Rosa 4D3 Engine

GROUP INDEX
HOW TO READ THIS MANUAL
GENERAL ......................................
00
ENGINE ..........................................
11
LUBRICATION ...............................
12
FUEL AND ENGINE CONTROL ....
13A
ELECTRONICALLY
CONTROLLED FUEL SYSTEM..... 13E
FOREWORD COOLING ....................................... 14
This Shop Manual is published for the information and
guidance of personnel responsible for maintenance of
INTAKE AND EXHAUST................ 15
Mitsubishi 4D3 series diesel engine, and includes proce-
dures for adjustment and maintenance services.
We earnestly look forward to seeing that this manual is
made full use of in order to perform correct services with
no wastage.
For more details, please consult your nearest authorized

Mitsubishi dealer or distributors.
Kindly note that the specifications and maintenance ser-
vice figures are subject to change without prior notice in
line with improvement which will be effected from time to
time in the future.
Jul. 2003
Applicable models
4D34T6
©2003 Mitsubishi Fuso Truck & Bus Corporation

1
HOW TO READ THIS

MANUAL
CONTENTS
HOW THIS MANUAL IS STRUCTURED. . . . .2 TERMS AND UNITS . . . . . . . . . . . . . . . . . . . 12

2 HOW TO READ THIS MANUAL
HOW THIS MANUAL IS STRUCTURED

T1011000100011
HOW TO READ THIS MANUAL 3
Service procedures
TERMS AND UNITS
TERMS AND UNITS

T1011000200018
The terms and units in this manual are defined as follows.
• This service manual contains important cautionary instructions and supplementary information under the
following four headings which identify the nature of the instructions and information:
• Front and rear

The forward running direction of the vehicle is the front and the reversing direction is the rear.
• Left and right
Left hand side and right hand side, when facing the forward running direction of the vehicle, are respec-
tively left and right.
• Terms of service standards
(1) Standard value
Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard
clearance between two parts when assembled, and the standard value for an assembly part, as the case
may be.
(2) Limit
When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength
and must be replaced or repaired.
• Tightening torque
Appropriate tightening torque has particular importance in respect of performance. Accordingly, tightening
torque is specified in locations that are to be tightened.
Where there is no specified figure for tightening torque, follow the table covering standard tightening
torques.
When the item is to be tightened in a "Wet" state, wet is indicated. Where there is no indication, read it as
dry, and tighten at specified torque.
TERMS AND UNITS
• Units
Tightening torques and other parameters are given in SI* units with metric units added in brackets [ ].
Item SI unit [metric unit] Conversion factor

Force N [kgf] 9.80665 N [1 kgf]
Moment of force N•m [kgf•m] 9.80665 N•m [1 kgf•m]
Positive pressure kPa [kgf/cm2] 98.0665 kPa [1 kgf/cm2]
Pressure Vacuum kPa [mmHg] 0.133322 kPa [1 mmHg]
pressure Pa [mmH2O] 9.80665 Pa [1 mmH2O]
Volume dm3 [L] 1 dm3 [1 L]
Power kW [PS] 0.7355 kW [1 PS]
Heat quantity J [kcal] 4186.05 J [1 kcal]
Heat flow W [kcal/h] 1.16279 W [1 kcal/h]
Angle ° -
Temperature ℃ -
Electric current A -
Voltage V -
Resistance Ω -
Electric power W -
00-1
GROUP 00
GENERAL
CONTENTS
EQUIPMENT MODEL . . . . . . . . . . . . 00-2 TABLE OF STANDARD TIGHTENING

TORQUES. . . . . . . . . . . . . . . . . . . . . . 00-3
ENGINE NO.. . . . . . . . . . . . . . . . . . . . 00-2
00-2 GENERAL
Equipment Model
Equipment Model
T1001000100098
Equipment name Model description Code description

Engine 4 D 3 4 1. No. of cylinders (4: Four cylinders)
2. Stands for diesel engine
4)
3. Series number
3)
2)
4. Version number
1)
Engine No.
T1001000200103
The serial number for engine is given to the respective engine in manufacturing sequence: every engine has
its own number. This number is required for incidental inspection of the engine. Please do not fail to mention
this number to the dealers when ordering spare parts.
Engine number
Engine number is punch-marked on the position as illustrated.
GENERAL 00-3
Table of Standard Tightening Torques

T1001000300133
• Use specified bolts and nuts and tighten them with the applicable torques according to the following table,
unless otherwise specified.
• Threads and contact seats shall be dry.
• Where there is difference in strength classification between nut and bolt (or stud bolt), the torque specified
for bolt shall apply.
Hex-head Bolt and Stud Bolt (Unit: N⋅m [kgf⋅m])
Strength
4T 7T 8T
classification
Representation
(Stud) (Stud) (Stud)

Nominal diameter
2 to 3 4 to 6 5 to 7
M5 - - -
[0.2 to 0.3] [0.4 to 0.6] [0.5 to 0.7]
4 to 6 7 to 11 8 to 12
M6 - - -
[0.4 to 0.6] [0.7 to 1.1] [0.8 to 1.2]
9 to 14 17 to 26 20 to 29
M8 - - -
[0.9 to 1.4] [1.7 to 2.6] [2.0 to 3.0]
19 to 28 18 to 26 36 to 52 33 to 49 45 to 60 41 to 59
M 10
[1.9 to 2.8] [1.8 to 2.7] [3.5 to 5.5] [3.5 to 5.0] [4.5 to 6.0] [4.3 to 6.0]
35 to 50 31 to 46 70 to 95 65 to 85 85 to 110 75 to 100
M 12
[3.4 to 5.0] [3.1 to 4.7] [7.0 to 9.5] [6.5 to 8.5] [8.5 to 11] [7.5 to 10]
60 to 85 55 to 75 120 to 160 110 to 140 130 to 180 120 to 160
M 14
[6.0 to 8.5] [5.5 to 7.5] [12 to 16] [11 to 14] [13 to 18] [12 to 17]
90 to 130 90 to 120 180 to 240 160 to 220 200 to 270 190 to 260
M 16
[9.5 to 13] [9.0 to 12] [18 to 24] [16 to 22] [20 to 27] [19 to 26]
140 to 190 120 to 160 260 to 340 220 to 290 290 to 390 260 to 340
M 18
[14 to 19] [12 to 16] [25 to 35] [22 to 30] [30 to 40] [26 to 35]
190 to 260 170 to 230 350 to 470 320 to 420 410 to 550 370 to 490
M 20
[19 to 26] [17 to 23] [36 to 48] [32 to 43] [41 to 56] [37 to 50]
260 to 340 230 to 300 470 to 640 430 to 570 550 to 740 490 to 670
M 22
[26 to 35] [23 to 31] [48 to 65] [43 to 58] [56 to 75] [50 to 68]
340 to 450 290 to 390 630 to 840 540 to 730 730 to 980 630 to 840
M 24
[34 to 46] [29 to 40] [63 to 86] [55 to 74] [74 to 100] [64 to 86]
00-4 GENERAL
Hex-head Flange Bolt (Unit: N⋅m [kgf⋅m])

Strength
4T 7T 8T
classification
Representation
Nominal diameter
4 to 6 8 to 12 9 to 14
M6 - - -
[0.4 to 0.6] [0.8 to 1.2] [0.9 to 1.4]
10 to 15 19 to 28 22 to 32
M8 - - -
[1.0 to 1.5] [1.9 to 2.8] [2.2 to 3.3]
21 to 30 20 to 28 39 to 58 37 to 53 50 to 65 45 to 65
M 10
[2.1 to 3.1] [1.9 to 2.9] [3.9 to 6.0] [3.6 to 5.4] [5.0 to 6.5] [4.5 to 6.5]
38 to 54 35 to 51 80 to 110 70 to 95 90 to 120 85 to 110
M 12
[3.8 to 5.5] [3.4 to 5.2] [8.0 to 11] [7.0 to 9.5] [9.0 to 12] [8.5 to 11]
GENERAL 00-5
Hex-head Nut (Unit: N⋅m [kgf⋅m])

Strength
4T 6T
classification
Representation
Standard Coarse
Standard screw Coarse screw
Nominal diameter screw screw
2 to 3 4 to 6
M5 - -
[0.2 to 0.3] [0.4 to 0.6]
4 to 6 7 to 11
M6 - -
[0.4 to 0.6] [0.7 to 1.1]
9 to 14 17 to 26
M8 - -
[0.9 to 1.4] [1.7 to 2.6]
19 to 28 18 to 26 36 to 52 33 to 49
M 10
[1.9 to 2.8] [1.8 to 2.7] [3.5 to 5.5] [3.5 to 5.0]
35 to 50 31 to 46 70 to 95 65 to 85
M 12
[3.4 to 5.0] [3.1 to 4.7] [7.0 to 9.5] [6.5 to 8.5]
60 to 85 55 to 75 120 to 160 110 to 140
M 14
[6.0 to 8.5] [5.5 to 7.5] [12 to 16] [11 to 14]
90 to 130 90 to 120 180 to 240 160 to 220
M 16
[9.5 to 13] [9.0 to 12] [18 to 24] [16 to 22]
140 to 190 120 to 160 260 to 340 220 to 290
M 18
[14 to 19] [12 to 16] [25 to 35] [22 to 30]
190 to 260 170 to 230 350 to 470 320 to 420
M 20
[19 to 26] [17 to 23] [36 to 48] [32 to 43]
260 to 340 230 to 300 470 to 640 430 to 570
M 22
[26 to 35] [23 to 31] [48 to 65] [43 to 58]
340 to 450 290 to 390 630 to 840 540 to 730
M 24
[34 to 46] [29 to 40] [63 to 86] [55 to 74]
00-6 GENERAL
Hex-head Flange Nut (Unit: N⋅m [kgf⋅m])

Strength
4T
classification
Representation
Standard Coarse
Nominal diameter screw screw
4 to 6
M6 -
[0.4 to 0.6]
10 to 15
M8 -
[1.0 to 1.5]
21 to 30 20 to 28
M 10
[2.1 to 3.1] [1.9 to 2.9]
38 to 54 35 to 51
M 12
[3.8 to 5.5] [3.4 to 5.2]
Tightening torque for flair nut for general purpose (Unit: N⋅m [kgf⋅m])
Pipe diameter φ 4.76 mm φ 6.35 mm φ 8 mm φ 10 mm φ 12 mm φ 15 mm
Tightening torque 17 [1.7] 25 [2.6] 39 [4.0] 59 [6.0] 88 [9.0] 98 [10.0]
Tightening torque for air piping nylon tube for general purpose [DIN type] (Unit: N⋅m [kgf⋅m])
Standard diameter 6×1 10×1.25 12×1.5 15×1.5
Tightening torque 20: 20 to 25.9 34: 34 to 44 49: 49 to 58.8 54: 54 to 58.9
[2.0: 2.0 to 2.6] [3.5: 3.5 to 4.5] [5.0: 5.0 to 6.0] [5.5: 5.5 to 6.0]
Tightening torque for air piping nylon tube for general purpose [SAE type] (Unit: N⋅m [kgf⋅m])
Standard diameter 1/4 3/8 1/2 5/8
Tightening torque 13: 13 to 16.9 29: 29 to 33.9 49: 49 to 53.9 64: 64 to 68.9
[1.3: 1.3 to 1.7] [3.0: 3.0 to 3.5] [5.0: 5.0 to 5.5] [6.5: 6.5 to 7.0]
11-1
GROUP 11
ENGINE
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . 11-2 REMOVAL AND INSTALLATION OF ENGINE

................................. 11-12
STRUCTURE AND OPERATION
Engine Body . . . . . . . . . . . . . . . . . . . . . . . . 11-3 CYLINDER HEAD AND VALVE MECHANISM
Connecting Rods. . . . . . . . . . . . . . . . . . . . . 11-4 ................................. 11-14
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . 11-5 TIMING GEARS . . . . . . . . . . . . . . . . . 11-34
TROUBLESHOOTING . . . . . . . . . . . . 11-6 CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11-40
ON-VEHICLE INSPECTION AND PISTONS, CONNECTING RODS AND

ADJUSTMENT CYLINDER SLEEVE . . . . . . . . . . . . . . 11-48
Inspection of Engine Compression . . . . . . . 11-7
Inspection and Adjustment of Valve Clearance FLYWHEEL. . . . . . . . . . . . . . . . . . . . . 11-66
...................................... 11-9
CRANKSHAFT AND CRANKCASE. . 11-70
11-2 ENGINE
SPECIFICATIONS
SPECIFICATIONS
T1111000100137
Item Specifications
Engine model 4D34T6 (EURO3)
Type 4-cylinder in-line, water-cooled 4-cycle diesel
Combustion chamber type Direct injection type
Valve mechanism Overhead valve (OHV) type
Maximum output kW [PS]/rpm 105 [143]/2700
Maximum torque N⋅m [kgf⋅m]/rpm 412 [42]/1600
Bore × stroke mm φ 104 × 115
Total displacement cm3 [L] 3907 [3.907]
Compression ratio 18.5
Remarks
Output and torque represent performance of run-in engine operating under the standard ambient conditions
and accessories specified below.
BAROMETRIC TEMPERATURE OF
STANDARD ACCESSORIES
PRESSURE INLET AIR
Fan, Intake and exhaust
EEC 80/1269/EEC 99 kPa, dry 25.0°C
system of vehicle
ENGINE 11-3

Engine Body
T1111011100119
AT302747
1 Rocker arm 9 Piston

2 Valve spring 10 Connecting rod
3 Camshaft 11 Timing gear
4 Cylinder sleeve 12 Tappet
5 Cylinder head 13 Inlet valve
6 Flywheel 14 Push rod
7 Crankshaft
8 Exhaust valve A: Direction of rotation
11-4 ENGINE
Connecting Rods
T1111010700130
1 Connecting rod bushing

2 Connecting rod
3 Connecting rod cap
4 Connecting rod bolt
5 Upper connecting rod bearing
6 Lower connecting rod bearing
A: Alignment mark
B: Mass mark
A B
AT302851
Piston
T1111011200086
A: Part Number
A B: Mass mark
B
C: Oversize mark
D: Cooling cavity
C
“ ”
Front mark
D
AT302878
ENGINE 11-5
Timing Gears
T1111010500114
“2”
“1”
“3”
AT302564
1 Camshaft gear 7 Idler bushing

2 Injection pump gear 8 Bolt
3 Crankshaft gear 9 Thrust plate
4 Oil pump gear 10 Power steering oil pump gear
5 Idler gear
6 Idler shaft A: Oil hole
Alignment marks are punch-marked on each timing gear to ensure proper engagement of the gears at instal-
lation.
11-6 ENGINE
TROUBLESHOOTING
TROUBLESHOOTING
T1111020100139
Symptoms
(a) (b) Remarks
Possible causes
Oil viscosity unsuitable X Refer to group 12 in this manual
Fuel incorrect or unsuitable X
Valve clearance faulty X X
Head gasket faulty X X
Valve and valve seat worn, and carbon deposits X X
Valve spring fatigued X X
Piston ring worn or damaged X X
Piston ring grooves worn or damaged X X
Injection timing faulty Refer to group 13A, 13E in this
X X
manual
Injection pump malfunctioning Refer to group 13A, 13E in this
X X
manual
Cooling system malfunctioning X Refer to group 14 in this manual
Injection nozzle malfunctioning Refer to group 13A in this
X X
manual
Fuel system sucking air Refer to group 13A in this
X
manual
Air cleaner mesh clogged X Refer to group 15 in this manual
Muffler clogged X Refer to group 15 in this manual
Pipes and hoses installed incorrectly X
Ancillary equipment of injection pump, alternator, etc. faulty, Refer to group 13A, 13E in this
and faulty installation of same X manual
Refer to Electrical manual
V-belt loose or damaged X Refer to group 14 in this manual
Crankshaft pulley mounted incorrectly X
Air cleaner or muffler malfunctioning X Refer to group 15 in this manual
Rocker shaft and bracket faulty X
Rocker shaft bracket lubrication faulty X
Timing gear backlash faulty X
Timing gear system and idler shaft area lubricated poorly X
Connecting rod small end bushing worn and piston pin worn X
Crankshaft pin and big end bearing of connecting rod worn or
X
damaged
Crankshaft journal and main bearing worn or damaged X
Crankshaft and camshaft end play excessive X
Tappet and camshaft worn X
(a): Decrease of power
(b): Engine noise abnormal
ENGINE 11-7
ON-VEHICLE INSPECTION AND ADJUSTMENT

Inspection of Engine Compression
T1111030400089
Service standard
Location Maintenance item Standard value Limit Remedy
1960 kPa
Each cylinder (200 rpm) 2550 kPa [26 kgf/cm2] Inspect
[20 kgf/cm2]
Engine
- within
Compression Pressure difference between
- 390 kPa Inspect
each cylinder
[4 kgf/cm2]
Special tool (Unit: mm)

Location Tool name and shape Part No. Application
Compression gauge Measurement of engine

- MH061460
adapter compression
M14 1.5 MH061460
The decrease of engine compression is a signal that it is time to

overhaul the engine. It is strongly recommended that this item
is inspected periodically and that you record the history of dete-
rioration in engine performance as this will help you to diag-
nose causes of future irregularities.
When the vehicle is still new or immediately after installation of
new parts, there may be a slight increase in engine compres-
sion, but normal performance will be restored soon.
• Before inspection make sure that engine oil, starter and bat-
tery are in normal condition.
• Before inspecting the vehicle do the following:
• Run the engine to bring the temperature of the coolant
up to approximately 75 to 85°C.
• Turn all the lights and accessory equipment OFF.
• Put transmission in neutral.
• Set the steering wheel at center and straight position.
• Remove F37 fuse 2 of fuse box 1 in instrument panel to pre-
1 vent from fuel injecting when the engine is cranked by
starter.
2 AT302502
11-8 ENGINE
• Remove all the injection nozzles. Refer to group 13A in this

manual.
B • Check that no foreign particles are sticking to waste cloth B
A covering injection nozzle mounting hole A after turning over
the engine.
WARNING
You must stay clear of injection nozzle mounting hole
A when you turn over the engine during this inspec-
tion. Assume that all cylinders have cracked, and that
AT100397
coolant, engine oil, fuel, etc. have seeped into the cyl-
inder chambers. If this is the state when the engine is
turned over, there is an extreme danger of these sub-
stances being injected out of the injection nozzle
mounting hole at high temperature.
• Mount gasket 2 and ST compression gauge adaptor in
ST injection nozzle mounting hole A and fasten them with noz-
4
zle bridge 3, then mount compression gauge 4.
2 • Measure engine compression while turning over the engine.
• Measure engine compression of cylinders and calculate the
A difference among the cylinders.
• If the engine compression and pressure difference between
3 each cylinder deviate from the limit, reinspect by pouring a
small amount of engine oil into injection nozzle mounting
AT100398 hole A.
• When pressure is high: It is likely that either wear or
damage of the slide-contact area of both the piston ring
and the cylinder inner surface has taken place.
• When pressure is low: It is likely that burning of the
valve, faulty contact of valve surfaces and/or faults in
the cylinder head gasket have developed.
ENGINE 11-9
Inspection and Adjustment of Valve Clearance

T1111030300112
Service standard (Unit: mm)

- Valve clearance (When engine is cold) 0.4 - Adjust
Special tools (Unit: mm)

- Cranking handle MH061289 Cranking of engine
36 MH061289
Valve clearance adjustment

- Flat-blade screwdriver MH060008 (Used for an installed
engine)
MH060008
Inspect and adjust the valve clearance while the engine is cold
in the following way.
.
[Inspection]
• Set No.1 piston or No.4 piston at top dead center in the
compression cycle. In order to do this, turn crankshaft pul-
ley 1 clockwise using ST cranking handle to align punched
mark on the crankshaft pulley with pointer A.
NOTE: .
• The cylinder whose push rod is not pushing up the inlet/
outlet rocker is the one whose piston is at top dead cen-
ter in the compression cycle.
• There is a pointer A in two locations, and the punched
mark on crankshaft pulley 1 can be aligned to either of
them, as long as the mark is in the position as illus-
trated.
AT302877
11-10 ENGINE
• Measure valve clearance B when either No.1 or No.4 piston

is at top dead center in the compression cycle in accor-
B dance with the following tabulated sequence of each valve.
Piston No. 1 2 3 4
Valve
In. Ex. In. Ex. In. Ex. In. Ex.
arrangement
C No.1 piston at top
dead center in the X X X - - X - -
AT201063
compression cycle
No.4 piston at top
dead center in the - - - X X - X X
compression cycle
NOTE: Be sure when taking measurements using feeler gauge

C that some resistance is felt when inserting the gauge. If the
gauge can be inserted freely without any resistance, an accu-
rate measurement cannot be obtained.
• If the measured value deviates from the limit, adjust as fol-
lows:
.
[Adjustment]
• Adjust valve clearance B so that feeler gauge C encounters
2 3
D some resistance when it is inserted. Do this by loosening
lock nut 2 and turning adjusting screw 3.
• After adjusting, tighten adjusting screw 3 using screwdriver
D and tighten lock nut 2. Reinspect valve clearance B using
feeler gauge C.
C
B
AT201064
• When turning adjusting screw 3 on an engine that is

installed, using a ST flat-blade screwdriver will make the
work easier.
ST
AT100404
ENGINE 11-11
MEMO
11-12 ENGINE
REMOVAL AND INSTALLATION OF ENGINE

T1111050200236
Disassembly sequence
2 Trq
1 Trq
AT302749
1 Nut 2 Bolt
SP 3 Engine and transmission assembly
WARNING
Fix engine and transmission assembly 3 temporarily with the engine lifter and the transmis-
sion jack before removal of parts.
Assembly sequence
Follow the disassembly sequence in reverse.
Tightening torques (Unit: N⋅m [kgf⋅m])

Location Parts to be tightened Tightening torque Remarks
1 Nut (Front mounting installation) 69 to 88 [7 to 9] -
2 Bolt (Rear mounting installation) 130 to 180 [13 to 18] -
ENGINE 11-13
Service Procedure
T1111090201482
Preparatory operations for removal

3 • Support engine and transmission assembly 3 on engine
lifter A and transmission jack B.
• Make sure that the wiring and hoses are disconnected.
AT302566
(3) Removal of engine and transmission

assembly
• Lower engine and transmission assembly 3 to fullest extent
3
keeping it horizontal.
• Lift the vehicle using the jack, and move engine and trans-
mission assembly 3 forward.
AT302567
11-14 ENGINE
CYLINDER HEAD AND VALVE MECHANISM

Overview
T1111090100813
AT302750
1 Oil filler cap 12 Rocker and bracket assembly

2 Spacer (Refer to P.11-20 of the same
Insulator group.)
3
SP 13 Push rod
4 Breather cap
SP 14 Cylinder head and valve assembly
5 Rocker cover gasket
(Refer to P.11-24 of the same
6 Outer rocker cover group.)
7 Washer SP 15 Cylinder head gasket
8 Insulator SP 16 Tappet
9 Inner rocker cover gasket SP *: Crankcase
10 Inner rocker cover (Refer to P.11-70 of the same
11 Cylinder head bolt group.)
DP: Locating pin
<X>: Non-reusable parts
ENGINE 11-15
Assembly sequence

13 Push rod deflection - 0.4 Replace
Basic diameter: 28,
Clearance between tappet and crankcase
16, * Standard value: 0.2 Replace
tappet hole
0.05 to 0.09
Tightening torque (Unit: N⋅m [kgf⋅m])

Wet
11 Cylinder head bolt 145 [15]+90° Bolt reusable
up to 3 times
Lubricant
Location Points of application Specified lubricant Quantity
11 Thread area of cylinder head bolt Engine oil As required
13 Both ends of push rod Engine oil As required
16 External periphery of tappet Engine oil As required
Special tools
Further tightening of
11 Socket wrench MH061560
cylinder head bolt
16 Tappet extractor MH063329 Removal of tappet
MH063329
11-16 ENGINE
Service Procedure
T1111090201493
(13) Push rod deflection

If the measured value is higher than the limit, replace push rod
13.
AT302751
(14) Cylinder head and valve assembly

.
[Removal]
C • Before undoing cylinder head bolts 11, first loosen adjusting
screw C of rocker A that pushes down valve spring B.
11 A
14
B
AT100413
• Loosen cylinder head bolts 11 gradually in the numbered

order as illustrated and remove them.
AT100414
[Installation]
CAUTION
Before installing cylinder head bolt 11, check the punched
mark D, marked on each bolt head. (When there are two or
11 D
less punched marks on the bolt head, the bolt can be
reused.) The punched marks indicate the number of times
the bolt has been tightened in plastic portion. When there
are three punched marks (tightened three times in the
past) on the bolt head, the bolt must be replaced by a new
one.
AT100638
ENGINE 11-17
• Carry out primary fastening, by gradually tightening cylinder

head bolts 11 in the numbered order as illustrated.
• After carrying out temporary tightening, tighten the bolts 11
again at specified torque (145 N⋅m [15 kgf⋅m]) in the order
* * * * as shown.
* *: In addition, tighten them together with locker and bracket
assembly according to the following procedure.
AT100415
• Rotate ST socket wrench holder E to the left and make the

spring inside the wrench effective.
F: Socket
G: Rod
H: Rod (for connecting)
AT302752
• Set so that rod H (for connecting) is pressed against rocker

shaft bracket L by the force of the spring, the injection pipe
or other surrounding parts.
• Select a notch J on holder E that is easily visible.
• Using the notch selected as the point of reference, rotate
notch K on socket F to the right by 90° (one notch = 5°) and
tighten.
CAUTION
Because cylinder head bolts 11 are fastened by the plastic
AT302753
zone fastening method, do not tighten further after they
have been tightened at the specified angle.
11-18 ENGINE
(15) Cylinder head gasket

.
[Removal]
CAUTION
Be careful not to scratch the cylinder head or crankcase *
when removing cylinder head gasket 15.
Size classification .
A B C [Installation]
• Install cylinder head gasket 15 to crankcase * in the direc-
tion as shown.
• Measure the piston protrusion value of each cylinder before
installing cylinder head gasket. Then, select the cylinder
“UP” head gasket 15 with thickness corresponding to its average
15 piston protrusion value from the table below.
mark
Measurement of piston protrusion: Refer to P.11-50 of the
same group.
* • If there are one cylinder or more which have piston protru-
D sion value with 0.05 mm or more compared with the aver-
age piston protrusion value, use the gasket with one-rank-
up thickness (A → B, B → C).
Specification (Unit: mm)
AT302853 Average protrusion Size classification of
value of piston cylinder head gasket
0.466 to 0.526 A
0.526 to 0.588 B
0.588 to 0.648 C
• Identify the kind of cylinder head gasket 15 (engine model

and size classification) based on the notched part D.
CAUTION
When changing piston, connecting rod, etc., make sure to
measure the protrusion value of piston because it varies.
(16) Removal of tappet

ST: Tappet extractor
ST
16
AT100420
ENGINE 11-19
(16, *) Clearance between tappet and crankcase

tappet hole
If the measured value is higher than the limit, replace the faulty
parts.
16
AT100421
11-20 ENGINE
Rocker and Bracket Assembly

T1111051300139
Overview
6
Lub 4 7
8
3
2
AT100422
1 Set bolt 6 Adjusting screw

2 Rocker shaft bracket 7 Rocker
3 Rocker assembly 8 Rocker shaft spring
SP 4 Rocker bushing SP 9 Rocker shaft
5 Lock nut
Assembly sequence

4, 9 Clearance between rocker bushing and Basic diameter: 19, 0.2 Replace
rocker shaft Standard value: 0.06 to 0.11
Lubricant
4 Inner surface of rocker bushing Engine oil As required
ENGINE 11-21

19
19 Removal and installation of
4 Rocker bushing puller MH061378
rocker bushing
21
MH061378
Service Procedure
T1111090201501
(4, 9) Rocker bushing and rocker shaft

.
[Installation]
If the clearance is higher than the limit, replace the faulty parts.
AT302754
Rocker bushing
.
[Removal]
ST: Rocker bushing puller
ST
AT100425
[Installation]
• Match oil hole A of rocker bushing 4 with oil hole B of rocker
7.
• Set clinch C and split D of rocker bushing 4 in the direction
ST as illustrated.
• Install rocker bushing 4 from chamfered side E of rocker 7.
4
D C
E A
7 B AT100426
11-22 ENGINE
(9) Installation of rocker shaft

When installing rocker shaft 9, bring oil passage hole for lubri-
C
cation A to front sideB.
C: Fixing hole of set bolt
B A AT100427
ENGINE 11-23
MEMO
11-24 ENGINE
Cylinder Head and Valve Assembly

T1111051400136
Overview
9
Lub 1 10 16
2
11 Trq
3
<X> 14 12 Trq
4 <X>15
13
5
<X> Lub 6
Lub 18
8
17
Lub 7 22
23
20 21
<X>19 <X>
AT302854
1 Valve cap 13 Nozzle bridge

SP 2 Valve cotter 14 O-ring
3 Upper retainer 15 Nozzle tip gasket
SP 4 Outer valve spring 16 Injection nozzle (Refer to group
SP 5 Inner valve spring 13A in this manual.)
SP Valve stem seal
SP 17 Inlet valve guide
6
SP Inlet valve
SP 18 Exhaust valve guide
7
SP Exhaust valve
SP 19 Inlet valve seat
8
Nut
SP 20 Exhaust valve seat
9
Connecting plate
SP 21 Water director
10
Glow plug (Refer to Electrical 22 Stud
11
manual.) SP 23 Cylinder head
12 Bolt
CAUTION
Be careful of the protrusion of injection nozzle 16 from the bottom surface of cylinder head 23.
ENGINE 11-25
Assembly sequence
NOTE: When inlet valve 7 and exhaust valve 8 have been removed, replace valve stem seal 6.
Service standards (Unit: mm)

4 Outer valve Without load 66.1 63.0 Replace
spring Installed load 275 (Tolerance: -1.4 to 230 N Replace
(Installed length 47.25) +1.4) N [23.7 kgf]
[27.9 (Tolerance: -1.4 to
+1.4) kgf]
Tilt - 2.5 Replace
5 Inner valve Without load 60.0 57.0 Replace
spring Installed load 120 (Tolerance: -5.9 to 100 N Replace
(Installed length 40.3) +5.9) N [10.3 kgf]
+0.6) kgf]
Tilt - 2.5 Replace
7 Inlet valve Stem diameter 8.96 to 8.97 8.85 Replace
Recess from head 0.75 to 1.25 1.5 Inspect
bottom surface each part
Valve margin 1.5 1.2 Replace
Valve seat angle 45° (Tolerance: -15’ to +15’) - Correct or
replace
7, 17 Clearance between stem of inlet valve and Basic diameter: 9, 0.15 Replace
inlet valve guide Standard value: 0.04 to
0.06
8 Exhaust valve Outer diameter of stem 8.93 to 8.94 8.85 Replace
Recess from cylinder 0.95 to 1.45 1.7 Inspect
head bottom surface each part
Valve margin 1.5 1.2 Replace
Valve seat angle 45° (Tolerance: -15’ to +15’) - Correct or
replace
8, 18 Clearance between exhaust valve stem Basic diameter: 9, 0.2 Replace
and exhaust valve guide Standard value: 0.07 to 0.1
19 Seat width of inlet valve seat 2.8 (Tolerance: -0.2 to +0.2) 3.6 Correct or
replace
20 Seat width of exhaust valve seat 2 (Tolerance: -0.2 to +0.2) 2.8 Correct or
replace
23 Cylinder head Distortion of bottom 0.05 or less 0.2 Correct or
replace
Height from top to 95 (Tolerance: -0.1 to +0.1) 94.6 Replace
bottom
11-26 ENGINE

