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Manual de Taller Daihatsu Hijet 1989 - 1998 Manual Taller
Manual de Taller Daihatsu Hijet 1989 - 1998 Manual Taller
1989-1998
Daihatsu Hijet
S100 -S140
Multi-Purpose Utility Vehicle
Includes Engines
EF-NS EF-ES EF-TS
Daihatsu Hijet Factory English Service Manual
2WD &4WD
AT-MT Models
Chapter 1
• Vehicle Types
• My Vehicle ID Plate Location & Meaning of ID Plate
• VIN Decoder (Truck)
• VIN Decoder (Van)
» VIN Decoder (Panel Van)
• Rear Differential Decoder
• Manual Transmission Decoder
• Engine Types
• Tire Size and Air Pressure
• Wheel Sizes & Replacements
• 4WD Towing Instructions
• Fuse Box
• Vehicle Lift Positions
• Vehicle Jacking Positions
Chapter 2
Chapter 3
Steering System . , -
47 68
Cr»titiniu» rl
Chapter 4
Chapter 5
Chapter 6
Chapter 7
Engine , -158
.119
Chapter 8
• Starter
• Starter Circuit & Specifications
• Alternator
• Charging Circuit & Specifications
Chapter 9
Fuel System . -
.165 184
• Carburetor Assembly
• Carburetor Removal & Replacement
• Carburetor Setting and CO HC Levels
• Carburetor Component Diagram
• Fuel Filter & Part Numbers
• Fuel Tank & Components (Van) Base Carbureted
• EFI Fuel Injection
• EFI Fuel Injection Components & Parts Location
• Engine Control Computer Connector Pin Guide
• Fuel Pump: Mechanical (Head Type), & Electric (Body or Tank)
• Fuel Lines EFNS (Truck)
• Fuel Lines: EFES
• -
Fuel Lines: Turbo Vehicle
• Fuel Lines: EFNS (Van)
• Fuel Lines: EFES (Van) Fuel Injected
Chapter 10
O.nntiirnpd
Chapter 11
Clutch System. -
.221 230
Vehicle Identification
• Vehicle Types
• My Vehicle ID Plate Location & Meaning of ID Plate
• VIN Decoder (Truck)
• VIN Decoder (Van)
• VIN Decoder (Panel Van)
• Rear Differential Decoder
• Manual Transmission Decoder
• Engine Types
• Tire Size and Air Pressure
• Wheel Sizes & Replacements
• 4WD Towing Instructions
• Fuse Box
• Vehicle Lift Positions
• Vehicle Jacking Positions
Vehicle Types
Truck Van
Vehicle Senes
' E N G I N E EF - NS 659cc
COLOR W 09 TRIMLCS3
~
A7 ENGINE NO.
y
"I 9' 4 "/
^
s Number
Note: This CODE is Important for This Book! You Need the Ohasis
Order Parts.
Engine Series (Example: EFNS) to Match Specifications and
Note: Pre 1989 W as A Sticker and Can be Lost Easy. Important to Keep
Paperwork
-
VIN Decoder
Truck
Truck
Sample: MN (Truck )
V — S 1 O O P- P M R S
i
Fuel Regulation S: Carburetor SOHC
E: Electronic Fuel Injection SOHC
G: Carburetor DOHC
Vehicle Grade R: Standard
D: Delux
F: Izu
Transmission M: Manual 5 Speed
H: Automatic 3 Speed
Rear Body Type P: One W ay Door
-
T: 3 W ay
D: Dump Truck Bed
Z: High Roof 3-W ay
Vehicle Type P: Pickup Truck
Engine Series O: 660cc EF Engine
Driveline 0: 2WD Rear Leaf
1: 4WD Rear Leaf
Vehicle Series SI: Hijet
Emission Code -
V: From H 2 (From 1990 )
VIN Decoder
Van
Van
Panel Van
V -S I O O C- C M L S
Transmission
- 5 speed Manual
H: 3 Speed Automatic
Rear Body Type C: Panel Yan Du:tl Sliding DR
Y: Panel Yan Single Sliding DR
Z: High Roof Dual Sliding DR
=
Example: 50 Ratio 5.571 SJL20Y EFTS Series
6.666 -
01 05 SP100P
6.285 05 SP100P /SP110P
6.666 - -
09 11 13 SP110P
6.285 17 SY100
6.666
6.285 29
-
61 21-62 SYIOOY /SIOOY
EFES S120Y
5.571 - -
49 50-51 52 EFTS S120Y
6.666 -
33 37 EFES
5.875 -
41 48, 53 S130Y EFES EFTS
Transmission Identification
Manual Transmission
hi
= -
Example: 214 2WD Non Turbo Van
EF-NS
Tire Size and Air Pressure (kg.cm)
Air (kg.cm)
Vehicle Series Size F R
SIOOP, SHOP 5.00- 22-4
Sioot':. si ioc - -
5.00 12 6 2.0 2.1
SlOOCT. snoer I 45R 12
AT 5.00- 12-4 2.2 2.1
S100V MT 5.00- 12-6 .
