4/10
DISASSEMBLY FU11/12
INSPECTION FU-13
ADJUSTMENT
1. PRE-TEST CHECK AND PREPARATION FU-14/17
2. 2L-T: CHECK BOOST COMPENSATOR FOR AIR TIGHTNESS FU-18
3. w/ HAC: CHECK HIGH ALTITUDE COMPENSATOR FOR AIR TIGHTNESS FU-18
4. PRE-SET FULL LOAD INJECTION VOLUME FU-18
2L w/ ACSD: (Part No. 22100-5B320, 5B360) FU-18
2L w/o ACSD: (Part No.22100-54770, 54780, 54800, 54810) FU-19
2L-T: (Part No. 22100-5B460, 5B670) FU-19
3L: (Part No. 22100-54850, 54860, 54870, 54880) FU-19
3l: (Part No. 22100-54710, 5B510) FU-19
5L w/ HAC: (Part No. 22100-5B720) FU-19
5L w/o HAC: (Part No. 22100-5B710) FU-19/20
5. w/o HAC: PRE-SET LOAD SENSING TIMER FU-20
6. PRE-SET MAXIMUM SPEED FU-20/21
2L w/o ACSD: (Part No. 22100-54770, 54780, 54800, 54810) FU-21
2L-T: (Part No. 22100-5B460, 5B670) FU-21
3L: (Part No. 22100-54710, 5B510) FU-21
3L: (Part No. 22100-54850, 54860, 54870, 54880) FU-21
5L: (Part No. 22100-5B710, 5B720) FU-21/22
7. ADJUST PUMP INNER PRESSURE FU-22
8. CHECK OVERFLOW VOLUME FU-22/23
9. w/ ACSD: RELEASE COLD STARING SYSTEM FU-23
10. ADJUST TIMER FU-23
2Lw/o ACSD: (Part No. 22100-54770, 54780, 54800, 54810) FU-23
2L-T: (Part No. 22100-5B460, 5B670) FU-24
3L w/ ACSD: (Part No. 22100-5B510) FU-24
3L w/o ACSD: (Part No. 22100-54710, 54850, 54860, 54870, 54880) FU-24
5L w/o ACSD: (Part No. 22100-5B720) FU-24/25
11. ADJUST FULL LOAD INJECTION VOLUME FU-25/26
2L-T: (Part No. 22100-5B460, 5B670) FU-26
3L: (Part No. 22100-54850, 54860, 54870, 54880) FU-26
3L: (Part No. 22100-54710, 5B510) FU-26
5L w/ HAC: (Part No. 22100-5B720) FU-26
5L w/o HAC: (Part No. 22100-5B710) FU-27
CONTINUED
TO MODEL INDEX
PAGE 2 OF 3
12. ADJUST MAXIMUM SPEED FU-27
2L-T: (Part No. 22100-5B460, 5B670) FU-28
3L: (Part No. 22100-54710, 5B510) FU-28
3L: (Part No. 22100-54850, 54860, 54870, 54880) FU-28
5L: (Part No. 22100-5B710, 5B720) FU-28
13 CHECK IN INJECTION VOLUME FU-29
2L w/ HAC: (Part No. 22100-54800, 54810) FU-29
2L w/o HAC for w/ ACSD: (Part No. 22100-5B320, 5B360) FU-29
2L w/o HAC for w/o ACSD: (Part No. 22100-54770, 54780) FU-29
2L-T: (Part No. 22100-5B460, 5B670) FU-30
3L w/ HAC: (Part No. 22100-54870, 54880) FU-30
3L w/o HAC: (Part No. 22100-54710, 5B510) FU-30
3L w/o HAC: (Part No. 22100-54850, 54860) FU-31
5L w/ HAC: (Part No. 22100-5B720) FU-31
5L w/o HAC: (Part No. 22100-5B710) FU-31/33
14 L-T: ADJUST FULL LOAD MINIMUM INJECTION VOLUME FU-33
15 2L-T: ADJUST BOOST COMPENSATOR FU-33
16 2L-T: CHECK FOR CHARACTERISTIC TENDENCY FU-34
17 2L-T: CHECK HYSTERESIS FU-34
18 w/o HAC (2L, 3L), 2L-T, 5L: ADJUST LOAD SENSING TIMER FU-35
MEASURE THE INJECTION VOLUME
2L, 3L, 5L: FU-35
2L-T: FU-35
MEASURE THE INJECTION VOLUME AT THE DROP POINT (STARTING POINT) FU-35
2L, 3L, 5L: FU-35
2L-T: FU-35
PUMP INNER PRESSURE STOPS DROPPING FU-36
2L w/ ACSD: (Part N. 22100-5B320, 5B360) FU-36
2L w/o ACSD: (Part No. 22100-54770, 54780) FU-36
2L-T: (Part No. 22100-5B460, 5B670) FU-36
3L: (Part No. 22100-54710, 5B510) FU-36
3L: (Part No. 22100-54850, 54860) FU-36
5L w/o ACSD: (Part No. 22100-5B720) FU-37
CHECK THE TIMER PISTON FLUCTUATION WHEN THE ADJUSTING LEVER IS MOVED
FROM THE MAXIMUM SPEED SIDE TO THE IDLE SPEED SIDE FU-37
2L w/o ACSD: (Part No. 22100-54770, 54780) FU-37
2L-T: (Part No. 22100-5B460, 5B670) FU-37
3L w/o ACSD: (Part No. 22100-54710, 54850, 54860) FU-37
5L w/o ACSD: (Part NO. 22100-5B720) FU-37/38
CONTINUED
TO MODEL INDEX
PAGE 3 OF 3
19. ADJUST IDLE SPEED FU-38

2L: (Part No. 22100-54770, 54780, 54800, 54810, 5B320, 5B360) FU-38
2L-T: (Part No. 22100-5B460, 5B670) FU-38
3L: (Part No. 22100-54710, 54850, 54860, 54870, 54880, 5B510) FU-38
5L: (Part No. 22100-5B710, 5B720) FU-39
20. w/ ACSD: ADJUST COLD STARTING SYSTEM FU-39
2L: (Part No. 22100-5B320, 5B360) FU-40
2L-T: (Part No. 22100-5B460, 5B670) FU-40
3L: (Part No. 22100-5B510) FU-40
5L: (Part No. 22100-5B710) FU-40
21. w/ ACSD: ADJUST FAST IDLE SPEED FU-40
2L: (Part No. 22100-5B320, 5B360) FU-41
2L-T: (Part No. 22100-5B460, 5B670) FU-41
3L: (Part No. 22100-5B510) FU-41
5L: (Part No. 22100-5B710) FU-41/42
22. POST ADJUSTMENT CHECK FU-42
23. REMOVE INJECTION PUMP FROM PUMP TESTER FU-42
24. SEAL PARTS FU-42
REASSEMBLY
1. ASSEMBLE BOOST COMPENSATOR FU-43/45
2. PERFORM AIR TIGHT TEST FU-45
TO MODEL INDEX
FU--4
ENGINE FUEL -- INJECTION PUMP
INJECTION PUMP
FU00G--01
COMPONENTS
Turbo Water No.1 Timing Belt Cover
Hose (2L--T)
Gasket
Hose Clamp Timing Belt
(2L--T)
Drive Belt
Water Pump
Pulley
Timing Belt Guide

x9
Crankshaft
Fan and Fluid 235 (2,400, 173)
Pulley 2L--T
Coupling Assembly Clamp
PCV Hose
Collar Wire Clamp
Glow Plug Wire
Spacer
Glow Plug Connector
13 (130, 9)
Glow Plug
Gas Filter
Collar
z Gasket
Injection Pump Intake Pipe
Drive Pulley and Intake
Flange Assembly
w/ No.2 Cylinder Head Cover

64 (650, 47) No.2 Cylinder Oil
Head Cover Filter
Cap
Collar
PCV Hose
zNon--reusable part B01368
CONTINUED
TO MODEL INDEX
FU--5
w/ TCV
Connector for
Pickup Sensor
Connector for
Timing Control
Valve and Fuel
Cut Solenoid
Pipe Clamp
24.5 (250, 18)
Injection Pipe
Pipe Clamp
Accelerator Link
Water Bypass Hose

(w/ ACSD)
Wire
Clamp Hose Clamp
Connecting Link
Boost Compersator Hose
Fuel Return Hose
(2L--T)
No.2 Cylinder Block Idle--Up Vacuum Hose (w/ A/C)
Insulator
(Europe and Australia) Fuel Return Hose
Fuel Inlet Hose

Injection Pump
Connector for Fuel Cut Solenoid

and Pickup Sensor (w/ TCV)
No.3 Cylinder Block Insulator
(Europe and Australia)
Injection Pump Stay
(2L, 3L, 5L)
Injection Pump Stay
(2L--T)
CONTINUED
TO MODEL INDEX
FU--6
24.55 (250, 18)
z Gasket
Fuel Inlet Pipe
z Gasket
24.55 (250, 18)
Injection Pump
(2L--T)
z Gasket z Gasket
Fuel Return Pipe
Injection Pump
(w/ HAC)
Injection Pump
(w/o HAC)
24.55 (250, 18)
z Gasket
Fuel Return Pipe
z Gasket
CONTINUED
TO MODEL INDEX
FU--7
2L--T
Diaphragm Cover
Spring Seat
No.2 Adjusting Diaphragm

Lever
Spring Seat
No.1 Adjusting
Lever Push Rod
Return Spring Boost Compensator Spring
Overflow Screw
Rubber Cap
Guide Bushing Full Load Set Screw
Plate Washer
z O--Ring
z Gasket Idle Speed Adjusting Screw
Maximum Speed Adjusting Screw
Governor Cover
Connecting Pin
Control Lever
z Gasket
Support Pin Lead Wire
z O--Ring
Plate Washer (w/ Pickup Sensor)
Spring Seat
z Gasket
Damper Spring
Speed Control
Spring Fuel Cut Solenoid
z O--Ring Lead Wire

Adjusting Lever Spring
Shaft (w/o Pickup Sensor)
Valve
Lead Clamp Strainer
Pickup Sensor Wave Washer
Connector Bracket
z O--Ring
z Set Key
Idle--Up Actuator
(w/ A/C)
z Gasket
Thermo Wax
Idle--Up Lever
CONTINUED
TO MODEL INDEX
FU--8
w/ HAC
Pnematic Bellows Cover
z Gasket
Rubber Cap
Rubber Cap
No.2 Adjusting
Level
Pnematic Bellows
No.1 Adjusting
Lever Full Load Set Screw
Push Rod
Return Spring
Idle--Up
Rubber Cap
Pnematic Bellows Actuator
Spring (w/ A/C)
z Gasket Plate Washer

Governor Cover z O--Ring
Connecting Pin Idle Speed Adjusting Screw
Maximum Speed
Lever Control
Adjusting Screw
Spring Lead Wire
z Gasket
z Gasket (w/ Pickup Sensor)
z O--Ring Control Lever
Plate Washer Support Pin
Spring Seat
z Gasket
Damper Spring
Speed Control Spring Fuel Cut
Adjusting Lever Solenoid
Shaft z O--Ring
Spring Lead Wire
Valve (w/o Pickup Sensor)
Lead Clamp
Strainer
Wave Washer
Pickup Sensor Connector Bracket
z O--Ring
z Set Key
CONTINUED
TO MODEL INDEX
FU--9
w/o HAC
Maximum Speed Adjusting Screw
No.2 Adjusting
Lever
No.1 Adjusting
Lever Full Load Set Screw
Return Spring Plate Washer
z O--Ring
Idle Speed Idle--Up
Adjusting Actuator
Governor Cover
z O--Ring Screw w/o ACSD
Plate Washer for w/ A/C
Lead Wire
Speed Control (w/ Pickup Sensor for w/o TCV)
Adjusting Spring
Lever Shaft
Spring Seat
Fuel Cut Lead Wire
Damper Spring Solenoid (w/o Pickup Sensor)
Spring z O--Ring
Valve
Connector Bracket Strainer
(w/ TCV) Wave
Washer
Lead Wire
Lead Clamp (w/ Pickup Sensor for w/ TCV)
w/ Pickup Sensor
for w/ TCV Lead Clamp Connector Bracket (w/o TCV)
Pickup Sensor
(w/ TCV) z Gasket Timing Control
Pickup Sensor
Valve (w/ TCV)
(w/o TCV) z O--Ring z O--Ring
Set Key
Thermo Wax (w/ ACSD)
11.3 (115, 8)
Idle--Up Actuator
Pipe Clamp (w/ TCV) (w/ A/C)
Pipe Clamp (w/ TCV)
z Gasket
Overflow Pipe (w/ TCV)
z Gasket
z Gasket
z Gasket
15.7 (160, 12) Idle--Up Lever
(w/ ACSD)
CONTINUED
TO MODEL INDEX
FU--10
Bearing Retainer
z E--Ring
Governor Sleeve
No.2 Flyweight Washer
Flyweight Holder
No.1 Flyweight Washer
Governor Gear Bearing
Adjusting Washer Stop Ring
Governor Shaft Face Camplate
Flyweight Coupling Spring
z O--Ring
z Gasket
Governor Link
Regurator Valve Fuel Inlet Hollow Screw Coupling
8.85 (90, 78 in.∙lbf) 36.8 (375, 27)
z Gasket Roller and Washer
O--Ring
O--Ring Clip
Pump Body Roller Ring Stopper Pin
RH Timer Cover Slide Pin
z Gasket Set Key
z Oil Seal
z Joint Rubber
z Gasket Blade Drive Shaft