11 Glow plug 15 to 20 [1.5 to 2.0] -
12 Bolt (Nozzle bridge mounting) 25 [2.5] -
Lubricant
1 Slide-contact areas of valve cap and rocker Engine oil As required
6 Lip of valve stem seal Engine oil As required
7, 8 Valve stem Engine oil As required

Valve lifter MH061668
Removal and installation of

2
valve cotter
Valve lifter hook MH061679
Valve stem seal 28 9

6 MH061293 Installation of valve stem
installer (diameter)
MH061293
Fitting of valve and valve

7, 8 Valve lapper 30091-07500
guide
30091-07500
ENGINE 11-27

13
Valve guide remover

MH061066 Removal of valve guide
(diameter)
9 MH061066
17, 18
28.5
Valve guide installer
MH061998 Press-fitting of valve guide
(diameter)
15 18
MH061998
A:MH061067
9
A: Caulking tool body B:MH061275
19, 20 B: Caulking ring <Inlet> Press-fitting of valve seat
C: In φ47.6, Ex φ40.6 C MH061069
B A <Exhaust>
MH061067
Service Procedure
T1111090201512
(2) Valve cotter

.
[Removal]
Remove valve cotter 2 making sure that valve springs 4, 5 are
ST-a
squarely and evenly pressed down by ST-a valve lifter and ST-
b valve lifter hook.
ST-b
.
3 2 [Installation]
4
5 Follow the removal procedure in reverse.
6
2 CAUTION
Be sure not to press down on valve springs 4, 5 too hard
AT302746
because this would cause upper retainer 3 to contact valve
stem seal 6 and damage it.
(4, 5) Installation of outer and inner valve springs

Install outer and inner valve springs 4, 5 into cylinder head 23
in the direction as illustrated.
A: Tightly coiled area
A 4
5
23
AT302568
11-28 ENGINE
(6) Installation of valve stem seal

• Apply engine oil to lip A of valve stem seal 6.
• Tap down ST valve stem seal installer until it hits cylinder
ST head 23.
A
6
23
AT302569
(7, 8) Inlet valve and exhaust valve

.
[Inspection]
1. Inspection of stems
If the measured value is lower than the limit or in the case of
excessive wear, replace valves 7, 8.
CAUTION
Be sure to lap valve seats 19, 20 when valves 7, 8 are
replaced with new ones. Refer to P.11-29 of the same
group.
2. Valve seat angle and valve margin

If the measured value is higher than the limit, repair or
replace valves 7, 8.
7, 8
A: Valve seat angle
B: Valve margin
A B
AT100069
[Correction]
NOTE: .
• Be sure to keep the grinding work as light as possible.
• Be sure to replace valves 7, 8 after grinding if valve margin
deviates from the limit.
• Be sure to lap valve 7, 8 and valve seats 19, 20 after grind-
ing. Refer to P.11-24 of the same group.
35
30
25
AT100068
ENGINE 11-29
(7, 8, 17, 18) Valve and valve guide

.
[Inspection]
When the clearance is higher than the limit, replace the faulty
parts.
7, 8
17, 18
AT302570
Valve guide
.
[Removal]
ST: Valve guide remover
ST
17, 18
AT302571
[Installation]
Tap down valve guides 17, 18 with ST valve guide installer until
ST it hits cylinder head 23.
CAUTION
23 • The length of fit of valve guides 17, 18 is standardized.
10 mm Be sure to use ST valve guide installer.
• Be sure to distinguish between valve guides 17, 18.
17, 18 Exhaust valve guide 18 is longer.
AT302572
(7, 8, 19, 20) Valve and valve seat

.
[Inspection]
• Apply red lead evenly to entire surface A of valve seats 19,
20 that contact valves 7, 8.
• Fit valves 7, 8 to valve seats 19, 20 and tap once without
ST rotating.
A ST: Valve lapper
NOTE: Be sure to carry out inspection under the condition
that valves 7, 8 and all parts of valve guides 17, 18 are nor-
mal.
AT100442
11-30 ENGINE
• Check how much red lead has transferred to valves 7, 8 to

determine the contact of the valve and the seat. According
to the degree of abnormality, take proper measures to cor-
rect it.
Contact Remedy measures
condition
Minor fault Valve lapping
Major fault Repair of valve and seat or replacement of
AT100076 both
.
[Correction]
Valve polishing is done in the following manner:
• Apply valve lapping compound thinly to contact surface A of
valves 7, 8 with valve seats 19, 20.
CAUTION
Take care not to smear stems B of valves 7, 8 with the com-
pound.
NOTE: .
• Start with medium grit compound (120 to 150 grit) and
for finishing up, use finer grit (200 grit or finer).
• Mixing with a small amount of engine oil will make the
compound consistent and make even application easier.
• Tap valves 7, 8 against valve seats 19, 20 several times
while rotating the valves slightly at each strike.
• Clean off the compound with gas oil.
ST • Apply engine oil to contact surface A of valve seats 19, 20
and smooth the surface.
• Check the contact of valves 7, 8 and valve seats 19, 20.
• If contact does not take place completely around the seat,
replace valve seats 19, 20.
ST: Valve lapper
AT100443
(19, 20) Valve seat

.
[Inspection]
1. Valve seat width
If the measured value is higher than the limit, replace valve
7, 8
seats 19, 20.
19, 20 A: Valve seat width
NOTE: Be sure to lap and fit valves 7, 8 and valve seats 19,
A
20 after correction or replacement.
AT302573
ENGINE 11-31
2. Extent of valve recess from the bottom surface of cylinder

head
7, 8
If the measured value is higher than the limit, correct or
19, 20 replace the faulty parts.
B: Extent of valve recess
B AT302574
[Correction]
• Grind valve seats 19, 20 using valve seat cutter or valve
B C seat grinder.
• After grinding, do another light abrasion using 400 grit
emery paper placed between the cutter and the seat.
A
• Adjust the seat width A of valves 7, 8 using 15° or 75° cutter
19, 20 to make seat width conform to the standard value.
7, 8
C: Valve seat angle
CAUTION
Be sure that as a result of grinding, recess B of valves 7, 8
AT302575
does not become higher than the limit.
• After correction is done, be sure to carry out lapping and fit-
ting on valves 7, 8 and valve seats 19, 20.
.
[Removal]
Valve seats 19, 20 have been set in by the cooling-off-process,
and have to be thinned by grinding off the inner side for
19, 20
removal under normal temperature.
D: Part to be ground
0.5 to 1.0 mm
D AT302576
[Installation]
• Make sure that the diameter of valve seat hole of cylinder
head 23 conforms to the standard value.
E: Inlet valve seat hole diameter
F: Exhaust valve seat hole diameter
E F
46(Tolerance:
0 to +0.025)mm
39(Tolerance:
0 to +0.025)mm
AT302855
11-32 ENGINE
• Immerse valve seats 19, 20 in liquid nitrogen and cool them

substantially. Press-fit into the cylinder head using ST-a
ST-a caulking tool body and ST-b caulking rings inlet and
exhaust.
G ST-b
CAUTION
Be sure, when press-fitting, to place the chamfered side G
19, 20 of ST-b caulking rings inlet and exhaust against valve
seats 19, 20.
• After installation of valve seats 19, 20, work until they con-
AT302577 tact valves 7, 8 smoothly.
(21) Installation of water director

With indent A set in the direction as illustrated, press-fit water
director 21 into cylinder head 23 to the specified depth.
4 mm 23
A
21
AT302578
(23) Inspection of cylinder head

Measure the extent of distortion of the bottom of cylinder head
23, and if the measured value is higher than the standard
value, grind using a surface grinder.
CAUTION
Be sure to keep the amount of grinding within the limit of
the height of cylinder head 23.
23
AT302579
ENGINE 11-33
MEMO
11-34 ENGINE
TIMING GEARS
TIMING GEARS
Overview
T1111090100824
Inspection before disassembly (Refer to P.11-36 of the same group)
Trq 19
11 Lub 20 18 Trq
21
10 23
<X> Lub 6 23
22
8 Lub
<X> 14
<X> Lub 7
<X> Lub 9 *c *d
14 *b
13
17
Trq 4 12 *e
3 Trq
2 Lub 16 *a
Trq 15
1 5
*f
AT30286
1 Bolt 20 Nut
2 Pulley(for air conditioner) 21 Pressure hose (Refer to group 37
3 Nut of Chassis manual.)
Crankshaft pulley 22 O-ring
4
Bolt 23 Power steering oil pump (Refer to
5
group 37 of Chassis manual.)
6 O-ring
7 O-ring Crankshaft gear (Refer to P.11-70
*a:
8 Vacuum pump assembly (Refer to of the same group.)
group 35 of Chassis manual.) *b: Oil pump gear (Refer to group 12 in
9 Front oil seal this manual.)
10 Bearing *c: Camshaft gear (Refer to P.11-40 of
SP 11 Timing gear case the same group.)
12 Bolt *d: Injection pump gear (Refer to
SP 13 Thrust plate group 13A in this manual.)
SP 14 Idler gear assembly *e: Key (Refer to P.11-70 of the same
SP Idler gear bushing group.)
15
*f: Front oil seal slinger (Refer to
16 Idler gear
P.11-70 of the same group.)
SP 17 Idler shaft
18 Clamp
19 Rubber hose (Refer to group 37 of
Chassis manual.)
ENGINE 11-35
TIMING GEARS
NOTE: Do not remove front oil seal 9 unless it is faulty.
Assembly sequence
CAUTION
Be sure to install key *e when installing crankshaft pulley 4.

Idler gear assembly and 0.07 to 0.15 0.3
crankshaft gear
Idler gear assembly and 0.07 to 0.17 0.3
camshaft gear
Backlash of Idler gear assembly and 0.07 to 0.17 0.3
- Replace
each gear injection pump gear
Crankshaft gear and oil pump 0.10 to 0.18 0.3
gear
Camshaft gear and power 0.08 to 0.16 0.3
steering oil pump gear
- Idler gear end play 0.05 to 0.15 0.3 Inspect
Basic diameter:
Clearance between idler gear bushing and idler 45, Standard
15, 17 0.1 Replace
shaft value: 0.03 to
0.06

1 Bolt (pulley mounting) 26 to 32 [2.7 to 3.3] -
3 Nut (Crankshaft pulley mounting) 590 [60] -
12 Bolt (Thrust plate mounting) 24 [2.4] Wet
18 Clamp (Rubber hose mounting) 2.9 to 3.4 [0.3 to 0.35] -
20 Nut (Pressure hose mounting) 29 to 39 [3 to 4] -
Lubricant and/or sealant

Specified lubricant and/or
Location Points of application Quantity
sealant
6, 7, 22 Entire body of O-ring Engine oil As required
9 Front oil seal lip Engine oil As required
11 Mounting surface of timing gear case THREEBOND 1207C As required
12 Thread area of bolt Engine oil As required
11-36 ENGINE
TIMING GEARS

49
Idler gear bushing Removal and installation of

15 MH062224
puller idler gear bushing
44.5
MH062224
Service Procedure
T1111090201523
Inspection before disassembly
1. Backlash of each gear
Measure three or more locations on the pairing gears and if
the measurements are higher than the limit, replace the
faulty parts.
AT302755
2. Idler gear end play

If the measured value is higher than the limit, replace the
faulty parts.
AT302756
(11) Installation of timing gear case

Apply sealant A to the mounting surface of timing gear case 11
1 to 1.5 mm
evenly without break. After applying sealant, within three min-
A utes, mount to the front plate.
CAUTION
• Be sure to clean and wipe off oily substances from the
surface where sealant A is to be applied.
• Make sure that sealant A is not transferred to other
areas while the mounting work is being done.
• Be sure to reapply sealant A if the bolt is loosened or
AT100455
removed by any cause whatsoever after mounting.
• Do not start the engine within an hour of mounting.
ENGINE 11-37
TIMING GEARS
(13) Installation of thrust plate

A: Chamfered side
13
12 AT302581
(14) Installation of idler gear assembly

Install idler gear assembly 14 by matching alignment marks on
14
*d the gears that engage with those on the assembly.
*c *a: Crankshaft gear
*c: Camshaft gear
*d: Injection pump gear
Alignment
mark
Alignment
mark *a Alignment mark
AT302582
(15, 17) Idler gear bushing and idler shaft

.
[Inspection]
AT100458
Idler gear bushing

.
[Removal]
ST: Idler gear bushing puller
15 AT302583
.
11-38 ENGINE
TIMING GEARS
[Installation]
• Install idler gear 16 by press-fitting idler gear bushing 15 in
the direction as illustrated.
• After press-fitting, finish the fitting by bringing the clearance
ST
between idler gear bushing 15 and idler shaft 17 to the stan-
dard value.
15 ST: Idler gear bushing puller
16
marks “1”, “2”, “3”

AT302857
ENGINE 11-39
TIMING GEARS
MEMO
11-40 ENGINE
CAMSHAFT
CAMSHAFT
Overview
T1111090100835
Inspection before disassembly (Refer to P.11-42 of the same group.)
1 Bolt SP 9 No.3 camshaft bushing

SP 2 Camshaft assembly SP 10 No.4 camshaft bushing
SP 3 Camshaft gear SP 11 Sealing cap
SP 4 Thrust plate SP 12 No.5 camshaft bushing
5 Key
SP 6 Camshaft *: Crankcase (Refer to P.11-70 of the
SP No.1 camshaft bushing same group.)
7
SP No.2 camshaft bushing <X>: Non-reusable parts
8
NOTE: Do not remove camshaft gear 3 unless it is faulty.
Assembly sequence
ENGINE 11-41
CAMSHAFT

- Camshaft end play 0.05 to 0.22 0.3 Replace
Basic diameter:
Interference between camshaft gear and 30, Standard Reassemble up to 3
3, 6 -
camshaft value: 0.03 to times
0.07
Replace
Long diameter
7.195 (Tolerance:
Inlet 6.70 47.105
-0.05 to +0.05)
Short diameter
Difference between 39.910
long and short
6 Camshaft diameters Replace
Long diameter
7.321 (Tolerance:
Exhaust 6.82 46.979
-0.05 to +0.05)
Short diameter
39.658
Deflection 0.02 or less 0.05 Replace
Basic diameter:
No.1 to 54.5, Standard
0.15
No.4 value: 0.04 to
6 to 10, Clearance between camshaft and 0.09
Repair or replace
12 camshaft bushing Basic diameter:
53, Standard
No.5 0.15
value: 0.04 to
0.09
Lubricant
7 to 10,
Inner surface of camshaft bushing Engine oil As required
12

Camshaft bushing installer
C
and extractor
B
No.1: A,C φ58.5
B φ54.5
7 to 10, No.2, 3: A,C φ58 Removal and press-fitting
A MH061276
12 B φ54.5 MH061276 of camshaft bushing
No.4: A,C φ57.5
B φ54
No.5: A,C φ57
B φ53
11-42 ENGINE
CAMSHAFT
Service Procedure
T1111090201534

.
Camshaft end play

If the measured value is higher than the limit, replace the faulty
parts.
AT302757
(2) Camshaft assembly

.
[Removal]
Remove camshaft assembly 2 by undoing bolts 1 through the
holes in camshaft gear 3.
1 NOTE: Be careful not to damage the camshaft bushings when
3
you remove camshaft assembly 2.
AT100464
[Installation]
• Before installing camshaft assembly 2, measure the end
play between thrust plate 4 and camshaft 6.
• If the measured value is higher than the limit, replace the
faulty parts.
• Install the camshaft assembly by matching the alignment
mark on camshaft gear 3 with the alignment mark on the
idler gear. Refer to P.11-34 of the same group.
AT302641
ENGINE 11-43
CAMSHAFT
(3) Camshaft gear

.
[Removal]
A: Press
AT302759
[Installation]
• Before installing the camshaft gear 3, check the number of
punched marks B at the center area of the camshaft gear 3.
The camshaft 6 can be reassembled three times.
If three markes are already punched, use the new camshaft
gear 3 and camshaft 6.
AT302760
• Install the camshaft gear 3 to the camshaft 6 in the direction

shown in the figure, install the key 5 to prevent the camshaft
gear 3 from rotating.
A: Press
B: Jig
CAUTION
When using a press, be sure to press the center area of the
camshaft gear 3. If the gear area is pressed, the camshaft
AT302761
gear will be damaged.
• After installing the camshaft gear 3, mark a reassemble sign
of punched mark B of the camshaft gear 3 center area.
(3, 6) Exposed thread of camshaft gear and

camshaft
If interference is lower than the standard value, replace the
faulty parts.
AT302762
11-44 ENGINE
CAMSHAFT

Install thrust plate 4 on camshaft 6 in the direction as illustrated.
AT302763
(6) Inspection of camshaft

1. Difference between long diameter and short diameter
If the measured value is lower than the limit, replace
6
camshaft 6.
NOTE: Measure at point A, as illustrated, because the cam
B
D is tapered.
B: Long diameter
C C: Short diameter
6.5 mm 6.5 mm
D: Front of the engine
A A
AT100470
2. Degree of bend
Inspection of camshaft 6 for its degree of bend is done by
E measuring No. 3 journal G by supporting the shaft at No.1
F journal E and No. 5 journal F. If the measured value is
6
higher than the limit, replace the camshaft.
NOTE: Degree of bend of camshaft 6 is a half of the indi-
cated value of the gauge after rotating the shaft one full turn.
G
AT100471
(6 to 10, 12) Camshaft and camshaft bushing

.
[Inspection]
If the clearance is greater than the limit, replace the faulty parts.
NOTE: Measure camshaft bushings 7 to10 and 12 with leaving
them installed on crankcase.
AT100472
ENGINE 11-45
CAMSHAFT
Camshaft bushing
.
[Removal]
Remove camshaft bushings by using ST camshaft bushing
installer and extractor which has adapter B set by each bushing
7 to 10, 12 No.
ST
NOTE: Remove No.1 to 4 camshaft bushings 7 to 10 from the
front of the engine, and No. 5 camshaft bushing 12 from the
rear of the engine by pushing ST camshaft bushing installer
B and extractor.
AT100473
[Installation]
• Identify, by referring to the table below, No.1 to No.5 cam-
marks “1”, “A”, “2”, “C”, “4” shaft bushings by noting marks on camshaft bushings 7 to
10, 12. If you cannot identify the mark, measure outer diam-
eter D of the bushing and refer to the table below.
D Bushing No. (from the Mark Outer diameter D (mm)
front of the engine)
No.1 1 φ58.50
7 to 10, 12
AT200126
No.2 A φ58.25
No.3 2 φ58.06
No.4 C φ57.75
No.5 4 φ57.06
• For press-fitting, mount guide E to ST camshaft bushing

installer and extractor.
7 to 10, 12
• Install camshaft bushings 7 to 10, 12 in the order of No.4 to
No.1.
• Install No.5 camshaft bushing 12 from the rear of the engine
ST and No.4 to No.1 camshaft bushings 7 to 10 from the front
of the engine.
E AT100475
*
• Align oil hole F of No.5 camshaft bushing 12 in the direction
12 as illustrated.
F
40˚
AT100476
11-46 ENGINE
CAMSHAFT
• Press in until surface G of No.5 camshaft bushing 12 is

flush with chamfered part H of crankcase *.
* 12 J: Front of the engine
G
J ST
H
AT100477
• Align oil hole K, of No.2 to No.4 camshaft bushings 8 to 10,

8 to 10 * in the direction as illustrated, and press-fit in the order of
No.4, 3, 2.
K
40˚
AT100478
• Press in until surface L of No.2 to No.4 camshaft bushings 8

to 10 is flush with surface M of crankcase *.
*
J: Front of the engine
J L
ST M
8 to 10
AT100479
• For press-fitting of No.4 camshaft bushing 10, use tool N as

N ST
illustrated.
200 mm
50 mm
30 mm
17.5 mm
AT100480
• Align oil holes P, Q of No.1 camshaft bushing 7 in the direc-

* tion as illustrated.
7
P P: φ3 mm
15˚ Q: φ8 mm
40˚ *: Crankcase
Q
AT302764
ENGINE 11-47
CAMSHAFT
• Align oil hole Q of No.1 camshaft bushing 7 with oil hole R

* of crankcase * and press in until camshaft bushing surface
S S is flush with crankcase surface T.
ST J T
7 J: Front of the engine
7
Q
J
* R
AT100482
(11) Installation of sealing cap

Press-fit sealing cap 11 into crankcase * to the specified depth.
* * A: Front of the engine
A
11
2.5 mm
AT302585
11-48 ENGINE
PISTONS, CONNECTING RODS AND CYLINDER SLEEVE

Overview
T1111090100846
AT302765
1 Bolt SP 6 Cylinder sleeve

SP 2 Lower connecting rod bearing
3 Connecting rod cap *a: Crankshaft (Refer to P.11-70 of the
SP Upper connecting rod bearing same group.)
4
*b: Crankcase (Refer to P.11-70 of the
SP 5 Piston and connecting rod
same group.)
assembly (Refer to P.11-58 of the
*c: Oil pan (Refer to group 12 in this
same group.)
manual.)
Assembly sequence
ENGINE 11-49

- Extent of piston protrusion 0.43 to 0.69 - Inspect
- End play of connecting rod 0.15 to 0.45 0.6 Inspect
Basic diameter:
65, Standard
Oil clearance 0.2
2, 4 Connecting rod bearing value: 0.04 to Replace
0.09
Expansion - Less than 69.5
Basic diameter: Adjust or
Clearance between piston and connecting rod 104, Standard replace
5, 6 -
assembly and cylinder sleeve value: 0.12 to with
0.16 oversizes
Inner diameter 104 to 104.03 104.25 Adjust or
Circular accuracy 0.01 or less - replace
6 Cylinder sleeve
with
Cylindrical accuracy 0.03 or less - oversizes
Replace
Interference between Standard 0.17 to 0.23 - with
6, *b cylinder sleeve and oversizes
crankcase
Oversize 0.19 to 0.21 - Replace

30 [3]+90°
1 Bolt Wet
(Tolerance: -5° to +5°)
Lubricant
2, 4 Inner surface of bearing Engine oil As required
*b Sleeve hole of crankcase Spindle oil (ISO VG 32) As required
11-50 ENGINE

Further tightening of
1 Socket wrench MH061560 connecting rod cap
installation bolt
A
A: Piston guide clamp B A: MH061890 Installation of piston and
5
B: Piston guide lever B: MH061658 connecting rod assembly
MH061890
Cylinder sleeve Installation of cylinder

6 MH062228
installer sleeve
103 MH062228
Service Procedure
T1111090201545

1. Extent of piston protrusion from the upper surface of
crankcase *b
NOTE: Always inspect the extent of piston protrusion
A
because it affects the engine performance greatly.
*b • Measure piston protrusion at two points on the top of the
piston, and produce the average value.
A: Front of the engine
• If the average valve deviates from the limit, inspect clear-
ance of the related parts.
AT302507
2. End play of connecting rod

• Measure the end play on each connecting rod.
faulty parts.
AT100489
ENGINE 11-51
(2, 4) Connecting rod bearing

.
[Installation]
Install connecting rod bearings 2, 4 by matching lugs A.
2 4
CAUTION
B A Be sure to distinguish between upper and lower connect-
A ing rod bearings 2, 4. The upper bearing has oiling open-
ing B while the lower bearing has no oiling opening.
.
[Inspection]
CAUTION
AT100490 • Do not forcibly open or expand connecting rod bear-
ings 2, 4.
• When either upper or lower connecting rod bearings 2,
4 needs replacing, replace as a set.
1. Expansion at free state
If the measured value is lower than the limit, replace
connecting rod bearings 2, 4.
AT100491
2. Clearance between connecting rod bearing and crankshaft

(Oil clearance)
If the measured value is higher than the limit, replace the
faulty parts. When replacing connecting rod bearings 2, 4
with undersized ones, correct pin outer diameter A of
crankshaft *a to the specified undersize. Refer to P.11-77 of
the same group.
AT302766
11-52 ENGINE
(5) Installation of piston and connecting rod

assembly
CAUTION
B • Be sure to fit piston ring A in the correct position. Refer
to P.11-58 of the same group.
• Be careful not to scratch or damage head B of the pis-
A ton (a part of the combustion chamber).
• Make sure that the connecting rod does not hit oil jet C.
AT100493
• Install the piston front mark directed towards the front of the
engine using the following procedure.
D: Front of the engine
AT302767
• Match the inner diameter of ST-a piston guide clamp to the

outer diameter of the piston skirt by turning adjusting bolt E
of ST-b piston guide lever.
• After adjusting, set ST-a clamp and ST-b lever at the top of
the piston so that the clamp is flush with the top of the pis-
ton.
AT302768
ENGINE 11-53
• After the piston is inserted, mount connecting rod cap 3 to

the connecting rod by matching alignment marks F using
the following procedure.
NOTE: After installation of connecting rod cap 3, inspect the
following points:
• Piston protrusion: Refer to P.11-58 of the same group
• End play of the connecting rod: Refer to P.11-48 of the
same group
AT302769
After tightening bolt 1 at specified torque, tighten by an addi-

tional 90°: 85° to 95°, using ST socket wrench.
• Rotate ST socket wrench holder G to the left and make the
H: Socket
J: Rod
K: Rod (for connecting)
AT302770
• Set so that rod K (for connecting) is pressed against crank-

shaft *a by the force of the spring.
• Select a notch L on holder G that is easily visible.
notch M on socket H to the right by 90° (Tolerance: -5° to
+5°) (1 notch = 5°) and tighten.
AT302771
11-54 ENGINE
(5, 6) Piston and connecting rod assembly and

cylinder sleeve
.
[Inspection]
• Measure the clearance between the inner diameter of cylin-
der sleeve 6 and outer diameter of the piston part of piston
and connection rod assembly 5.
• A: Measuring point on the crankcase (in direction of the
crankcase axis)
• B: Measuring point on the crankcase (vertical to the crank-
case axis)
• C: Measuring point on the piston outer diameter (vertical to
the piston pin hole)
• If the measured value is higher than the standard value,
correct according to one of the following methods, depend-
ing on the condition of the parts.
CAUTION
Even if only one cylinder is faulty, correct all the cylinders
to oversize ones of the same size.
• Replacing the piston with an oversize one
• Replacing cylinder sleeve 6
• After determining the proper method of correction, correct
AT302772 by following one of the procedures described below.
.
[Correction]
Piston
<When replacing the pistons with an oversize ones>
Amount of oversize: 0.5, 1.0 mm
• Measure the outer diameter C of the oversize piston to be
used.
• Bore each cylinders so that the clearance between the pis-
ton and the cylinder sleeves conform to the standard value.
CAUTION
To prevent deformation as a result of the rise in tempera-
ture during boring, bore the cylinders in the following
order.
No. 2 → No. 4 → No. 1→ No. 3
• Dimension after boring finish (tolerance +0.005 to -0.005) =
oversize piston outer dimension C (measured value) +
clearance between piston and cylinder (service standards
mean value) - 0.02 mm (honing extent)
• Boring is followed by honing to obtain the proper dimen-
sions (tolerance +0.005 to -0.00).
Dimension after final finish (tolerance +0.005 to -0.005) =
oversize piston outer dimension C (measured value) +
clearance between piston and cylinder (service standards
mean value)
NOTE: .
• Honing finished surface coarseness: 3.2 μm or less
• Honing cross-hatching angle: 15 to 25° (half angle)
• Cylinder bore secureness: 0.05 mm
• Check the clearance between the piston and the cylinder.
ENGINE 11-55
NOTE: Piston rings must be replaced with the correspond-

ing oversized ones.
Cylinder sleeve
<When replacing the cylinder sleeve>
.
[Removal]
G
• Mount a boring machine on crankcase *b and centralize.
Centralization should be done at the lower part of cylinder
sleeve 6 which is less unevenly worn.
• Bore until the wall thickness of cylinder sleeve 6 is approxi-
H mately 0.5 mm.
• Insert tool G (Screwdriver, etc. part of which has been
altered) into the gap between crankcase *b and cylinder
sleeve 6, and tapping the tool lightly break up and remove
the sleeve.
6 *b AT100501 CAUTION
Make sure rounded side H of the tip of tool G faces crank-
case *b.
.
[Inspection]
• Before installing cylinder sleeve 6, inspect the sleeve hole
15 mm
of crankcase *b. Bore and correct, if there is a flaw or if

*b there is not enough interference.
NOTE: .
99 mm
D1 • When a sleeve hole of crankcase *b needs boring,

183 mm
remove cylinder sleeves 6 from all of the cylinders and

B
D2 A bore the sleeve holes uniformly.
• After applying spindle oil (ISO VG 32) to the sleeve hole
D3
of crankcase *b press fit cylinder sleeve 6 into the hole.
AT100435 Inspect interference as follows:
15 mm
• Measure the inner diameter of the sleeve hole of crankcase

6 *b and the outer diameter of cylinder sleeve 6 at each of the
locations for measurement as illustrated.
• Find the mean value for the vertical directions (D1, D2, D3)
99 mm
D1
183 mm
and diametrical directions (A, B). Measure the interference.