2 1 A. i
Sidewall
11 0
i '
jgggp
»
Steel
Wheels
mI '
_ 3 W8 XIJ
« tt ivunoj
C OCBX 17'"*"^
etn-iao-ooo (VuNOj
rVUWOJ 4!W8X t ?
«e» wwsw ax* m»*c; «*n
.
4 i 'U X 1.1
<
i oiu <eoj;
*
;
i
Aluminum
Wheels
< nopx ;? JSAWSUO) 4 SDJXO
*»« '.•»»»«»> -
«a»n ann»fttt <enuOi
g% '
i
t
^ce-sre - fr-coo
i
’ wmtti j tarca
Steel Wheels
4WD Towing Instructions
Select SW
vc _dl.(K;oi
liFHr=Vn
Lock
/
Transfer Shift Control
/ Lever
f
Fuse Box
Fuse Box
mm HOAI
rar
V'. Lower Left of Steering DCF
H Column j
W
r15A ~
F TOA ;
its OPENEfl HEAQ - lh )
Mil— op
\
<z 10A 10A
£3 E r itOOiBw
It l *’ a *>
^MNT j j G2
VII n rr\ I 20A
a
l T$
I
i i
A ]
WP - TUM
; /N Ci HEADER
8 £ jS|i floAi
~
-
W
;
iq
' ! ,coa0A-' I STOP
» . V i52L» — r !
<
"i
«
Jr;Li
> 4
~ ! . iij
ZM1 r LL
TAIL
>
*
5A]
K*«Uh«
oT
i
,
*
? !
\
i
; •
\
Lift Posistions
Front
Atrai
Truck & Van
Jacking Positions
Front
ja _
Rear
‘Support both Axels on each side with proper jack stands *
Chapter 2
General Maintenance
A dirty air filter can casue the oxygen sensor to mis-adjust due to air
restriction. A clean air filter will alow the system to blance correctly.
Note: Do not run vehicle without an air filter. Damage to the system
will occur
!!
S 120-8130 Truck
EF-TS, EF-RS
Part# 17801-87514-000
EF-TS
Remove side under cover
Remove spark plug wires
Remove Plug 1 & 2
-
4 jfr 4 f 0»»
dsrrrf
Prepare an extension socket setup as in the
diagram on the right
Note: Instalation of spark plugs will differ slightly between the different vehicle
types.
Note: Check vehicle specific tune-up specifications on the sticker placed in the
engine compartment.
General Maintenance
Ignition Timing
Timing ( BTDC/RPM)
EF-NS 7*7950
EF-ES 57850
EF-TS 107900
-
EF NS Series
——
IG Switch (IG1)
Distributor
o crs^o 1
Engine ir '
R2
AM60A 10A
2.00sq ( Van)
0.85( Truck)
Battery Ay
21
/
i Ingnition Coil
1
'
1
4
2
4 4
3
Lr
Ignitor
IG Switch
-
EF-ES EF TS Series
AM60A § ( Van )
2.00sq ( V )
I.OOsq (T)
1 Distributor
Engine Control
Computer
7
4 4 4
A- A
•
-
v
1. IG Switch On
2. Use a Voltmeter and Check Power to Connector
General Maintenance
Tune-Up parts
*
Fuel Filter (Truck)
Fuel Hose #1
:xus
1
©’»
EF-ES
EF-ES Series Engines Idle System is Computer Controled
James Note: Idle Curcuit Trouble is 99% of the Time die ISC Valve
ISC is Connected to ECU (Rotary ISC ) (RSO & RSC Connection)
EF-TS
EF-TS Series
Using a SST connector Pn#09991-87604-000
attach tachometer.