Timer Piston
Drive Gear
Timer Spring Washer *1 Drive Shaft Washer
Sub--Piston
Feed Pump Cover
Timer
Inner Timer Spring *1 Feed Pump Rotor
Spring *2 z Gasket *1 Feed Pump Liner
Timer z O--Ring *1 LH Timer Cover *1
Outer Spring *2 Timer Distributive Head Plug Plug Bolt
Spring Washer * 2 Adjusting Screw *1 68.65 (700, 51) z Gasket Spring
z O--Ring
z Gasket *2
z O--Ring Lever Support
Timer Adjusting Spring
Screw *2
Distributive Head
LH Timer Cover *2 Plunger Spring Guide 58.85 (600, 43)
Delivery Valve
Plunger Spring Shim
Delivery Holder
Upper Spring Shim
Plunger Spring Valve
z Gasket
z O--Ring
Upper Plunger Plate
Spill Ring
Pump Plunger
Lower Spring Seat
Plunger
Adjusting Shim Lower Plunger Plate
Lead Clamp
(w/ TCV)
z Non--reusable part
*1 2L w/o TCV, 3L w/o ACSD
*2 2L w/ TCV, 2L--T, 3L w/ ACSD, 5L B01362
TO MODEL INDEX
FU--11
FU00H--01
4 mm
DISASSEMBLY
2L -- T:
Hexagon
Wrench DISASSEMBLE BOOST COMPENSATOR
(a) Using a 4 mm hexagon wrench, remove the bolt and gas-
ket.
(b) Remove the rubber cap and overflow screw.
B01345
(c) Remove the boost compensator diaphragm.

(1) Using a 5 mm hexagon wrench, remove the 4 bolts
and diaphragm cover.
5 mm
Hexagon
Wrench
B01347
(2) Remove these parts:

Diaphragm
. Diaphragm assembly
Assembly
. Spring
Spring
B01348
Spring Seat (3) Remove the nut, and disassemble these parts:
Diaphram . 2 spring seats
. Diaphragm
. Push rod
Spring Seat
Push Rod
B01387
(d) Remove the guide bushing.
CONTINUED
S03281
TO MODEL INDEX
FU--12
(e) Remove the control lever.

(1) Using a 4 mm hexagon wrench, remove the 2 bolts
and gaskets.
4 mm
Hexagon
Wrench
B01350
(2) Using a small screwdriver, push out the support pin

and remove the control lever.
B01351
(3) Using needle nose pliers, remove the connecting

pin.
Tape NOTICE:
Be careful not to damage the connecting pin. Tape the tip
of the pliers.
B01352
TO MODEL INDEX
FU--13
FU00I--01
INSPECTION
INSPECT SPRING LENGTH
Using vernier calipers, measure the free length of each spring.
Spring free length: mm (in.)
Delivery valve spring 24.4 (0.961)
Plunger spring 30.0 (1.181)
Coupling spring 16.6 (0.654)
EM0801
Pneumatic bellows spring (w/ HAC) 30.0 (1.181)
Boost compensator spring (2L--T) 19.4 (0.764)
If the free length is not as specified, replace the spring(s).
TO MODEL INDEX
FU--14
FU00J--01
ADJUSTMENT
1. PRE -- TEST CHECK AND PREPARATION
(a) The specifications for test nozzle and nozzle holders are
as follows.
Test nozzle: DN12SD12 (DENSO)
Test nozzle opening pressure:
14,220 -- 15,200 kPa
(145 -- 155 kgf/cm2, 2,062 -- 2,205 psi)
(b) Check the accuracy of the tachometer.
Allowable error: ± 40 rpm
(c) Install the angle gauge stand.
(d) Mount the injection pump body on the pump tester.
HINT:
Place a mark on the key groove portion of the coupling.
S04623
(e) Install an injection pipe with these specifications:

Outer diameter 6.0 mm (0.236 in.)
Inner diameter 2.0 mm (0.079 in.)
Length 840 mm (33.07 in.)
Minimum bending radius 25 mm (0.98 in.) or more
B00057
Fuel Inlet Hollow Screw Fuel Inlet Pipe (f) Remove the fuel inlet hollow screw.
(g) Connect the fuel inlet pipe with an adapter.
S04624 S04625 B00051
w/ HAC w/o HAC (h) Install an overflow hose with the 2 gaskets and an over-
Overflow Screw flow screw.
HINT:
Always use the overflow screw installed on the pump to be ad-
justed.
(i) Using a 5 mm hexagon wrench, remove the 2 bolts and
Overflow Hose RH timer cover.
S04630 S04650 B00052
CONTINUED
TO MODEL INDEX
FU--15
(j) Install the inner pressure gauge with the timer measuring
device.
Timer Measuring Part No. 95095--10231, 95095--10480 (DENSO)
Device Torque: 8.35 N∙m (85 kgf∙cm, 74 in.∙lbf)
HINT:
Bleed the air by the air bleed screw.
Air Bleed (k) Connect SST (turbocharger pressure gauge) to the boost
Screw compensator
5 mm Hexagon Wrench S04645 SST 09992 -- 00242
2L--T Inner Pressure Gauge

SST
Turbocharger Fuel Pressure Gauge
Pressure Gauge
Adjusting Valve
D C B A Fuel Filter
Nozzle
Measuring Fuel Feed
Cylinder Pump
Fuel Tank
Timer Measuring Device
B01354
w/ HAC Inner Pressure Gauge

Fuel Pressure Gauge
Vacuum Gauge
Adjusting Valve
D C B A Fuel Filter
Nozzle
Measuring Fuel Feed
Cylinder Pump
Fuel Tank
S02310
CONTINUED
TO MODEL INDEX
FU--16
w/o HAC Inner Pressure Gauge

Fuel Pressure Gauge
Adjusting Valve
D C B A Fuel Filter
Nozzle
Measuring Fuel Feed
Cylinder Pump
Fuel Tank
S03392
(l) Apply about 6 volts of DC power to the fuel cut solenoid.

NOTICE:
S When applying voltage to the solenoid, position the
battery as far away from the solenoid as possible so
that a spark does not occur.
S When connecting the battery cable, connect the sole-
noid side first.
HINT:
Connect the battery through a 10 W bulb.
(m) The pressure for feeding fuel to the injection pump should
be 20 kPa (0.2 kgf/cm2, 2.8 psi). The fuel temperature for
pump testing should be 40 -- 45˚C (104 -- 113˚F).
(n) Install an angle gauge to the stand, and set it to the adjust-
ing lever.
Part No. 95095 -- 10360 (Stand w/ angle gauge)
(o) Secure the adjusting lever fully on the maximum speed
side.
CONTINUED
Maximum Speed Side

B00449
TO MODEL INDEX
FU--17
(p) Check the installation direction of the camplate as follows:

(1) Disconnect the injection pipe from the position
marked ”C” on the distributive head.
(2) Using SST, remove the delivery valve holder.
SST 09260 -- 54012 (09269 -- 54020)
SST S03391
(3) Check that fuel is flowing out when the mark is in the
position shown in the illustration.
If not, it is improperly assembled.
(4) Disassemble and change the camplate position
180˚ in the opposite direction.
HINT:
At this time, disconnect the fuel cut solenoid wire harness.
B00425 B00470 B00903
(5) Using SST, install the delivery valve holder.

SST 09260 -- 54012 (09269 -- 54020)
(6) Connect the injection pipe.
SST S03391
(q) Bleed the air from the injection pipes.

(r) Race the injection pump for 5 minutes at 2,000 rpm.
HINT:
Do this operation by replacing the overflow screw to a hollow
screw.
NOTICE:
Check that there is no fuel leakage or abnormal noise.
B00426
HINT:
30 Seconds S Measure the volume of each injection cylinder with a mea-
suring cylinder.
S Before measuring the injection volume, first hold the cylin-
der tilted for at least 30 seconds to discard all the fuel.
CONTINUED
B00427 B00428 B00439

TO MODEL INDEX
FU--18
2L--T Pressure 2. 2L -- T:
CHECK BOOST COMPENSATOR FOR AIR
TIGHTNESS
(a) Operate the boost compensator with 0 kPa (0 kgf/cm2, 0
psi) to 120 ± 6.7 kPa (1.22 ± 0.07 kgf/cm2, 17.4 ± 1.0 psi)
of pressure for 10 seconds for each and repeat this opera-
tion 4 times.
(b) Apply 133 kPa (1.36 kgf/cm2, 19.3 psi) of pressure to the
B01355 boost compensator.
(c) Measure the time it takes for pressure to drop to 131 kPa
(1.34 kgf/cm2, 19.1 psi).
Pressure drop: 10 seconds or more
3. w/ HAC:
w/ HAC
CHECK HIGH ALTITUDE COMPENSATOR FOR AIR
TIGHTNESS
(a) Apply 73 kPa (548 mmHg, 21.56 in.Hg) of vacuum to the
high altitude compensator.
(b) Measure the time it takes for vacuum to drop to 72 kPa
(540 mmHg, 21.26 in.Hg).
Vacuum Vacuum drop: 5 seconds or more
S04631 4. PRE -- SET FULL LOAD INJECTION VOLUME
(a) Set the adjusting lever to maximum position.
(b) 2L--T:
Apply 62.7 kPa (0.64 kgf/cm2, 9.1 psi) of pressure to the
boost compensator.
(c) w/ HAC:
Apply 101 kPa (760 mmHg, 29.83 in.Hg) of vacuum to the
(d) Measure the injection volume.
2L w/ ACSD:
(Part No. 22100--5B320, 5B360)
Injection volume of
No. of measuring
Pump rpm each cylinder
strokes
cc (cu in.)
11.04 -- 11.36
1,200 200
(0.67 -- 0.69)
CONTINUED
TO MODEL INDEX
FU--19
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
Injection volume of
No. of measuring
strokes
cc (cu in.)
10.42 -- 10.74
1,200 200
(0.64 -- 0.66)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
strokes
cc (cu in.)
13.70 -- 14.02
1,000 200
(0.84 -- 0.86)
3L:
(Part No. 22100 -- 54850, 54860, 54870, 54880)
Injection volume of
No. of measuring
strokes
cc (cu in.)
11.56 -- 11.88
1,200 200
(0.71 -- 0.72)
3L:
(Part No. 22100 -- 54710, 5B510)
Injection volume of
No. of measuring
strokes
cc (cu in.)
10.96 -- 11.28
1,200 200
(0.67 -- 0.69)
5L w/ HAC:
(Part No. 22100 -- 5B720)
Injection volume of
No. of measuring
strokes
cc (cu in.)
12.82 -- 13.14
1,600 200
(0.78 -- 0.80)
5L w/o HAC:
(Part No. 22100 -- 5B710)
Injection volume of
No. of measuring
strokes
cc (cu in.)
12.18 -- 12.50
1,200 200
(0.74 -- 0.76)
CONTINUED
TO MODEL INDEX
FU--20
w/ Cap Seal Type (e) w/ Cap Seal Type:

(1) Disconnect the dust cover from the fuel cut sole-
noid.
(2) Using a small screwdriver, pry the 4 claws.
(3) Remove the cap seal.
Pry
B01365
w/ Collar Seal Type (f) w/ Collar Seal Type:

90˚ or More Remove the collar seal as follows:
Lock Nut
(1) Hold the full load set screw, and release the collar
Collar Seal
seal from the spot weld by turning the lock nut coun-
terclockwise by 90˚ or more.
S04642
w/ Collar Seal Type

(2) Using a screwdriver, pry out the collar seal.
(g) w/ Wire Seal Type:
Cut off the wire seal.
S04643
Full Load Set Screw (h) Adjust by turning the full load set screw.
HINT:
The injection volume will increase about 3 cc (0.18 cu in.) with
each 1/2 turn of the screw.
S04644
w/ HAC 5. w/o HAC:

0.5 -- 2.0 mm PRE -- SET LOAD SENSING TIMER
Governor Shaft
Using a 5 mm hexagon wrench, adjust the protrusion of the gov-
ernor shaft.
Protrusion: 0.5 -- 2.0 mm (0.020 -- 0.079 in.)
6. PRE -- SET MAXIMUM SPEED
5 mm Hexagon Wrench (b) 2L--T:
B00054 B00055 B00421 Apply 62.7 kPa (0.64 kgf/cm2, 9.1 psi) of pressure to the
boost compensator.
CONTINUED
TO MODEL INDEX
FU--21
(c) w/ HAC:
(d) Measure the injection volume.
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
Injection volume of
No. of measuring
strokes
cc (cu in.)
4.0 -- 5.6
2,575 200
(0.24 -- 0.34)
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
Injection volume of
No. of measuring
strokes
cc (cu in.)
4.0 -- 5.6
2,450 200
(0.24 -- 0.34)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
strokes
cc (cu in.)
4.3 -- 6.3
2,400 200
(0.26 -- 0.38)
3L:
(Part No. 22100 -- 54710, 5B510)
Injection volume of
No. of measuring
strokes
cc (cu in.)
4.6 -- 6.2
2,200 200
(0.28 -- 0.38)
3L:
(Part No. 22100 -- 54850, 54860, 54870, 54880)
Injection volume of
No. of measuring
strokes
cc (cu in.)
4.6 -- 6.2
2,300 200
(0.28 -- 0.38)
5L:
(Part No. 22100 -- 5B710, 5B720)
Injection volume of
No. of measuring
strokes
cc (cu in.)
4.6 -- 6.2
2,300 200
(0.28 -- 0.38)
CONTINUED
TO MODEL INDEX
FU--22
Maximum Speed Adjusting Screw (e) Cut off the seal wire.
(f) Adjust the injection volume with the maximum speed ad-
justing screw.
7. ADJUST PUMP INNER PRESSURE
(b) 2L--T:
boost compensator.
S04648 (c) w/ HAC:
(d) Measure the pump inner pressure at the below listed rpm.
2L, 3L, 5L:
Pump rpm Inner pressure kpa (kgf/cm2, psi)
500 314 -- 372 (3.2 -- 3.8, 46 -- 54)
2,100 648 -- 706 (6.6 -- 7.2, 94 -- 102)
2L--T:
Pump rpm Inner pressure kpa (kgf/cm2, psi)
500 353 -- 411 (3.6 -- 4.2, 51 -- 60)
2,100 687 -- 745 (7.0 -- 7.6, 100 -- 108)
If the pressure is low, adjust by lightly tapping the regulator

valve piston while watching the pressure gauge.
Tap
HINT:
If the pressure is too high or if the regulator valve was tapped
in too far, the regulator valve must be replaced.
8. CHECK OVERFLOW VOLUME
(a) Set adjusting lever to maximum position.
(b) 2L--T:
B00429 B00430 B00440 Apply 62.7 kPa (0.64 kgf/cm2, 9.1 psi) of pressure to the
boost compensator.
(c) w/ HAC:
CONTINUED
TO MODEL INDEX
FU--23
(d) Measure the overflow volume at the below listed rpm.

Pump rpm Overflow volume cc/min. (cu in./min.)
2,200 367 -- 800 (22.4 -- 48.8)
HINT:
Always use the overflow screw installed on the pump to the ad-
justed.
B00431

Turn RELEASE COLD STARING SYSTEM
(a) Using a screwdriver, turn the cold starting lever counter-
clockwise approx. 20˚.
(b) Put a metal plate (thickness of 8.5 -- 10.0 mm (0.335 --
0.394 in.)) between the cold starting lever and thermo
wax plunger.
HINT:
S03761 Keep the cold starting system released until all measurements
and adjustments are finished.
10. ADJUST TIMER
(a) Set the timer measuring device at zero.
(b) 2L--T:
boost compensator.
(c) w/ HAC:
B00432 (d) Measure the timer piston stroke at the below listed rpm.
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
Pump rpm Piston stroke mm (in.)
w/ TCV OFF
600
1.00 -- 1.80 (0.0394 -- 0.0709)
w/ TCV OFF
4.00 -- 4.80 (0.1575 -- 0.1890)
1,200
w/ TCV ON
3.70 -- 5.10 (0.1457 -- 0.2008)
w/ TCV OFF
2,000
8.00 -- 8.80 (0.3150 -- 0.3465)
w/ TCV OFF
2,300
8.76 -- 9.24 (0.3449 -- 0.3638)
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
800 0.70 -- 1.50 (0.0276 -- 0.0591)
1,200 2.10 -- 2.90 (0.0827 -- 0.1142)
2,000 4.90 -- 5.70 (0.1929 -- 0.2244)
2,300 5.86 -- 6.34 (0.2307 -- 0.2496)
CONTINUED
TO MODEL INDEX
FU--24
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
800 1.20 -- 2.00 (0.0472 -- 0.0787)
1,200 2.80 -- 3.60 (0.1102 -- 0.1417)
2,000 6.70 -- 7.50 (0.2638 -- 0.2953)
2,300 7.26 -- 7.74 (0.2858 -- 0.3047)
3L w/ ACSD:
(Part No. 22100 -- 5B510)
800 2.10 -- 2.90 (0.0827 -- 0.1142)
1,200 3.50 -- 4.30 (0.1378 -- 0.1693)
2,000 6.40 -- 7.20 (0.2520 -- 0.2835)
2,300 7.06 -- 7.54 (0.2780 -- 0.2968)
3L w/o ACSD:
(Part No. 22100 -- 54710, 54850, 54860, 54870, 54880)
800 0.60 -- 1.40 (0.0236 -- 0.0551)
1,200 1.80 -- 2.60 (0.0709 -- 0.1024)
2,000 4.40 -- 5.20 (0.1732 -- 0.2047)
2,300 4.86 -- 5.34 (0.1913 -- 0.2102)
5L w/ ACSD:
(Part No. 22100 -- 5B710)
800 1.65 -- 2.45 (0.0650 -- 0.0965)
1,200 3.41 -- 4.21 (0.1343 -- 0.1657)
1,900 6.49 -- 7.29 (0.2555 -- 0.2870)
2,200 6.96 -- 7.44 (0.2740 -- 0.2929)
5L w/o ACSD:
(Part No. 22100 -- 5B720)
850 0.23 -- 1.03 (0.0091 -- 0.0406)
1,200 1.77 -- 2.57 (0.0697 -- 0.1012)
2,000 5.30 -- 6.10 (0.2087 -- 0.2402)
2,300 6.36 -- 6.84 (0.2504 -- 0.2693)
HINT:
Check that the hysteresis is within 0.3 mm (0.012 in.).
CONTINUED
TO MODEL INDEX
FU--25
(e) Using a 5 mm hexagon wrench, adjust by turning the timer

adjusting screw.
HINT:
Turn clockwise to reduce the stroke, turn counterclockwise to
5 mm Timer increase the stroke.
Hexagon Adjusting
Wrench Screw
S03389
(f) Check the timer stroke for characteristic tendency.
Long Spring
Piston Stroke
Short Spring
Pump rpm
B00433
2L w/ TCV, 2L--T, 3L w/ ACSD, 5L If tendency is not as specified, select and replace the timer (in-
ner) spring.
HINT:
Timer Spring The timer stroke will increase with a long spring and decrease
with a short spring.
Free
Length
2L w/o TCV, 3L w/o ACSD
Timer Inner
Spring
Free
Length
S03807
S02315 B00053
Minus 0˚ Plus 11. ADJUST FULL LOAD INJECTION VOLUME

(a) The adjusting lever angle for the adjustment below should
Idle Speed Side Maximum
be as shown in the illustration.
Speed Side
Adjusting lever angle:
A (Maximum speed side) B (Idle speed side)
2L, 3L, 5L Minus 12.5 -- 22.5˚
Plus 23.5 -- 33.5˚
2L--T Minus 9.5 -- 19.5˚
S03942
CONTINUED
TO MODEL INDEX
FU--26
(b) 2L--T:
boost compensator.
(c) w/ HAC:
(d) Measure the full load injection volume.
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
Injection volume of
No. of measuring
strokes
cc (cu in.)
11.04 -- 11.36
1,200 200
(0.67 -- 0.69)
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
Injection volume of
No. of measuring
strokes
cc (cu in.)
10.42 -- 10.74
1,200 200
(0.64 -- 0.66)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
strokes
cc (cu in.)
13.70 -- 14.02
1,000 200
(0.84 -- 0.86)
3L:
(Part No. 22100 -- 54850, 54860, 54870, 54880)
Injection volume of
No. of measuring
strokes
cc (cu in.)
11.56 -- 11.88
1,200 200
(0.71 -- 0.72)
3L:
(Part No. 22100 -- 54710, 5B510)
Injection volume of
No. of measuring
strokes
cc (cu in.)
10.96 -- 11.28
1,200 200
(0.67 -- 0.69)
5L w/ HAC:
(Part No. 22100 -- 5B720)
Injection volume of
No. of measuring
strokes
cc (cu in.)
12.82 -- 13.14
1,600 200
(0.78 -- 0.80)
CONTINUED
TO MODEL INDEX
FU--27
5L w/o HAC:
(Part No. 22100 -- 5B710)
Injection volume of
No. of measuring
strokes
cc (cu in.)
12.18 -- 12.50
1,200 200
(0.74 -- 0.76)
Full Load Set Screw (e) Adjust by turning the full load set screw.
HINT:
The injection volume will increase about 3 cc (0.18 cu in.) with
each 1/2 turn of the screw.
S04644
CLICK HERE TO VIEW CHAPTER INDEX 12. ADJUST MAXIMUM SPEED

(a) w/ HAC:
(b) 2L--T:
boost compensator.
(c) Measure the injection volume at each pump rpm.
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
No. of
Adjusting Injection volume of each cylinder
Pump rpm measuring Remark
lever angle cc (cu in.)
strokes
2,200 8.0 -- 9.6 (0.49 -- 0.59) --
Plus 23.5 -- 33.5˚ 2,575 200 4.0 -- 5.6 (0.24 -- 0.34) Adjust
2,850 1.3 (0.08) or less --
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780, 54800, 54810)
No. of
strokes
2,250 7.66 -- 9.26 (0.47 -- 0.57) --
Plus 23.5 -- 33.5˚ 2,450 200 4.0 -- 5.6 (0.24 -- 0.34) Adjust
2,700 1.3 (0.08) or less --
CONTINUED
TO MODEL INDEX
FU--28
2L -- T:
(Part No. 22100--5B460, 5B670)
No. of
strokes
2,250 6.72 -- 8.92 (0.41 -- 0.54) --
Plus 23.5 -- 33.5˚ 2,400 200 4.3 -- 6.3 (0.26 -- 0.38) Adjust
2,750 1.3 (0.08) or less --
3L:
(Part No. 22100--54710, 5B510)
No. of
strokes
2,000 8.44 -- 10.44 (0.52 -- 0.64) --
Plus 23.5 -- 33.5˚ 2,200 200 4.6 -- 6.2 (0.28 -- 0.38) Adjust
2,450 1.3 (0.08) or less --
3L:
(Part No. 22100--54850, 54860, 54870, 54880)
No. of
strokes
2,100 9.08 -- 11.08 (0.55 -- 0.68) --
Plus 23.5 -- 33.5˚ 2,300 200 4.6 -- 6.2 (0.28 -- 0.38) Adjust
2,550 1.3 (0.08) or less --
5L:
(Part No. 22100--5B710, 5B720)
No. of
strokes
2,100 9.4 -- 11.4 (0.37 -- 0.45) --
Plus 23.5 -- 33.5˚ 2,300 200 4.6 -- 6.2 (0.28 -- 0.38) Adjust
2,550 1.3 (0.08) or less --
Maximum Speed Adjusting Screw (d) Adjust by turning the maximum speed adjusting screw.
CONTINUED
S04648
TO MODEL INDEX
FU--29
13. CHECK IN INJECTION VOLUME