D2 B
A <When there is sufficient interference>
D3 • Install STD cylinder sleeve 6.
<When there is not sufficient interference>

AT100462
• Install cylinder sleeve 6 which is 0.5 mm oversize in diame-
ter.
.
11-56 ENGINE
[Installation]
<When there is sufficient interference>
• Press-fit cylinder sleeve 6 into crankcase *b from the cham-
fered end.
E: Pressure (press-fitting load: 46.1 to 88.2 kN [4700 to
9000 kgf])
ST: Cylinder sleeve installer
NOTE: .
• After applying spindle oil (ISO VG 32) to the sleeve hole of
crankcase *b press fit cylinder sleeve 6 into the hole.
AT302641
• Align the upper face of cylinder sleeve 6 with the upper face
of crankcase *b when press-fitting.
• Measure the outer diameter of the standard size piston to
be used.
• Bore and hone to make the clearance between the piston
and the cylinder sleeve conform to the standard value.
Refer to P.11-54 of the same group.
<When there is not sufficient interference>
15 mm
• Measure the interference between the outer diameter of cyl-

*b inder sleeve 6 and the inner diameter of the cylinder of
crankcase *b.
99 mm
D1 • Make sure the interference in vertical directions (D1, D2,

183 mm
D3) and diametrical directions (A, B) conform to the mean

B value.
D2 A
• Bore and hone the cylinder area until measured value con-
D3 forms to the standard value. Refer to P.11-48 of the same
AT100435
group.
15 mm
NOTE: .
6 • Honing finished surface coarseness: 8 μm or less
• Honing cross-hatching angle: 15 to 25° (half angle)
• Cylinder bore secureness: 0.05 mm
99 mm
D1
• Press-fit oversize cylinder sleeve 6.
183 mm
B Refer to <When there is sufficient interference> in this

D2 A page.
D3
AT100462
ENGINE 11-57
MEMO
11-58 ENGINE
PISTONS AND CONNECTING RODS ASSEMBLY

T1111051000194
Overview
1
2
Lub
5 6
4
8 Lub
Lub
7
AT201190
SP 1 1st compression ring SP 5 Piston pin

SP 2 2nd compression ring SP 6 Piston
SP 3 Oil ring SP 7 Connecting rod bushing
4 Snap ring SP 8 Connecting rod
Assembly sequence
ENGINE 11-59

1 to 3 Deviation of piston ring 1st compression ring 0.3 to 0.45
fitted position 2nd compression ring 0.4 to 0.55 1.5 Replace
Oil ring 0.25 to 0.45
1 to 3, 6 Clearance between 1st compression ring 0.03 to 0.08 0.2
piston ring and piston 2nd compression ring 0.07 to 0.10 Replace
ring groove 0.15
Oil ring 0.03 to 0.06
5, 6 Clearance between piston and piston pin Basic diameter: 36, 0.05 Replace
Standard value: 0.007
to 0.021
5, 7 Clearance between piston pin and connecting Basic diameter: 36, 0.1 Replace
rod bushing Standard value: 0.03
to 0.04
Connecting rod Bend - 0.05 Repair or
8
Twist - 0.1 replace
Lubricant
5 Exterior peripheral area of piston pin Engine oil As required
7 Exterior peripheral area of connecting rod Engine oil As required
bushing
8 Bushing attachment area of connecting rod Engine oil As required

60 to 120
Removal and installation of
1 to 3 Piston ring tool MH060014
piston ring
MH060014
Connecting rod bushing Removal and installation of

7 MH062225
puller kit connecting rod bushing
MH062225
11-60 ENGINE
　 Service Procedure
T1111090201556
(1 to 3, 6) Piston ring and piston
Piston ring
.
[Removal]
ST ST: Piston ring tool
AT100508
[Installation]
• Install oil ring 3 in such a manner that split D and the butting
joint of the expander spring E come to the points as illus-
E
Front B trated.
mark • Compression rings 1 and 2 have a manufacturer’s mark A
“ ” at the split, and installation should be made with the mark
outward.
A B: The split of the 1st compression ring
1, 2
C D C: The split of the 2nd compression ring
D: Oil ring slit
AT200127
E: Oil ring expander spring butt joint
.
[Inspection]
1. Clearance of piston ring slit
• Install piston rings 1 to 3 into the crankcase cylinder sleeve
using the head of piston 6 to level the piston rings.
• Measure the clearance of the piston ring slit while keeping
them level and stationary. If the measured value is higher
6 than the limit, replace the piston ring.
NOTE: .
• Use piston 6 to ensure that piston rings 1 to 3 are kept
level when inserting them into the crankcase cylinder
1 to 3 AT100510 sleeve.
• Insert piston rings 1 to 3 into the lower part of the crank-
case cylinder sleeve, where the area is less worn, when
measuring clearance of piston rings slit.
• Exchange the whole set of piston rings 1 to 3 as a set if
any of the rings is faulty.
ENGINE 11-61
2. Clearance between piston ring and ring groove

faulty parts.
• Measure using feeler gauge G, by pressing 1st compres-
sion ring 1 against piston 6 with straight edge F.
NOTE: .
• Measurement has to be conducted around the whole
periphery of piston 6 after removing carbon deposits.
• Be sure to exchange the whole set of piston rings 1 to 3
AT100485 as a set if any of the rings is faulty.
G
6
1
AT100486
(5, 6) Clearance between piston pin and piston

6
5
AT100512
(5, 6, 8) Piston pin and connecting rod and piston

.
[Disassembly]
• Drift out piston pin 5 using a rod.
• When removal of piston pin 5 is difficult, warm piston 6
6
5 using a piston heater or hot water.
AT100513
.
11-62 ENGINE
[Installation]
• Apply engine oil to piston pin 5 and assemble connecting
A rod 8 and piston 6 in the direction as illustrated.
Front mark “ ” A: Piston mass (piston mass punched mark)
5 6 B: Connecting rod mass mark (Alphabetical: A, B, C, D, E,
F, G)
C: Mounting base of connecting rod cap
• When piston pin 5 insertion is difficult, warm piston 6 using
8 a piston heater or hot water.
B CAUTION
C • Be sure to install piston 6 for one engine should not be
AT302741
more than 10 g.
• Be sure to install connecting rods 8, to be used in one
engine, that have identical mass mark B.
• Be sure that after inserting piston pin 5 the connecting
rod operates smoothly without excessive play.
(5, 7) Piston pin and connecting rod bushing

.
[Inspection]
If the clearances are higher than the limit, replace the faulty
parts.
AT302774
ENGINE 11-63
Connecting rod bushing

Use ST connecting rod bushing puller kit to replace connecting
C rod bushing 7.
(Components of ST connecting rod bushing puller kit)
B E A: Base
D
B: Bracket
F C: Puller
D: Collar
E: Plate
A F: Collar
AT201202
G G: Nut
.
C [Pulling-out]
• Remove upper connecting rod bearing from the big end of
connecting rod 8.
D • Place connecting rod 8 on base A and fix it to the base at
7 B 8
E two points, bracket B and plate E.
• Fit collar D in puller C in the direction as illustrated, and pull
out connecting rod bushing 7 with a gradual load of approx-
imately 49 kN [5000 kgf].
A
AT100499
[Press-fitting]
• Apply engine oil to the exterior peripheral area of connect-
ing rod bushing 7 and the inner area of the bushing fitting
ring of connecting rod 8.
• Fit collar F, connecting rod bushing 7 and collar D in puller
C in the arrangement and direction as illustrated and mount
them with nut G.
• Align oiling holes H of connecting rod bushing 7 and con-
necting rod 8, and gradually press in the bushing with
approximately 49 kN [5000 kgf] load.
• After press-fitting, ream connecting rod bushing 7 to make
its clearance with piston pin 5 conform to the standard
value.
NOTE: After press-fitting connecting rod bushing 7, insert pis-
ton pin 5 and make sure that the rod moves smoothly without
any excessive play.
AT302775
11-64 ENGINE
(8) Degree of bend or distortion of connecting rod

• Mount connecting rod bushing 7 and piston pin 5 to con-
A C
necting rod 8.
• Measure degree of bend A and distortion B of connecting
100 mm
rod 8. If the measured value is higher than the limit, repair
or replace the connecting rod.
5 C: Connecting rod aligner (Measuring instrument)
NOTE: .
• When making measurements by mounting connecting rod 8
to connecting rod aligner C, make sure that the upper con-
necting rod bearing and the lower connecting rod bearing
AT100502
are mounted on the rod.
• Mount the connecting rod cap by tightening the bolt at spec-
ified torque. Refer to P.11-49 of the same group.
B
100 mm
5
C
AT100506
ENGINE 11-65
MEMO
11-66 ENGINE
FLYWHEEL
FLYWHEEL
Overview
T1111090100857
6
5
4
1 Trq Lub
2
< Automatic transmission > 2 1 Trq Lub

3
DP 4
*
< Manual transmission >
6
5
AT302586
1 Bolt SP 5 Ring gear

2 Plate < Manual transmission > 6 Flywheel
Wear plate < Automatic
transmission > *: Crankshaft assembly (Refer to
3 Bearing < Manual transmission > P.11-70 of the same group.)
SP 4 Flywheel assembly DP: Locating pin
Assembly sequence
NOTE: Be sure to check eccentric vibration of flywheel 6 after installing flywheel assembly 4. Refer to P.11-
58 of the same group.
ENGINE 11-67
FLYWHEEL

Flywheel Height of friction surfaces 24.5 23.5 Repair or replace
assembly Distortion of friction surfaces 0.05 or less 0.2 Repair or replace
4 < Manual
transmissio Vibration of friction surfaces - 0.2 Repair or replace
n>

39 [4.0]+40°
1 Bolt (Flywheel mounting) Wet
(Tolerance: -5° to +5°)
Lubricant
Special tools
Socket wrench MH062183
4 Installation of flywheel
Magnetic base MH062356
Service Procedure
T1111090201460
<Manual transmission>
.
Run-out of flywheel assembly

If the measured value is higher than the limit, check the fas-
tening of bolt 1 , the attachment surface of crankshaft
assembly, and depending on the condition found, either
repair or replace fywheel assembly 4.
1
AT302701
11-68 ENGINE
FLYWHEEL
(4) Flywheel assembly

.
[Inspection]
1. Height of friction surfaces
If the measured value is lower than the limit, repair or
replace flywheel assembly 4.
A A 4 A: Height of friction surface
AT302858
2. Distortion of friction surface

If the measured value is lower than the limit, repair or
replace flywheel assembly 4.
4
NOTE: If any fault is found in ring gear 5, replace it first, then
begin the inspection work.
5 AT302705
[Correction]
Make sure when grinding the friction surfaces for correction,
that height A is not lower than the limit while maintaining the
degree of parallel with surface B within 0.1 mm.
A A
B
AT302859
[Installation]
• After tightening bolts 1 at specified torque (39 N⋅m [4
ST-a kgf⋅m]), tighten further according to the following procedure.
C
• Rotate ST-a socket wrench holder B to the left, making the
B
C: Socket
D E D: Rod
E: Rod (for connecting)
AT302860
ENGINE 11-69
FLYWHEEL
• Set so that rod E (for connecting) is pressed against ST-b

magnetic base.
H • Select a notch G on holder B that is easily visible.
10
G notch H on socket C to the right by 40° (Tolerance: -5° to
+5°) (1 notch = 10°) and tighten.
ST-a
ST-b E AT302861
(5) Ring gear

.
[Inspection]
Check and see if there is any damage, wear or other fault, and
if any fault is found, replace ring gear 5.
.
[Removal]
Heat the ring gear 5 to approx. 200°C with an acetylene torch
or the like, and then remove it from the flywheel 6.
WARNING
Be careful not to burn yourself.
.
[Installation]
5 • Heat the ring gear 5 to approx. 200°C with an acetylene
A torch or the like.
WARNING
Be careful not to burn yourself.
• With the side of the chamfered teeth of ring gear 5 facing
you, mount it on flywheel 6.
A: Chamfered ring gear side
6 AT302707
11-70 ENGINE
CRANKSHAFT AND CRANKCASE

Overview
T1111090100868
3 Trq
4
1
<X>
Lub
2
23
22
<X>
21
Lub
20 12
*b
<X> 18
*a
19
<X>17
14 16
15
Lub
6
13
11 Lub
7 Lub <X>
10
9 5 Trq
8 Lub
AT302862
1 Bolt 15 Front oil seal slinger

SP 2 Rear oil seal SP 16 Crankshaft gear
3 Bolt 17 Key
4 Rear plate SP 18 Rear oil seal slinger
5 Bolt SP 19 Crankshaft
SP 6 Lower main bearing SP 20 Upper main bearing
SP 7 No.1 main bearing cap 21 Front plate
SP 8 No.2 main bearing cap 22 Gasket
SP 9 No.3 main bearing cap SP 23 Crankcase
SP 10 No.4 main bearing cap
SP 11 Rear main bearing cap *a: Check valve (Refer to group 12 in
SP Thrust plate this manual.)
12
SP Side seal *b; Oil jet (Refer to group 12 in this
13 manual.)
14 Crankshaft assembly
NOTE: Do not remove crankshaft gear 16, rear oil seal slinge 18 check valve *a and oil jet *b unless they are
faulty.
ENGINE 11-71
Assembly sequence

- Crankshaft end play 0.10 to 0.26 0.4 Inspect
Basic diameter: 78,
No.1,2,4,5 Standard value: 0.04
to 0.09
Oil clearance 0.15 Replace
Basic diameter: 78,
6, 20 Main bearing
No.3 Standard value: 0.06
to 0.12
less than
Expansion at free state - Replace
82.5
Degree of bend 0.02 or less 0.05 Replace
Circular Repair or
0.01 or less 0.03
19 Crankshaft accuracy replace
Pin and journal
Cylindrical Repair or
0.006 or less -
accuracy replace
Repair or
23 Crankcase top surface distortion 0.07 or less 0.2
replace

3 Bolt (Rear plate mounting) 64 [6.5] -
Wet
5 Bolt (Main bearing cap mounting) 59 [6]+90°
Bolt reusable up to 3 times

Specified lubricant
and/or sealant
Rear oil seal lip Engine oil As required
2
Rear oil seal mounting surface to crankcase THREEBOND 1207C As required
6, 20 Inner surface of main bearing Engine oil As required
Pack into side seal driving groove on rear main
11 THREEBOND 1207C As required
bearing
13 Side seal tip and groove THREEBOND 1207C As required
11-72 ENGINE

Installation of main bearing

5 Socket wrench MH061560
cap
Removal of rear main

11 Bearing cap extractor MH061083
bearing cap
M8 1.25
60 MH061083
16 Gear puller MH061326 Removal of crankshaft gear
MH061326
100
Rear oil seal slinger Installation of rear oil seal

18 15 MH062677
installer slinger
103
MH062677
Service Procedure
T1111090201567

Crankshaft assembly end play
If the measured value is higher than the limit, replace thrust
plates 12 with oversized ones. Refer to P.11-75 of the same
group.
<Available oversize ones>
+0.15, +0.30, +0.45 mm
AT100537
ENGINE 11-73
(2) Mounting of rear oil seal

• Apply engine oil to lip area A of rear oil seal 2.
AT302641
• Apply sealant C along groove line B of rear oil seal 2 evenly

C without break. (φ2 mm)
2 mm
• After applying sealant C, within three minutes, mount rear
oil seal 2.
CAUTION
• Do not start the engine within an hour of mounting rear
2 oil seal 2.
• Be sure to reapply sealant C if bolt 1 (for mounting rear
B
oil seal 2) is loosened or removed by any cause what-
AT100539
soever after mounting.
(6, 20) Main bearing

.
[Inspection]
CAUTION
• Do not forcibly expand main bearings 6, 20.
• Be sure to replace both upper and lower main bearings
6, 20 as a pair when replacement is necessary.
1. Expansion at free state
If the measured value is lower than the limit, replace main
bearing 6, 20.
6, 20
AT100643
11-74 ENGINE
2. Clearance between main bearing and crankshaft

23 6,20 If the measured value is lower than the limit, replace faulty
parts.
When replacing main bearings 6, 20 with undersize ones,
correct the outer diameter of the journal part B of crankshaft
19 to the specified undersize dimensions. Refer to P.11-76
of the same group.
5
7 to 11
19
AT302588
[Installation]
Install main bearings 6, 20 by matching lugs A.
B CAUTION
Be sure to distinguish between main bearings 6, 20.The
20 upper bearing has oiling opening B while the lower bear-
6
ing has no oiling opening.
A A
AT100540
(7 to 11) Main bearing cap

.
[Removal]
Use ST bearing cap extractor to remove rear main bearing cap
11 because side seal 13 is installed between crankcase 23 and
the rear main bearing.
ST
11
AT100542
.
ENGINE 11-75
[Installation]
• Install main bearing caps 7 to 10, aligning front mark
7 8 9 10 11 towards the front of engine A.
• Install rear main bearing cap 11, aligning stamped mark
towards the direction as illustrated.
A • Before installing bolts 5 punch a mark on each bolt head to
indicate the number of times the bolt has been used.
CAUTION
Front mark “ ” When there are three punched marks on the bolt head, the
mark “R” bolt cannot be reused and must be replaced with a new
AT200128 one.
• After tightening bolts 5 at torque of (59 N⋅m [6 kgf⋅m]),
tighten by an additional 90°: 85 to 95°, using a ST socket
wrench.
• Rotate ST socket wrench holder B to the left and make the
C: Socket
D: Rod
E: Rod (for connecting)
AT302777
• Set so that rod E (for connecting) is pressed against crank-

shaft assembly 14 by the force of the spring.
• Select a notch F on holder B that is easily visible.
notch G on socket C and tighten by 90° (1 notch = 5°).
CAUTION
Because bolts 5 are fastened by the plastic zone fastening
method, do not tighten further after they have been tight-
ened at the specified angle.
AT302778
• After installation, check the following points:
• Crankshaft assembly 14 can be rotated easily by hand.
• The end play of crankshaft assembly 14. Refer to P.11-
72 of the same group.

Install thrust plates 12 on both front and rear of rear main bear-
11 ing cap 11 and on the rear end of crankcase 23 in the direction
A as illustrated.
B
12 A: Oil groove
12
B: Locating pin
A
B
CAUTION
When installing oversize thrust plates 12, mount them on
12
23 the front and rear of rear main bearing cap 11. It is not nec-
A essary that the thrust plates used are all of the same size,
AT302589
but use the same-size-combination of thrust plates for
mounting on the rear of crankcase 23 and on the rear of
the rear bearing cap.
Available oversize: 0.15, 0.30, 0.45 mm
11-76 ENGINE
(13) Installation of side seal

• Squeeze sealant into side seal press-fitting groove A of rear
main bearing cap 11.
• Apply sealant to tip B of side seal 13.
• Press-fit side seal 13 between rear main bearing cap 11
and crankcase 23 in the direction as illustrated.
C: Rear main bearing cap side
23
D: Crankcase side
• After press-fitting, apply sealant to side seal fitted area E on
rear main bearing cap 11.
AT302590
(16) Crankshaft gear

.
[Removal]
ST Never remove by striking, hitting or hammering crankshaft gear
16.
ST: Gear puller
.
17 [Installation]
16 Before installing heat up crankshaft gear 16 using a piston
heater or similar device to approximately 100°C.
WARNING
AT100548 Be careful not to burn yourself.
(18) Installation of rear oil seal slinger

Install rear oil seal slinger 18 using ST oil seal slinger installer.
18
Strike installer A until it hits guide B positively.
ST
19 B A AT100549
(19) Crankshaft
.
[Inspection]
1. Cylindrical and circular accuracy of the journal and the pin
If the measured value is higher than the limit, grind and
correct crankshaft 19 to convert it to the undersize
19
specifications or replace it.
AT100550
ENGINE 11-77
2. Degree of bend
A 19 B
The degree of bend of crankshaft 19 is measured at No.3
journal C by holding No.1 journal A and No.5 journal B. If the
measured value is higher than the limit, replace the
crankshaft.
NOTE: The degree of bend of crankshaft 19 is half of the
indicated value of the gauge after rotating the shaft 360°.
C AT100551
[Correction]
NOTE: Be sure to replace main bearings 6, 20 with those that
meet the undersize specifications after crankshaft 19 is cor-
rected by grinding.
• Set C, distance between the center line of the journal A and
that of the pin B, constant.
C: 57.5 mm: 57.45 to 57.55 mm
• Set the width of journal D and pin E so they are constant.
D: 35 mm (32 mm for No.1 journal)
E: 41 to 41.2 mm
AT302779
• Finish the fillet F smoothly.
F: R4 +0.2 to -0.2 mm
• Check and confirm that there has been no cracking caused
by grinding using the magnetic particle inspection method
(Magnafluxing). Also make sure the surface hardness has
not deteriorated (Shore hardness to be maintained at not
less than Hs 75).
• When grinding G, set crankshaft 19 and grinder H so that
G J they both rotate counterclockwise as viewed from the front
of the crankshaft.
• To finish grinding J using a grindstone or emery paper K,
rotate crankshaft 19 clockwise.
K
19
H
19
AT201239
Undersize specifications of crankshaft (Unit: mm)

Undersize scales
0.25 0.50 0.75 1.00
Finish outer No.1, 2, 4, 5 77.68 to 77.70 77.43 to 77.45 77.18 to 77.20 76.93 to 76.9
diameter of journals
journal No.3 journal 77.66 to 77.68 77.41 to 77.43 77.16 to 77.18 76.91 to 76.93
Finish outer diameter of pin 64.69 to 64.71 64.44 to 64.46 64.19 to 64.21 63.94 to 63.96
Circular accuracy 0.01 or less
Cylindrical accuracy 0.006 or less
11-78 ENGINE
(23) Crankcase top surface distortion

If the measured value is higher than the limit, grind and correct
A using a surface grinder.
A: Lines to be measured
CAUTION
When grinding crankcase 23 be sure that the extent of pis-
ton protrusion does not deviate from the standard value.
Piston protrusion: Refer to P.11-50 of the same group.
23
AT302591
12-1
GROUP 12
LUBRICATION
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . 12-2 ON-VEHICLE INSPECTION AND

ADJUSTMENT
STRUCTURE AND OPERATION Replacement of Oil Filter . . . . . . . . . . . . . . . 12-10
Lubrication System (Flow of Oil) . . . . . . . . . 12-3 Replacement of Engine Oil . . . . . . . . . . . . . 12-12
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Replacement of Oil Pressure. . . . . . . . . . . . 12-13
Oil Cooler and Oil Filter. . . . . . . . . . . . . . . . 12-4
Lubrication of Related Parts . . . . . . . . . . . . 12-6 OIL PAN, OIL STRAINER AND OIL JET
................................. 12-14
TROUBLESHOOTING . . . . . . . . . . . . 12-9
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . 12-16
OIL COOLER AND OIL FILTER. . . . . 12-20

12-2 LUBRICATION
SPECIFICATIONS
SPECIFICATIONS
T1121000100086
Item Specifications
Mode of lubrication Oil pump type
Oil filter type Spin-on type
Oil cooler type Shell and plate type (Multiple-plate type)
Grade API classification CD, CD/SF, CE, CE/SF,
CF-4 or JASO classification DH-1
Engine oil Quantity of oil Oil pan Approximately 8 [8]
dm3[L] Oil filter Approximately 1 [1]
LUBRICATION 12-3

Lubrication System (Flow of Oil)
T1121010200084
4
13 19
14
2 5 6
A 15 16 20
7 8
17 21 24
3 10
9 12 25
22
23
18
26
11
AT302510
1 Main oil gallery 15 Timing gear

2 Bypass valve (Built into oil filter) 16 Connecting rod bearing
3 Regulator valve 17 Connecting rod bushing
4 Engine oil pressure switch 18 Piston
5 Full-flow filter element 19 Camshaft bushing
6 Bypass filter element 20 Rocker bushing
7 Bypass valve 21 Push rod
8 Oil cooler 22 Tappet
9 Oil pump 23 Check valve for oil jet
10 Relief valve (Built into oil pump) 24 Turbocharger
11 Oil strainer 25 Vacuum pump
12 Injection pump bearing 26 Oil pan
13 Crankshaft main bearing
14 Idler bushing A: Orifice
12-4 LUBRICATION
Oil Pump
T1121010300081
1 Crankshaft gear
2 2 Oil pump gear
1 3 Oil pump
4 Relief valve
A: To oil cooler
B: From oil strainer
C: To oil pan
A
3
Oil pump 3 is a gear type, driven by rotation of the
crankshaft transmitted by crankshaft gear 1 that
C engages oil pump gear 2. Relief valve 4 is installed
on the oil pump and when the oil pump discharge
pressure becomes higher than the standard pressure
B level, part of the engine oil is returned to the oil pan
by relief action of the valve, protecting the lubricating
4 system from breakdown caused by excessive oil
AT201242 pressure.
Oil Cooler and Oil Filter

T1121010700056
2
B
1
A
3
E
8
4
D 5
6
7
AT100556
1 Engine oil pressure switch 8 Bypass valve

2 Oil cooler
3 Regulator valve A: Coolant exit port
4 Bypass filter element B: Coolant entry port
5 Oil filter element C: To oil cooler
6 Full-flow filter element D: To oil pan
7 Bypass valve E: To main oil gallery
LUBRICATION 12-5
Operation of bypass valve

C
When the viscosity of the engine oil is high at low tempera-
tures, or when oil cooler 2 element is clogged, flow resistance
8 is high, and if this happens, bypass valve 8 opens to let the
engine oil return directly to oil filter element 5 without going
through the oil cooler.
AT100557
Operation of regulator valve

When the oil pressure in the main oil gallery becomes higher
than the standard level, regulator valve 3 opens to let part of
E the oil return to oil pan D, thereby regulating the oil pressure.
3
D
AT100558
Operation of engine oil pressure switch

When pressure for delivering the oil to main oil gallery E
becomes lower than the standard level, the built-in electric con-
tact point of engine oil pressure switch 1 closes to light warning
E
lamp in the meter cluster, warning the driver that the oil pres-
1
sure is abnormal.
AT100560
12-6 LUBRICATION
Oil filter element

This oil filter uses a spin-on filter paper type element that inte-
E grates full-flow filter element 6 and bypass filter element 4.
When the filter element is clogged, bypass valve 7, installed at
the base of the filter, opens to let the oil bypass the element
D
and flow directly to main oil gallery E, preventing engine sei-
zure.
7
AT100559
Lubrication of Related Parts

T1121010800053
Main bearing and connecting rod bearing
1 Main oil gallery 4 Connecting rod bearing

2 Main bearing
3 Crankshaft A: Connecting rod oil passage
Oil flows through the oil passage in crankshaft 3 and into the connecting rod oil passage A and lubricates the
small end of the connecting rod.
LUBRICATION 12-7
Timing gear
1 Thrust plate 8 Idler gear

2 Camshaft 9 Idler shaft
3 Idler gear bushing 10 Vacuum pump
4 Injection pump gear 11 Camshaft gear
5 Oil pipe
6 Timing gear case A: From main oil gallery
7 Bearing B: Oil jet (for forced lubrication of
injection pump gear)
Engine oil from main oil gallery A flows through the inside of camshaft 2 and idler shaft 9 and lubricates each
gear along the way including vacuum pump 10.
Valve mechanism
1 Crankcase
A 6 Cylinder head
2
5 Rocker shaft
3
4 4 Rocker shaft bracket
3 5 Rocker bushing
6 Rocker
7 Push rod
8 Tappet
2
9 Camshaft
10 No.1 camshaft bushing
7
1 A: Rocker oil hole
B: From main oil gallery
8
C: To oil pan
C
B 10
AT100563
12-8 LUBRICATION
Oil jet
1 Piston
2 Oil jet
3 Check valve
A 1 A: Main oil gallery
An oil jet 2 is installed, in the lower part of main oil

gallery A, for each cylinder and cools piston 1 by
2 injecting engine oil toward the inside of the piston.
3 AT100564 The oil jet is fitted with check valve 3 which opens
and closes at standard oil pressure levels. This pre-
vents a decrease of oil volume at low oil pressure as
well as a decrease of oil pressure itself.
Turbocharger
1 Bearing housing
2 Snap ring
3 Piston ring
4 Bearing
A: From main oil gallery

B: To oil pan
Engine oil is delivered via the oil pipe from the main
oil gallery to bearing housing 1 and lubricates bear-
ing 4.
Piston rings 3 fitted on both sides of the turbine
wheel shaft act as oil seals.
AT302694
Vacuum pump
1 Timing gear case
1 A B Vacuum pump
2
A: Main oil gallery

B: To camshaft
C: To crankshaft
Engine oil is delivered from main oil gallery A to vac-

C
uum pump 2 through the oil passage of timing gear
2 AT100566 case 1 to lubricate the vanes. Then, the oil is dis-
charged to the timing gear case through the air outlet
port together with air to be returned to the oil pan.
LUBRICATION 12-9
TROUBLESHOOTING
TROUBLESHOOTING
T1121020100099
Symptoms
(a) (b) (c) (d) Remarks
Possible causes
Oil cooler element installed incorrectly X X X
Gasket faulty X X X
O-ring faulty X X X
Oil cooler Oil cooler element clogged X X
Oil cooler element damaged X X X
Bypass valve spring fatigued or worn X
Regulator valve spring fatigued or worn X
Malfunctioning X X
Oil pump gear interfering with oil pump
Oil pump X X
case or cover
Relief valve spring fatigued or worn X
Mounted incorrectly X
Oil filter Element clogged X X
Gasket faulty X
Oil strainer installed incorrectly or clogged X X
Crankshaft front oil seal faulty Refer to Group
X
11 in this manual
Crankshaft rear oil seal faulty Refer to Group
X
11 in this manual
Timing gear case mounted incorrectly X Refer to Group
11 in this manual
Oil jet for piston cooling faulty X
Oil working its way up into combustion chamber X
Oil working its way down into combustion chamber X
Oil viscosity too high X
Oil quality unsuitable X
Oil deterioration X
Fuel mixed with oil X
(a): Engine difficult to start
(b): Overheating
(c): Oil pressure low
(d): High oil consumption (oil leakage)
12-10 LUBRICATION

Replacement of Oil Filter
T1121030200086
1 Oil filter drain plug 9.8 (Tolerance: -2 to +2) -
[1 (Tolerance: -0.2 to +0.2)]

101.2
2 Oil filter wrench MH061587 Removal of oil filter
MH061587
[Removal]
Loosen oil filter drain plug 1 and discharger the engine oil from
inside oil filter 2.
AT302695
[Removal]
WARNING
• Wipe up any spilled oil since it can cause a fire.
• Do not touch the engine while it is hot as you
might burn yourself.
ST • When replacing the oil filter, take care not to spill
oil on the V-belt.
AT100569
.
LUBRICATION 12-11
[Installation]
• Clean the surface of oil cooler body 3 that contacts oil filter
2.
• Apply engine oil thinly and evenly to gasket area A of oil fil-
3
ter 2.
• Screw in oil filter 2 to oil cooler body 3 until gasket area A
A sits on the body. From this position, tighten further by rotat-
ing by three quarters of a turn.
• After installation, let the engine run and check that there is
2
no oil leakage from gasket area A.
AT100570 • Check the oil level and if it is low, top it up.
12-12 LUBRICATION
Replacement of Engine Oil

T1121030300094

2 Drain plug (Oil pan) 34 to 39 [3.5 to 4.0] -
3 Drain plug (Oil filter) 9.8 (Tolerance: -2 to +2) -
[1 (Tolerance: -0.2 to +0.2)]
Lubricant
Location Points of application Specified lubricant Remarks
- Oil pan Engine oil (API classification CD, Approximately
CD/SF, CE ,CE/SF, CF-4 or JASO 8 dm3 [8L]
classification DH-1)
- Oil filter Engine oil (API classification CD, Approximately
CD/SF, CE ,CE/SF, CF-4 or JASO 1 dm3 [1L]
classification DH-1)
.
[Draining]
WARNING
• Wipe up any spilled oil since it can cause a fire.
• Do not touch oil when the engine is hot since it can
inflict severe burns.
• Warm up the engine, then remove oil filler cap 1.
• Remove oil pan drain plug 2 and oil filter drain plug 3. Then,
drain the engine oil.
.
[Filling]
CAUTION
When pouring oil into the engine, take care not to spill any
on the V-belts. Contact with oil could make the V-belts slip,
rendering the cooling system less effective.
Tighten oil pan drain plug 2 and oil filter drain plug 3 to their
specified torque. Remove oil filler cap 1, and add new engine
oil to the specified level.
2 AT302511
LUBRICATION 12-13
Replacement of Oil Pressure

T1121030400080
Service standards
At no-load minimum 145 kPa 49 kPa
Oil pressure (Oil revolution [1.5 kgf/cm2] [0.5 kgf/cm2]
- temperature 70 to Inspect
90°C) At no-load maximum 295 to 490 kPa 195 kPa
revolution [3 to 5 kgf/cm2] [2 kgf/cm2]

2 Engine oil pressure switch 7.8 to 15 [0.8 to 1.5] When engine is cool
Sealant
Location Points of application Specified sealant Quantity
- Thread area of engine oil pressure Teflon tape 3 1/2 turns
switch
.
• Remove engine oil pressure switch 2 installed on oil cooler

1.
AT201262
• Install the oil pressure gauge after installing adapter 3 on oil

cooler 1.
• Warm up the engine until oil temperature reaches 70 to
90°C.
• Measure oil pressure at no-load minimum revolution and at
no-load maximum revolution. If the measured values are
lower than the limit, overhaul the lubricating system.
• After measurement, install engine oil pressure switch 2 and
tighten at specified torque.
CAUTION
Install engine oil pressure switch 2 when the engine is
cool.
Inspection of engine oil pressure switch. Refer to Electrical
manual.
12-14 LUBRICATION
OIL PAN, OIL STRAINER AND OIL JET

Overview
T1121090100320
1 Trq
5 Lub
6
8 Trq Lub
<x> *
Lub 9
7
AT302512
1 Drain plug 7 O-ring

2 Stiffener 8 Check valve
3 Rubber spacer 9 Oil jet
4 Bolt
SP 5 Oil pan *: Crankcase (Refer to group 11 in
Oil strainer this manual.)
6
Assembly sequence
CAUTION
Make sure that you do not tighten check valve 8 higher than specified torque, because excessive
tightening causes faulty operation resulting in engine burning.