Measure the injection volume at each pump rpm, boost pres-
sure (2L -- T) and HAC vacuum (w/ HAC).
2L w/ HAC:
(Part No. 22100 -- 54800, 54810)
No. of Injection volume Variation
Adjusting HAC vacuum
Pump rpm measuring of each cylinder limit Remark
lever angle kPa (mmHg, in.Hg)
strokes cc (cu in.) cc (cu in.)
10.6 -- 15.4 1.2
100 101 (760, 29.83) Volume during starting
(0.65 -- 0.94) (0.07)
11.2 -- 13.8
350 101 (760, 29.83) -- --
(0.68 -- 0.84)
9.32 -- 10.32 0.5
500 101 (760, 29.83) --
(0.57 -- 0.63) (0.03)
10.42 -- 10.74 0.4
Plus 23.5 -- 33.5˚ 101 (760, 29.83) 200 Basic full load injection volume
(0.64 -- 0.66) (0.02)
9.88 -- 10.48
1,200 90.7 (680, 26.78) -- --
(0.60 -- 0.64)
8.38 -- 8.98
70.7 (530, 20.88) -- --
(0.51 -- 0.55)
8.95 -- 9.85 0.5
2,100 101 (760, 29.83) --
(0.55 -- 0.60) (0.03)
2L w/o HAC for w/ ACSD:

(Part No. 22100 -- 5B320, 5B360)
Adjusting
lever angle
10.6 -- 15.4 1.2
100 Volume during starting
(0.65 -- 0.94) (0.07)
10.1 -- 11.1 0.5
500 --
(0.62 -- 0.68) (0.03)
Plus 23.5 -- 33.5˚ 200
11.04 -- 11.36 0.4
1,200 Basic full load injection volume
(0.67 -- 0.69) (0.02)
9.7 -- 10.7 0.5
2,000 --
(0.59 -- 0.65) (0.03)
2L w/o HAC for w/o ACSD:

(Part No. 22100 -- 54770, 54780)
Adjusting
lever angle
10.6 -- 15.4 1.2
(0.65 -- 0.94) (0.07)
11.2 -- 13.8
350 -- --
(0.65 -- 0.84)
9.32 -- 10.32 0.5
Plus 23.5 -- 33.5˚ 500 200 --
(0.57 -- 0.63) (0.03)
10.42 -- 10.74 0.4
(0.64 -- 0.66) (0.02)
8.95 -- 9.85 0.5
2,100 --
(0.55 -- 0.60) (0.03)
CONTINUED
TO MODEL INDEX
FU--30
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Boost No. of Injection volume Variation
Adjusting
Pump rpm pressure measuring of each cylinder limit Remark
lever angle
kPa (kg/cm2, psi) strokes cc (cu in.) cc (cu in.)
13.6 -- 18.4 1.2
100 0 (0, 0) Volume during starting
(0.83 -- 1.12) (0.07)
10.94 -- 11.74 0.5
700 0 (0, 0) --
(0.67 -- 0.72) (0.03)
Plus 23.5 -- 33.5˚ 200
13.70 -- 14.02 0.4
1,000 62.7 (0.64, 9.1) Basic full load injection volume
(0.84 -- 0.86) (0.02)
11.48 -- 12.48 0.5
1,800 62.7 (0.64, 9.1) --
(0.70 -- 0.76) (0.03)
3L w/ HAC:
(Part No. 22100 -- 54870, 54880)
11.6 -- 16.4 1.2
(0.71 -- 1.00) (0.07)
12.2 -- 14.8
350 101 (760, 29.83) -- --
(0.74 -- 0.90)
10.44 -- 11.44 0.5
500 101 (760, 29.83) --
(0.64 -- 0.70) (0.03)
Plus 23.5 -- 33.5˚ 200
11.56 -- 11.88 0.4
101 (760, 29.83) Basic full load injection volume
(0.71 -- 0.72) (0.02)
1,200
9.44 -- 10.04
70.7 (530, 20.88) -- --
(0.58 -- 0.61)
10.19 -- 11.09 0.5
2,000 101 (760, 29.83) --
(0.62 -- 0.68) (0.03)
3L w/o HAC:
(Part No. 22100 -- 54710, 5B510)
Adjusting
lever angle
11.6 -- 16.4 1.2
(0.71 -- 1.00) (0.07)
11.4 -- 14.0
350 -- --
(0.70 -- 0.85)
9.64 -- 11.04 0.5
Plus 23.5 -- 33.5˚ 500 200 --
(0.59 -- 0.67) (0.03)
10.96 -- 11.28 0.4
(0.67 -- 0.69) (0.02)
9.39 -- 10.69 0.5
1,900 --
(0.57 -- 0.65) (0.03)
CONTINUED
TO MODEL INDEX
FU--31
3L w/o HAC:
(Part No. 22100 -- 54850, 54860)
Adjusting
lever angle
11.6 -- 16.4 1.2
(0.71 -- 1.00) (0.07)
12.2 -- 14.8
350 -- --
(0.74 -- 0.90)
10.44 -- 11.44 0.5
Plus 23.5 -- 33.5˚ 500 200 --
(0.64 -- 0.70) (0.03)
11.56 -- 11.88 0.4
(0.71 -- 0.72) (0.02)
10.19 -- 11.09 0.5
2,000 --
(0.62 -- 0.68) (0.03)
5L w/ HAC:
(Part No. 22100 -- 5B720)
13.6 -- 18.4 1.2
(0.83 -- 1.12) (0.07)
10.92 -- 12.32 0.5
500 101 (760, 29.83) --
(0.67 -- 0.75) (0.03)
200 12.82 -- 13.14 0.4
Plus 23.5 -- 33.5˚ 101 (760, 29.83) Basic full load injection volume
(0.78 -- 0.80) (0.02)
1,600 11.10 -- 11.70
85.3 (640, 25.19) -- --
(0.68 -- 0.71)
12.30 -- 12.98 0.5
1,900 101 (760, 29.83) --
(0.75 -- 0.79) (0.03)
5L w/o HAC:
(Part No. 22100 -- 5B710)
Adjusting
lever angle
13.6 -- 18.4 1.2
(0.83 -- 1.12) (0.07)
10.36 -- 11.36 0.5
500 --
(0.63 -- 0.69) (0.03)
Plus 23.5 -- 33.5˚ 200
12.18 -- 12.50 0.4
(0.74 -- 0.76) (0.02)
11.01 -- 11.91 0.5
2,000 --
(0.67 -- 0.73) (0.03)
CONTINUED
TO MODEL INDEX
FU--32
If the injection volume at 100 rpm is not as specified, replace the

governor sleeve plus as follows:
SST (1) Using SST and a press, press out the sleeve plug
assembly from the governor sleeve.
SST 09236 -- 00101 (09237 -- 00070)
B00434
(2) Remove the E--ring, stop ring, bearing and 2 bear-

New Sleeve Plug ing retainers from the sleeve plug.
Bearing and
2 Bearing
Retainers
Stop Ring
New E--Ring
B00435
(3) Measure the head thickness of the sleeve plug, and

Head Thickness select a new sleeve plug.
Governor sleeve plug head thickness: mm (in.)
3.0 (0.118) 3.5 (0.138) 4.0 (0.157)
3.1 (0.122) 3.6 (0.142) 4.1 (0.161)
3.2 (0.126) 3.7 (0.146) 4.2 (0.165)
3.3 (0.130) 3.8 (0.150) --
3.4 (0.134) 3.9 (0.154) --
B00471
HINT:
Lengthening the plug by 0.1 mm (0.004 in.) will decrease injec-
tion volume by 0.6 cc (0.04 cu in.).
If the variation limit is greater than specified, replace the deliv-
ery valve.
(4) Install the bearing, 2 retainers and stop ring to the

New Sleeve Plug new sleeve plug with a new E--ring.
Bearing and
2 Bearing CONTINUED
Retainers
Stop Ring
New E--Ring
B00435
TO MODEL INDEX
FU--33
(5) Using a press, press in the sleeve plug assembly to

the governor sleeve.
14. 2L -- T:
ADJUST FULL LOAD MINIMUM INJECTION VOLUME
(b) Release the pressure from the boost compensator.
(c) Measure the injeciton volume.
(Part No. 22100--5B460, 5B670)
B00436 Injection volume of
No. of measuring
strokes
cc (cu in.)
10.94 -- 11.74
700 200
(0.67 -- 0.72)
2L--T 3 mm Hexagon (d) Using a 3 mm hexagon wrench, adjust by turning the timer
Wrench slide stopper.
15. 2L -- T:
ADJUST BOOST COMPENSATOR
Timer (a) Set the adjusting lever to maximum position.
Slide (b) Apply 13.3 kPa (0.14 kPa (0.14 kgf/cm2, 2.0 psi) of pres-
Stopper sure to boost compensator.
B01356 (Part No. 22100--5B460, 5B670)
Injection volume of
No. of measuring
strokes
cc (cu in.)
10.76 -- 11.56
1,000 200
(0.66 -- 0.71)
2L--T Guide Bushing (d) Remove the rubber cap and overflow screw.
(e) Using a screwdriver, adjust the injection volume by the
guide bushing.
HINT:
When the guuide bushing is turned clockwise, as seen from
above, the injeciton volume will increase.
(f) Install the overflow screw.
Arrow
Mark Torque: 24.55 N∙m (250 kgf∙cm, 18 ft∙lbf)
B01357 (g) Install the rubber cap with the arrow mark facing down-
ward.
CONTINUED
TO MODEL INDEX
FU--34
2L--T 16. 2L -- T:
c CHECK FOR CHARACTERISTIC TENDENCY
a
(b) Apply 40.0 kPa (0.41 kgf/cm2, 5.8 psi) of pressure to
b boost compensator.
Injection Volume

(Part No. 22100--5B460, 5B670)
Injection volume of
Pump rpm No. of measuring
strokes
cc (cu in.)
12.54 -- 13.14
1,000 200
(0.77 -- 0.80)
a
e
Injection Volume
d
b
Boost Pressure
(a) Adjust full--load injection volume

(b) Adjust full--load minimum injection volume
(c) Adjust cold starting injeciton volume
(d) Adjust boost compensator characteristic
(e) Adjust boost compensator characteristic
tendency
B00473
B00472
B00904 17. 2L -- T:
CHECK HYSTERESIS
Compare the injection volume when the boost compensator
pressure is lowered from 107.0 kPa (1.09 kgf/cm2, 15.5 psi) to
13.3 kPa (0.14 khf/cm2, 2.0 psi), and conversely, when it is
raised from zero.
HINT:
Make measurements after moving the adjusting lever between
idle and maximum 3 times for each lowering of the pressure.
(Part No. 22100--5B460, 5B670)

No. of
Boost pressure Injection volume of each cylinder Hysteresis
Pump rpm measuring
kPa (kg/cm2, psi) cc (cu in.) cc (cu in.)
strokes
107.0 (1.09, 15.5) 13.5 (0.82) or less
73.3 (0.75, 10.7) 13.60 -- 14.12 (0.83 -- 0.86)

1,000 200 0.4 (0.02) or less
40.0 (0.41, 5.8) 12.54 -- 13.14 (0.77 -- 0.80)
13.3 (0.14, 2.0) 10.76 -- 11.56 (0.66 -- 0.71)
If not within standard value, check each sliding part of the boost
compensator and check whether or not there is any oil.
CONTINUED
TO MODEL INDEX
FU--35
w/o HAC (2L, 3L), 2L--T, 5L 18. w/o HAC (2L, 3L), 2L -- T, 5L:
5 mm ADJUST LOAD SENSING TIMER
Hexagon (a) Using a 5 mm hexagon wrench, adjust the starting and
Wrench end points of the load sensing timer by turning the gover-
nor shaft.
(b) Set the adjusting lever to maximum position.
(c) Measure the injection volume.
2L, 3L, 5L:
Governor Shaft Adjusting lever
Pump rpm
No, of measuring
position strokes
Maximum speed side 1,200 200