1 Drain plug 34 to 39 [3.5 to 4.0] -
8 Check valve 29 [3] Wet
LUBRICATION 12-15

Location Points of application Specified lubricant and/or sealant Quantity
5 Oil pan to crankcase attachment surface THREEBOND 1207C As required
7 Entire body of O-ring Engine oil As required
8 Thread area of check valve Engine oil As required
Service Procedure
T1121090200305
(5) Installation of oil pan
• Apply sealant A to lower connecting surface of oil pan 5 as
illustrated evenly without break.
• After applying sealant A, within three minutes, mount oil
pan 5 to crankcase *.
CAUTION
• Be sure to clean and wipe off oily substances from the
surface where sealant A is to be applied.
• Make sure that sealant A is not transferred to other
areas while the mounting work is being done.
• Do not start the engine within an hour of mounting oil
pan 5.
• Be sure to reapply sealant A if bolts 4 (for mounting oil
pan 5) are loosened or removed by any cause whatso-
ever after mounting.
12-16 LUBRICATION
OIL PUMP
OIL PUMP
Overview
T1121090100331
*a
*b
DP
1
10
Lub <X>
2 Trq
6
5
4
3
*c
9
AT302863
1 Oil pump assembly 10 O-ring

2 Bolt
3 Snap ring *a: Crankcase (Refer to group 11 in
Relief valve this manual.)
4
Relief valve spring *b: Crankshaft gear (Refer to group 11
5 in this manual.)
SP 6 Seat
*c: Drive gear
SP 7 Oil pump cover
DP: Locating pin (Bushing)
SP 8 Driven gear assembly
SP 9 Oil pump case assembly
Assembly sequence
LUBRICATION 12-17
OIL PUMP

- Backlash of oil pump gear and 0.10 to 0.18 0.3 Replace
crankshaft gear Refer to group 11 in
this manual
4 Relief valve opening pressure 1080 (Tolerance: -98 to +98) - -
kPa
[11 (Tolerance: -1 to +1)
kgf/cm2]
5 Installed load of relief valve spring 215 (Tolerance: -11 to +11) - Replace
(Installed length: 33.4) N⋅m
+1.1) kgf⋅m]
7, 8, 9 Clearance between gear shaft and Basic diameter: 20, 0.15 Replace
oil pump case and oil pump cover Standard value: 0.04 to 0.07
7, *c Clearance between gear shaft and Basic diameter: 20, 0.15 Replace
oil pump cover Standard value: 0.04 to 0.07
8, 9, *c Difference between height of each 0.01 to 0.07 0.18 Replace
gear and depth of oil pump case
Clearance between tooth tip of each 0.10 to 0.19 0.2 Replace
gear and oil pump case
Tightening torque1 (Unit: N⋅m [kgf⋅m])

2 Bolt (Oil pump cover mounting) 9.8 (Tolerance: -2 to +2) -
[1.0 (Tolerance: -0.2 to +0.2)]
Lubricant
Service Procedure
T1121090200316
(6) Installation of seat

A: Oil pump cover side
AT302696
12-18 LUBRICATION
OIL PUMP
(7 to 9) Inspection of oil pump cover, driven gear

assembly, and oil pump case assembly
• Measure the clearance of driven gear shaft part A to oil
7 8 9 pump cover 7 and oil pump case assembly 9 and the clear-
ance of driven gear shaft part B to the oil pump cover.
• If the measured values are higher than the limits, replace
any faulty parts.
A
AT100580
(7, 9) Installation of oil pump cover and oil pump

case assembly
• Prepare two pins A of 9 mm in outer diameter and position
oil pump cover 7 and oil pump case assembly 9 as illus-
trated.
A
9
8
7 AT100581
• Tighten the illustrated bolts 2 at specified torque.

A
A
AT100582
LUBRICATION 12-19
OIL PUMP
• Remove pins A, replacing them with bolts 2 and tighten at

B specified torque.
NOTE: Confirm smooth movement by rotating oil pump
2 gear B by hand. If it catches, disassemble and reassemble
it.
2
AT100583
(8, 9) Inspection of driven gear assembly, and oil

pump case assembly
1. Difference between height of each gear and depth of oil
9
*c pump case
If the measured value is higher than the limit, replace faulty
parts.
8 AT100584
2. Clearance between tooth tip and oil pump case

If the measured value is higher than the limit, replace faulty
parts.
8 *c
9
AT100585
12-20 LUBRICATION
OIL COOLER AND OIL FILTER

Overview
T1121090100342
<X>
<X>
<X>
<X>
AT302864
1 Oil filter (Refer to P.12-10 of the 11 Drain plug

same group.) 12 Plug
2 Oil cooler assembly 13 O-ring
3 Nut 14 Spring
4 Gasket 15 Bypass valve
SP 5 Oil cooler element 16 Oil cooler body
6 Engine oil pressure switch (Refer 17 Gasket
to Electrical manual.)
7 Plug *: Crankcase assembly (Refer to
8 O-ring group 11 in this manual.)
9 Spring <X>: Non-reusable parts
10 Regulator valve
Assembly sequence
LUBRICATION 12-21
Service standards
5 Oil cooler element air leakage (Air 0 cm2 [0 mL] - Replace
pressure 980 kPa [10kgf/cm2], 15 seconds
10 Regulator valve opening pressure 590 (Tolerance: -29 to +29) - Replace
kPa
+0.3) kgf/cm2]
15 Bypass valve opening pressure 390 (Tolerance: -29 to +29) - Replace
kPa
+0.3) kgf/cm2]

3 Nut (Oil cooler element mounting) 20 (Tolerance: -4.9 to +4.9) -
[2.0 (Tolerance: -0.5 to +0.5)]
6 Engine oil pressure switch 7.8 to 15 [0.8 to 1.5] -
7 Plug (Regulator valve spring mounting) 20 (Tolerance: -4.9 to +4.9) -
[2.0 (Tolerance: -0.5 to +0.5)]
11 Drain plug (Oil cooler) 34 [3.5] -
12 Plug (Bypass valve spring mounting) 20 (Tolerance: -4.9 to +4.9) -
[2.0 (Tolerance: -0.5 to +0.5)]

Specified lubricant and/or
sealant
1 Gasket area of oil filter with thin application Engine oil As required
(Refer to P.12-10 of the same group.)
6 Thread area of engine oil pressure switch Teflon tape 3 1/2 turns
8,13 Entire body of O-ring Engine oil As required
12-22 LUBRICATION
Service Procedure
T1121090200327
Cleaning
• Check and see if any carbon deposits and sludge have
developed in the oil passage of oil cooler element 5 and its
bypass. Clean any deposits out thoroughly with cleaning
solvent.
• Also clean any water scale and fur in oil cooler element 5
and oil cooler body 16.
(5) Inspection of oil cooler element

• Immerse oil cooler element 5 in water tank after plugging
exit port A and connecting the hose to engine oil entry port
B.
• Apply air pressure of 980 kPa [10 kgf/cm2] via the hose and
see if there is any air leakage from any part of oil cooler ele-
ment 5.
• If you see any leakage, replace oil cooler element 5.
13A-1
GROUP 13A
FUEL AND ENGINE

CONTROL
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . 13A-2 Inspection and Adjustment of No-Load Minimum

Maximum Revolution . . . . . . . . . . . . . . . . . . 13A-14
STRUCTURE AND OPERATION Bleeding of Fuel System . . . . . . . . . . . . . . . 13A-15
Fuel System (Fuel of Flow) . . . . . . . . . . . . . 13A-3 Replacemant of Fuel Filter . . . . . . . . . . . . . 13A-16
Engine Control . . . . . . . . . . . . . . . . . . . . . . 13A-4
Speed Limiter System . . . . . . . . . . . . . . . . . 13A-5
ENGINE CONTROL . . . . . . . . . . . . . . 13A-18
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-8
FUEL FILTER . . . . . . . . . . . . . . . . . . . 13A-24
Injection Nozzle. . . . . . . . . . . . . . . . . . . . . . 13A-9
FUEL TANK . . . . . . . . . . . . . . . . . . . . 13A-26

TROUBLESHOOTING . . . . . . . . . . . . 13A-10
INJECTION PUMP . . . . . . . . . . . . . . . 13A-28
ON-VEHICLE INSPECTION AND
ADJUSTMENT
INJECTION NOZZLE . . . . . . . . . . . . . 13A-32
13A-2 FUEL AND ENGINE CONTROL
SPECIFICATIONS
SPECIFICATIONS
T1131000100087
Injection Pump
Item Specifications
Manufacturer DENSO
Body model V4
Injection system type Distributor type electronic controlled pump
Spill-valve type electromagnetic valve Electronic controlled system
Timer Control system Recompression chamber control
Driving system Timer control valve (TCV)
Feed pump type Vane system
Injection Nozzle
Item Specifications
Manufacturer DENSO
Model and type Hole type 2-spring model
Number of orifices 6
Orifice diameter mm φ 0.18
Fuel Filter
Item Specifications
Fuel filter type Spin-on type
Water level warning device With
Priming pump With
FUEL AND ENGINE CONTROL 13A-3

Fuel System (Flow of Fuel)
T1131010200096
1
2
3 4
9
5
6
8 7 10
AT302615
1 Injection nozzle 6 Fuel filter

2 Fuel leak-off pipe 7 Fuel suction pipe
3 Injection pipe 8 Injection pump
4 Fuel return pipe 9 Overflow valve
5 Fuel tank 10 Fuel hose
• Fuel in fuel tank 5 is sucked up by feed pump which is driven by the drive shaft of injection pump 8, and is
filtered through fuel fllter 6 into the injection pump.
• Filtered fuel is sent into injection pump 8 where the fuel pressure is boosted,and is injected through injec-
tion nozzle 1 into the combustion chamber.
• Excess fuel forced out from injection nozzle 1 returns to fuel tank 5 through fuel leak-off pipe 2.
• When fuel pressure is higher than the specified level in injection pump 8, overflow valve 9 opens to let the
fuel return from fuel return pipe 4 to fuel tank 5.
Engine Control
T1131010300093
1
2
AT302513
1 Idling adjustment volume 4 Accelerator pedal

2 Engine electronic control unit 5 Accelerator position sensor
3 Injection pump
• Electronic engine control is available from engine electronic control unit 2. (Refer to group 13E in this
manual)
• Accelerator position sensor 5 detects depression of accelerator pedal 4 and engine electronic control unit
2 computes it to provide the optimum fuel injection.
Speed Limiter System

T1131010600050
1
2
5
3
7
AT302514
1 Accelerator position sensor 5 Speed limiter assembly

2 Accelerator control cable 6 Vehicle speed sensor
3 Accelerator pedal 7 speed limiter electronic control unit
4 Speed limiter cable
• The speed limiter system detects and controls the vehicle speed so that the vehicle speed may not
exceed 100 km/h.
• When the vehicle speed is 100 km/h or more, the signal from vehicle speed sensor 6 is sent to speed limit
electronic control unit 7. Then, speed limiter assembly 5 is activated to control the output voltage from
accelerator position sensor 1 and to control the vehicle speed.
When the speed limiter system is not operating
2 1
A B
A
1
4
B D
4
C
3
AT302515
• When accelerator pedal 3 is depressed, speed limiter cable 4 attached to lever A of accelerator position
sensor 1 is pulled. (Lever B engaged with accelerator control cable 2 is interlocked with lever A of accel-
erator position sensor.)
• When speed limiter assembly 5 is not operating, speed limiter cable 4 slides in oblong hole D of clevis C
and operation of accelerator pedal 3 is not disturbed.
When the speed limiter system is operating
1
E
1
A B
B 4
4
3
To speed limiter electronic control unit

AT302516
• When the vehicle speed is 100 km/h or more, speed limiter electronic control unit 7 receives the signal
from vehicle speed sensor 6 to activate speed limiter assembly 5.
• Speed limiter cable 4 is pulled and lever A of accelerator position sensor 1 is locked.
• If accelerator pedal 3 is depressed further, spring E of lever B only is compressed and lever A of acceler-
ator position sensor 1 is still locked. The vehicle speed is then limited.
Fuel Filter
T1131010400090
A B
3
D
AT302616
1 Fuel filter head A: To injection pump

2 Fuel filter cartridge B: From fuel tank
3 Water level sensor C: Manual pump
D: Drain hole
• The fuel filter removes not only dirt and other foreign particles, but also separates water from the fuel by
fuel filter cartridge 2.
• The separated water is collected under the filter.
• Water level sensor 3 is installed on the filter; the sensor lights the warning lamp in meter cluster when
water reaches the specified level.
• The collected water can be drained through drain hole D by loosening water level sensor 3.
• Manual pump C is installed on fuel filter head 1 to bleed the air in fuel system.
Injection Nozzle
T1131010500097
2 4
5 C
5
AT302617
1 No.1 pressure spring 6 Needle valve

2 Pressure pin
3 No.2 pressure spring A: From injection pump
4 Spring seat (for adjustment of pre- B: To leak-off pipe
lift) C: Pre-lift
5 Washer (for adjustment of needle
valve-lift)
• The nozzle is fitted with a pre-lift (clearance) between washer 5 and spring seat 4, and the injection open-
ing pressure of the nozzle is determined by the repercussive force of No.1 pressure spring 1.
• When the pressure of the fuel sent by the injection pump (internal pressure of nozzle) overcomes the
force of No.1 pressure spring 1 , needle valve 6 rises by the amount of the pre-lift C. As a result, the force
is transmitted in the following order and No.1 pressure spring is lifted. 6→2→1
• When washer 5 rises by the amount of pre-lift C it strikes spring seat 4. Then, the repercussive becomes
the combined forces of No.1 pressure spring 1 and No.2 pressure spring 3, and the rise of needle valve 6
is momentarily halted.
• When the fuel pressure rises, and the internal nozzle pressure overcomes the combined force of the two
springs, needle valve 6 rises further, resulting in the main fuel spray from the nozzle. As a result, the force
is transmitted in the following order and No.2 pressure spring 3 is lifted.
TROUBLESHOOTING
TROUBLESHOOTING
T1131020100090
*: Must be serviced by DENSO service station.
(a): Engine does not start ( h ): Engine starts but stalls
(b): Engine hard to start ( i ): Engine revolution does not reach specified
(c): Engine knocks maximum speed
(d): Engine output inconsistent ( j ): Engine does not shut off
(e): Engine output does not develop full power ( k ): Accelerator pedal hard to depress
( f ): Engine maximum revolution too high ( l ): Fuel supply insufficient
(g): Engine idling unstable (m): Engine warning lamp lights
Symptoms
(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) Remarks
Possible causes
Refer to
group 13E
Electronic controlled fuel system faulty X
in this
manual
Injection Injection pump body faulty X X X X X X X X X X *
pump
Mounting incorrect X X X X
body
Overflow valve operated *
X X X X X
incorrectly
Injection Needle valve stuck X
nozzle Valve opening pressure too low X X
Injection nozzle clogged X X X X X
Nozzle air tightness incorrect X X X X X
Valve opening pressure too high X
Spring broken X X
Needle valve not moving
X
smoothly
Valve opening pressure faulty X
Spring fatigued X
Filter clogged X X X X
No fuel in fuel tank X
Fuel pipe clogged or fuel leaking from
X
connections
Air or water in fuel system X X X X
Low-quality fuel being used X X X X
Engine Accelerator pedal stopper bolt
X X
control adjusted incorrectly
Wiring of accelerator control
X
cable incorrect
Sliding of accelerator control
X
cable incorrect
Accelerator position sensor
X
faulty
TROUBLESHOOTING
Symptoms
Possible causes
Speed Wiring of speed limiter cable
X X X
limiter incorrect
system Sliding of speed limiter cable
X X X
incorrect
Fuel hose pipe cracked X
Fuel tank air tightness incorrect X
Oil viscosity unsuitable Refer to
X X group 12 in
this manual
Valve clearance incorrect Refer to
X X group 11 in
this manual
Cylinder head gasket faulty Refer to
X X group 11 in
this manual
Valve and valve seat worn and carbon Refer to
deposits X X group 11 in
this manual
Valve spring fatigued Refer to
X X group 11 in
this manual
Piston ring worn or damaged Refer to
X X group 11 in
this manual
Piston ring groove worn or damaged Refer to
X group 11 in
this manual
Piston and cylinder liner worn Refer to
X X group 11 in
this manual
Cooling system malfunctioning Refer to
X X group 11 in
this manual
Starter switch faulty Refer to
X X Electrical
manual
Glow relay faulty Refer to
X Electrical
manual
Engine speed sensor, backup-engine Refer to
speed sensor disconnected, short- group 13E
X X X
circuited, loose connection in this
manual
TROUBLESHOOTING
Symptoms
Possible causes
Boost pressure sensor disconnected, Refer to
short-circuited, loose connection group 13E
X X X X X
in this
manual
Water temperature sensor disconnected, Refer to
short-circuited, loose connection group 13E
X X X
in this
manual
Injection quantity adjustment resistance Refer to
loose connection group 13E
X X X
in this
manual
Idling adjustment volume loose Refer to
connection group 13E
X X X X
in this
manual
Main relay faulty, fuse broken Refer to
X X X X Electrical
manual
*: Must be serviced by DENSO service station.
(a): Engine does not start ( h ): Engine starts but stalls
(b): Engine hard to start ( i ): Engine revolution does not reach specified
(c): Engine knocks maximum speed
(d): Engine output inconsistent ( j ): Engine does not shut off
(e): Engine output does not develop full power ( k ): Accelerator pedal hard to depress
( f ): Engine maximum revolution too high ( l ): Fuel supply insufficient
(g): Engine idling unstable (m): Engine warning lamp lights
TROUBLESHOOTING
MEMO

Inspection and Adlustment of No-Load Minimum Maximum Revolution
T1131030500066
Service standards
650 (Tolerance: -25
No-load Normal idling revolution - Cheak
to +25) rpm
minimum
Air conditioner 900 (Tolerance: -25
- revolution - Cheak
(idling Idle-up idling under operation to +25) rpm
revolution) revolution Warm-up system 825 (Tolerance: -25
- Cheak
under operation to +25) rpm
2950 (Tolerance: -50
- No-load maximum revolution - Cheak
to +50) rpm
.
Before inspecting, put the vehicle into the following state .

• Warm-up the engine to bring the temperature of the coolant
up to approximately 80 to 95°.
• Turn all the lights and accessory equipment OFF.
• Put transmission in neutral (Put it to the P range for auto-
matic transmission.)
• Put the steering wheel to a neutral position.
Inspection and adjustment of no-load minimum revolution

[Normal idling revolution]
• Inspect idling speed.
• If idling speed deviates from the standard value, inspect
the electronic controlled injection system.
(Refer to group 13E in this manual)
NOTE: ldling speed is automatically controlled by the idling
speed control system.
.
[Idle-Up idling revolution]

• Inspect idling speed.
• Turn Idle-Up operation switch (air conditioner switch or
warm-up switch) ON
• Inspect engine speed.
• If engine speed deviates from the standard value, inspect
each system. (Refer to group 55 of chassis manual, Electri-
cal manual)
.
Inspection and adjustment of no-load maximum revolution

• When lever A of accelerator position sensor 1 strikes full-
load stopper bolt B, make sure that engine speed is within
1 B the standard value.
A NOTE: Engine speed should not be adjusted by stopper bolt B.
.
• If engine speed deviates from the standard value, inspect

accelerator position sensor 1.
(Refer to group 13E in this manual)
• If any abnormality is not found after inspection of the above-
AT302517
mentioned items, inspect further the diagnosis code of fuel
system, injection pump, and Engine electronic control
unit.(Refer to group 13E in this manual)
Bleeding of Fuel System

T1131030600063

1 Air vent plug 6 (Tolerance: -1 to +1)[0.6(Tolerance: -0.1 to +0.1)] -
.
• Loosen air vent plug 1 of fuel filter.

• Move up and down manual pump 2, and feed the fuel.
2 • Keep sending fuel until no bubble is left in the fuel which
comes out from air vent plug 1.
• When there are no more air bubbles, tighten air vent plug 1.
• Continue to send the fuel until manual pump 2 becomes
1
hard.
• Before starting the engine, make sure to wipe spilled fuel
thoroughly.
AT302618 • Make sure that any fuel leakage is not found.
WARNING
• Fuel ignites easily. Do not get it near flame or heat.
• Wipe up any spilled diesel fuel thoroughly since it
can cause a fire.
Replacement of Fuel Filter

T1131030700060
Lubricant
Gasket contact surfaces of fuel filter cartridge
1 Engine oil As required
and fuel filter head
.
[Removal]
A: Filter wrench
(Available on the market: Approximately 90 mm in filter diam-
eter)
A WARNING
1
• Wipe up any spilled diesel fuel thoroughly since it
can cause a fire.
2
NOTE: Reuse water level sensor 2 if any abnormality is not
AT302619 found.
[Installation]
WARNING
• Do not use improper fuel filter cartridge 1 since it
can cause fuel leakage, resulting in a fire. Make
sure to use a genuine filter.
CAUTION
• To prevent abnormal injection etc., pay a most careful
attention that the dust and foreign particles should not
be entered into fuel filter cartridge 1 and the fuel pipe
• Install it by screwing clockwise by hand until seal surface of
3 filter head 3 contacts gasket C of fuel filter cartridge 1.
• Tighten it further by three quarters.
• After installation, run the engine to check for fuel leakage.
C • Bleed air in a fuel system. (Refer to P.13A-15 in this man-
ual)
1
AT302620
MEMO
ENGINE CONTROL
ENGINE CONTROL
Overview
T1131090100655
12
1 Lub
14
Lub 3
Lub 5 4
Lub 2 6 12 13
Lub
15
8 7
10 9 Lub
Lub 11
16
Lub
17
*a 19
Lub 23 18
Lub
22
Lub 23
25 24 *b
21
20
AT302865
1 Harness connector 16 Return spring

SP 2 Accelerator control cable 17 Stopper
3 Accelerator position sensor (Refer 18 Accelerator stopper bolt
to group 13E in this manual) SP 19 Bracket
4 Bushing 20 Cover
5 Collar 21 Nut
6 Return spring 22 Clevis pin
7 Lever SP 23 Speed limiter cable
8 Return spring 24 Harness connector
9 Collar 25 Speed limiter assembly
10 Bushing
SP 11 Accelerator pedal assembly *a: Brake pedal support assembly
12 Bushing (Refer to group 35A of chassis
13 Collar manual)
Pedal pad *b: Wire KIT (Refer to P.13A-19 of the
14
same group)
15 Accelerator pedal arm
ENGINE CONTROL
Assembly sequence
Work after assembly
Refer to P.13A-19 of the same group.
Lubricant
Both ends (Lever and accelerator pedal arm
Chassis Grease [NLGI
2 mounting locations) of accelerator control As required
No.1 (Li soap)]
cable
4, 10, 12 Sliding surfaces of bushing and collar As required
No.1 (Li soap)]
6, 8, 16 Retum spring As required
No.1 (Li soap)]
22 Clevis pin As required
No.1 (Li soap)]
End of speed limiter cable (Exposed inner Chassis Grease [NLGI
23 As required
cable at accelerator position sensor side) No.1 (Li soap)]
Service Procedure
T1131090200500
Work after assembly

1. Inspection and adjustment of accelerator position sensor
voltage (Refer to group 13E in this manual)
2. Sealing paint
Apply sealing paint to A as shown in the figure.
A
A
A
AT302519
ENGINE CONTROL
3. Sealing of harness connector

10mm Put wire C at harness connector connection B and caulk the
D plastic seal at the position where plastic seal D is 10 mm from
C the wire end.
B
CAUTION
Put wire C at the harness connector of the equipment
related to the speed limiter circuit and caulk plastic seal D
for sealing. (Refer to Electrical manual)
AT302520
(2) Installation of accelerator control cable

• Attach accelerator control cable 2 to accelerator pedal arm
15. Attach clip A to marking B of the cable at the angle as
shown in the figure.
D C • Attach inner cable C of accelerator control cable 2 as
E shown in the figure.
• When the accelerator pedal is not depressed, adjust nut E
Approx. so that lever D may not be pulled with accelerator control
2 62mm cable 2. Do not make inner cable C loose.
• After installation, start the engine. Pull the stop button to
A
make sure that engine stops operating.
10
B
10mm
15
AT302866
ENGINE CONTROL
(11) Adjustment of accelerator pedal assembly

• When accelerator pedal assembly 11 is fully depressed,
check if lever A of accelerator position sensor 3 is in contact
with stopper bolt B. If it is not in contact, adjust the stopper
3 B bolt.
A • While it is in contact, adjust the clearance with accelerator
stopper bolt 18 as shown in the figure.
11
0 to 2mm
18
AT302867
(19) Installation of bracket

• Attach bracket 19 as shown in the figure.
A: White paint
19 B: Brake pedal
B A
AT302655
(23) Installation of speed limiter cable

• Make sure that the lengths of stopper bolts A and B of
B accelerator position sensor 3 are as shown in the figure.
16mm • If abnormality is found, make adjustment.
15mm
AT302524
ENGINE CONTROL
• When the accelerator pedal is not depressed, adjust nut C

so that speed limiter cable 23 may be as shown in the fig-
ure. Make sure that stopper bolt A is in contact with lever D
Approx.
34mm of accelerator position sensor 3.
3
A D
23
C AT302868
• Stop speed limiter assembly 25.

• When the accelerator pedal is fully depressed, adjust speed
limiter cable 23 with nut G so that there may be no clear-
3 B
ance between clevis E and clevis pin F (0 mm).
Make sure so that stopper bolt B is in contact with lever D of
D accelerator position sensor 3.
E 0mm
E
25
23
G
STOP
AT302869
• After attachment, check the following.

J • When the accelerator pedal is not depressed, make
23
sure that J of speed limiter cable 23 shown in the figure
is not loose. If it is loose, make adjustment again.
• When the accelerator pedal is operated, speed limiter
cable 23 smoothly slides without sticking. If any abnor-
mality is found, check wiring of the cable.
AT302527
ENGINE CONTROL
MEMO
FUEL FILTER
FUEL FILTER
Overview
T1131090100666
7
*
B
Trq
5 <X>
6
1
Lub
4
A <X>
Lub
3
Trq
2
AT302870
1 Fuel hose 6 Gasket

2 Water level sensor (Refer to 7 Fuel filter head
Electrical manual)
3 O-ring A: From fuel tank
4 Fuel filter cartridge (Refer to B: To injection pump
P.13A-16 of the same group) *: Bracket
5 Air vent plug <X>: Non-reusable parts
Assembly sequence

2.5 (Tolerance: -0.5 to +0.5)
2 Water level sensor -
[0.25 (Tolerance: -0.05 to +0.05)]
6 (Tolerance: -1 to +1)
5 Air vent plug -
[0.6 (Tolerance: -0.1 to +0.1)]
Lubricant
3 O-ring Engine oil As required
Gasket of fuel filter cartridge (contact surface
4 Engine oil As required
of fuel filter head)
FUEL FILTER
MEMO
FUEL TANK
FUEL TANK
Overview
T1131090100547
Trq
2 1 7 8 *
6
Trq
10
9
9
11
3 12
Trq Trq
13
4
5 Trq
AT302871
1 Suction hose 9 Air vent tube

2 Return hose 10 Bolt
3 Drain plug SP 11 Fuel check valve
4 Nut 12 Bolt
5 Fuel tank band 13 Fuel tank bracket
6 Fuel tank
7 Screw *: Chassis harness
Fuel gauge unit (Refer to Electrical (Refer to Electrical manual)
8
manual)
WARNING
• Always empty the tank before starting work.
• Wipe any spilled fuel to prevent possible fire.
• Never bring flames ctose to the work area, since flames can cause an explosion.
Assembly sequence
FUEL TANK

19.6 (Tolerance: -4.9 to +4.9)
3 Drain plug -
[2.0 (Tolerance: -0.5 to +0.5)]
10 (Tolerance: -2.0 to +2.0)
4 Nut (Fuel tank band mounting) -
[1.0 (Tolerance: -0.2 to +0.2)]
7 Screw (Fuel gauge unit mounting) 1.0 to 1.5 [0.1 to 0.15] -
10 Bolt (Fuel check valve mounting) 4.9 to 8.8 [0.5 to 0.9] -
59 (Tolerance: -9.8 to +9.8)
12 Bolt (Fuel tank bracket mounting) -
[6.0 (Tolerance: -1.0 to +1.0)]
Service Procedure
T1131090200458
(11) Fuel check valve
Install fuel check valve 11 in the position adjusted to the stan-
dard angle.
AT302879
INJECTION PUMP
INJECTION PUMP
Overview
T1131090100677
Trq 6
Trq
7 8 Trq 10
9 11
15 2
1
12
Trq
3
* 13
14
Lub
12 <X> 5
Trq
AT302872
1 Harness connector (engine speed 9 Fuel suction pipe

sensor) 10 Injection pipe
2 Harness connector (spill valve) SP 11 Pump bracket
3 Harness connector (injection rate 12 Bolt
adjustment ROM) SP 13 Injection pump assembly
4 Harness connector (timercontrol 14 O-ring
valve) TDC sensor (Refer to group 13E in
15
5 Harness connector (fuel this manual)
temperature sensor)
6 Overflow valve Timing gear case Assembly (Refer
*:
7 Fuel return pipe to group 11 in this manual)
8 Eyebolt <X>: Non-reusable parts
Assembly sequence
INJECTION PUMP
WARNING
• Wipe up any spilled diesel fuel thoroughly since it can cause a fire.
CAUTION
• Request maintenance of injection pump assembly 13 to DENSO service station.
• Be sure to protect all openings by covering them after removal of pipes and hoses because the
engine performance is adversely affected if dirt and foreign particles enter in injection pump
Assembly 13.
• Be sure to check that seat surface of injection pipe 10 has neither damages nor staggers.

6 Overflow valve (fuel return pipe mounting) 19.6 to 24.5 [2.0 to 2.5] -
8 Eyebolt (fuel suction pipe mounting) 19.6 to 29.5 [2.0 to 3.0] -
10 Injection pipe (union nut fastening) 29.4 [3.0] -
12 Bolt (injection pump assembly mounting) 23.5 [2.4] -
Lubricant

12 Removal and installation of

13 Socket wrench 31391-14100
injection pump assembly
31391-14100
- Cranking handle MH061289 Cranking of engine
36 MH061289
INJECTION PUMP
Service procedure
T1131090200511
(11) Pump bracket

.
• Align the bolt holes of pump bracket 11 with the threaded

11 pump bracket mounting holes in injection pump assembly
A
13 and crankcase, and set pump bracket 11 at the mounting
position, making sure that the mounting faces contact firmly.
B • Temporarily tighten bolts A and B alternately.
CAUTION
If the mounting faces of pump bracket 11 are not com-
13 pletely seated, the fuel injection volume can deviate.
• After tightening the bolts temporarily, check pump bracket
AT302624
11 and injection pump assembly 13 for proper installation to
make sure no excessive force is applied. Then, further
tighten bolts A and B alternately.
(13) Injection pump assembly

.
[Removal]
ST: Socket wrench
ST
AT302625
[Installation]
• To bring engine No.1 cylinder piston to top dead center in
B the compression cycle, align pointer B of timing gear case *
with indent mark on crankshaft pulley A by turning the
* crankshaft pulley clockwise using ST cranking handle. At
A
mark"0" this point, make sure that the inlet and outlet valves of No.1
cylinder are not depressed by the push rod. If they are
mark"0" depressed, make another full rotation of the crankshaft pul-
ley.
ST
B AT302875
D
• Aligns indent C on the timer case with indent D on the injec-
C
tion pump gear.
AT302627
INJECTION PUMP
• By aligning guide bar E of the timer case with guide hole F

of the front plate, push in the idler gear up to a fraction of an
inch short of engaging the injection pump gear.
F AT302628
• After making sure that alignment mark C on the timer case

D C aligns with indent D on the injection pump gear, push in the
injection pump assembly 13. As this fitting is taking place,
the indent D will move to the extent of one tooth in the direc-
tion of G.
G
AT302629
• After installing injection pump assembly 13, make sure that

plate positioning pin H is at the center of installation hole J
H of TDC (top dead center) sensor.
If the plate positioning pin H is not located at center, make a
fresh start of installing the injection pump assembly.
AT302630
INJECTION NOZZLE
INJECTION NOZZLE
Overview
T1131090100688
Refer to P.13A-34 of the same group.
2 16
Trq 15 20
1 14
6
<X> 8
5 9
<X> 19
Trq
21 3 10
11 18
4 12 17
13
*
Trq
7
AT302876
1 Injection pipe 13 Nozzle

2 Leak-off pipe 14 No.2 pressure spring
3 Bolt 15 Adjusting shim (for adjustment of
4 Bridge No.2 valve opening pressure)
O-ring 16 Spring seat
5
SP Injection nozzle assembly 17 Pressure pin
6
Retaining nut 18 No.1 pressure spring
7
Spring seat (for adjustment of pre- 19 Adjusting shim (for adjustment of
8
lift) No.1 valve opening pressure)
Tip packing 20 Nozzle holder
9
Straight pin 21 Nozzle gasket
10
11 Washer (for adjustment of needle
valve lift) *: Cylinder head (Refer to group 11 in
Needle valve this manual.)
12
Assembly sequence
INJECTION NOZZLE
WARNING
Wipe up any spilled fuel because it can cause a fire.
CAUTION
• Be sure not to touch the slide-contact area of needle valve 12 because any scratches or corrosion
might spoil the airtightness of nozzle 13. It must be handled with utmost care.
• Never change the combination of needle valve 12 and nozzle 13 for each cylinder.
• Be sure to protect all openings by covering them after removal of hoses and pipes because the
engine performance is adversely affected if dirt and foreign particles enter injection nozzle assem-
bly 6.
NOTE: Remove carbon deposits and clean injection nozzle assembly 6 before working on it, then test the
injection pressure and jet spray condition, and check for fuel leakage before disassembly. If no fault is found,
do not disassemble.
17.7 (Tolerance: 0 to
No.1 valve +0.98)MPa [180 (Tolerance:
Injection pressure of -
opening pressure
injection nozzle 0 to +10)kgf/cm2]
6 Adjust
assembly (Valve 22.1 (Tolerance: 0 to
opening pressure) No.2 valve +0.98)MPa [225 (Tolerance: -
opening pressure
0 to +10)kgf/cm2]
0.08
- Amount of pre-lift - Adjust
(Tolerance: -0.01 to +0.01)
0.25
- Amount of needle valve lift - Adjust

1 Union nut (Injection pipe mounting) 25 [2.5] -
3 Bolt (Bridge mounting) 25 [2.5] -
29.4
7 Retaining nut -
+0.5)]
INJECTION NOZZLE
Special tools
Cleaning of injection
- Nozzle cleaning tool ★ 105789-0010
nozzle assembly
Disassembly,
assembly,
- Tool set *95093-00040
adjustment of
injection nozzle
Measurement of pre-
- *1 Attachment measure *95093-10300
lift
Assembly of
- *1 Base *95093-10230
injection nozzle
No.2 valve opening
- Master spring seat *95093-10330
pressure
★ Bosch Automotive Systems code number.
* DENSO code number.
*1 The component of tool set 95093-00040.
Service Procedure
T1131090200522

Attach injection nozzle assembly 6 to nozzle tester A, and con-
duct the following inspectlon.
WARNING
Never touch the spray from nozzle 13 or let your
hands get too close to the spray point during the test.
NOTE: Before inspection, bleed the air out in a couple of bursts
by pressing nozzle tester A Iever.
1. Valve opening pressure
• Raise the pressure of nozzle tester A by operating the lever,
and measure the pressure that the gauge registers when
A
the pressure is released which will be observed by the sud-
den movement of the gauge indicator.
• If the measured value deviates from the standard value, dis-
assemble the nozzle and clean, and adjust it using adjust-
6 ing shims 15, 19.
• If the performance cannot reach the standard value even
after adjustment, replace injection nozzle assembly 6.
AT302632
2. Spray condition
• Test injection spray condition by quick lever actions of noz-
zle tester A at the speed of 1 or 2 seconds per strok.
B: Even spray from all five orifices (Good)
C: Even and symmetrical spray. (Goob)
D: Asymmetrical spray. (Faulty)
E: Spray direction deviates from nozzle axis line. (Faulty)
F: Thin and insufficient spray. (Faulty)
G: Irregular spray. (Faulty)
B C D E F G
AT302633
INJECTION NOZZLE
• If faulty spray cannot be corrected, disassemble injection

nozzle assembly 6 and clean every part and repeat the test.
if faulty spray still occurs after repeating test, replace the
injection nozzle assembly.
• Make sure there is no post-spray dripping after injection.
3. Fuel tightness and leakage at related contact points
• Maintain interior pressure of nozzle at 1960 kPa [20 kgf/
cm2] lower than the valve opening pressure, and check and
see if any fuel seeps out of the nozzle tip within 10 seconds.
• If any fault is found, disassemble injection nozzle assembly
6 and clean every part and repeat the test. If any fault is still
found, replace the injection nozzle assembly.
AT302634
(6) Injection nozzle assembly

.
[Disassembly]
CAUTION
• Be sure not to touch sliding part A of needle valve 12 with
your hands.
A
12 • Never change the combination of removed needle valve 12
and nozzle 13 for each cylinder.
AT302635
[Cleaning]
B
Clean needle valve 12 and nozzle 13 with gas oil (cleaning sol-
vent). Remove carbon deposits with ST cleaning tool in the fol-
lowing manner:
• Clean needle valve 12 by removing carbon deposits from its
12 tip using cleaning bar B of ST cleaning tool.
CAUTION
Never use a wire brush or hard steel for cleaning.
AT302637 .
INJECTION NOZZLE
• To clean nozzle 13 , remove carbon deposits from the ori-

C
fices of the nozzle using needle cleaner C of ST cleaning
tool, by inserting it into the orifices and turning it.
Needle cleaner diameter: φ 0.18 mm or less
13
AT302638
D • Clean the seat of nozzle 13 using cleaning needle D of ST

13 cleaning tools.
• Use FUSO carbon remover to remove hard-to-remove,
burnt-on carbon deposits.
AT302639
[Inspection]
• Immerse needle valve 12 and nozzle 13 in gas oil (cleaning
solvent) and clean them thoroughly.
• Check and see if needle value 12 drops by its own weight
into the nozzle from the position where a third of its length is
pulled out. (Repeat this several times rotating the needle
valve.)
12
• If needle valve 12 does not drop smoothly, repeat cleaning
13 and repeat the test. If any fault is still found, replace both
the needle valve and nozzle 13 together as a set.
AT302640
.
[Assembly]
• Assembly tip packing 9 and washer 11 (for adjustment of
9 needle valve lift) as shown in the figure.
11
12
AT302636
.
INJECTION NOZZLE
[Adjustment]
While assembling the parts, adjust in the following order.
CAUTION
• Clean all of the parts before adjustment inside uncon-
taminated cleaning solvent (gas oil, etc.), and make
sure all dirt and foreign particles are removed.
• Never touch the slide area of needle valve 12.
Maximum needle valve lift
Adjustment of pre-lift
No.2 valve opening pressure
No.1 valve opening pressure
Adjustment of needle valve maximum lift

• Mount ST-a attachment measure on dial gauge E.
E ST-a
2 mm or more
AT302641
• Mount nozzle 13, needle valve 12 and spring seat (for

8 adjustment of pre-lift) 8 on ST-b base.
12
8
12 13
13
ST-b
AT302642
• Mount ST-a attachment measure on nozzle 13.

E • Set the indicator of dial gauge E at zero point.
ST-a
8
13
AT302643
INJECTION NOZZLE
• Remove ST-a attachment measure, change the direction of

8 spring seat (for adjustment of pre-lift) 8 and install.
8
AT302644
• Mount ST-a attachment measure on nozzle 13 and mea-

sure dimension L1 again.
13 12
L1
ST-a
AT302645
• Remove ST-a attachment measure and needle valve 12

9 and install tip packing 9 on nozzle 13 as illustrated.
ST-a
13
12
AT302646
• Set the indicator of diai gauge E on ST-b base at zero point.
ST-b
AT302647
• Mount ST-a attachment measure on tip packing 9 and mea-

9 L2 sure dimension L2.
ST-a
9
13
AT302648
INJECTION NOZZLE
• Measure thickness L3 of washer (for adjustment of needle

valve lift) 11.
L3
11
AT302649
• Use the following equation to calculate needle valve 12

12 9
maximum lift F based on measured values L1, L2 and L3.
11 Maximum lift F = (L1 +L2 ) - L3
• If the resultant value deviates from the standard value,
adjust using washer (for adjustment of needle valve lift) 11.
13 F Thickness of washer 11 (thickness: L3)
1.90, 1.925, 1.95, 1.975, 2.00 mm (5 types)
AT302650
Adjustment of pre-lift
• Measure tip packing 9 thickness L4.
• Measure dimension L5 of spring seat (for adjustment of pre-
9 lift) 8.
L4
8
L5
AT302651
• Use the following equation to calculate the amount of pre-lift

11 12 8 9 G based on measured values L1, L3, L4, L5.
Amount of pre-lift G =L4 - L5 - (L3 - L1)
• If the resultant value deviates from the standard value,
adjust using spring seat (for adjustment of pre-lift) 8.
13 Thickness of spring seat 8 (thickness : L5)
G
3.07 to 3.28 mm (increment, 0.01 mm, 22 types)
AT302652
INJECTION NOZZLE
Adjustment of No.2 valve opening pressure

• Install on nozzle holder 20 the parts as illustrated. Instead
of spring seat (for adjustment of pre-lift) 8 install ST-c mas-
20 ter spring seat.
• Tighten retaining nut 7 at specified torque.
• Mount on the nozzle tester and measure No.2 valve open-
ing pressure.
16
CAUTION
15
Never touch the spray from the nozzle.
14 If the measured value deviates from the standard value, adjust
ST-c using adjusting shim (for adjustment of No.2 valve opening
9 10 pressure) 15.
Thickness of adjusting shim 15 (thickness)
11
13
12 Changes in valve opening pressure resulting from changes in
7
adjusting shim 15 thickness.
345 kPa [3.5 kgf/cm2] / 0.025 mm
AT302653
Adjustment of No.1 valve opening pressure

• Install on nozzle holder 20 the parts as illustrated.
• Tighten retaining nut 7 at specified torque.
19 • Mount on the nozzle tester and measure No.1 valve open-
20
ing pressure.
18 CAUTION
17 Never touch the spray from the nozzle.
16 If the measured value deviates from the standard value, adjust
15
using adjusting shim (for adjustment of No.1 valve opening
14 8 pressure) 19.
Thickness of adjusting shim 19 (thickness)
9
10
0.8 to 2.0, 2.05, 2.075 to 2.2 mm
(increment, 0.025 mm, 56 types)
11 Changes in valve opening pressure resulting from changes in
13 adjusting shim 19 thickness.
12 345 kPa [3.5 kgf/cm2] / 0.025 mm
7
AT302654
13E-1
GROUP 13E
ELECTRONICALLY
CONTROLLED FUEL
SYSTEM
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . 13E-2 Diagnostic Trouble Codes and Check items 13E-20

Service Data of Multi-Use Tester II . . . . . . . 13E-33
STRUCTURE AND OPERATION Actuator Test by Multi-Use Tester II . . . . . . 13E-35
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13E-3 Checks at Connector of Engine Electronic Control Unit
Electronic Control System. . . . . . . . . . . . . . 13E-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13E-36
Pin Configuration of Engine Electronic Control Unit Checks on Transient Troubles. . . . . . . . . . . 13E-39
...................................... 13E-9
INSPECTION OF ELECTRICAL EQUIPMENT
TROUBLESHOOTING . . . . . . . . . . . . 13E-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13E-40
Inspection Procedures . . . . . . . . . . . . . . . . 13E-14
Connection of Multi-Use Tester II . . . . . . . . 13E-16 LOCATIONS OF PARTS . . . . . . . . . . 13E-50
Reading and Erasing Diagnostic Trouble Codes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13E-17 ELECTRICAL WIRING DIAGRAM . . . 13E-53
13E-2 ELECTRONICALLY CONTROLLED FUEL SYSTEM
SPECIFICATIONS
SPECIFICATIONS
T1135000100067
Items Specifications
Manufacturer DENSO
Model V4
Distribution type electronically controlled
Type
pump
Spill valve (Solenoid valve) Electronically controlled type
Control scheme High pressure chamber control
Injection pump Timer
Drive method Timer control valve (TCV)
assembly
Valve opening pressure
Overflow valve 343 {3.5}
kPa {kgf/cm2}
Type Vane type
Feed pump
Theoretical delivery rate cc 6.4 (per rotation)
Fuel temperature sensor Provided
Engine speed sensor Provided
Engine electronic Manufacturer V DENSO
control unit Rated voltage 24
Manufacturer DENSO
Drive unit
Rated voltage V 24
ELECTRONICALLY CONTROLLED FUEL SYSTEM 13E-3

General
T1135010200065
The engine system adopts a distribution type injection pump, which features small size and light weight and
yet high speed, as well as an engine electronic control unit which controls the fuel injection rate, fuel injection
timing, etc., thereby operating the engine in an optimum condition.
T1131090100581
Theory of Operation
2 3 4 5
6
7
1
8
21
11
10
9
20
19
18 17 16 15 14 13 12
AT302660
1 Fuel filter 12 Rotor

2 Fuel temperature sensor 13 Timer control valve
3 Overflow valve 14 Timer piston
4 Pump chamber 15 Inner cam
5 Spill valve 16 Plunger
6 Drive unit 17 Feed pump
7 Engine electronic control unit 18 Injection pump proper
8 Injection nozzle 19 Fuel tank
9 Fuel chamber 20 Drive shaft
10 Delivery valve 21 Engine speed sensor
11 Injection rate adjusting read-only
memory
• The feed pump 17 in the injection pump proper 18, pumps up the fuel from the fuel tank 19, keeping the
inside of the injection pump. full of the fuel at all times.
• The rotor 12 rotates in the inner cam 15.
• The drive unit 6 converts the spill valve 5 drive signal delivered from the engine electronic control unit 7
into a high voltage signal to enhance the responsiveness of the spill valve.
• The fuel injection rate is increased or reduced by adjusting the opening time of the spill valve 5.
• When the spill valve 5 is opened, the inside of the rotor 12 is filled with the fuel.
• After it has been filled, the spill valve 5 closes to confine the fuel in the rotor 12. In this condition, as the
drive shaft 20 rotates, the fuel is pressurized by the inner cam 15 and plunger 16 and fed through the
delivery valve 10 to the injection nozzle 8 from which it is injected.
• Then the spill valve 5 opens, and a resultant decline in the fuel pressure in the rotor 12 causes the deliv-
ery valve 10 to close, thereby bringing the fuel injection to an end.
• The overflow valve 3 returns the fuel to the fuel tank 19 when the fuel pressure in the injection pump
exceeds a predetermined value.
• The fuel injection timing is controlled by the timer control valve 13 which controls the fuel pressure acting
on the timer piston 14.
• The timer control valve 13 is activated by commands from the engine electronic control unit 7.
Electronic Control System

T1135010300062
System Block Diagram
Input Signal Engine Electronic Control Unit Output Signal

Drive
unit 18 Spill valve 19
Engine speed signal 1 Fuel Injection Amount
Fuel temperature signal 2 Control
Coolant temperature signal 3
Timer control valve (TCV) 20
Crank angle signal 4
Boost pressure signal 5
Boost air temperature signal 6 Warning lamp
Engine start signal 7
Fuel Injection Timing
Accelerator pedal position signal 8 Control Indicator lamp
Warmup accelerating signal 9
Fuel injection amount adjustment signal 10 Warmup Accelerating Intake silencer 3-way magnetic valve 21
Auxiliary brake signal 11 Function
Vehicle speed signal 12
Exhaust brake 3-way magnetic valve
Diagnostic signal 13
Clutch pedal position signal 14 Diagnostic Function
Transmission neutral signal 15 Tachometer
1st and reverse position signal 16

Cooler switch operation signal 17
AutomaticTransmission Electronic Cntrol Unit

AutomaticTransmission Electronic Cntrol Unit
Exhaust brake cut signal
Engine speed
Idle up inhibit signal
Accelerator opening
Information Signal Part Names Major Function or Operation

1 Engine speed signal Engine speed sensor Detection of engine speed
2 Fuel temperature signal Fuel temperature sensor Detection of fuel temperature
3 Coolant temperature signal Water temperature sensor Detection of coolant temperature
4 Crank angle signal TDC sensor Detection of crank angie signal
5 Boost pressure signal Boost pressure sensor Detection of boost air temperature
6 Boost air temperature signal Boost air temperature sensor Detection of boost air temperature
Recognition of engine start when starter
7 Engine start signal Starter switch
switch is placed at start position
Detection of amount that accelerator
Accelerator positon sensor
Accelerator pedal position pedal has been depressed
8
signal Detection of released/depressed
Accelerator switch
accelerator pedal
ldle adjusting potentiometer
9 Warmup accelerating signal Acceleration of warmup
Warming switch
Fuel injection amount Injection rate adjusting read-
10 Adjustment of fuel injection amount
adjustment signal only memory
11 Auxiliary brake signal Stop lamp relay Control of auxiliary brake
12 Vehicle speed signal Vehicle speed sensor Detection of vehicle speed
Diagnosis switch Transmission of diagnosis signal
13 Diagnostic signal Erasure of diagnostic trouble code

Memory clear switch Transmission of past diagnostic trouble
code
Detection of released/depressed clutch
14 Clutch pedal position signal Clutch switch
pedal
15 Transmission neutral signal Transmission neutral switch Detection of transmission neutral status
1st and reverse position Detection of transmission 1st and reverse
16 Torque limit switch
signal position
Cooler switch operation
17 Cooler switch Detection of cooler operation
signal
Assurance of high voltage for high speed
18 - Drive unit
drive of spill valve
Control of fuel injection amount and
19 - Spill valve
injection rate
Timer control valve operation
20 Timer control valve (TCV) Operation of timer piston
signal
Intake silencer 3-way Operation of intake silencer 3-way
21 -
magnetic valve magnetic valve
Fuel Injection Rate Control
Engin electronic
control unit
EEngine speed sensor
ETDC sensor
EWater temperature sensor Various control
Spill valve
maps Drive unit
EFuel temperature sensor
EAccelerator position sensor 1
EAccelerator position sensor 2
EInjection rate adjusting resistor
EInjection rate adjusting read-only memory Target injection
ETorque limit switch rate
EBoost pressure sensor
• During operation of the engine, the engine electronic control unit processes the individual information sig-
nals according to the control maps to select an appropriate injection mode from among the "basic","maxi-
mum" and "minimum".
• After selection of the injection mode, the engine electronic control unit calculates the minimum value to
ensure that the maximum injection rate is not exceeded and determines the target injection rate.
• Once the target injection rate has been determined, the engine electronic control unit outputs a signal to
drive the spill valve.
• The signal to drive the spill valve is passed through the drive unit so that its responsiveness for high
speed driving will be enhanced.
• The drive unit immediately converts the signal voltage delivered from the engine electronic control unit to
a high voltage.
Fuel Injection Timing Control
Engin electronic control unit

EEngine speed sensor
ETDC sensor
EWater temperature
sensor
EFuel temperature sensor Various control
EAtmospheric pressure maps Target injection
Timer control valve (TCV)
sensor timing
EAccelerator position
sensor 1
EAccelerator position
sensor 2
EBoost air temperature
sensor
• During operation of the engine, the engine electronic control unit processes the individual information sig-
nals according to the control maps to calculate the target injection timing, and drives the timer control
valve (TCV) in such a way that the real timing computed on the basis of the engine speed sensor and
TDC sensor will match the target timing.
• Controls at the time of an engine start are achieved by the start compensation map contained in each con-
trol map.
Warmup Accelerating Function
Engin electronic control unit

EWater
temperature
sensor
Comparative
EAccelerator computing
position sensor 1
ldling speed control
EAccelerator
position sensor 2
EIdle adjusting
potentiometer
Target injection
timing
The warmup accelerating function varies the idling speed according to the engine coolant temperature to
accelerate warmup. The function includes the automatic and manual modes. Either of the modes can be
selected by pushing/pulling the idle adjusting potentiometer.
Pin Configuration of Engine Electronic Control Unit

T1135010400069
C: CC12B D: CC22A
6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 22 21 20 19 18 17 16 15 14 13 12
A: CC26A B: CC16A
A
13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
B 26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9
C
D
AT302641
Connector A: CC26A
Connection destination or terminal Connection destination or terminal
Pin No. Pin No.
name name
1 - 14 -
2 Intake silencer 3-way magnetic vaive 15 -
Injection rate adjusting read-only memory
3 16 Drive unit (FAIL signal)
(DATA)
Injection rate adjusting read-only memory
4 - 17
(CLK)
5 - 18 Magnetic valve surge OUT 1
6 PWM accelerator OUT (signal) 19 Magnetic valve surge OUT 2
Pulse divider (Vehicle speed sensor
7 20 Drive unit (Spill valve signal)
signal)
Engine electronic control unit main relay
8 21 Warning lamp (Red)
1
Engine electronic control unit main relay
9 22 Warning lamp (Umber)
2
10 Drive unit relay 23 -
11 - 24 Engine electronic control unit POWER-1
12 Timer control valve 25 Exhaust brake 3-way magnetic valve
13 Ground (ANALOG) 26 Ground (POWER)
Connector B: CC16A
Pin No. Pin No.
name name
1 Water temperature sensor (signal) 9 Boost pressure sensor (signal)
2 Injection rate adjusting resistor (signal) 10 Idle adjusting potentiometer (signal)
3 Accelerator position sensor 1 (+5V) 11 Accelerator position sensor 1 (signal)
4 Accelerator position sensor 2 (+5V) 12 Fuel temperature sensor (signal)
Boost pressure sensor, Idle adjusting
5 13 Accelerator position sensor 2 (signal)
potentiometer (+5V)
6 Accelerator position sensor (Ground-1) 14 -
7 - 15 Boost air temperature sensor (signal)
8 Accelerator position sensor (Ground-2) 16 Sensor ground
Connector C: CC12B
Pin No. Pin No.
name name
1 - 7 Torque limit switch
2 - 8 Idle up cancel
3 - 9 -
4 Engine speed OUT (signal) 10 Tachometer output (signal)
5 TDC sensor (signal) 11 TDC sensor (ground)
6 Engine speed sensor (signal) 12 Engine speed sensor (ground)
Connector D: CC22A
Pin No. Pin No.
name name
1 - 12 Ground (ANALOG)
2 Starter switch (S terminal) 13 Multi-Use Tester II (K-LINE)
3 Starter switch (M terminal-1) 14 Starter switch (M terminal-2)
4 - 15 Memory clear switch
5 - 16 -
Transmission neutral switch
<Manual transmission>
6 Clutch switch 17
Exhaust brake cut relay
<Automatic transmission>
7 - 18 -
8 - 19 Warming switch
9 Diagnosis switch 20 Cooler switch
10 Accelerator switch 21 Exhaust brake switch
11 Ground (POWER) 22 Engine electronic control unit POWER-2
MEMO
Engine Electronic Control Unit
2 3
1
8
4
6
5
7
AT302828
AT302829
TROUBLESHOOTING
TROUBLESHOOTING
Inspection Procedures
T1135020200099
Diagnostic Function
• Whenever the starter switch is placed at ON, the diagnostic function is activated to check all the sensors,
etc. If any of them is found faulty, the warning lamp in the meter cluster is lit to alert the driver. At the same
time, the fault location is stored in memory, and the system enters the backup mode.
Warning Lamp Indications
(Red) (Umber)
Safety-critical error
ON OFF
(Vehicle must not be driven)
Non-safety-critical error
OFF ON
(Vehicle can be driven despite poor control feeling)
• The stored fault location can be read as a diagnostic trouble code by the Multi-Use Tester II or the diagno-
sis switch.
CAUTION
• Check to ensure that the battery voltage is within the specified range.
• Check all the harness and device connectors for looseness. Always remove a connector at least
20 seconds after placing the starter switch at the LOCK position.
• Do not forget to clear the diagnostic trouble code by the Multi-Use Tester II or memory clear
switch after a fault has been rectified.
• As a rule, inspection operations should be performed with the starter switch at the LOCK position.
Some checks, however, may have to be made with the starter switch at the ON position. In such a
case, use care to make sure that no short circuit develops between pins of the connectors or with
the body.
• The resistance value of each component is affected by the temperature and the accuracy of the
tester. The reading, therefore, does not always fall within the standard limits. Note that the check
values shown in the text are the values obtained at normal temperature (10 to 35°C).
• Whether or not the system automatically returns to normal from the backup mode after a fault has
been removed depends on the diagnostic trouble code (fault location). When the system returns
to normal, the warning lamp will be OFF.
• Even when the fault has been removed and the system has been automatically returned to the nor-
mal mode, the diagnostic trouble code of the fault remains stored in the engine electronic control
unit.
• When a fault occurs at a point where the system is not automatically reset, perform the memory
clear procedure to let the system exit from the backup mode. Refer to P.13E-17 of the same group.
TROUBLESHOOTING
Inspection Flowchart
The system inspection can be performed effectively by use of the Multi-Use Tester II. The types of system
inspections may be broadly divided as shown below in accordance with the trouble symptoms and diagnostic
trouble code outputs.
• Inspections based on diagnostic trouble codes stored in the engine electronic control unit
• Inspections of transient troubles
Vehicle brought into workshop
Read diagnostic trouble codes. *1
Trouble code output Normal code No communications can be made

output with Multi-Use Tester ll.
Normal code output

after erasure
ldentity cause for diagnostic Check for

trouble code issue and transient troubles
rectify. *2
If no communications can be made with all the other systems,

it is highly likely that the diagnostic circuit is faulty.
If no communications can be made with this system only, an open
Driving test circuit in the diagnostic output circuit or power supply circuit
(including the ground circuit) of this system is suspected.
EIf the same diagnostic trouble code is issued during test driving, reexamine the cause for the
diagnostic trouble code issue and rectify. *2
EIf none of the diagnostic trouble codes stored in the engine electronic control unit before the test
driving is issued, perform the checks on transient troubles in addition to the checks based on the
diagnostic trouble codes.
Erase the diagnostic trouble codes. *1
*1: Refer to P.13E-17 of the same group. *2: Refer to P.13E-27 of the same group.
TROUBLESHOOTING
Connection of Multi-Use Tester II

T1135020300096
Special Tools
Location Name and Shape of Special Tool Part No. Application
- Multi-Use Tester II MB991496 Inspection of system
MB991496
To supply power to Multi-

Multi-Use Tester II Use Tester II proper and
- harness (for MK327601 communicate with
communications) vehicle side electrical
MK327601
devices
Data for inspection and

Read-only memory pack
- MH062867 control of engine
(MRT-E10)
electronic control unit
MH062867
Memory card (set in

- Multi-Use Tester II MB991500 To write data
proper)
MB991500
Multi-Use Tester II To use Multi-Use Tester II

- MB991499
harness as a circuit tester
MB991499
• Place the starter switch at the LOCK position.