Starting Point of
Injection Pump
2L -- T:
Inner Pressure
Load Sensing Timer

End Point of Load Sensing Timer Adjusting lever No, of measuring
Pump rpm
position strokes
Maximum speed side 1,000 200
Idle Speed Maximum

Side Speed Side
B00054 Adjusting Lever Position
B00050 B00422
w/o HAC (2L, 3L), 2L--T, 5L (d) Slowly move the adjusting lever from the maximum speed
side to the idle speed side, and secure it at the point
where the pump inner pressure begins to drop.
(e) Measure the injection volume at the drop point (starting
kg/cm2
point).
2L, 3L, 5L:
Slowly
Move Injection volume of
No of measuring
strokes
B00438 cc (cu in.)
Measured value
1,200 200 at step (d) minus
1.0 (0.06) ± 0.4 (0.02)
2L -- T:
Injection volume of
No of measuring
strokes
cc (cu in.)
Measured value
1,000 200 at step (d) minus
0.6 (0.04) ± 0.4 (0.02)
w/o HAC (2L, 3L), 2L--T, 5L (f) Using a 5 mm hexagon wrench, adjust the load sensing
5 mm
timer by turning the governor shaft, and perform the mea-
Hexagon
surement again as specified.
Wrench
HINT:
The injection volume will increase approx. 3 cc (0.2 cu in.) with
each 1/2 turn of the governor shaft.
Governor Shaft B00054

CONTINUED
TO MODEL INDEX
FU--36
w/o HAC (2L, 3L), 2L--T, 5L (g) Check the end point injection volume by slowly moving
the adjusting lever from the maximum speed side to the
Stop idle speed side, and secure it at the point where the pump
inner pressure stops dropping.
kg/cm2
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
Slowly
Move Injection volume of
No. of measuring
strokes
B00437 cc (cu in.)
9.0 -- 9.4
1,200 200
(0.55 -- 0.57)
2L w/o ACSD:
(Part No. 22100 -- 54770, 54780)
Injection volume of
No. of measuring
strokes
cc (cu in.)
8.38 -- 8.78
1,200 200
(0.51 -- 0.54)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
strokes
cc (cu in.)
8.0 -- 8.4
1,000 200
(0.49 -- 0.51)
3L:
(Part No. 22100 -- 54710, 5B510)
Injection volume of
No. of measuring
strokes
cc (cu in.)
8.12 -- 8.52
1,200 200
(0.50 -- 0.52)
3L:
(Part No. 22100 -- 54850, 54860)
Injection volume of
No. of measuring
strokes
cc (cu in.)
8.72 -- 9.12
1,200 200
(0.53 -- 0.56)
5L w/ ACSD:
(Part No. 22100 -- 5B710)
Injection volume of
No. of measuring
strokes
cc (cu in.)
9.5 -- 9.9
1,200 200
(0.58 -- 0.60)
CONTINUED
TO MODEL INDEX
FU--37
5L w/o ACSD:
(Part No. 22100 -- 5B720)
Injection volume of
No. of measuring
strokes
cc (cu in.)
9.58 -- 9.98
1,200 200
(0.58 -- 0.61)
w/o HAC (2L, 3L), 2L--T, 5L (h) Check the timer piston fluctuation when the adjusting le-
ver is moved from the maximum speed side to the idle
speed side.
2L w/ ACSD:
(Part No. 22100 -- 5B320, 5B360)
Pump rpm Timer piston fluctuation mm (in.)
Move w/ TCV OFF
1,200
1.80 -- 2.60 (0.0709 -- 0.1024)
B00424 2L w/o ACSD:
(Part No. 22100 -- 54770, 54780)
1,200 0.62 -- 1.02 (0.0244 -- 0.0402)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
1,000 1.40 -- 1.80 (0.0551 -- 0.0709)
3L w/ ACSD:
(Part No. 22100 -- 5B510)
1,200 1.44 -- 1.84 (0.0567 -- 0.0724)
3L w/o ACSD:
(Part No. 22100 -- 54710, 54850, 54860)
1,200 0.62 -- 1.02 (0.0244 -- 0.0402)
5L w/ ACSD:
(Part No. 22100 -- 5B710)
1,200 1.03 -- 1.43 (0.0406 -- 0.0563)
5L w/o ACSD:
(Part No. 22100 -- 5B720)
1,200 0.82 -- 1.22 (0.0323 -- 0.0480)
CONTINUED
TO MODEL INDEX
FU--38
w/o HAC Hole Diameter If the timer stroke is not as specified when the load sensing is
(2L, 3L), at maximum retard angle, select a new governor sleeve.
2L--T, HINT:
5L A large hole diameter decreases the timer stroke and a smaller
hole diameter increases the timer stroke.
Governor Sleeve
B00056
w/o HAC (2L, 3L), 2L--T, 5L (i) Check the protrusion of the governor shaft.
0.5 -- 2.0 mm Protrusion: 0.5 -- 2.0 mm (0.020 -- 0.079 in.)
Governor Shaft
B00049 B00055 B00423
CLICK HERE TO VIEW CHAPTER INDEX 19. ADJUST IDLE SPEED

(a) Measure the injection volume for each pump rpm.
2L:
(Part No. 22100 -- 54770, 54780, 54800, 54810, 5B320, 5B360)
No. of
Adjusting Injection volume of each cylinder Variation limit
lever angle cc (cu in.) cc (cu in.)
strokes
350 1.7 -- 2.7 (0.10 -- 0.16) 0.34 (0.02) Adjust

Minus 12.5 -- 22.5˚ 200
525 1.2 (0.07) or less -- --
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
No. of
strokes
Minus 9.5 -- 19.5˚ 350 200 3.18 -- 4.18 (0.19 -- 0.26) 0.34 (0.02) Adjust
3L:
(Part No. 22100 -- 54710, 54850, 54860, 54870, 54880, 5B510)
No. of
strokes
350 1.8 -- 2.8 (0.11 -- 0.17) 0.34 (0.02) Adjust

Minus 12.5 -- 22.5˚ 200
525 1.2 (0.07) or less -- --
CONTINUED
TO MODEL INDEX
FU--39
5L:
(Part No. 22100 -- 5B710, 5B720)
No. of
strokes
350 2.54 -- 3.54 (0.16 -- 0.22) 0.34 (0.02) Adjust

Minus 12.5 -- 22.5˚ 200
575 1.2 (0.07) or less -- --
Idle Speed (b) Adjust injection volume by turning the idle speed adjust-
Adjusting ing screw.
Screw
S04647
CLICK HERE TO VIEW CHAPTER INDEX

20. w/ ACSD:
w/ ACSD ADJUST COLD STARTING SYSTEM
(a) Remove the overflow screw and check the fuel tempera-
Set Key
ture in the fuel pump.
Fuel temperature: 15 -- 35˚C (59 -- 95˚F)
(b) Set the set key of the pump drive shaft in a vertical or hori-
zontal position.
(c) Set the scale of the timer measuring device to zero.
S03373
w/ ACSD Metal Plate (d) Check the adjusting lever opening angle and consider
Turn this angle as zero.
(e) Remove the metal plate between the cold starting lever
and thermo wax plunger.
S03761
w/ ACSD (f) Torque the cold starting lever clockwise to approx. 4.9
N∙m (50 kgf∙cm, 43 in.∙lbf) and keep the lever tightened
for about 10 seconds. Then release the torque.
(g) Measure the timer piston stroke.
4.9 N∙m
CONTINUED
S03390
TO MODEL INDEX
FU--40
2L:
(Part No. 22100 -- 5B320, 5B360)
Fuel temperature Piston stroke
Pump rpm
C (˚F) mm (in.)
1.50 -- 1.90
25 (77) 350
(0.0591 -- 0.0748)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Pump rpm
C (˚F) mm (in.)
1.70 -- 1.90
25 (77) 350
(0.0669 -- 0.0748)
3L:
(Part No. 22100 -- 5B510)
Pump rpm
C (˚F) mm (in.)
0.85 -- 1.05
25 (77) 350
(0.0335 -- 0.0413)
5L:
(Part No. 22100 -- 5B710)
Pump rpm
C (˚F) mm (in.)
1.10 -- 1.30
25 (77) 400
(0.0433 -- 0.0512)
w/ ACSD (h) Adjust by turning the timer adjusting screw.

HINT:
Screw in for stroke decrease.
Timer Adjusting
Screw S03388

Turn ADJUST FAST IDLE SPEED
(a) Release the cold starting system.
(1) Using a screwdriver, turn the cold starting lever
counterclockwise approx. 20˚.
(2) Put a metal plate (thickness of 8.5 -- 10.0 mm (0.335
-- 0.394 in.)) between the cold starting lever and
thermo wax plunger.
S03761 (b) Set the adjusting lever to idle position.
(c) Measure the injection volume. CONTINUED
TO MODEL INDEX
FU--41
2L:
(Part No. 22100 -- 5B320, 5B360)
Injection volume of
No. of measuring
strokes
cc (cu in.)
q = 1.7 -- 2.7
350 200
(0.10 -- 0.16)
2L -- T:
(Part No. 22100 -- 5B460, 5B670)
Injection volume of
No. of measuring
strokes
cc (cu in.)
q = 3.18 -- 4.18
350 200
(0.19 -- 0.26)
3L:
(Part No. 22100 -- 5B510)
Injection volume of
No. of measuring
strokes
cc (cu in.)
q = 1.8 -- 2.8
350 200
(0.11 -- 0.17)
5L:
(Part No. 22100 -- 5B710)
Injection volume of
No. of measuring
strokes
cc (cu in.)
q = 2.54 -- 3.54
400 200
(0.16 -- 0.22)
(d) Remove the metal plate between the cold starting lever
w/ ACSD (e) Torque the cold starting lever clockwise to approx. 4.9
N∙m (50 kgf∙cm, 43 in.∙lbf) and keep the lever tightened
for about 10 seconds. Then release the torque.
(f) Measure the injection volume.
2L, 3L:
Injection volume of
4.9 N∙m Pump rpm
No. of measuring
each cylinder
strokes
cc (cu in.)
S03390 q plus 2.0 -- 2.2

350 200
(0.12 -- 0.13)
2L -- T:
Injection volume of
No. of measuring
strokes
cc (cu in.)
q plus 0.22 -- 0.42
350 200
(0.01 -- 0.03)
CONTINUED
TO MODEL INDEX
FU--42
5L:
Injection volume of
No. of measuring
strokes
cc (cu in.)
q plus 1.24 -- 1.44
400 200
(0.08 -- 0.09)
w/ ACSD (g) Adjust the injection volume by turning the fast idle adjust-
First Idle ing screw.
Adjusting 22. POST ADJUSTMENT CHECK
Screw (a) Check the injection stops when the fuel cut solenoid har-
ness is removed.
Pump revolution: 100 rpm
S04646
w/ ACSD Metal Plate (b) w/ ACSD:

Turn Release the cold starting system.
(1) Using a screwdriver, turn the cold starting lever
counterclockwise approx. 20˚.
(2) Put a metal plate (thickness of 8.5 -- 10.0 mm (0.335
-- 0.394 in.)) between the cold starting lever and
thermo wax plunger.
S03761
(c) Check the adjusting lever movement.

Adjusting lever angle:
2L, 3L, 5L 43 -- 49˚
2L--T 41 -- 51˚
(d) w/ ACSD:
Remove the metal plate between the cold starting lever
23. REMOVE INJECTION PUMP FROM PUMP TESTER
Move B00450
Maximum Speed Adjusting Screw 24. SEAL PARTS

Seal the full load set screw and maximum speed adjusting
screw with new lead seals.
Full Load
Set Screw
S04649
TO MODEL INDEX
FU--43
FU00K--01
REASSEMBLY
1. ASSEMBLE BOOST COMPENSATOR
(a) Install the control lever.
(1) Insert the connecting pin into the governor cover.
B01353
(2) Using a small screwdriver, install the control lever

with the support pin.
B01351
(3) Using a 4 mm hexagon wrench, install 2 new gas-

kets and the 2 bolts.
4 mm
Hexagon
Wrench
B01350
(b) Install and adjust the guide bushing to the dimension A as

shown in the illustration.
A Dimension A: 18.5 -- 20.0 mm (0.728 -- 0.787 in.)
Guide
Bushing
Gui
S03343
(c) Install the boost compensator diaphragm.