• Connect the ST-b Multi-Use Tester II harness to ST-a Multi-
Use Tester II and insert the ST-c read-only memory pack.
• Connect the Multi-Use Tester II connector A (16 pins) to the
data link connector B (16 pins).
NOTE: For the operating procedures for the Multi-Use Tester II,
refer to the instruction manual for the Multi-Use Tester II.
ST-c ST-b
ST-a B
A AT302533
TROUBLESHOOTING
Reading and Erasing Diagnostic Trouble Codes

T1135020400060
Two types of methods are available for reading or erasing a diagnostic trouble code; one using the Multi-Use
Tester II and one using the vehicle side diagnostic functions.
(1) Method using Multi-Use Tester II

.
Current Diagnostic Trouble Code

• Check to see that the memory clear switch 1 is connected.
• Set the starter switch to ON.
• Operate the Multi-Use Tester II to read the current diagnos-
tic trouble code and determine the fault location.
.
Past Diagnostic Trouble Code

• Disconnect the memory clear switch 1.
• Operate the Multi-Use Tester II to read the past registered
1 AT302669 diagnostic trouble codes and determine the fault location.
.
Erasing Diagnostic Trouble Codes

• Operate the Multi-Use Tester II to erase all of the diagnostic
trouble codes stored in the engine electronic control unit.
(2) Method Not Using Multi-Use Tester II

(Method Using Diagnostic Switch and Memory
Clear Switch)
.
Current Diagnostic Trouble Code

• Disconnect the diagnosis switch 2.
3 • The diagnostic trouble code is displayed by flashes of the
warning lamp 3.
.
AT302670
TROUBLESHOOTING
Reading Diagnostic Trouble Code

• Diagnostic trouble codes are indicated by the number of
times the warning lamp 3 flashes and their duration.
10s digit Units digit
• The flashing intervals also differ between the 10s digit
ON and units digit.
• 10s digit: 1.2 second interval
• Units digit: 0.4 second interval
OFF • Each diagnostic trouble code is displayed from the 10s
digit followed by the units digit. As for a code which has
1.2 1.2 no 10s digit, units digit only is displayed.
0.4
• Each diagnostic trouble code is displayed three times in
0.4 succession.
0.4 • If there is no more code stored, the sequence is then
Diagnosis switch repeated from the beginning with each code indicated three
disconnected
First diagnostic trouble code dis- times.
played (Diagnostic trouble code 12) • When the diagnosis switch 2 is connected, the engine elec-
ON
Second tronic control unit will immediately stop displaying codes.
OFF diagnos-
tic
trouble
2.4 2.4 2.4 2.8 code
displayed
AT302846
Past Diagnostic Trouble Codes

• After reading the current diagnostic trouble codes (with the
diagnosis switch 2 disconnected), disconnect the memory
3 clear switch 1. Then the warning lamp 3 will restart flashing.
• This time, the warning lamp displays the past diagnostic
trouble codes. Determine the fault locations based on the
indicated codes.
1 AT302672
Erasing Diagnostic Trouble Codes

Disconnect the memory clear switch 1 and the diagnosis switch
2 then reconnect them. Then all the diagnostic trouble codes
A second
or more 3 seconds
stored in the engine electronic control unit will be cleared.
Connected
Released Memory cleared

at this point
AT302673
TROUBLESHOOTING
CAUTION
• If the contents of memory are not to be cleared after
display of the stored codes, set the starter switch to
OFF with the memory clear switch 1 disconnected.
Thereafter, connect the memory clear switch.
• When you change the combination of the injection
pump and engine electronic control unit, you must
rewrite the pump data stored in the engine electronic
control unit. For this purpose, be sure to perform the
diagnostic trouble code erasing procedure.
• Whenever the engine electronic control unit has been
replaced with a new one, be sure to erase the diagnos-
tic trouble codes by disconnecting the memory clear
switch 1 and diagnosis switch 2 after connecting all the
connectors. Upon completing the procedure, confirm
that no diagnostic trouble code is stored.
TROUBLESHOOTING
Diagnostic Trouble Codes and Check Items

T1135020500067
Diagnostic Trouble Code List

Multi-Use Tester II Screen Display
Where Described
Diagnostic Trouble code Message
06 EDU/SPV Refer to P.13E-21 of
07 OVER REV the same group
14 TDC SNSR Refer to P.13E-22 of

15 NE SNSR the same group
16 ACCEL SNSR-2 Refer to P.13E-23 of

19 AIR PRES SNSR the same group
21 WTR TEMP SNSR Refer to P.13E-24 of

23 TCV the same group
Refer to P.13E-25 of
24 ACCEL SNSR-1
the same group
25 SPEED SNSR Refer to P.13E-26 of
26 PUMP ROM the same group
27 SILENCER M/V Refer to P.13E-27 of

31 IDL VOLUME the same group
32 BOOST PRES Refer to P.13E-28 of

33 ECU SYSTEM the same group
34 Q RESISTOR
the same group
41 FUEL TEMP Refer to P.13E-30 of
44 BOOST TEMP the same group
46 EDU RELAY Refer to P.13E-31 of

65 ACCEL SW the same group
66 STARTER SW (S)
the same group
TROUBLESHOOTING
Diagnostic Trouble Code Issued Conditions and Check Items

06 EDU/SPV
Code issued Diagnostic trouble code 06 is intended for checking the drive unit and spill valve for
condition [Reset anyihing abnormal. The code is issued when the FAIL signal is not input the specified
condition] number of consecutive times from the drive unit to the engine electronic control unit
despite the fact that the battery voltage is normal, the engine is running at a speed
higher than the idling speed, and the drive unit is outputting the spill valve drive signal.
[Starter switch OFF]
Action taken by
engine electronic Engine stopped
control unit
Warning lamp
(Red)
illuminated
• Open or short circuit between • Check on the basis of the service data of the
engine electronic control unit and Multi-Use Tester II. (Refer to P.13E-33 of
drive unit, or between drive unit and the same group)
spill valve No. 83: Spill valve operation check
• Faulty drive unit • Test the actuator by the Multi-Use Tester ll.
• Faulty spill valve (Refer to P.13E-35 of the same group)
No. 9B: Spill valve operation check
Probable cause • Check the drive unit.
and check item (Ask your DENSO service station to do the
job.)
• Check the spill valve.
Refer to P.13E-40 of the same group:
Inspection of Electrical Devices #536
• Check the circuit between engine electronic
control unit and drive unit or the circuit
between the drive unit and spill valve.
Refer to P.13E-55 of the same group
07 OVER REV
Code issued Diagnostic trouble code 07 is intended for checking whether the engine speed has
condition [Reset reached an overspeed.
condition] When the engine speed reaches an overspeed, the code is issued.
(When the engine speed decreases to fall within the normal range, a reset is made.)
Action taken by
engine electronic Spill valve operation stopped
control unit
Warning lamp
(Red)
illuminated
• Faulty spill valve of injection pump Check the injection pump assembly (Ask your
assembly DENSO service station to do the job.)
Probable cause
• Overrevved engine during driving
and check item
downhill
• Faulty engine electronic control unit
TROUBLESHOOTING
14 TDC SNSR
Code issued Diagnostic trouble code 14 is intended for checking the TDC sensor operation. It is
condition [Reset issued when the TDC sensor signal is not input to the engine electronic control unit the
condition] specified number of consecutive times while the engine is running.
[When nomal TDC sensor signal input is restored, the system is reset.]
Action taken by
engine electronic Injection timing feedback control stopped and open-loop control executed
control unit
Warning lamp
(Umber)
illuminated
• Open or short circuit between • Perform checks at engine electronic control
engine electronic control unit and unit connector. (Refer to P.13E-36 of the
TDC sensor same group)
• Faulty TDC sensor 01: Measure resistance of TDC sensor.
Probable cause • Faulty engine electronic control unit • Check TDC sensor.
and check item Refer to P.13E-40 of the same group:
• Check circuit between engine electronic
control unit and TDC sensor.
Refer to P.13E-55 of the same sensor
15 NE SNSR
Code issued Diagnostic trouble code 15 is issued when the signal from the engine speed sensor is
condition [Reset not input the specified number of times to the engine electronic control unit while the
condition] engine is in operation.
[When the signal from the engine speed sensor returns to normal, a reset is made.]
Action taken by
engine electronic Synchronous control of spill valve with timer control valve interrupted
control unit
Warning lamp
(Red)
illuminated
• Open or short circuit in harness • Perform checks on the basis of the service
between engine electronic control data of the Multi-Use Tester II. (Refer to
unit and engin speed sensor P.13E-33 of the same group)
• Faulty engine speed sensor No. 01: Measure engine speed.
• Gap of engine speed sensor • Perform checks at engine electronic control
maladjusted unit connector. (Refer to P.13E-36 of the
• Faulty engine electronic control unit same group)
Probable cause
and check item 02: Measure resistance of engine speed
sensor.
• Check engine speed sensor.
Refer to group P.13E-40 of the same group:
control unit and engine speed sensor.
Refer to P.13E-55 of the same sensor
TROUBLESHOOTING
16 ACCEL SNSR-2
Code issued Diagnostic trouble code 16 is intended for checking the accelerator position sensor 2
condition [Reset for an abnormal voltage.
condition] The code is issued when the voltage of the accelerator position sensor 2 is out of the
specified limits. When diagnostic trouble code 24 is also registered, the portion
between the accelerator position sensors is faulty.
[When the voltage of the accelerator position sensor 2 falls within the specified limits, a
reset is made.]
Action taken by (1): Ordinary controls are made by using only accelerator position sensor 1
engine electronic (2): When accelerator position sensor 1 is also faulty, controls are made on the
control unit assumption that the pedal is depressed 30% when accelerator switch is OFF and 0%
when accelerator switch is ON.
Warning lamp (1): -
illuminated (2): (Umber)
unit and acceleraor position sensor P.13E-33 of the same group)
2 No. 0B: Accelerator pedal opening
• Faulty accelerator position sensor 2 measurement.
• Faulty engine electronic control unit No. 0C: Measurement of accelerator
position sensor output voltage.
• Perform checks at engine electronic control
Probable cause unit connector. (Refer to P.13E-36 of the
and check item same group)
03: Measurement of accelerator position
sensor 2 output voltage.
• Check accelerator position sensor 2.
control unit and accelerator position sensor
2.
19 AIR PRES SNSR
Code issued Diagnostic trouble code 19 is intended for checking the atmospheric pressure sensor
condition [Reset (built into the engine electronic control unit) for anything abnormal. The code is issued
condition] when a voltage signal from the atmospheric pressure sensor is out of the specified
limits. [When the output voltage of the atmospheric pressure sensor falls within the
specified range, a reset is made.]
Action taken by
Controls achieved on the assumption that atmospheric pressure is 100 kPa {760
engine electronic
mmHg}.
control unit
Warning lamp
-
illuminated
• Faulty atmospheric pressure Perform checks on the basis of the service
Probable cause sensor (built into engine electronic data of the Multi-Use Tester II. (Refer to P.13E-
and check item control unit) 33 of the same group)
• Faulty engine electronic control unit No. 14: Atmospheric pressure measurement.
TROUBLESHOOTING
21 WTR TEMP SNSR

Code issued Diagnostic trouble code 21 is intended for checking for open or short circuit in the
condition [Reset harness of the coolant temperature sensor or anything abnormal in coolant temperature
condition] sensor. The code is issued when the output voltage from the coolant temperature
sensor is out of the specified limits. [When the output voltage of the coolant
temperature sensor falls within the specified range, a reset is made.]
Action taken by
Maintains coolant temperature at -20°C and temperature of others at 80°C at engine
engine electronic
startup.
control unit
Warning lamp
-
illuminated
unit and coolant temperature P.13E-33 of the same group)
sensor No. 10: Engine coolant temperature
• Faulty coolant temperature sensor measurement
Probable cause • Faulty engine electronic control unit • Check coolant temperature sensor.
and check item
control unit and coolant temperature sensor.
23 TCV
Code issued Diagnostic trouble code 23 is intended for checking the harness of the timer control
condition [Reset valve for open or short circuit and checking the timer control valve for anomalies. The
condition] code is issued when the real advance angle position of the timer continues to be out of
the specified limits under the condition that fuel injection timing feedback control is in
progress after completion of engine warmup. [When the advance angle re-enters the
specified range with the engine at a speed of less than 1200 rpm, a reset is made.]
Action taken by Controls are made on the assumption that the coolant temperature is -20°C when the
engine electronic engine is started, and 80°C during operation
control unit
Warning lamp
-
illuminated
unit and timer control valve P.13E-33 of the same group)
• Faulty timer control valve No. 09: Timer advance angle measurement
Probable cause • Faulty engine electronic control unit • Check timer control valve.
and check item Refer to group P.13E-40 of the same group:
control unit and timer control valve.
TROUBLESHOOTING
24 ACCEL SNSR-1
Code issued Diagnostic trouble code 24 is intended for checking the accelerator position sensor 1
condition [Reset for abnormal voltage. The code is issued when the output voltage of the accelerator
condition] position sensor 1 is out of the specified limits. When diagnostic trouble code 16 is also
registered, the portion between the accelerator position sensors is faulty.
[When the output voltage of the accelerator position sensor 1 re-enters the specified
range, a reset is made.]
Action taken by (1): Ordinary controls are continued by using only the accelerator position sensor 2.
engine electronic (2): When accelerator position sensor 2 is also faulty, controls are made on the
control unit assumption that the pedal is depressed 30% When accelerator switch is OFF and 0%
when accelerator switch is ON.
Warning lamp (1): -
illuminated (2): (Umber)
unit and acceleraor position sensor P.13E-33 of the same group)
1 No. 0B: Accelerator pedal opening
• Faulty accelerator position sensor 1 measurement.
• Faulty engine electronic control unit No. 0C: Measurement of accelerator
position sensor output voltage.
Probable cause unit connector. (Refer to P.13E-36 of the
and check item same group)
04: Measurement of accelerator position
sensor 1 output voltage.
• Check accelerator position sensor 1.
control unit and accelerator position sensor
1.
TROUBLESHOOTING
25 SPEED SNSR
Code issued Diagnostic trouble code 25 is intended for checking the harness of the vehicle speed
condition [Reset sensor for open/short circuit and checking the vehicle speed sensor for anomalies. The
condition] code is issued when there are no pulse inputs from the vehicle speed sensor to the
engine electronic control unit in the specified time duration. [When a pulse is input, a
reset is made.]
Action taken by
engine electronic ISC (Idle Speed Control) disabled
control unit
Warning lamp
-
illuminated
unit and vehicle speed sensor P.13E-33 of the same group)
• Faulty vehicle speed sensor No. 0D: vehicle speed measurement.
• Faulty engine electronic control unit • Perform checks at engine electronic control
unit connector. (Refer to P.13E-36 of the
same group)
Probable cause
and check item 05: Measurement of vehicle speed signal
voltage.
• Check vehicle speed sensor.
control unit and vehicle speed sensor.
26 PUMP ROM
Code issued Diagnostic trouble code 26 is intended for checking for an error in the loaded pump
condition [Reset read-only memory data necessary for control of the injection rate. The code is issued
condition] when any of the following situations occurs.
• Loaded read-only memory has unmatched data.
• Read-only memory data cannot be read.
• Loaded data exceeds the upper limit of correction.
• There is a mismatch between engine electronic control unit backup data and loaded
data.
[No automatic reset takes place.]
Action taken by
engine electronic Initial values used
control unit
Warning lamp
-
illuminated
• Open or short circuit in harness • Check injection rate adjusting read-only
between engine electronic control memory. (Ask your DENSO service station
unit and injection rate adjusting to do the job.)
Probable cause
read-only memory • Check circuit between engine electronic
and check item
• Faulty injection rate adjusting read- control unit and injection rate adjusting
only memory read-only memory.
• Faulty engine electronic control unit Refer to P.13E-55 of the same group
TROUBLESHOOTING
27 SILENCER M/V
Code issued Diagnostic trouble code 27 is intended for checking the harness of the intake silencer 3-
condition [Reset way magnetic valve for open/short circuit.
condition] [No automatic reset takes place.]
Action taken by
engine electronic Intake silencer control disabled
control unit
Warning lamp
-
illuminated
• Open or short circuit in harness • Check intake silencer 3-way magnetic
between engine electronic control valve.
unit and intake silencer 3-way Refer to P.13E-40 of the same group:
Probable cause magnetic valve Inspection of Electrical Device #565
and check item • Faulty intake silencer 3-way • Check circuit between engine electronic
magnetic valve control unit and intake silencer 3-way
• Faulty engine electronic control unit magnetic valve.
31 IDL VOLUME
Code issued Diagnostic trouble code 31 is intended for checking the harness of the idle adjusting
condition [Reset potentiometer for open or short circuit and checking the idle adjusting potentiometer for
condition] anomalies.
The code is issued when the voltage of the idle adjusting potentiometer continues to be
out of the specified limits for the predetermined period of time.
[When the voltage of the idle adjusting variable resistor re-enters the specified range, a
reset is made.]
Action taken by
engine electronic Operation mode fixed to auto idle
control unit
Warning lamp
-
illuminated
unit and idle adjusting P.13E-33 of the same group)
potentiometer No. 0E: Measurement of idle adjusting
• Faulty idle adjusting potentiometer variable resistor voltage.
Probable cause same group)
and check item 06: Measurement of idle adjusting variable
resistor output voltage.
• Check idle adjusting potentiometer.
control unit and idle adjusting potentiometer.
TROUBLESHOOTING
32 BOOST PRES
Code issued Diagnostic trouble code 32 is intended for checking the harness of the boost pressure
condition [Reset sensor for open or short circuit and checking the boost pressure sensor for anomalies.
condition] The code is issued when the output voltage of the boost pressure sensor continues to
be out of the specified limits for the predetermined period of time.
[When the voltage of the boost pressure sensor re-enters the specified range, a reset is
made.]
Action taken by
engine electronic Controls are made on the assumption that the boost pressure is 100 kPa {760 mmHg}
control unit
Warning lamp
-
illuminated
unit and boost pressure sensor P.13E-33 of the same group)
• Faulty boost pressure sensor No. 15: Boost pressure measurement
Probable cause • Faulty engine electronic control unit • Check boost pressure sensor.
and check item Refer to P.13E-40 of the same group:
control unit and boost pressure sensor.
33 ECU SYSTEM
Code issued Diagnostic trouble code 33 is issued in the following cases.
condition [Reset (1): A/D converter out of order
condition] [When A/D converter returns to normal, a reset is made.]
(2): Mutual monitoring error, interruption processing error
[When starter switch is turned OFF, a reset is made.]
Action taken by (1): All Fail Safe functions against a faulty A/D input are activated.
engine electronic (2): Engine stopped
control unit
Warning lamp (1): (Umber)
illuminated (2): (Red)
Probable cause
Faulty engine electronic control unit -
and check item
TROUBLESHOOTING
34 Q RESISTOR
Code issued Diagnostic trouble code 34 is intended for checking the harness of the injection rate
condition [Reset adjusting resistor for open or short circuit and checking the injection rate adjusting
condition] resistor for anomalies.
The code is issued when the output voltage of the injection rate adjusting resistor
continues to be out of the specified limits for the predetermined period of time.
[When the voltage of the injection rate adjusting resistor re-enters the specified range, a
reset is made.]
Action taken by
engine electronic The injection rate correction value is fixed to No. 1 value.
control unit
Warning lamp
-
illuminated
unit and injection rate adjusting P.13E-33 of the same group)
resistor No. 13: Resistor No. check of injection rate
Probable cause • Faulty injection rate adjusting
and check item adjusting resistor.
resistor • Check circuit between engine electronic
• Faulty engine electronic control unit control unit and injection rate adjusting
resistor.
TROUBLESHOOTING
41 FUEL TEMP
Code issued Diagnostic trouble code 41 is intended for checking the harness of the fuel temperature
condition [Reset sensor for open or short circuit and checking fuel temperature sensor for anomalies.
condition] The code is issued when the output voltage of the fuel temperature sensor continues to
be out of the specified limits for the predetermined period of time.
[When the voltage of the fuel temperature sensor re-enters the specified range, a reset
is made.]
Action taken by
engine electronic Control is made on the assumption that fuel temperature is 100°C
control unit
Warning lamp
-
illuminated
unit and fuel temperature sensor P.13E-33 of the same group)
• Faulty fuel temperature sensor No. 11: Fuel temperature measure.
same group)
Probable cause
and check item 10: Measurement of fuel temperature
sensor resistance.
• Check fuel temperature sensor.
control unit and fuel temperature sensor.
44 BOOST TEMP
Code issued Diagnostic trouble code 44 is intended for checking the harness of the boost air
condition [Reset temperature sensor for open or short circuit and checking the boost air temperature
condition] sensor for anomalies.
[When the voltage of the boost air temperature sensor re-enters the specified range, a
reset is made.]
Action taken by
engine electronic Control is made on the assumption that boost air temperature is 25°C
control unit
Warning lamp
-
illuminated
• Open or short circuit in harness • Check boost air temperature sensor.
between engine electronic control Refer to P.13E-40 of the same group:
unit and boost air temperature Inspection of Electrical Devices #304
Probable cause
sensor • Check circuit between engine electronic
and check item
• Faulty boost air temperature sensor control unit and boost air temperature
• Faulty engine electronic control unit sensor.
TROUBLESHOOTING
46 EDU RELAY
Code issued Diagnostic trouble code 46 is issued in the following cases.
condition [Reset (1): Drive unit relay is not ON with drive unit relay ON command issued.
condition] [When the drive unit relay is turned ON by the drive unit relay ON command, and the
voltage exceeds 16V, a reset is made.]
(2): Drive unit relay is not OFF with drive unit relay OFF command issued.
[When the drive unit relay is turned OFF by the drive unit relay OFF command, and the
voltage exceeds 16V, a reset is made.]
Action taken by (1): Drive unit relay OFF
engine electronic (2): Ordinary controls continued
control unit
Warning lamp (1): (Red)
illuminated (2): -
• Open or short circuit in harness • Check drive unit relay.
between engine electronic control Refer to P.13E-40 of the same group:
Probable cause unit and drive unit relay Inspection of Electrical Devices #228
and check item • Faulty drive unit relay • Check circuit between engine electronic
control unit and drive unit relay
65 ACCEL SW
Code issued Diagnostic trouble code 65 is intended for checking the harness of the accelerator
condition [Reset switch for open or short circuit and checking the accelerator switch for anomalies.
condition] The code is issued when the accelerator position sensor 1 or 2 shows an opening of
more than 20% with the accelerator switch ON.
[If the accelerator switch turns OFF when the accelerator position sensor shows an
opening of more than 20%, a reset is made.]
Action taken by
engine electronic Ordinary controls continued
control unit
Warning lamp
-
illuminated
unit and accelerator switch P.13E-33 of the same group)
• Faulty accelerator switch No. 43: Check of accelerator switch
• Faulty engine electronic control unit operating signal.
and check item 09: Measurement of accelerator switch
operating voltage.
• Check accelerator switch.
control unit and accelerator switch.
TROUBLESHOOTING
66 STARTER SW (S)
Code issued Diagnostic trouble code 66 is intended for checking the harness of the starter switch for
condition [Reset open or short circuit and checking the starter switch for anomalies.
condition] The code is issued when a start signal is input with the engine running at a speed
higher than the specified speed.
[When the start signal is no longer input, a reset is made.]
Action taken by
engine electronic Ordinary controls continued (Startup control not performed)
control unit
Warning lamp
-
illuminated
unit and starter switch P.13E-33 of the same group)
• Faulty starter switch No. 41: Start signal ON/OFF check.
and check item 11: Measurement of starter switch signal
voltage.
• Check starter switch.
(Refer to Electrical manual)
control unit and starter switch.
TROUBLESHOOTING
Service Data of Multi-Use Tester II

T1135020600064
Screen Display of Multi-Use Tester ll Condition When

Judging Criteria
No. Item Name Data Checking
Synchronized with
01 ENGINE SPEED XXXX. rpm Racing (Engine running)
tachometer
03 INJ VOL XXX.X% Starter switch ON 0%
Warm engine running at
09 TCV ANG DIFF XXX.X °CA 0 °CA
idle
Accelerator pedal released 0%
Slowly depressed Slowly increased
0B ACCEL(%) XXX.X%
Accelerator pedal fully
100 %
depressed
Accelerator pedal slowly
0C ACCEL(V) X.XXX V depressed from released 0.95 to 4.05 V
position
Synchronized with
0D VEHICLE SPEED XXX. X Km/h During driving
speedometer
0E IDL VOL SNSR X.XXX V Slow to fast 2.6 to 1.2 V
Equivalent to atmospheric
Engine cold
temperature
10 WATER TEMP XXX.X °C Engine warmup in progress Slowly increased
Engine stopped after
Slowly decreased
warmup
Engine cold
temperature
11 FUEL TEMP XXX.X °C Engine warmup in progress Slowly increased
Engine stopped after
Slowly decreased
warmup
12 AIR TEMP XXX.X °C Engine cold
temperature
Matches No. marked on
13 Q RESISTOR XXXX - injection rate adjusting
resistor.
Altitude 0 m 101 kPa
14 AIR PRESS XXXX. kPa Altitude 600 m 98 kPa
Altitude 1200 m 88 kPa
15 BOOST PRESS XXXX. kPa Engine speed 2950 rpm 137 kPa
16 BATT VOLTAGE XX. XX V Starter switch ON Matches battery voltage.
Engine cranked by starter
ON
switch
41 START SIG ON/OFF
Starter switch at any other
OFF
position than S
TROUBLESHOOTING

Judging Criteria
Accelerator pedal
ON
43 ACCEL SW ON/OFF depressed
Accelerator pedal released OFF
Air compressor in operation ON
44 A/C SW ON/OFF Air compressor not in
OFF
operation
Warming switch ON ON
45 COLD START SW ON/OFF
Warming switch OFF OFF
Diagnostic switch
OFF
connected
46 DIAGNOSIS SW ON/OFF
Diagnostic switch
ON
disconnected
Memory clear switch
OFF
connected
47 DIAG RESET SW ON/OFF
Memory clear switch
ON
disconnected
Exhaust brake switch ON
(when exhaust brake is ON
active)
51 EXH.BRAKE SW ON/OFF
Exhaust brake switch OFF
(when exhaust brake is OFF
inactive)
Clutch pedal depressed ON
52 CLUTCH SW ON/OFF
Clutch pedal released OFF
Transmission at neutral OFF
53 NEUTRAL SW ON/OFF Transmission at any other
ON
position than neutral
Transmission in 1st/rev.
ON
gear
56 TORQUE LMT SW ON/OFF
Transmission in position
OFF
other than above
When engine is idling ON
61 SILENCER M/V ON/OFF When engine is running at
OFF
2500 rpm (racing)
When exhaust brake is
ON
active
71 EXH.BRAKE M/V ON/OFF
When exhaust brake is
OFF
inactive
Starter switch ON (engine
ON
not made to start)
73 DIAG LAMP (R) ON/OFF
No error generated after
OFF
engine has started
TROUBLESHOOTING

Judging Criteria
Starter switch ON (engine
ON
not made to start)
No error generated after
74 DIAG LAMP (U) ON/OFF OFF
engine has started
When warmup system is
OFF
inactive
When engine is running ON(ON → OFF repeated)
83 SPV ON/OFF
When engine is stationary OFF
Actuator Test by Multi-Use Tester II

T1135020700061
Screen Display of Multi-Use Tester ll

Operation Check Procedures
No. Item Name
91 SILENCER M/V ON/OFF sound of magnetic valve
94 EXH.BRAKE M/V ON/OFF sound of magnetic valve
97 DIAG LAMP (R) ON/OFF state of warning lamp (Red)
98 DIAG LAMP (U) Operating state of warning lamp (Umber)
99 A/C SIG A/C SW = ON
9A IDL-UP CNCL ldle up cancel
9B SPV Operating sound of solenoid valve
9C TCV-OFF No operating sound of solenoid valve
9D TCV-ON Operating sound of solenoid valve
TROUBLESHOOTING
Checks at Connector of Engine Electronic Control Unit

T1135020900065
This method of checks is useful for checking whether all the signals of the engine electronic control unit are
transmitted without any error through the vehicle side harness and connector.
The numbers in the table correspond to the call numbers used in "Diagnostic Trouble Codes and Check
Items" for referencing this section.
Pin Configuration of Engine Electronic Control Unit
C: CC12B D: CC22A
6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 22 21 20 19 18 17 16 15 14 13 12
A: CC26A B: CC16A
A
13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
B 26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9
C
D
AT302641
No. Item Reference Page

01 Resistance of TDC sensor
02 Resistance of engine speed sensor
03 Output voltage of accelerator position sensor 2
04 Output voltage of accelerator position sensor 1 Refer to P.13E-37 of same group
05 Signal voltage of vehicle speed sensor
06 Output voltage of idle adjusting potentiometer
07 Voltage of clutch switch
08 Voltage of transmission neutral switch
09 Voltage of accelerator switch
Refer to P.13E-38 of same group
10 Resistance of fuel temperature sensor
11 Voltage of starter switch (start signal)
Checking Procedures
CAUTION
Each item is checked by one of two methods; one by disconnecting the connectors and one by leav-
ing the connectors connected.
Pay heed to the following points.
• Be sure not to touch any other pin than the one to be checked.
Especially, use utmost care that a short circuit is never produced between pins by the tester.
• All the illustrations of the connectors in the tabte show the connectors on the engine electronic
control unit side. Be careful not to confuse the pins with those to be checked.
TROUBLESHOOTING
Check Item Checking Procedure

01 [Conditions]
Resistance of TDC • Starter switch OFF
sensor • Disconnect connector and make checks at vehicie side harness connector (25°C ).
[Judging Criteria]
Between pins: C ( 5 ) - C (11)
125.5 (Tolerance: -17 to +17) Ω
02 [Conditions]
Resistance of • Starter switch OFF
engine speed • Disconnect connector and make checks at vehicie side harness connector.
sensor [Judging Criteria]
Between pins: C ( 6 ) - C (12)
230 (Tolerance: -25 to +25) Ω
03 [Conditions]
Output voltage of • Starter switch OFF
accelerator • Leave vehicle side harness connected (make checks from back side of connector).
position sensor 2 [Judging Criteria]
Between pins [(+) - ( - )] : B (13) - B ( 8 )
• When accelerator pedal is released: 0.95 V
• When accelerator pedal is depressed: 4.05 V
04 [Conditions]
Output voltage of • Starter switch OFF
accelerator • Leave vehicle side harness connected (make checks from back side of connector).
position sensor 1 [Judging Criteria]
Between pins [(+) - ( - )] : B (11) - B ( 6 )
• When accelerator pedal is released: 0.95 V
• When accelerator pedal is depressed: 4.05 V
05 [Conditions]
Signal voltage of • Starter switch ON
vehicle speed • Leave vehicle side harness connected (make checks from back side of connector).
sensor • Using chassis dynamometer or something else, slowly rotate wheels.
[Judging Criteria]
Between pins [(+) - ( - )] : A ( 7 ) - A ( 13 )
• Hi: Approx. 8 (Tolerance: -1 to +1) V
• Lo: 0.5 V or less
06 [Conditions]
Output voltage of • Starter switch ON
idle adjusting • Leave vehicle side harness connected (make checks from back side of connector).
potentiometer [Judging Criteria]
Between pins [(+) - ( - )] : C (10) - C ( 16 )
• When knob is pulled: Approx. 1 to 3 V
• When knob is pushed all the way: Approx. 3.6 to 4.3 V
07 [Conditions]
Voltage of clutch • Starter switch ON
switch • Leave vehicle side harness connected (make checks from back side of connector).
[Judging Criteria]
Between pins [(+) - ( - )] : D ( 6 ) - D ( 11 )
• When clutch pedal is depressed: 24 V
• When clutch pedal is released : 0 V
TROUBLESHOOTING
Check Item Checking Procedure