Spring Seat
(1) Apply adhesive to the push rod threads.
Diaphragm
Adhesive:
part No.08833 -- 00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(2) Assemble these parts with the nut. CONTINUED
Spring Seat
S Push rod
Push Rod
B01387 S Diaphragm
S 2 spring seats
TO MODEL INDEX
FU--44
(3) Adjust the installation direction of boost compensa-

tor diaphragm assembly.
S Install the diaphragm assembly.
Matchmarks HINT:
Turn Do not assemble the spring.
S While pushing on the diaphragm, using verni-
er calipers, measure the dimension X as
shown in the illustration.
Dimension X: 8.3 -- 8.4 mm (0.327 -- 0.331 in.)
HINT:
Measure at the center of the hole.
S Adjust the dimension X by turning the dia-
X phragm, and place matchmarks on the dia-
phragm and governor cover.
S Remove the diaphragm assembly.
B01346
B01382 B01381
(4) Insert 1.5 -- 2.5 cc (0.09 -- 0.15 cu in.) of engine oil

into the bushing hole.
1.5 -- 2.5 cc
B01349
(5) Install these parts:

Diaphragm S Spring
Assembly S Diaphragm assembly
Spring
B01348
(6) Using a 5 mm hexagon wrench, install the dia-

phragm cover with the 4 bolts.
5 mm
Hexagon
Wrench CONTINUED
B01347
TO MODEL INDEX
FU--45
(d) Install the overflow screw.

4 mm Torque: 24.55 N∙m (250 kgf∙cm, 18 ft∙lbf)
Hexagon (e) Install the rubber cap with the arrow mark facing down-
Wrench ward.
(f) Using a 4 mm hexagon wrench, install a new gasket and
the bolt.
Arrow Mark
B01345
2L--T
Plug 2. PERFORM AIR TIGHT TEST

(a) Plug each port with a bolt and plug.
Bolt
w/ HAC
Plug
Bolt
w/o HAC
Bolt
B01358
B01389
B01390 B01380
49 kPa → 490 kPa

(b) Connect an air hose to the fuel inlet pipe and place the in-
jection pump into diesel fuel.
(c) Apply 49 kPa (0.5 kgf/cm2, 7 psi) of pressure and confirm
that there are no leaks.
(d) Next check that there are no leaks with 490 kPa (5.0
kgf/cm2, 71 psi) of pressure applied.
(e) Remove the bolt and plug from each port.
S04636
TO MODEL INDEX
COOLING
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . CO -- 1
..............................
COMPONENTS CO-- 1
RADIATOR ....................... CO-- 2
.......................
ON-VEHICLE INSPECTION CO-- 2/3
COMPONENTS ....................... CO-- 4
DISASSEMBLY ....................... CO-- 5
REASSEMBLY ....................... CO-- 6/5

RM520E)
TO MODEL INDEX
CO--1
COOLING -- THERMOSTAT
THERMOSTAT
CO047--01
COMPONENTS
2L--T
Radiator Cap
Check Connector
Water Outlet
Water Outlet (2L, 3L, 5L)
zGasket
Thermostat

TO MODEL INDEX
CO--2
COOLING -- RADIATOR
RADIATOR CO048--01
ON -- VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
Remove the radiator cap from the water outlet (2L--T) or radia-
tor (2L, 3L, 5L).
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2L--T 2. 2L -- T:
INSPECT RADIATOR CAP
Radiator Cap Tester NOTICE:
S If the radiator cap has contaminations, always rinse
it with water.
S Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.
Using a radiator cap tester, pump the tester and measure the
Radiator Cap
CO0034 relief valve opening pressure.
Standard opening pressure:
93 -- 123 kPa (0.95 -- 1.25 kgf/cm2, 13.5 -- 17.1 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
2L, 3L, 5L 3. 2L, 3L, 5L:

Radiator Cap Tester INSPECT RADIATOR CAP
NOTICE:
S If the radiator cap has contaminations, always rinse
it with water.
30˚ or More
S Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.
Radiator Cap S When performing steps (a) and (b) below, keep the ra-
CO1242 diator cap tester at an angle of over 30˚ above the hor-
izontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed: 1 push within 1 second
CONTINUED
TO MODEL INDEX
CO--3
COOLING -- RADIATOR
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
93 -- 123 kPa (0.95 -- 1.25 kgf/cm2, 13.5 -- 17.1 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
4. REINSTALL RADIATOR CAP
TO MODEL INDEX
CO--4
COOLING -- RADIATOR
CO049--01
COMPONENTS
Upper Tank (2L--T)
Bushing
Radiator Cap (2L, 3L, 5L)
Collar
Upper Tank (2L, 3L, 5L)
Radiator
Bracket z O--Ring
Core
Collar
Bushing
Bushing
Collar
z O--Ring
Bushing Radiator
Bracket
Lower Tank
Collar
Drain Plug
z O--Ring

TO MODEL INDEX
CO--5
COOLING -- RADIATOR
CO04A--01
DISASSEMBLY
1. REMOVE RADIATOR BRACKETS
Remove the 4 bolts, 4 collars, 2 brackets and 4 bushings.
2. 2L, 3L, 5L:
REMOVE RADIATOR CAP
3. REMOVE DRAIN PLUG
(a) Remove the drain plug.
(b) Remove the O--ring.
4. ASSEMBLE SST
Part A
SST 09230 -- 01010
(a) Install the claw to the overhaul handle, inserting it in the
hole in part A as shown in the diagram.
Dimension B (b) While gripping the handle, adjust the stopper bolt so that
SST Stopper Bolt
dimension B is as shown in the illustration.
Dimension B: 0.2 -- 0.3 mm (0.008 -- 0.012 in.)
NOTICE:
Claw Overhaul Handle CO1205 If this adjustment is not done the claw may be damaged.
Tank 5. UNCAULK LOCK PLATES

Using SST to release the caulking, squeeze the handle until
stopped by the stopper bolt.
Lock SST 09230 -- 01010
SST
Plate
Stopper
Bolt
B00469
6. REMOVE TANKS AND O -- RINGS

Lightly tap the bracket of the radiator (or radiator inlet or outlet)
with a soft--faced hammer, and remove the tank and the O--ring.
Tap
B00013
TO MODEL INDEX
CO--6
COOLING -- RADIATOR
CO04B--01
REASSEMBLY
Lock Plate Lock Plate 1. INSPECT LOCK PLATE FOR DAMAGE
HINT:
S If the sides of the lock plate groove are deformed, reas-
sembly of the tank will be impossible.
S Therefore, first correct any deformation with pliers or simi-
lar object. Water leakage will result if the bottom of the
Core lock plate groove is damaged or dented.
CO1267
NOTICE:
The radiator can only be recaulked 2 times. After the 2nd
time, the radiator core must be replaced.
2. INSTALL NEW O -- RINGS AND TANKS

(a) After checking that there are no foreign objects in the lock
plate groove, install a new O--ring without twisting it.
f Normal X Twisted
HINT:
When cleaning the lock plate groove, lightly rub it with sand pa-
per without scratching it.
X Twisted
O--Ring
CO0317
(b) Install the tank without damaging the O--ring.

CORRECT (c) Tap the lock plate with a soft--faced hammer so that there
is no gap between it and the tank.
WRONG
Tap
Tank
Lock
Plate B00466
3. ASSEMBLE SST
Part SST 09230 -- 01010, 09231 -- 14010
(a) Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part A as shown in the illustration.
Dimension B (b) While gripping the handle, adjust the stopper bolt so that
SST Stopper Bolt dimension B is as shown in the illustration.
Dimension B: 8.4 mm (0.331 in.)
Punch Assembly Overhaul Handle CO1206 CONTINUED

TO MODEL INDEX
CO--7
COOLING -- RADIATOR
4. CAULK LOCK PLATE

(a) Lightly press SST against the lock plate in the order
5 3 7 shown in the illustration. After repeating this a few times,
fully caulk the lock plate by squeezing the handle until
1 2 stopped by the stopper plate.
SST 09230 -- 01010
6 4 8
Tank
Stopper
Bolt
Lock
SST Plate
B00011
B00467 B00907
HINT:
(2)
S Do not stake the areas protruding around the ports (1),
flange (2) and bracket (3).
(1)
(3)
(1)
B00905
S The points shown in the illustration cannot be staked with

the SST. Use pliers or similar object and be careful not to
damage the core plates.
B00012
B00014 B00996
(b) Check the lock plate height (H) after completing the caulk-
ing.
Plate height (H): 7.40 -- 7.80 mm (0.2913 -- 0.3071 in.)
H
If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
5. INSTALL DRAIN PLUG
(a) Install a new O--ring to the drain plug.
(b) Install the drain plug.
B00468 6. 2L, 3L, 5L:
INSTALL RADIATOR CAP CONTINUED
TO MODEL INDEX
CO--8
COOLING -- RADIATOR
7. INSPECT FOR WATER LEAKS

(a) Tighten the drain plug.
SST (b) Plug the inlet pipes of the radiator with SST.
SST 09230 -- 01010
(c) Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi)
(d) Submerge the radiator in water.
B00015
(e) Inspect for leaks.

HINT:
Tank On radiators with resin tanks, there is a clearance between the
tank and lock plate where a minute amount of air will remain,
giving the appearance of an air leak when the radiator is sub-
Lock
Plate merged in water. Therefore, before doing the water leak test,
first swish the radiator around in the water until all air bubbles
O--Ring disappear.
S01713 8. INSTALL RADIATOR BRACKETS
(a) Install the 2 bushings and 2 collars to each bracket.
(b) Install the 2 brackets with the 4 bolts.
TO MODEL INDEX
LUBRICATION
OIL AND FILTER. . . . . . . . . . . . . . . . . . . . . . . . . LU -- 1

INSPECTION

RM520E)
TO MODEL INDEX
LU--1
LUBRICATION -- OIL AND FILTER
Europe OIL AND FILTER LU02I--01
Recommended Viscosity (SAE): INSPECTION

CHECK ENGINE OIL QUALITY
20W--50
Check the oil deterioration, entry of water, discoloring or thin-
15W--40
ning.
10W--30 If the quality is visibly poor, replace the oil.
5W--30 Oil grade:
API CF--4 (You may also use API CF, CE or CD)
˚C --29 --18 --7 4 16 27 38
˚F --20 0 20 40 60 80 100
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE
Others
Recommended Viscosity (SAE):

20W--50
15W--40
10W--30
5W--30
40
30
˚C--29 --18 --7 4 16 27 38

˚F --20 0 20 40 60 80 100
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE
P23182
B01366 B01379
TO MODEL INDEX
STARTING
PRE-- HEATING SYSTEM

(Super Glow Type) . . . . . . . . . . . . . . . . . . . . . ST--1/3
PRE-- HEATING SYSTEM
(Variable Delay Type) . . . . . . . . . . . . . . . . . . ST -- 4
STARTER (2.2 kW) . . . . . . . . . . . . . . . . . . . . . . . ST -- 5
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . ST--5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . ST- 6/7
INSPECTION ..................... ST- 8/10
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . ST-11/14
REASSEMBLY .................. ST-15/16
TEST ....................... ST--17
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . ST--18

RM520E)
TO MODEL INDEX
ST--1
STARTING -- PRE--HEATING SYSTEM (Super Glow Type)
Pre--Heating Timer
S--REL
PRE -- HEATING SYSTEM (Super
Glow Type) ST027--01
INSPECTION
1. INSPECT LIGHTING TIME OF GLOW INDICATOR
LIGHT
Sec. Sec. Turn the ignition switch ON, and measure the lighting time.
6.0 120
Light lighting time (T1): Refer to the chart graph
Light Lighting Time (T1)
T2 2. INSPECT AFTER GLOW TIME
After Glow Time (T2)

Turn the ignition switch ON, and measure the time battery volt-
4.2
T1 age is applied to terminal S--REL of the preheating timer.
After glow time (T2):
2.2 Refer to the chart graph (After starting the engine)
0.9
0.6
1
--13 8 28 55 83 ˚C
(8.6) (46.4) (82.4) (131) (181.4) (˚F)
50
S03946
(122)
S03945 Water Temperature Z18605
Wire Harness Side 3. INSPECT PRE -- HEATING TIMER

(a) Disconnect the pre--heating timer connector.
LOCATION: See relay locations in Electrical Wiring Dia-
CHG G--IND
S--REL
gram. LHD RHD

IG
(b) Inspect the pre--heating timer circuit.

Check the connector on the wire harness side as shown
THW
EG
TCV
STA
in these chart:
B01391
Tester connection Condition Specified value

Ignition switch OFF No voltage
G -IND
G- IND -- Ground
G d
Ignition switch ON Battery voltage
IG -- G
Ground
d
STA -- G
Ground
d
Ignition switch START Battery voltage
S--REL -- Ground -- Continuity
THW -- Ground -- Continuity
EG -- Ground -- Continuity
TCV (w/ TCV) -- Ground -- Continuity
(c) Reconnect the pre--heating timer connector.
4. INSPECT GLOW PLUG RELAY
(a) Remove the glow plug relay.
gram. LHD RHD
CONTINUED
TO MODEL INDEX
ST--2
Ohmmeter (b) Inspect the glow plug relay continuity.

No Continuity (1) Using an ohmmeter, check that there is no continu-
ity between terminals 1 and 2.
2 2 If there is continuity, replace the relay.
4 (2) Check that there is continuity between terminals 3
Ohmmeter 1
4 and 4.
3
If there is no continuity, replace the relay.
Continuity
S03356
Ohmmeter (c) Inspect the glow plug relay operation.

Continuity (1) Apply battery voltage across terminals 3 and 4.
2 between terminals 1 and 2.
4 If there is no continuity, replace the relay.
1 (d) Reinstall the glow plug relay.
3
Battery S03357
5. INSPECT WATER TEMPERATURE SENSOR

Ohmmeter
(a) Remove the water temperature sensor.
LOCATION: In the right rear of the cylinder block.
(b) Using an ohmmeter, measure the resistance of the water
temperature sensor between the terminals.
30
20
Resistance: Refer to the chart graph
If the resistance is not as specified, replace the sensor.
10
(c) Reinstall the water temperature sensor.
Resistance kΩ
5 Torque: 17.5 N∙m (178 kgf∙cm, 13 ft∙lbf)

3 Acceptable
2
1
0.5
0.3
0.2
0.1
--20 0 20 40 60 80 100
(--4) (32) (68) (104) (140) (176) (212)
S01196
S01699 Temperature ˚C (˚F) Z17274
Ohmmeter Continuity 6. INSPECT GLOW PLUGS

Using an ohmmeter, check that there is continuity between the
glow plug terminal and ground.
Standard resistance: Approx. 0.72 Ω at 20˚C (68˚F)
If there is no continuity, replace the glow plug.
CONTINUED
B01383
TO MODEL INDEX
ST--3
NOTICE:
S Be careful not to damage the glow plug pipes as it
could cause an open circuit or shorten life of the glow
plugs.
S Avoid getting oil and gasoline on the glow plug when
cleaning.
S During inspection, be sure to wipe any oil of the termi-
nal and bakelite washer with a dry cloth.
S Be careful no to apply more than 11 V to the glow plug
as it could cause an open circuit.
TO MODEL INDEX
ST--4
STARTING -- PRE--HEATING SYSTEM (Variable Delay Type)
PRE -- HEATING SYSTEM (Variable

Delay Type) ST028--01
INSPECTION
1. INSPECT LIGHTING TIME OF GLOW INDICATOR
LIGHT
Turn the ignition switch ON, and measure the lighting time.
Light lighting time: Approx. 5 seconds
2. INSPECT AFTER GLOW TIME

Pre--Heating Timer
Turn the ignition switch ON, and measure the time battery volt-
S--REL
age is applied to terminal S--REL of the pre--heating timer.
After glow time: Approx. 18 seconds
P08103
Wire Harness Side 3. INSPECT PRE -- HEATING TIMER

(a) Disconnect the pre--heating timer connector.
gram.
S--REL
CHG
IG
(b) Inspect the pre--heating timer circuit.

G--IND
Check the connector on the wire harness side as shown

EG
in these chart:
B01367
Tester connection Condition Specified value

G -IND
G- IND -- Ground
G d
IG -- G
Ground
d
S--REL -- Ground -- Continuity
EG -- Ground -- Continuity
(c) Reconnect the pre--heating timer connector.
4. INSPECT GLOW PLUG RELAY (See page ST -- 1)
5. INSPECT GLOW PLUG (See page ST --2)
TO MODEL INDEX
ST--5
STARTING -- STARTER (2.2 kW)
STARTER(2.2 kW)
ST029--01
COMPONENTS
Starter Housing
Starter Clutch Assembly
Steel Ball
Return Spring
Lead Wire z O--Ring
Magnetic Idler Gear

Bearing
Switch
Assembly Pinion Brush Holder
Gear
z Front Bearing
z Dust Protector
Armature
z Rear Bearing
z O--Ring
Field Frame
B00441
Magnetic Switch Assembly
17 (173, 13) Terminal Bolt

Wave Washer
Insulation Paper Terminal Insulator
Packing
z Terminal 30 Kit Part Terminal Insulator O--Ring
Contact Plate
Terminal Bolt
Lead Terminal
Plunger
z Gasket z Terminal C Kit Part
End Cover
O--Ring
Terminal Insulator
Terminal
Bolt Wave Washer
Lead Clamp 17 (173, 13) Terminal Bolt
Contact Plate
Terminal Insulator
B00442

TO MODEL INDEX
ST -- 6 & 7
STARTING STARTER (2.2 kW)
ST02A--01
Dust DISASSEMBLY
Protector 1. REMOVE LEAD WIRE
Remove the screw and lead wire.
2. REMOVE DUST PROTECTORS

3. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
B00461 magnetic switch terminal.
(b) Remove the 2 through bolts and 2 O--rings.
(c) Pull out the field frame together with the armature from the
magnetic switch.
(d) Remove the O--ring from the filed frame.
4. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY

AND GEARS
(a) Remove the 2 screws.
B00465 (b) Remove these parts from the magnetic switch:
S Starter housing
S Return spring
S Pinion gear
S Bearing
S Idler gear
S Starter clutch assembly
5. REMOVE STEEL BALL
Magnetic Finger Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
P05056
6. REMOVE BRUSH HOLDER

Using a screwdriver, hold the spring back and disconnect the
brush from the brush holder. Disconnect the 4 brushes, and re-
N00562
move the brush holder.
7. REMOVE ARMATURE FROM FIELD FRAME

Using a plastic--faced hammer, tap the field frame end and re-
move the armature.
P05488
TO MODEL INDEX
ST--8
ST02B--01
INSPECTION
1. INSPECT ARMATURE COIL
Ohmmeter (a) Check the commutator for open circuit.
Continuity tween the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
ST1098
(b) Check the commutator for ground.

tween the commutator and armature coil core.
Ohmmeter
If there is continuity, replace the armature.
2. INSPECT COMMUTATOR
(a) Check the commutator for the dirty and burnt surfaces.
If the surface is dirty or burnt, correct it with sandpaper (No. 400)
or on a lathe.
No Continuity ST1099
(b) Check the commutator circle runout.

(1) Place the commutator on V--blocks.
(2) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
S04640
(c) Using vernier calipers, measure the commutator diame-

ter.
Standard diameter: 35.0 mm (1.378 in.)
Minimum diameter: 34.0 mm (1.339 in.)
If the diameter is less than minimum, replace the armature.
ST1100
(d) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.7 mm (0.028 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.
CONTINUED
ST0040
TO MODEL INDEX
ST--9
3. INSPECT FIELD COIL (FIELD FRAME)

Continuity Ohmmeter (a) Check the field coil for open circuit.
tween the lead wire and field coil brush lead.
If there is no continuity, replace the filed frame.
B00453
No Continuity (b) Check the field coil for ground.

Ohmmeter
tween the coil end and filed frame.
If there is continuity, replace the field frame.
B00454
Brush Holder Side

4. INSPECT BRUSHES
Using vernier calipers, measure the brush length.
Standard length: 16.5 mm (0.650 in.)
Minimum length: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush holder and
Length field frame
Field Frame Side
Length
ST1103
B00455 B00900
5. INSPECT BRUSH SPRINGS

Check the brush spring load.
Take the pull scale reading the instant the brush spring
separates from the brush.
Standard spring installed load:
26.5 -- 32.3 N (2.7 -- 3.3 kgf, 6.0 -- 7.3 lbf)
Minimum spring installed load:
17.6 N (1.8 kgf, 4.0 lbf)
ST0019 If the installed load is less than minimum, replace the brush
springs.
CONTINUED
TO MODEL INDEX
ST--10
STARTING STARTER (2.2 kW)
Ohmmeter 6. INSPECT BRUSH HOLDER

No Continuity
Check the brush holder insulation.
tween the positive (+) and negative (--) brush holders.
If there is continuity, repair or replace the brush holder.
7. INSPECT CLUTCH AND GEARS
(a) Check the gear teeth on the pinion gear, idle gear and
clutch assembly for wear or damage.
ST1105
If damaged, replace the gear or clutch assembly.
If damaged, also check the ring gear of the flywheel for wear or
Free damage.
(b) Check the clutch pinion gear.

Lock Hold the starter clutch and rotate the pinion gear clock-
wise, and check that it turns freely. Try to rotate the pinion
gear counterclockwise and check that it locks.
If necessary, replace the clutch assembly.
8. INSPECT BEARINGS
P24184
Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
(See page ST -- 11)
9. INSPECT MAGNETIC SWITCH

Ohmmeter
Terminal (a) Check the pull--in coil for open circuit.
Terminal C Using an ohmmeter, check that there is continuity be-
50 tween terminals 50 and C.
If there is no continuity, replace the magnetic switch.
Continuity B00451
Switch
Body (b) Check the hold--in coil for open circuit.
Ohmmeter
Terminal tween terminal 50 and the switch body.
50 If there is no continuity, replace the magnetic switch.
Continuity B00452
TO MODEL INDEX
ST--11
ST02C--01
REPLACEMENT
1. REPLACE FRONT BEARING
(a) Using SST and a press, press out the bearing.
SST SST 09950 -- 00020
ST1110
(b) Using SST and a press, press in a new bearing.

SST SST 09201 -- 41020
ST1126
SST 2. REPLACE REAR BEARING

(a) Using SST, remove the bearing.
SST 09286 -- 46011
ST1107
Upward (b) Using a 10 mm (for thread diameter) nut and press, press
10 mm in a new bearing.
Nut NOTICE:
Be careful of the installation direction.
Downward
ST1108 ST0605 ST0606 B00901
(c) Using a punch, stake the armature shaft.
Punch
CONTINUED
ST0607
TO MODEL INDEX
ST--12
3. RE P L ACE MAG NE T I C S WI T CH TE RMI NAL KI T

PARTS
(a) Remove the 3 bolts, lead clamp, end cover, gasket and
plunger.
B00443
(b) Using vernier calipers, measure the contact plate for

depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
Wear
B00444
(c) Remove the terminal kit parts.

SST (1) Using SST, loosen the terminal nuts.
SST 09810 -- 38140
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O--ring, terminal bolt, contact
plate and terminal insulator (inside).
(3) Terminal 30:
B00445 Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O--ring, terminal bolt,
contact plate, terminal insulator (inside) and insula-
tion paper.
(d) Temporarily install these new terminal 30 kit parts:

Long
Short (1) Insulation paper
Inside (4) (2) Terminal insulator (inside)
(3)
(2) (3) Contact plate
(1) (4) Terminal bolt
(5) O--ring
(7) Downward
(6) Packing and terminal insulator (outside)
(8)
(6) Indentation Install the packing to the terminal insulator, and
Protrusion B00447 install them.
CONTINUED
TO MODEL INDEX
ST--13
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(7) Wave washer
(8) Terminal nit
NOTICE:
Be careful to install the insulation paper, terminal insulator
(inside) and wave washer in the correct direction.
(e) Temporarily install these new terminal C kit parts:

Long (7)
(1) (6) (1) Terminal insulator (inside)
Short
(2) (5) (2) Contact plate
(3) (4) (3) Terminal bolt
(4) O--ring
(5) Terminal insulator (outside)
Inside (6) Wave washer
(7) Terminal nut
Lead Terminal B00446 NOTICE:
Be careful to install the terminal insulator (inside) and wave
washer in the correct direction.
(f) Temporarily tighten the terminal nuts.
Wooden Block (g) Tighten terminal nuts.