08 [Conditions]
Voltage of • Starter switch ON
transmission • Leave vehicle side harness connected (make checks from back side of connector).
neutral switch [Judging Criteria]
Between pins [(+) - ( - )] : D ( 17 ) - D ( 11 )
• When the range selector is shifted: 24 V
• When the range selector is in neutral: 0 V
09 [Conditions]
Voltage of • Starter switch ON
accelerator switch • Leave vehicle side harness connected (make checks from back side of connector).
[Judging Criteria]
Between pins [(+) - ( - )] : D ( 10 ) - B ( 8 )
• When accelerator pedal is depressed: 0 V
• When accelerator pedal is released: 5 V
10 [Conditions]
Resietance of fuel • Starter switch OFF
temperature • Leave vehicle side harness connected (make checks from back side of connector).
sensor [Judging Criteria]
Between pins: B ( 12 ) - B (16)
2.5 (Tolerance: -1 to +1) kΩ
11 [Conditions]
Voltage of starter • Leave vehicle side harness connected (make checks from back side of connector).
switch • Starter switch (S position)
(starter signal) [Judging Criteria]
Between pins [(+) - ( - )] : D ( 2 ) - D ( 11 )
24 V
TROUBLESHOOTING
Checks on Transient Troubles

T1135021000065
A transient trouble often occurs in a specific condition. There-
fore, pinpointing the condition will make it easy to estimate the
cause. To pinpoint the condition for a transient trouble, ask the
customer in detail about the driving condition when the trouble
occurs, weather, occurrence frequency and symptoms, and
reproduce the symptoms of the trouble. Depending on the con-
dition where the trouble occurs, determine whether the cause
of the trouble is vibration, temperature or any other factor. If
the probable cause is vibratioh, perform the following checks
on the relevant connectors harnesses, etc. and check whether
the symptoms of the trouble are reproduced.
• Lightly move the connector up and down and to the right
and left.
• Lightly move the harness up and down and to the right and
left.
• Lightly shake the sensors and other devices by hand.
• Lightly shake the wiring harness located in the moving com-
ponents such as the suspension.
The connectors and other parts to be checked are identifiable
from the descriptions in the Probable Causes or the Checking
Procedures for the displayed diagnostic trouble code.
AT302674
#014 Checking Warming Switch

• Carry out continuity tests in accordance with the following
table.
LED LED
(3) (2) (1) (7) (8) (4) (night-time (1) (night-time (6)
illumination) illumination)
ON
OFF
:There must be continuity between the pins.
(8) (7) (6) (5) (4) • If there is anything wrong, replace the switch.
AT302534
#031 Checking Clutch Switch

• Perform continuity checks according to the following table.
(1) (2) (3) (4)
A
B
4 (Tolerance: -1 to +1)mm
A B • If there is anything wrong, replace the switch.
AT302675
#055 Checking Torque Limit Switch

25.7 (Tolerance: -0.75 to +0.25)mm • Perform continuity checks according to the following table.
(1) (2)
OFF
ON
OFF ON :There must be continuity between the pins.
• If there is anything wrong, replace the switch.
2 1
AT302675
#056 Checking Transmission Neutral Switch

• Perform continuity checks according to the following table.
25.7 (Tolerance: -0.75 to +0.25)mm
(1) (2)
OFF
ON
OFF ON :There must be continuity between the pins.
• If there is anything wrong, replace the switch.
AT302677
#157 Checking Idle Adjusting Potentiometer

• Disconnect the harness B of the idle adjusting variable
A B resistor A from the vehicle side harness C, and connect the
inspection harness D between them.
• Set starter switch to ON.
• Measure the output voltage of the idle adjusting variable
resistor A according to the foilowing table.
(2) (3)
Output voltage PULL
(Knob in pulled position) 1 to 3 V
D Standard
value Output voltage PUSH
C (Knob in pushed position) 3.6 to 4.3 V
(3) • If the reading is out of the standard value range, replace the
(2) idle adjusting potentiometer A.
(1)
D
LA3A
LA3A
AT302678
Output Characteristics
4.3
Output Voltage (V)
3.6 PUSH
3
PULL
1
0
Rotation angle
AT302837
#181 Checking Relay (Normally open type 4-pin)

• Perform continuity and operation checks according to the
following table.
(1) (2) (3) (4)
(2) When not energized
(4)(2)(1)(3)
When energized
(4) (1)
(3) :Apply a voltage of 24V DC across these pins.
AT302680
• If there is anything wrong, replace the relay.
#228 Checking Relay (Normally open type 5-pin)

• Perform continuity and operation checks according to the
(3) (2) (1) following table.
(1) (2) (3) (4) (6)
(6)(2) (1)(3)(4) When not energized
When energized
(6)
(4) :There must be continuity between the pins.
AT302535
:Apply a voltage of 24V DC across these pins.
• If there is anything wrong, replace the relay.
#262 Checking Water Temperature Sensor

• Put the water temperature sensor in a container filled with
(1)
engine oil.
(2) • Heat the engine oil to various specified temperatures while
stirring the engine oil.
• Measure the resistance value between pins (1) and (2)
(body).
Standard 20°C 2.3 to 2.6 kΩ

value 80°C 0.30 to 0.34 kΩ
AT302681
Reference value in parentheses

• If the reading is out of the standard value, replace the water
temperature sensor. Refer to Group 14 in this manual
#263 Checking Engine Speed Sensor

• Measure the resistance value between pins (1) and (2).
(2) (1) Standard value (at 20°C) 230 (Tolerance: -25 to +25) Ω
• If the reading is out of the standard value range, replace the

engine speed sensor.
AT302682
#265 Checking Vehicle Speed Sensor

• With 24V DC applied between pins (1) and (2), slowly rotate
A section A of the vehicle speed sensor.
• Measure the maximum voltage (high pulse voltage B) and
minimum voltage (Iow pulse voltage C) generated between
the specified pins.
2 1 B
4 3 D:Tester (when checking 25-pulse output)
C
E:Tester (when checking 8-pulse output)
D D
< 8 pulse> < 25 pulse>
AT302683
8-pulse Low pulse

1.5 V or less
output voltage
section
Between High pulse
pins (1) and 23.5 to 24 V
voltage
Standard (3)
value 25-pulse Low pulse
0.5 V or less
output voltage
section
Between High pulse
pins (1) and 7 to 9 V
voltage
(4)
• If the reading are out of the standard values, replace the

vehicle speed sensor.
#304 Checking Boost Air Temperature Sensor

• Place the boost air temperature sensor in glycerin in a con-
tainer.
• Raise the glycerin temperature to the specified values and
stir the glycerin.
• Measure the resistance between pins (1) and (2).
• If the measured value deviates from the standard value,
replace the boost air temperature sensor.
Refer to Group 15 in this manual
(1)(2) 5880 (Tolerance: -588

AT302684 0°C
to +588) Ω
Standard 2450 (Tolerance: -245
20°C
value to +245) Ω
322 (Tolerance: -48 to
80°C
+48) Ω
#316 Checking TDC Sensor

(1) (2) Standard value (at 20°C) 125.5 (Tolerance: -17 to +17) Ω
• If the reading is out of the standard value, replace the TDC

sensor.
AT302685
#318 Checking boost pressure sensor

NOTE: The standard of the boost pressure varies depending
on use or non-use of Multi-Use Tester II because inspection
conditions are different.
<When Multi-Use Tester II is used>
Refer to P.13E-33 of the same group.
<When Multi-Use Tester II is not used>
SIG • Apply DC5V between terminals (1) and (3) of boost pres-
+5V (3) (2) (1) GND sure sensor A.
A
• Apply the air pressure from pressure port B and check if the
relation of the output voltage between terminals (1) and (2)
of boost pressure sensor A to the air pressure is as shown
C in the characteristic diagram (figure in the left).
C: Pressure gauge
• If abnormality is found, replace boost pressure sensor A.
B
Output voltage (V)
4.50
3.22
0 101.3165.3
o1.03o1.69
p p
Air pressure (kPa {kgf/cm2})
AT302838
#323 Checking Fuel Temperature Sensor

(2)
Standard value (at 20°C) 2.5 (Tolerance: -1.0 to +1.0) kΩ
(1)
fuel temperature sensor. Ask your DENSO service station
to replace it.
AT302686
#324 Checking Accelerator Position Sensor

[Inspection]
H
A
• Measure the output voltage of the accelerator position sen-
G sor A from the back side of harness connector B according
1 2 3 4 5 C to the following table.
B
AT302537
Accelerator Position Accelerator Position Accelerator Switch

Sensor 1 Sensor 2
(1) (4) (5) (4) (3) (4)
Lever C position (+) (-) (+) (-) (+) (-)

0.95 (Tolerance: -0.15 to 0.95 (Tolerance: -0.15 to
Idling position D 4 V or more
+0) V +0) V
Accelerator 0.8 (Tolerance: -0.02 to 0.8 (Tolerance: -0.02 to
Standard switch operating
value position E +0.02) V +0.02) V
1 V or less
Full load position 4.05 (Tolerance: -0 to 4.05 (Tolerance: -0 to
F +0.15) V +0.15) V

(+) , ( - ) :Polarity when voltage is measured
D:Where accelerator position sensor lever C is in contact with
stopper bolt G.
E: Where voltage across pins (3) and (4) is reduced to 1V or
less by slowly depressing the accelerator pedal
F: Where accelerator position sensor lever C is in contact with
stopper bolt H.
• If the output voltage is out of the standard value range,
adjust by the following procedures.
L
[Adjustment]
K • Adjust the output voltage at the idling position D by loosen-
J ing the screw J and moving the accelerator position sensor
A A.
After the adjustment, retighten the screw.
• Adjust the output voltage at the full load position F by loos-
ening tne nut K and adjusting the stopper bolt L.
C After the adjustment, Iock the bolt with the nut.
AT302538
#351 Checking pulse divider

• Perform inspection when pulse divider A and vehicle speed
4 3 2 1 sensor B (25 pulse) are mounted on the vehicle.
10 9 8 7 6 5
• Turn ON the starter switch and rotate the wheel slowly.
25P OUT 1 Measure the maximum value (high pulse voltage D) and the
25P OUT 3 minimum value (low pulse voltage E) generated between
25P OUT 4 each output terminal ((1), (3), (4), (5), (6), (9), (10)) and ter-
25P OUT 5 minal (8) of pulse divider A.
A 25P OUT 6 C: Tester
25P OUT 9 C
25P OUT 10 Low pulse 0.5 V or less
8 Standard value (output
voltage) 8 (Tolerance: -1
2 High pulse
IN 7 to +1) V
SIG 4 • When the measurement value is out of the standard value,

B 2 replace pulse divider A.
1
1
D
2
E
4 3
AT302539
#536 Checking Spill Valve

• Measure the resistance between pins (3) - (6) and (1) - (4).
3 1
Standard value (at 20°C) 1.5 (Tolerance: -0.5 to +0.5) Ω
6 4 • If the reading is out of the standard value range, replace the

spill valve.
Ask your DENSO service station to replace it.
AT302540
#565 Checking 3-Way Magnetic Valve

Pertorm the following checks. If there is anything wrong,
replace the 3-way magnetic valve.
C
(1) Operation Check
• Apply DC voltage across pins (1) and (2) and slowly
increase, beginning at 0 V.
• Measure the voltage at the time when the 3-way magnetic
A valve is operated.
(Determine whether the magnetic valve is ON or OFF on
the basis of its operating sound.)
B
AT302687 Standard value
22 V or less
(Lowest operating voltage)
(2) Continuity and Air Tightness Checks

Perform continuity checks according to the following table.
Input port Output port Exhaust port

A B C
ON
OFF
Negative pressure at the time of check : 100 kPa {750 mmHg}
#584 Checking Timer Control Valve

Standard value (at 20°C) 11.3 (Tolerance: -3 to +3) Ω

timer control valve.
Ask your DENSO service station to replace it.
(1) (2) AT302842
#828 Checking Fuel Injection Rate Adjustment

Resistor
• Measure the resistance of the fuel injection rate adjustment
No. resistors with the following stamped nos.
1 270 (Tolerance: -13.5 to +13.5) Ω
2 510 (Tolerance: -25.5 to +25.5) Ω
3 820 (Tolerance: -41 to +41) Ω
No.
2 4 1300 (Tolerance: -65 to +65) Ω
1
5 2000 (Tolerance: -100 to +100) Ω
AT302843 Standard
Resistor
value 6 3300 (Tolerance: -165 to +165) Ω
No.
20°C
7 5600 (Tolerance: -280 to +280) Ω
8 15000 (Tolerance: -750 to +750) Ω
9 390 (Tolerance: -19.5 to +19.5) Ω
10 4300 (Tolerance: -215 to +215) Ω
11 9100 (Tolerance: -455 to +455) Ω
• If the reading is out of the standard value, replace the fuel

injection rate adjustment resistor.
CAUTION
Since the fuel injection rate adjustment resistors are
matched to the prestroke-control-type injection pump and
common rail, be sure to replace with resistors having the
same resistor nos.
MEMO
LOCATIONS OF PARTS
LOCATIONS OF PARTS
T1131090100592
1 to 28 20 21
22
7 6 1
28
16
15
5
24
25
23 4
9
8
F29 F15 F1
F30 F16 F2
F31 F17 F3
FUSE SPARE SPARE SPARE SPARE SPARE
F32 F18 F4
F33 F19 F5
F34 F20 F6
F35 F21 F7
F36 F22 F8
F37 F23 F9 11
F38 F24 F10
F39 F25 F11
F40 F26 F12 14
PULLER
F41 F27 F13

F42 F28 F14 12
13
10
AT302844
LOCATIONS OF PARTS
1 Starter switch 16 Multi-use tester-II connector

2 Clutch switch <M/T> 17 -
3 Accelerator position sensor 18 -
4 Drive unit 19 -
5 Idle adjusting potentiometer 20 Meter cluster
6 Pulse divider 21 Warming switch
7 Automatic transmission electronic 22 Exhaust brake switch
control unit <A/T> 23 Engine electronic control unit
8 Fuse box 24 Memory clear switch
9 Tail lamp relay 25 Diagnosis switch
10 Warming relay <ABS> 26 -
11 Engine electronic control unit main 27 -
relay 28 Connection of instrument panel
12 Drive unit relay harness and front chassis harness
13 Diode <A/T>
14 Exhaust brake Cut relay <A/T> M/T: Manual transmission
15 Fuel injection rate adjustment A/T: Automatic transmission
resistor ABS: Anti-lock brake system
LOCATIONS OF PARTS
T1131090100600
30 to 47
42
33
<M/T> 45
44
32
36 39 40
<A/T> 37
32 41 38
35
31
34
43
47
30
AT302692
LOCATIONS OF PARTS
30 High current fuse box 40 Spill valve

31 Battery 41 Fuel temperature sensor
32 Vehicle speed sensor 42 Water temperature sensor
33 Boost pressure sensor 43 Boost air temperature sensor
34 Intake silenser 3-Way magnetic 44 Torque limit switch <M/T>
valve 45 Transmission neutral switch <M/T>
35 Exhaust brake 3-Way magnetic 46 -
valve 47 Connection of front chassis
36 Top dead center (TDC) sensor harness and rear chassis harness
37 Injection rate adjusting read-only
memory M/T: Manual transmission
38 Timer control valve A/T: Automatic transmission
39 Engine speed sensor
13E-54

14-1
GROUP 14
COOLING
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . 14-2 Replacing Coolant and Cleaning Cooling System

...................................... 14-5
STRUCTURE AND OPERATION Air Bleeding of Cooling System . . . . . . . . . . 14-7
Cooling System (Flow of Coolant). . . . . . . . 14-2 Gas Leakage Test . . . . . . . . . . . . . . . . . . . . 14-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-8
TROUBLESHOOTING . . . . . . . . . . . . 14-4 COOLING FAN, V-BELT AND WATER PUMP

................................. 14-16
ADJUSTMENT THERMOSTAT . . . . . . . . . . . . . . . . . . 14-20
14-2 COOLING
SPECIFICATIONS
SPECIFICATIONS
T1141000100099
Item Specifications
Kind of cooling system Forced water circulation system
Water pump type Belt-driven involute type
Thermostat type Wax-pellet, bottom bypass type (with jiggling valve)
Automatic cooling fan coupling type Continuous control type
Radiator type Tube and corrugated fin type
Coolant capacity liter dm3 [L] 18 [18]

Cooling System (Flow of Coolant)
T1141010200097
AT302799
1 Radiator 5 Water pump

2 Thermostat 6 Cooling fan
3 Oil cooler 7 Radiator drain cock
4 Crank case drain cock
COOLING 14-3
Water Pump
T1141010300094
1 Case
2 Unit seal
3 Impeller
4 Unit bearing
1 5 Flange
2
A: Drain hole
5 3
4
A
AT302708
Thermostat
T1141010400080
1 Thermostat cover
2 Thermostat
3 Thermostat case
A B C
A: To radiator
B: Coolant at low temperature
C: Coolant at high temperature
1
D: From cylinder head
2
E: To water pump
Thermostat 2 is a bottom bypass type that uses wax

3
D pellets as its regulating element. As the wax changes
its form from solid to liquid according to changes in
temperature, the volume of the wax changes. There-
E fore, the position of the valve, changed by the cool-
AT100660
ant temperature, regulates the flow of the coolant to
the radiator and water pump (bypass side) and con-
trols the coolant temperature.
14-4 COOLING
TROUBLESHOOTING
TROUBLESHOOTING
T1141020100091
Symptoms
(a) (b) (c) (d) Remarks
Possible causes
Loose or damaged X X
V-belt Tension excessive X
Oily X
Water pump mounted incorrectly X X X
Unit bearing faulty X X
Impeller faulty X X
Water pump
Unit seal faulty X X
Unit bearing-to-flange and to-impeller
X X
fitting loose
Case mounted incorrectly X X
Gasket faulty X X
Valve opening temperature too high,
X
valve remains closed
Thermostat
Valve opening temperature too low,
X
valve remains open
Water leaking from water temperature
X X
sensor
Bearing faulty X X
Bimetal damaged X
Automatic cooling
fan coupling Bimetal contaminated with foreign
X X
particles
Silicon oil leaking X X
Oil cooler mounted incorrectly X X Refer to group 12
Oil cooler
Gasket faulty X X in this manual
Cylinder head mounted incorrectly X X Refer to group 11
Cylinder head
Gasket faulty X X in this manual
Coolant quantity insufficient X
Coolant passage furred and clogged X
Water hose mounted incorrectly X X
Exterior temperature extremely cold X
(a): Overheating (Low cooling effect) (c): Noise occurs
(b): Overcooling (d): Coolant loss excessive
COOLING 14-5

Replacing Coolant and Cleaning Cooling System
T1141030200099
2
AT302709
1 Pressure cap 2 Radiator drain cock

3 Crankcase drain plug

3 Crankcase drain plug 34 to 39 [3.5 to 4.0] -
Using the radiator for a long period of time without cleaning it will cause overheating because rust and scale
deposits will accumulate inside the cooling system. Periodical cleaning is recommended.
Draining coolant
First loosen pressure cap 1, to lower the pressure in the cooling system, before draining coolant.
WARNING
Be sure that the coolant temperature is low enough so that hot coolant does not spout out
when you loosen pressure cap 1.
Cleaning procedure
• Keep the coolant temperature at approximately 90°C so that the thermostat valve remains open and the
coolant continues to circulate in the radiator.
• For the sake of convenience you can raise the coolant temperature quickly by covering the front of the
radiator with corrugated cardboard or something similar.
• Set the temperature adjusting lever of the heater controller at maximum so that the coolant can circulate
freely in the heater piping area.
• In cases where a great amount of rust has accumulated it often happens that as a result of cleaning the
radiator starts leaking. Conduct a thorough check for leakage after cleaning.
• Soft water to be used should have the following properties.
CAUTION
Do not use hard water as it causes scale and rust.
Required properties of soft water
14-6 COOLING
Total hardness 300 ppm or less Chloride Cl- 100ppm or less
Sulfate SO-4 100 ppm or less Total dissolved solids 500 ppm or less
pH 6 to 8
Method of cleaning the cooling system depends on its condition.
Ordinary condition Extremely dirty coolant Clogged radiator
Cleaning method using FUSO Radiator cleaner

Cleaning method using water (Radipet 7)
Drain the coolant
Make a solution of FUSO Radiator Cleaner (Radipet 7)

in a 5 to 10% ratio to the total volume of coolant
(Work procedure)
Fill the surge tank with the solution
Keep the solution temperature at 90˚C and let the

engine idle for 30 minutes.
CAUTION
Be sure to allow the engine to idle for 30-
minutes only. Circulating the solution in
the system for more then an hour might
cause the system to brakedown
Drain the water and the solution
Fill with soft water (boiled preferably)
Keep the water temperature at 90˚C and let the engine idle
for 10 minutes
Drain the water
If the drained water is clear, cleaning has

been successful. If it is still muddy, repeat
the procedure.
COOLING 14-7
DANGER
If you accidentally splash FUSO Diesel Long Life Coolant, Fuso Antifreeze, or Radiator Anti-
rust (Radipet 9) in your eyes, wash it out immediately with water and seek medical attention.
WARNING
FUSO Diesel Long Life Coolant is flammable. Keep them away from heat and flames.
NOTE: .
• After cleaning the cooling system with cleaning fluid, fill it with coolant as soon as possible.
• To prevent freezing of the coolant and corrosion of the cooling system, add to the coolant the specified
proportion of FUSO Diesel Long Life Coolant. (See the Owner's Handbook for instructions on the use of
these products.)
Air Bleeding of Cooling System

T1141030300096
• Remove the pressure cap and keep the coolant tempera-
ture at 90°C while letting the engine idle and bleed the air
out completely. Keep the temperature adjusting lever of the
heater controller at maximum so that the coolant can circu-
late freely in the heater piping area.
• After completing adequate air bleeding of the cooling sys-
tem, refill coolant sufficiently enough for the radiator and the
reservoir tank.
Gas Leakage Test

T1141030400093
Air or exhaust gas in the coolant increases corrosion and rust-
ing in the system. Conduct the following test:
A • Remove the pressure cap.
WARNING
Be sure that the coolant temperature is low enough
so that hot coolant does not spout out when you
loosen pressure cap.
• Run the engine to bring the coolant temperature to approxi-
mately 90°C.
AT100662
• If air bubbles A continually rise from the coolant, it is an
indication that air or exhaust gas has gotten into the cool-
ant.
• If it is air, it is possible that cylinder head bolts, water pump
mounting bolts or hose connections are loose, or that the
hose is damaged.
• If it is exhaust gas, it is possible that the cylinder head gas-
kets are damaged, or that the cylinder head is cracked.
14-8 COOLING
RADIATOR
RADIATOR
Overview
T1141090100355
Lub
Trq
2
3
1 Lub Trq 4
7
5
14
13 6
Trq 8
Lub
12
11
10 Trq
9
AT302816
1 Shield cover assembly 9 Radiator guard

2 Clamp 10 Nut
SP 3 Upper hose 11 Support assembly
4 Clamp SP 12 Support cushion
SP 5 Lower hose 13 Radiator upper bracket
6 Clamp 14 Radiator assembly
SP 7 Lower hose (Refer to P.14-10 of the same
Water pipe group.)
8
Assembly sequence

2,4,6 Clamp 1.5 to 2.0 [0.15 to 0.2] Wet
10 Nut (Support cushion mounting) 11.8 to 14.7 [1.2 to 1.5] -
Lubricant
2,4,6 Thread area of hose clamp bolt Engine oil As required
COOLING 14-9
RADIATOR
Service Procedure
T1141090200374
(3,5,7) Mounting of hoses

Mount the hoses by inserting the following lengths.
A A: 30 mm
3
B B: 35 mm
5
A
B
7
A AT302711
(12) Installation of support cushion

Install support cushion 12 so that thread part A (shorter than
A the other side) comes to the radiator assembly 14 side for
mounting.
14 mm
12
22mm
AT302712
14-10 COOLING
RADIATOR
Radiator Assembly
T1141090100311
Overview
Trq 6 9 1
<X>
8
<X>
10
7
Trq 2
6
<X> <X>
11 8 5
6
Trq
14 3
<X> 13
12
11
<X>
7 6
Trq Trq 4
AT302548
1 Upper radiator shroud SP 9 Upper tank

2 Lower radiator shroud, right side 10 O-ring
3 Lower radiator shroud, Ieft side 11 Sub-plate
4 Drain cock SP 12 Lower tank
SP 5 Radiator assembly 13 O-ring
6 Bolt SP 14 Core
7 Side member
8 Sub-plate <X>: Non-reusable parts
CAUTION
• Do not disassemble radiator assembly 5 unless there is an abnormality.
• Gently handle upper tank 9 and lower tank 12, since they are made of a resin that can break on
impact.
Assembly sequence
Service standard
Air leakage from radiator 0 cm3 [0 mL] - Repair or
5
(Air pressure : 150 kPa [1.5kgf/cm2] replace
COOLING 14-11
RADIATOR

4 Drain cock 2 [0.2] -
6 Bolt (Side member mounting) 13 [1.3] -
Special tool
9, 12 Lock-and-break tool J94-Z013-10000 Removal of upper and lower tanks
The indicated part number is Toyo Radiator's part number.
Service Procedure
T1141090200330
(5) Inspection of radiator assembly
.
• Install hose A and radiator cap tester B to upper tank 9.

A
B • Insert plug C in lower tank 12, and immerse the entire body
C of the radiator in water.
• Apply an air pressure of 150 kPa [1.5 kgf/cm2] using radia-
tor cap tester B, and check for any air leakage.
• If any leakage is found, repair or replace radiator assembly
12 5.
9 AT302713
• Replace the following parts according to the leakage loca-

9,12
tion.
Leakage location Parts to be replaced
D
Tank joint D O-ring 10 or 13
8,11 Upper tank 9 Upper tank 9 and O-ring 10

Lower tank 12 Lower tank 12 and O-ring 13
F 10,13 Core 14 and O-ring 10, 13
E AT302549
Tube Joint E
*Tube F (solder) and O-ring 10, 13
Core 14 and O-ring 10, 13
Tube F
*Tube F (solder) and O-ring 10, 13
*: For repairing
14-12 COOLING
RADIATOR
(9,12) Upper tank and lower tank

B Use ST lock-and break tool for removal and reinstallation of the
A C tanks.
A : Attachment (for tank removal)
B : Attachment stopper bolt
C : Slide handle
E D D : Stopper-and-adjuster bolt
E : Attachment (for tank reinstallation)
AT302714
[Removal]
• Mount attachment A to ST Iock-and-break tool and set the
tool tip to the dimension indicated in the diagram. Tighten
A
stopper-and-adjuster bolt D to secure it in position.
ST
D
1.2 to 1.4 mm AT302715
• Use ST Iock-and-break tool to bend open tabs F of sub-

plates 8, 11 that retain tank 9,12 in place.
ST
9,12
8,11
F
AT302550
ST • After tabs F of sub-plates 8 and 11 are bent open, squeeze

the handle of ST Iock-and-break tool to straighten tabs F as
9,12 illustrated.
• After straightening all tabs F in the perimeter, hold the pipes
connected to the inlet/outlet, and remove tank 9,12.
8,11 F
AT302551
COOLING 14-13
RADIATOR
9, 12 • If it is difficult to remove tank 9,12, Iightly hit with rubber

hammer (or plastic hammer) G to remove.
CAUTION
Gently handle tank 9 and 12, since they are made of a resin
that can break on impact.
G
AT302716
[Inspection]
• Inspect tank mounting groove H of core 14 and make sure
there is no adhesion of foreign substance.
• If foreign substances are found, rub the area with #1000
sandpaper or , a like gently so as to avoid scratching the
surface, or use compressed air to remove them.
CAUTION
H
Be sure to inspect and clean tank mounting groove H on
14 the entire perimeter. If O-ring 10, 13 and tank 9, 12 are
installed on foreign substances, Ieakage can result. (Even
AT302552
a piece of hair can sometimes cause a leakage.)
• Inspect for dirtiness and scratches on mounting surface J of
J
J tank 9, 12 which contacts the core, and clean the surface.
If an abnormality is found on the surface, replace the tank.
CAUTION
To prevent adhesion of foreign substances on mounting
surface J, conduct work with bare hands.
.
9, 12
AT302717
[Installation]
• After installing tank 9, 12, set new sub-plates 8, 11 , one
each on the left and right sides (total of four sub-plates for
one radiator).
CAUTION
When installing O-ring 10, 13, tank, 9, 12, and sub-plates 8,
11, conduct work with bare hands to prevent adhesion of
8,11
foreign substances.
9,12
14
10,13
AT302553
14-14 COOLING
RADIATOR
• Mount attachment E to ST lock-and-break tool and set the

tool tip to the dimension indicated in the diagram. Tighten
stopper-and- adjuster bolt D to secure it in position.
E
D ST
10 mm AT302718
• Following the sequence shown in the diagram, bend tabs F

of sub-plates 8, 11 for caulking tank 9, 12.
(1) to (4) : Bend two tabs at the center.
(5) to (8) : Bend other tabs following the direction of the
arrow.
ST : Lock-and-break tool (with attachment E)
NOTE: Since ST Iock-and-break tool cannot be used to caulk
sides (1) and (2), use pliers with the tips wrapped in vinyl tape.
9,12
9,12
F
ST
10,13
AT302719
• After caulking, inspect and make sure that the caulked sec-
9,12 tion has the following dimension.
M : 8.95 to 9.35 mm
• Check for leakage. (Refer to P.14-11 of the same group.)
• After repair, apply paint on an easily visible location, so that
when the radiator is brought in for another repair, a
M mechanic will know that it has been repaired before.
10,13
AT302555
COOLING 14-15
RADIATOR
(14) Core
.
[Inspection]
Inspect tube joint A for water leaks.
14 If water leaks from tube joint A, replace core 14 or repair the
leak in the following method.
[Correction]
• To repair a leakage in the core 14 or tube joint, solder the
leaking location in the same method used for conventional
radiators (made of 100% brass).
CAUTION
A
AT302556 Do not let solder drip and form into a ball on the O-ring
seat (shaded area in the diagram).
• As soon as soldering is completed, wash the repaired sec-
tion repeatedly in hot water (as hot as possible) to remove
flux.
WARNING
Be careful not to burn yourself with hot water during
washing.
14-16 COOLING
COOLING FAN, V-BELT AND WATER PUMP

Overview
T1141090100366
*a
8
6
5
2
9
Lub 3
*b
1 <X>
7
4
AT302817
1 Cooling fan 8 Water pump assembly

SP 2 Automatic cooling fan coupling 9 O-ring
SP 3 V-belts < cooler compressor belts >
SP 4 V-belts < fan belts > *a: Timing gear case (Refer to group
Coupling plate 11 in this manual.)
5
Fan spacer *b: Crankshaft pulley (Refer to group
6 11 in this manual.)
7 Water pump pulley
Assembly sequence
CAUTION
• Be sure to replace water pump assembly 8 and automatic cooling fan coupling 2 as a complete
assembly unit when any fault occurs in them because they are non-serviceable items.
• Be sure to replace V-belts 4 as a set.
• Be sure to apply soapy water to O-ring 9 for easier fitting. Never use engine oil because it will
cause the O-ring to swell.

Fan belts 12 to 16
V-belts tension (Each
3, 4 Cooler compressor 8 to 11 - Adjust
one)
belts
COOLING 14-17
Lubricant
9 Periphery of O-ring Soapy water As required
Special tools
Measurement of tension of
3, 4 Belt tension gauge MH062345
V-belt
MH062345
Service Procedure
T1141090200385
(2) Automatic cooling fan coupling

.
[Inspection]
Conduct the following inspection on automatic cooling fan cou-
pling 2 and if any fault is found, replace the unit.
• Check for any leakage of lubricating oil sealed in the cou-
pling body.
• While rotating automatic cooling fan coupling 2 by hand,
check for any irregularity in rotation related to the bearing
2
function in the coupling or any abnormal noise.
• Check for any excessive play of automatic cooling fan cou-
pling 2 in the axial direction when the engine is cool.
AT302722
[Cleaning]
If there are any foreign particles sticking to bimetal A, remove
them by brushing lightly.
AT302723
14-18 COOLING
(3, 4) V-belts
.
[Inspection]
Measure the extent of flex A when the center of V-belts 3, 4 as
E E
3 illustrated is depressed with a force of 98 N⋅m [10 kgf⋅m].
3 B: Alternator pulley
A
A C: Water pump pulley
D
A D: Cooler compressor pulley (for air conditioning)
D E: Tension pulley
B F: Crankshaft pulley
C
F
AT302724
Use of special tool belt tension gauge

G • Set upper O-ring G of ST belt tension gauge to 98 N⋅m [10
kgf⋅m] (push load) on the graduation H.
• Set lower O-ring J of ST belt tension gauge to graduation K
H (maximum flex of belt).
ST
K AT302725
• Place ST belt tension gauge at the center of V-belts 3, 4

L G perpendicularly as illustrated and push top L all the way
down until the upper O-ring G hits the upper edge M.
M
3, 4
AT302726
• Measure the extent of flex A of V-belts 3, 4 at this point, and

A if the measured value deviates from the standard value,
adjust as follows.
3, 4
AT302727
.
COOLING 14-19
[Adjustment]
1. Adjustment of tension of V-belts (fan belts)
• Loosen alternator mounting bolts N (two places), and adjust
N the tension of V-belts 4 by moving the adjusting bolt P.
• After adjustment, tighten the bolts and nuts securely.
P CAUTION
• Bear in mind that excessive tension of V-belts 4 might
damage the belts and bearings that engage with the V-
4
belts.
N • Be sure to replace V-belts 4 as a set to maintain even
AT302728
tension between them.
• Be careful not to let oil stick to V-belts 4, if oil gets onto
the belts, it causes slipping, resulting in overheating
and insufficient battery charging.
2. Adjustment of tension of V-belts (cooler compressor belts)
3 R • Loosen tension pulley mounting nut Q, and adjust the ten-
R sion of V-belts 3 by adjusting bolt R.
3 • After adjustment, tighten the bolts and nuts securely.
CAUTION
• Bear in mind that excessive tension of V-belts 3 might
damage the belts and bearings that engage with the V-
Q belts.
Q • Be careful not to let oil stick to V-belts 3, if oil gets onto
AT302729
the belts, it causes slipping, resulting in poor perfor-
mance of the air conditioner.
14-20 COOLING
THERMOSTAT
THERMOSTAT
Overview
T1141090100377
<X> 3
Trq
Trq 10 9
*
6
<X>
5
<X> Lub 8
7
AT302819
SP 1 Pressure cap 9 Water temperature sensor

2 Thermostat cover (Refer to Electrical manual.)
SP Thermostat cover gasket 10 Water temperature sensor (for
3
engine control)
SP 4 Thermostat
(Refer to group 13E in this
5 Thermostat case manual.)
6 Thermostat case gasket
7 Bypass pipe *: Cylinder head (Refer to group 11 in
8 O-ring this manual.)
Assembly sequence
CAUTION
Be sure to apply soapy water to O-ring 8 for easier fitting. Never use engine oil because it will cause
the O-ring to swell.
COOLING 14-21
THERMOSTAT

+15) kPa
1 Valve opening pressure of pressure cap [0.9 (Tolerance: -0.15 - Replace
to +0.15) kgf/cm2]
Valve opening temperature - -
4 Thermostat +2) °C
valve lift (95°C) 10 or more - -

Water temperature sensor (for Multi purpose 34 (Tolerance: -4.9 to +4.9)
9 -
timing control unit) [3.5 (Tolerance: -0.5 to +0.5)]
34 (Tolerance: -4.9 to +4.9)
10 Water temperature sensor (for engine control) -
[3.5 (Tolerance: -0.5 to +0.5)]
Lubricant
8 Entire perimeter of O-ring Soapy water As required
Service Procedure
T1141090200396
(1) Inspection of pressure cap

1. Pressure valve opening pressure
If the measured value deviates from the standard value,
replace pressure cap 1.
1 AT302743
1 2. Inspection of vent valve

• Take note of liquid level B of reservoir tank A beforehand.
• Let the engine run at a high revolution. Before the overflow
reaches the capacity of reservoir tank A stop the engine.
C • Leave the engine in that condition for a while. After the cool-
ant temperature returns to the ambient temperature, check
the coolant level in reservoir tank A to see if it has returned
B to the same level as before when the engine was started.
• If the coolant level has not gone down, it is an indication of
A AT302731 a malfunction of vent valve C, therefore replace pressure
cap 1.
NOTE: Do not remove pressure cap 1 before the coolant
temperature returns to the ambient temperature. Doing so
will release the negative pressure inside the radiator and
disallow the coolant from returning to the radiator.
14-22 COOLING
THERMOSTAT
(3) Mounting of thermostat cover gasket

3
When mounting thermostat cover gasket 3, face sealant
applied surface A to thermostat case 5 and mount it to the
A case.
AT100678
(4) Inspection of thermostat

.
Stir the water using stick A to maintain an even water tempera-

ture in the container, then conduct the following tests. If the
B 4 measured value deviates from the standard value, replace ther-
A C
mostat 4.
E
1. Valve opening temperature
• Hold thermostat 4 with wire E so as not to get it too close to
heat source D.
• Heat the water gradually to raise the temperature to the
valve opening temperature.
• Maintain this temperature for five minutes and make sure
that valve B has opened.
F D • Make sure that valve B has closed when the water temper-
AT302744 ature has dropped to 65°C.
C: Water temperature gauge
2. Extent of valve lift
Keeping valve B fully open for five minutes in the water at a
temperature slightly higher than the valve opening
temperature, then measure valve lift F.
15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . 15-2 AIR DUCT AND AIR CLEANER . . . . 15-10
STRUCTURE, OPERATION TURBOCHARGER . . . . . . . . . . . . . . . 15-12

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Turbocharger Assembly . . . . . . . . . . . . . . . 15-3 INTERCOOLER . . . . . . . . . . . . . . . . . 15-18
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
INTAKE MANIFOLD . . . . . . . . . . . . . . 15-20
TROUBLESHOOTING . . . . . . . . . . . . 15-6
EXHAUST MANIFOLD . . . . . . . . . . . . 15-22
ADJUSTMENT EXHAUST PIPE AND MUFFLER . . . . 15-24
Measurement of Turbocharger Boost Pressure
...................................... 15-8 VERTICAL EXHAUST PIPE . . . . . . . . 15-26
15-2 INTAKE AND EXHAUST
SPECIFICATIONS
SPECIFICATIONS
T1151000100089
Maintenance item Specifications

Air cleaner element Cyclone filter paper type
Model TD05
Turbocharger
Manufacturer MITSUBISHI HEAVY INDUSTRIES
Intercooler type Air-cooled, tube and corrugated fin type
STRUCTURE, OPERATION
Air Cleaner
T1151010200087
1 Air box 2 Air cleaner assembly

3 Unloader valve
• Air cleaner assembly 2 uses a single element.

• Air box 1 and air cleaner assembly 2 are fitted with unloader valve 3.
Water, dust and dirt that collect in the unit are automatically vented by vibration caused by the change of
negative pressure when the engine revolution falls below the specified revolution.
INTAKE AND EXHAUST 15-3
Turbocharger Assembly
T1151010300136
AT302780
1 Actuator 9 Shaft and turbine wheel

2 Compressor wheel 10 Piston ring
3 Thrust sleeve 11 Thrust ring
4 Thrust bearing 12 Oil deflector
5 Bearing 13 Inserter
6 Bearing housing 14 Compressor cover
7 Turbine back plate
8 Turbine housing 2 to 13: Cartridge assembly
Waste gate mechanism

• The waste gate mechanism relieves the boost pressure of
excess exhaust gas using actuator 1. This controls the
boost pressure appropriately and prevents the turbocharger
from overrunning, and prevents excessive pressure in the
intake manifold.
• The boost pressure is fed by rubber hose from compressor
cover 14 into chamber A of actuator 1. When boost pres-
sure C acting on the chamber is lower than the preset
value, the actuator does not operate and waste gate valve
AT302781 B remains closed, therefore exhaust gas D is blown against
shaft and turbine wheel 9.
E: Intake air
• As the boost pressure in chamber A increases to become

higher than the preset value, waste gate valve B is opened
and the exhaust gas blown against shaft and turbine wheel
9 decreases. Therefore the rotation of compressor wheel 2
decreases, causing the boost pressure to decrease.
AT302782
Muffler
T1151010500033
AT302783
1 Muffler
2 Catalytic converter A: Exhaust gas intake
Catalytic converter 2 is built into muffler 1 to decrease the amount of particulate matter (PM) in the exhaust
gas.
MEMO
TROUBLESHOOTING
TROUBLESHOOTING
T1151020100092
Symptoms
(a) (b) (c) (d) (e) (f) Remarks
Possible causes
Air Air cleaner element clogged
X X X
cleaner
Bearing faulty X X X
Carbon deposits on shaft and
X X
turbine wheel
Shaft and turbine wheel
X X
interfering with turbine back plate
Shaft and turbine wheel
X X
interfering with turbine housing
Shaft and turbine wheel bent X X X
Shaft and turbine wheel broken X X X
Compressor wheel interfering
X X
Cartridge with compressor housing
Turbochar- assembly Thrust sleeve and thrust bearing
X X X
ger seized
Compressor wheel broken X X X
Engine oil leaking because piston
X X X
ring and inserter worn
Piston rings installation faulty X
Parts not sliding smoothly
because oil lubrication pipe and X X
eye bolt clogged
Oil seals damaged because oil
X X
return pipe clogged
Compressor housing installation faulty X X X X
Turbine housing installation faulty X X
Intercooler Foreign particles on intercooler front core X
Butterfly valve does not open X X X
Actuator Butterfly valve opening and closing adjusted
X X X
incorrectly
Front pipe, muffler, tailpipe deformed X
Front pipe, muffler or tailpipe installation faulty X
Valve clearance faulty Refer to group 11 in
X
this manual
Head gasket faulty Refer to group 11 in
X
this manual
Valve and valve worn and carbon deposits Refer to group 11 in
X
this manual
Valve spring fatigued Refer to group 11 in
X
this manual
TROUBLESHOOTING
Symptoms
(a) (b) (c) (d) (e) (f) Remarks
Possible causes
Piston rings worn or damaged Refer to group 11 in
X X
this manual
Piston ring grooves worn or damaged Refer to group 11 in
X X
this manual
Cooling system malfunctioning Refer to group 14 in
X
this manual
Engine oil excessive Refer to group 12 in
X
this manual
Main moving parts seized Refer to group 11 in
X
this manual
Fuel injection quantity uneven or excessive Refer to group 13A
X
in this manual
(a): Engine hard to start (d): Engine output insufficient
(b): Exhaust gas dark (e): Oil consumption excessive
(c): Exhaust gas whitish ( f ): Noise and vibration in intake/exhaust systems

Measurement of Turbocharger Boost Pressure
T1151030200090
Service standard
Boost pressure
36 kPa [270 mmHg]/ Inspect and
- (Air temperature 20°C, air pressure -
2950 rpm adjust
100 kPa [760 mmHg])
Special tool
Measurement of turbo
- Boost pressure gauge MH061366
boost pressure
• Before measuring turbo boost pressure, clean or replace air

cleaner element.
• Remove boost pressure sensor hose 1, and attach ST
ST boost pressure gauge.
• After warming up the engine, measure the boost pressure
at no-load maximum engine speed. Also measure the
1 engine speed and the air temperature.
• Correct the boost pressure at standard conditions. (Since
the boost pressure varies depending on the air temperature
AT302557
and engine speed.)
[Correction for air temperature]

Identify boost pressure coefficient depending on the air temper-
ature from the graph.
AT302845
.
[Correction for engine speed]

Subtract the engine speed (rpm) actually used for measuring
the boost pressure from the median of the no-load maximum
engine speed. Identify the boost pressure correction value (Pa)
according to the graph.
Median value: 2950 rpm
.
[Calculation of corrected boost pressure]

Given the measured boost pressure to be P, corrected boost
pressure Pb can be calculated from the following equation:
Pb = ktP + Pa
Pb: Corrected boost pressure
P: Measured boost pressure
AT302785
kt: Boost pressure correcting coefficient depending on air tem-
perature
Pa: Boost pressure correction value
If Pb is lower than the limit, the turbocharger must be inspected

and adjusted.
AIR DUCT AND AIR CLEANER

Overview
T1151090100776
* 11
Trq 7 Trq
8 10
17
4
6 Trq
Trq Trq 14
Trq
1 12
3
3
Trq
16
13
2 15
AT302820
1 Clamp SP 11 Air duct

2 Air duct 12 Clamp
3 Clamp 13 Air box
4 Air pipe 14 Rubber seal
5 Air hose SP 15 Air cleaner cap
6 Clamp SP 16 Air cleaner element
7 Clamp 17 Air cleaner case
8 Air hose
9 Insulator *: Turbocharger assembly (Refer to
10 Clamp P.15-14 of the same group.)
Assembly sequence

1, 3, 6,
Clamp (wire type) 4.5 to 5.5 [0.45 to 0.55] -
10, 12
7 Clamp (band type) 5.5 to 6.5 [0.55 to 0.65] -
Service Procedure
T1151090200814
(11) Installation of air duct

Insert air duct 11 all the way into air cleaner case 17 and
11 tighten with clamp 10.
10
17
AT302733
(15) Installation of air cleaner cap
Alignment
mark 17
16
15
AT302821
(16) Air cleaner element

.
[Cleaning]
• Blow compressed air of 685 kPa [7 kgf/cm2] or less through
16 air cleaner element 16 from inside.
• When using compressed air, move the blower’s nozzle up
and down along the pleats of air cleaner element 16 evenly.
CAUTION
• When cleaning air cleaner element 16, wear protective
goggles and a mask to protect the face. Also use a
dust catcher to prevent dust from scattering in the work
area.
AT302735
• Do not tap or hit air cleaner element 16 to remove dust.
• Do not blow compressed air through air cleaner ele-
ment 16 from the outside.
.
[Inspection]
• Illuminate the inside of air cleaner element 16.
• If parts of the filter paper are torn or thin, or if the packing of
the upper surface of air cleaner element 16 is damaged,
16 replace the air cleaner element.
NOTE: If the dust on air cleaner element 16 is wet due to oil
smoke or soot, replace the air cleaner element regardless of
the scheduled replacement interval.
AT302736
TURBOCHARGER
TURBOCHARGER
Overview
T1151090100787
Removal sequence
AT302786
1 Bolt SP 12 Gasket
2 Insulator
3 Eye bolt *a: Air hose (Refer to P.15-10 of the
Oil pipe same group.)
4
Oil return pipe *b: Air inlet hose (Refer to P.15-18 of
5 the same group.)
6 O-ring
*c: Front pipe (Refer to P.15-24 of the
7 Bolt same group.)
SP 8 Seal ring *d: Exhaust manifold (Refer to P.15-22
9 Exhaust pipe of the same group.)
10 Nut <X>: Non-reusable parts
SP 11 Turbocharger assembly (Refer to
P.15-14 of the same group.)
Assembly sequence

1 Bolt (Insulator mounting) 12 [1.2] -
3 Eye bolt 17 to 23 [1.7 to 2.3] -
7 Bolt (Exhaust pipe mounting) 41 to 54 [4.2 to 5.5] -
10 Nut (Turbocharger assembly mounting) 41 to 54 [4.2 to 5.5] -
TURBOCHARGER
Lubricant
6 O-ring Engine oil As required
11 Supply when installing turbocharger assembly Engine oil As required
Service Procedure
T1151090200825
(8) Installation of seal ring
Offset splits A of seal rings 8 at 180°.
AT302787
(11) Installation of turbocharger assembly

When installing turbocharger assembly 11, supply engine oil
via oil port A as required to ensure that parts move smoothly.
AT302788
(12) Installation of gasket

Install gasket 12 to exhaust manifold *d in the direction as illus-
trated.
A: Grommet lip
AT302789
TURBOCHARGER
Turbocharger Assembly
T1151050300129
Work before disassembly

<X>
AT302822
1 Hose SP 6 Snap ring

2 Actuator SP 7 Compressor cover
3 Bolt 8 O-ring
SP 4 Coupling SP 9 Cartridge assembly
SP 5 Turbine housing
Assembly sequence
Inspection after assembly
NOTE: Since cartridge assembly 9 is a unit construction, if the turbine wheel or compressor wheel is dam-
aged, or the cartridge assembly does not revolve smoothly, or any other fault is found, replace the assembly
as a unit.

Play in the shaft direction 0.05 to 0.09 0.1
Cartridge Play at right Turbine wheel side 0.40 to 0.53 0.58
9 Replace
assembly angles to the
Compressor wheel side 0.55 to 0.66 0.72
shaft
TURBOCHARGER

3 Bolt (Tightening of coupling) 3.9 to 4.9 [0.4 to 0.5] -
Lubricant
3 Thread area of bolt Molybdenum disulfide grease As required
8 Periphery of O-ring Engine oil As required
Service Procedure
T1151090200836
Work before disaasembly
Put alignment marks A on coupling 4, turbine housing 5, com-
pressor cover 7 and cartridge assembly 9.
AT302791
Inspection after assembly

Turn turbine wheel and compressor wheel of cartridge assem-
bly 9 to make sure they turn smoothly.
AT302792
(4) Installation of coupling

Install coupling 4 onto turbine housing 5 in the direction as illus-
trated.
AT302793
TURBOCHARGER
(5) Removal of turbine housing

A: Rubber-headed hammer
CAUTION
• When removing turbine housing 5, tap all around the
circumference lightly using rubber-headed hammer A
so as not to damage the turbine housing.
• Do not hit the blades of the turbine wheel against tur-
bine housing 5, since the blades can be easily bent.
AT302794
(5, 7) Cleaning of turbine housing and

compressor cover
• Visually inspect the condition of parts before cleaning to
check if there are any burns or scratches as these would
not be seen after cleaning. If any fault is found, replace the
faulty parts.
• Immerse the disassembled parts in nonflammable solvent A
A (DAIDO KAGAKU KOGYO DAICLEANER T-30), then take
C B them out and blow compressed air B on them. Remove any
foreign particles before cleaning by scraping them off using
plastic scraper or bristle-headed brush C.
AT100323
(6) Installation of snap ring

Install snap ring 6 onto compressor cover 7, with tapered side
A A facing upward.
WARNING
Use your hand to hold down snap ring 6 so that it
does not come off during installation.
6
7
AT100327
(7) Removal of compressor cover

CAUTION
• When removing compressor cover 7, tap all around the
circumference lightly using a rubber-headed hammer
so as not to damage the compressor cover.
• Do not hit the blades of compressor wheel against the
compressor cover 7, since the blades can be bent eas-
ily.
7 AT100328
TURBOCHARGER
(9) Inspection of cartridge assembly

1. Inspect the play in the shaft direction of the shaft and turbine
wheel assembly
If the measured value is higher than the limit, replace
cartridge assembly 9.
AT302795
2. Inspect the play at right angles to the shaft of shaft and

turbine wheel assembly
• Play on turbine wheel side
If the measured value is higher than the limit, replace car-
tridge assembly 9.
AT302796
• Inspect the play on compressor wheel side

If the measured value is higher than the limit, replace car-
tridge assembly 9.
AT302797
INTERCOOLER
INTERCOOLER
Overview
T1151090100798
8 Trq 7 *c *b
*a
Trq 7
10 1 Trq
Trq 9
12
11
Trq 2
1 Trq
4
3 Trq
6
13 5 Trq
14 Trq
AT302823
1 Clamp SP 12 Air inlet hose

2 Air inlet hose SP 13 Intercooler
3 Clamp 14 Boost air temperature sensor
4 Air inlet pipe (Refer to group 13E in this
Clamp manual.)
5
6 Air inlet hose
*a: Radiator (Refer to group 14 in this
7 Clamp manual.)
8 Air inlet hose *b: Intake manifold (Refer to P.15-20
9 Clamp of the same group.)
10 Air inlet pipe *c: Turbocharger assembly (Refer to
11 Clamp P.15-14 of the same group.)
Assembly sequence
Service standard
Air leakage from intercooler
13 0 cm3 [0 mL] - Replace
(Air pressure: 150 kPa [1.5 kgf/cm2])
INTERCOOLER

1, 3, 5, 9, 11 Clamp (Air inlet hose mounting) 2.9 to 3.4 [0.3 to 0.35] -
7 Clamp (Air inlet hose mounting) 3.9 to 4.9 [0.4 to 0.5] -
14.7 (Tolerance: -2 to +2)
14 Boost air temperature sensor -
[1.5 (Tolerance: -0.2 to +0.2)]
Service Procedure
T1151090200847
(12) Installation of air inlet hose
Align alignment mark on air inlet hose 12 with padded part A on
10 air inlet pipe 10 and air inlet of intercooler 13.
12
A 13
mark
A AT302824
(13) Inspection of intercooler

• Fit plug A on one of the air inlets of intercooler 13 and close
the hole on the boost air temperature sensor, while con-
necting the hose to the other. Then, immerse the entire
body of the intercooler in water and apply the specified air
pressure from the hose side (150 kPa [1.5kgf/ cm2]) to
check for any leakage.
• If any leakage is found, replace intercooler 13.
INTAKE MANIFOLD
INTAKE MANIFOLD
Overview
T1151090100806
9
5
Trq
4
1 7 6
* 10 Trq 3
Trq
<X>
Trq 8 2
AT302738
1 Nut 7 Joint pipe

2 Actuator assembly 8 Bolt
3 Hose 9 Intake manifold
4 Bolt 10 Gasket
5 Boost pressure sensor (Refer to
group 13E in this manual.) *: Cylinder head (Refer to group 11 in
6 Bolt this manual.)
Assembly sequence
Adjustment after assembly

Clearance between butterfly valve and intake 4.0 (Tolerance: 0 to
9 - Adjust
manifold +0.5)
INTAKE MANIFOLD

Nut (Actuator assembly and valve shaft
1 8 [0.8] -
mounting)
4 Bolt (boost pressure sensor mounting) 4.9 [0.5] -
6 Bolt (joint pipe mounting) 17 [1.7] -
8 Bolt (intake manifold mounting) 16 to 24 [1.6 to 2.4] -
Service Procedure
T1151090200773
Adjustment after assembly
While applying negative pressure of 67 kPa [500 mmHg] or
more to actuator assembly 2, adjust bracket hole C of the actu-
ator assembly so that clearance B between butterfly valve A
and intake manifold 9 conforms to the standard value.
B C
2
A 9
AT302739
EXHAUST MANIFOLD
EXHAUST MANIFOLD
Overview
T1151090100817
1 Insulator SP 7 Gasket
2 Nut
3 Distance piece *a: Cylinder head (Refer to group 11 in
Front exhaust manifold this manual.)
4
SP Joint *b: Insulator (Refer to P.15-12 of the
5 same group.)
6 Rear exhaust manifold
Assembly sequence

Nut (Front exhaust manifold and rear exhaust
2 41 to 54 [4.2 to 5.5] -
manifold mounting)
EXHAUST MANIFOLD
Service Procedure
T1151090200858
(5) Installation of Joint

A: Plastic hammer
4, 6
AT100712
(7) Installation of gasket

Install gasket 7 onto cylinder head *a in the direction as illus-
trated.
A: Grommet lip
AT302798
EXHAUST PIPE AND MUFFLER

Overview
T1151090100828
10
1
*
9
8
2
6 Trq
5
Trq
7
AT302825
1 End pipe 8 Exhaust brake unit (Refer to group

2 Tail pipe B 35A of chassis manual.)
Tail pipe A SP 9 Front pipe
3
Center pipe 10 Muffler
4
5 Nut
*: Exhaust manifold (Refer to P.15-22
6 Bolt
of the same group.)
7 Front pipe
Assembly sequence
WARNING
• Never hit or kick muffler 10, or the catalyzer in the muffler will be damaged.
• A small amount of water sometimes collects inside muffler 10. Never touch this water, if
you do by mistake, wash it off immediately with clean water.

5 Nut (Front pipe mounting) 25 to 30 [2.5 to 3.0] -
6 Bolt (Front pipe mounting) 39 to 49 [4.0 to 5.0] -
Service Procedure
T1151090200869
(9) Installation of front pipe

Install front pipe 9 so that the offset tolerance in the vertical and
horizontal sections between the front and back of bellows A
9 A
conforms to the standard value.
CAUTION
Be sure when installing bellows A of front pipe 9 that the
bellows are not forcibly bent and that the bellows do not
pull on themselves. This is because they are designed to
reduce the external noise of the vehicle and are not
5 mm or less designed to absorb dimensional tolerances in the installa-
AT302740
tion of pipes.
VERTICAL EXHAUST PIPE

Overview
T1151090100743
6 Lub 18
12
5
18
11 13
4 10
9
Lub 18
12
18
11 14
1 10
Lub 15 18
12
11 18
10
19
16
Lub12
2
8 19
17
12
Lub
7
3 AT302561
1 Exhaust pipe protector 11 Collar

2 Lower protector 12 Bolt
SP 3 Bottom protector 13 Support bracket A
4 Clamp 14 Support bracket B
5 Exhaust pipe clamp 15 Support bracket C
SP 6 Exhaust pipe A 16 Support bracket D
SP 7 Exhaust plpe B 17 Support bracket E
8 Gasket 18 Packing
SP 9 Exhaust pipe support 19 Packing
10 Insulator
Assembly sequence
Sealant
Location Points of application Specified sealant Quantity
12 Bolts (support bracket attaching) Sika Flex 11FC As required
Service Procedure
T1151090200784
(3) Installation of bottom protector

• Install the bottom protector 3 in such a way that it does not
contact the exhaust pipe B 7.
16 • The support bracket D 16 and support bracket E 17 have
bolt holes larger than attaching bolts in diameter. Adjust
17
their securing positions as required to ensure that the pro-
7
tection is not brought in contact with the exhaust pipe.
3
AT302562
(6, 7, 9) Installation of exhaust pipes and exhaust

pipe support
• Install the exhaust pipe A 6 and exhaust pipe support 9 ver-
tically.
• The support bracket A 13, support bracket B 14 and support
bracket C 15 have bolt holes larger than attaching bolts in
13 diameter. Adjust their securing positions as required to
ensure that the exhaust pipe and pipe support are arranged
vertically.
6
14
9
15
7 AT302563
235(K)

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GROUP INDEX

HOW TO READ THIS MANUAL

For more details, please consult your nearest authorized

©2003 Mitsubishi Fuso Truck & Bus Corporation

HOW TO READ THIS

HOW THIS MANUAL IS STRUCTURED. . . . .2 TERMS AND UNITS . . . . . . . . . . . . . . . . . . . 12

HOW THIS MANUAL IS STRUCTURED

TERMS AND UNITS

• Front and rear

Item SI unit [metric unit] Conversion factor

EQUIPMENT MODEL . . . . . . . . . . . . 00-2 TABLE OF STANDARD TIGHTENING

Equipment name Model description Code description

Table of Standard Tightening Torques

(Stud) (Stud) (Stud)

Hex-head Flange Bolt (Unit: N⋅m [kgf⋅m])

Hex-head Nut (Unit: N⋅m [kgf⋅m])

Hex-head Flange Nut (Unit: N⋅m [kgf⋅m])

SPECIFICATIONS . . . . . . . . . . . . . . . 11-2 REMOVAL AND INSTALLATION OF ENGINE

TROUBLESHOOTING . . . . . . . . . . . . 11-6 CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11-40

ON-VEHICLE INSPECTION AND PISTONS, CONNECTING RODS AND

STRUCTURE AND OPERATION

1 Rocker arm 9 Piston

1 Connecting rod bushing

1 Camshaft gear 7 Idler bushing

ON-VEHICLE INSPECTION AND ADJUSTMENT

Special tool (Unit: mm)

Compression gauge Measurement of engine

M14 1.5 MH061460

The decrease of engine compression is a signal that it is time to

• Remove all the injection nozzles. Refer to group 13A in this

Inspection and Adjustment of Valve Clearance

Service standard (Unit: mm)

Special tools (Unit: mm)

- Cranking handle MH061289 Cranking of engine

Valve clearance adjustment

• Measure valve clearance B when either No.1 or No.4 piston

NOTE: Be sure when taking measurements using feeler gauge

• When turning adjusting screw 3 on an engine that is

REMOVAL AND INSTALLATION OF ENGINE

Tightening torques (Unit: N⋅m [kgf⋅m])

Preparatory operations for removal

(3) Removal of engine and transmission

CYLINDER HEAD AND VALVE MECHANISM

1 Oil filler cap 12 Rocker and bracket assembly

Service standard (Unit: mm)

Tightening torque (Unit: N⋅m [kgf⋅m])

16 Tappet extractor MH063329 Removal of tappet

(13) Push rod deflection

(14) Cylinder head and valve assembly

• Loosen cylinder head bolts 11 gradually in the numbered

• Carry out primary fastening, by gradually tightening cylinder

• Rotate ST socket wrench holder E to the left and make the

• Set so that rod H (for connecting) is pressed against rocker

(15) Cylinder head gasket

• Identify the kind of cylinder head gasket 15 (engine model

(16) Removal of tappet

(16, *) Clearance between tappet and crankcase

Rocker and Bracket Assembly