(1) Put a wooden block on the contact plate and press
40 mm
it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
37 mm
20 mm Press force: 981 N (100 kgf, 221 lbf)
NOTICE:
Contact S Check the diameter of the hand press ram. Then cal-
Plate culate the gauge pressure of the press when 981 N
S03786
(100 kgf, 221 lbf) of force is applied.

Gauge pressure:
100 kgf
(kgf/cm2) = Ram diameter (cm) 2
x 3.14 (π)
2
221 lbf
(psi) = Ram diameter (in.) 2
x 3.14 (π)
2
2
(kPa) = (kgf/cm ) x 98.1
(kPa) = (psi) x 6.9 CONTINUED
TO MODEL INDEX
ST--14
S If the contact plate is not pressed down with the spe-

cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(2) Using SST, tighten the nuts to the specified torque.

SST 09810 -- 38140
SST Torque: 17 N∙m (173 kgf∙cm, 13 ft∙lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
S03785
(h) Clean the contact surfaces of the remaining contact plate

and plunger with a dry shop rag.
(i) Reinstall the plunger, a new gasket, the end cover and
lead clamp with the 3 bolts.
B00448
TO MODEL INDEX
ST--15
ST02D--01
REASSEMBLY
HINT:
Use high--temperature grease to lubricate the bearings and
gears when assembling the starter.
1. PLACE ARMATURE INTO FIELD FRAME
(a) Apply grease to the armature bearings.
(b) Using a press, press in armature.
P04699
2. INSTALL BRUSH HOLDER

(a) Align the claw of the brush holder with the claw groove of
the field frame.
(b) Place the brush holder on the field frame.
ST0096
(c) Using a screwdriver, hold the brush spring back, and con-
nect the brush into the brush holder. Connect the 4
brushes.
NOTICE:
Check that the positive (+) lead wires are not grounded.
(d) Install a new O--ring to the groove of the field frame.
N00562
3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE

(a) Apply grease to the steel ball.
(b) Insert the steel ball into the clutch shaft hole.
P24191
4. INSTALL STARTER HOUSING, CLUTCH ASSEMBLY

AND GEARS
(a) Apply grease to the return spring.
(b) Insert the return spring into the magnetic switch hole.
CONTINUED
B00456
TO MODEL INDEX
ST--16
(c) Place these parts on the starter housing:

(1) Starter clutch assembly
(1) (2) Idler gear
(3) Bearing
(4) Pinion gear
(3)
(2) (4) B00464
(d) Install the starter housing to the magnetic switch with the
2 screws.
B00462
Align 5. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY

(a) Install a new O--ring to the groove of the filed frame.
(b) Align the claws of the brush holder with the grooves of the
magnetic switch, and install the field frame and armature
shaft assembly.
Align (c) Align the punch mark of the field frame with the line of the
magnet switch.
B00463
(d) Install a new O--ring to the through bolt.

New Dust
(e) Install the field frame and armature assembly with the 2
Protector
through bolts.
(f) Connect the lead wire to terminal C, and install the nut.
6. INSTALL DUST PROTECTORS
Install 2 new dust protectors.
B00461 7. INSTALL LEAD WIRE
Install the lead wire with the screw.
TO MODEL INDEX
ST--17
ST02E--01
Terminal C
Terminal 50 TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid during out the coil.
1. PERFORM PULL -- IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
B00457
Terminal C 2. PERFORM HOLD -- IN TEST

Disconnect With battery connected as above with the clutch pinion gear
out, disconnect the negative (--) lead from terminal C. Check
that the pinion gear remains out.
B00458
3. INSPECT CLUTCH PINION GEAR RETURN

Disconnect the negative (--) lead from the switch body. Check
Disconnect
that the clutch pinion gear returns inward.
B00459
Ammeter 4. PERFORM NO -- LOAD PERFORMANCE TEST

(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
shows the specified current.
Specified current: 120 A or less at 11.5 V
Terminal 50
Terminal 30 Battery B00460

TO MODEL INDEX
ST--18
STARTING -- STARTER RELAY
STARTER RELAY ST02F--01
INSPECTION
1. REMOVE STARTER RELAY
LOCATION: See relay locations in Electrical Wiring Diagram.
Ohmmeter Ohmmeter 2. INSPECT STARTER RELAY

(a) Inspect the relay continuity.
No
(1) Using an ohmmeter, check that there is no continu-
Continuity 1
ity between terminals 1 and 2.
Continuity If there is continuity, replace the relay.
2 (2) Check that there is continuity between terminals 3
4 3 and 4.
S00420
Ohmmeter (b) Inspect the relay operation.

(1) Apply battery voltage across terminals 3 and 4.
Continuity 1
between terminals 1 and 2.
2 3. REINSTALL STARTER RELAY
4 3 Battery
S00421
TO MODEL INDEX
CHARGING
ALTERNATOR (Hi-- Speed Compact Type) . . . CH-- 1

RM520E)
TO MODEL INDEX
CH--1
CHARGING -- ALTERNATOR (Hi--Speed Compact Type)
ALTERNATOR (Hi--Speed Compact Type)

CH01Q--01
COMPONENTS
Drive End Frame (Stator) Bearing Cover
Rotor
Bearing Retainer
z Front Bearing
z Oil Seal
Alternator Washer
Vacuum Pump
z Rear Bearing
Terminal Insulator
Brush Holder Cover
(Black Colored Screw)
Brush Holder
Cord Clamp Rubber
Insulator
Rear End Cover
Spring
Brush
IC Regulator
Rectifier End Frame
Rectifier Holder
ALPHABETICAL INDEX
TO MODEL INDEX
ID -- 1
ALPHABETICAL INDEX (A - T)
A R
Page Page
ABBREVIATIONS USED IN THIS MANUAL RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO -- 2
(TERMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN -- 8 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . IN -- 4
ALTERNATOR (Hi-- Speed Compact Type) . . . . . . . . . . . CH -- 1
S
C
STANDARD BOLT (SERVICE SPECIFICATIONS) . . . . SS -- 1
CHARGING (SERVICE SPECIFICATIONS) . . . . . . . . . . SS-- 19 STARTER (2.2 kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-- 5
COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 1 STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-- 18
COOLING (PREPARATION) . . . . . . . . . . . . . . . . . . . . . . . PP -- 11 STARTING (PREPARATION) . . . . . . . . . . . . . . . . . . . . . . PP -- 15
COOLING (SERVICE SPECIFICATIONS) . . . . . . . . . . . SS-- 13 STARTING (SERVICE SPECIFICATIONS) . . . . . . . . . . . SS-- 17
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 12
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 9
T
E TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN -- 8
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO -- 1
ENGINE FUEL (PREPARATION) . . . . . . . . . . . . . . . . . . . PP-- 7 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC -- 1
ENGINE FUEL (SERVICE SPECIFICATIONS) . . . . . . . SS-- 11 TURBOCHARGING (PREPARATION) . . . . . . . . . . . . . . PP -- 5
ENGINE MECHANICAL (PREPARATION) . . . . . . . . . . . PP-- 1 TURBOCHARGING
ENGINE MECHANICAL (SERVICE SPECIFICATIONS) . . . . . . . . . . . . . . . . . . SS-- 9
(SERVICE SPECIFICATIONS) . . . . . . . . . . . . . . . . . . SS-- 3
ENGINE SERIAL NUMBER
(IDENTIFICATION INFORMATION) . . . . . . . . . . . . . . IN -- 3
F
FOR ALL OF VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . IN -- 7
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU -- 1
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU -- 2
G
GENERAL INFORMATION
(HOW TO USE THIS MANUAL) . . . . . . . . . . . . . . . . . IN -- 1
GENERAL INFORMATION
(REPAIR INSTRUCTIONS) . . . . . . . . . . . . . . . . . . . . . IN -- 4
H
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . IN -- 1
I
IDENTIFICATION INFORMATION . . . . . . . . . . . . . . . . . . IN -- 3
IDLE SPEED AND MAXIMUM SPEED . . . . . . . . . . . . . . EM-- 5
INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU -- 3
INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU -- 4
INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 3
INTAKE SHUTTER (5L) . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-- 7
L
LUBRICATION (PREPARATION) . . . . . . . . . . . . . . . . . . . PP -- 14
LUBRICATION (SERVICE SPECIFICATIONS) . . . . . . . SS-- 15
O
OIL AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU -- 1
P
PRE -- HEATING SYSTEM (Super Glow Type) . . . . . . . . ST-- 1
PRE -- HEATING SYSTEM (Variable Delay Type) . . . . . . ST-- 4
PRECAUTION (FOR ALL OF VEHICLES) . . . . . . . . . . . IN -- 7

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Back To Engine Index BACK TO MAIN MODEL IND VIEW THE MAIN INDEX

RM582E 2L, 2L-T, 3L & 5L Pages From Supplement

Manual Name Pub. No.

S 2L, 3L Engine Repair Manual RM520E

S HILUX Electrical Wiring Diagram EWD307F

MAIN INDEX: HILUX

HOW TO USE THIS MANUAL . . . . . . . . . . . . . IN-- 1

HOW TO USE THIS MANUAL

Intake Air Control Valve

14.5 (145, 10)

Actuator Vacuum Hose

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

The procedures are presented in a step--by--step format:

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

IDENTIFICATION INFORMATION IN00Q--03

ENGINE SERIAL NUMBER

REPAIR INSTRUCTIONS IN003--04

(h) Carefully observe all specifications for bolt tightening

Illustration Symbol Part Name Abbreviation

MEDIUM CURRENT FUSE M--FUSE

HIGH CURRENT FUSE H--FUSE

(k) Care must be taken when jacking up and supporting the

(l) Observe the following precautions to avoid damage to the

(2) To disconnect vacuum hoses, pull on the end, not

Example (m) Tag hoses before disconnecting them:

FOR ALL OF VEHICLES

ABBREVIATIONS USED IN THIS MANUAL

ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . PP-- 1

REFER TO 2L, 3L ENGINE REPAIR MANUAL (Pub No.

(09222--03016) Remover & Replacer 2L--T, 3L, 5L

(09222--03021) Guide 2L--T, 3L, 5L

(09222--03026) Base 2L--T, 3L, 5L

09222--64012 Connecting Rod Bushing Remover

(09222--02022) Remover & Replacer 2L

09275--54011 Plunger Stroke Measuring Tool

09275--54020 Maximum Speed Adjusting Screw 2L--T, w/ HAC

09992--00025 Cylinder Compression Check Gauge

(09992--00121) No. 4 Attachment

(09992--00211) Gauge Assy

09200--00010 Engine Adjust Kit .

SST (Special Service Tools)

SST (Special Service Tools)

09228--64040 Fuel Filter Wrench Except Europe

09236--00101 Water Pump Overhaul Tool Set

(09237--00070) Shaft ”C” Governor sleeve plug

09260--54012 Injection Pump Tool Set

09082--00040 TOYOTA Electrical Tester.

SSM (Service Special Materials)

SST (Special Service Tools)

Engine oil (4WD) API CF--4

SST (Special Service Tools)

09810--38140 Starter Magnet Switch Nut Wrench 2.2 kW

09950--00020 Bearing Remover Armature rear bearing for 2.2 kW

STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . SS-- 1

HOW TO DETERMINE BOLT STRENGTH

Mark Class Mark Class

SPECIFIED TORQUE FOR STANDARD BOLTS

Diameter Pitch Specified torque

Valve clearance at cold Intake 0.20 -- 0.30 mm (0.008 -- 0.012 in.)

A/C idle--up speed -- 900 -- 1,000 rpm

Idler pulley Free length 44.4 -- 45.4 mm (1.748 -- 1.787 in.)

Cylinder head Warpage Maximum 0.20 mm (0.0079 in.)

Manifold Warpage Maximum 0.40 mm (0.0157 in.)

Camshaft Circle runout Maximum 0.10 mm (0.0039 in.)