Set Idle to 900+-50 RPM
CO-HC Levels
EF-NS (Use Mixture Screw to Adjust) -
•A
Idle CO-HC Level
CO 1.5+-1.0% to -0.5%
HC 900 PPM ( Parts Per Millionjor Less Throttle Ad Screw
*
’ r
Co 1.5+-1.0% to -0.5%
HC Below 900 PPM
Manual Transmision
Remove plug:
Level should be within 0~5 mm
Capacity:
2WD 1.1 Liters
4WD 2.3 Liters (Including Transfer Case)
Automatic Transmision
#Check while warm (70-80C)#
Engine Condition:
Before performing engine work it is
important to check oil condition . Oil
is the best indicator to the internal
condition of the engine.
Oil Filter
Denso
Tokyo Roki
- -
EF Series S1G0 S110 S120 S130 -
- - - -
PN: 15601 87204 000 or PN: 15601 87703 000
.
1 Loosen Tie Rod End Lock Nut
'
Lock Nut
1h i!
\\ \
4 U ji! i
xs \V
^wiH n
/ .
;
2. Measure Toe In
Front
o8
1
\
-
4. Torque Tie Rod End Lock Nut to T: 450+ 100kg.cm
Note: lTse an Camber & Caster Gage to Set PCumber & Caster
Specifications
—
Camber Specification: 0*15'H 15'
i
'
Specifications
Caster:
-
3*08+ 1 (Truck)
-
3*04+ 1 ( Van )
King Pin Degree 13*03+ -!
=
Front Side Slip In 5mm~Out 5mm
Note: ( *) = Degree
General Maintenance
Valve Adjustment
-
EF-NS - EF TS (Cold Settings )
( IN )
0.1S+-0.05nun
( EX)
0.25+-0.05mm
-
EF ES ( Cold )
(IN )
0.20+ -0.05mm
( EX)
0.30+ -0.05mm
- - -
EF NS EF TS Cylinder #1TDC
Cylinder #1 Ciiudei #2 Cvliiiitei #3
IN EX IN EX IN EX
o O o o
-
EF ES Series
CySiider #1 Cylinder #2 Cylinder #3
IN EX IN EX IN EX
O O O O
Chapter 3
Steering System
=
T: kg.cm
Type 1
( -».)
( 6.)
( 4.) T:125+ -25
(5.) T:75+-25
(7 - )
(3.)
Ignition Snitch
(9.)
(? •)
5/- - B> (3.) T:130+ 30
-
/
I 'g
- . -
(8 ) T: 250+ 50kg.cm
.
1 Cover: Steering Column
.
2 Cover: Main Shaft Joint
.
3 Bolt: Column Attachment
4. Cover: Steering Column Upper
.
5 Bolt: Attachemnt
6. Nut: Ingnition Cylinder
.
7 Ignition Switch
.
8 Bolt: Steering Shaft U Joint -
.
9 Column Body *
= =
Note: ( B) Bolt ( N) Nut
Steering System
Steering Column Removal
-
Note: Disconnect ( ) negative Battery Terminal
Connectors
Steering System
Lower
-
Note: When Installing IT Joint Make Sure Front Wheels
are Facing Forward
-
IT Joint Torque: 250+-50kg.cm
-
Caution: Do Not Over-Torque U Joint, U-Joint Will Be
Damaged and Can Fail
IT-Joint
(33
-
LR
To
Gearbox
Steering System
Tilt Steering Column Components
(6.)T; 130+-30
(- •)
*
'ij
( 9. )
’i
Ignition Snitch
/
f
/ r -
(3.) T: 130+ 30
/ 1ilt Lever
/
i
/
/
/
/
/
/
/
/
/
«
V
>B
(8 .) -
lT-Joint Bolt T: 250+ 50kg.em
=
(B) Bolt
=
( N ) Nut
Upper Joint
=
(S) Screw
Ua -
.
T:250+ -50 « - -
-T:250+-50
-
T:1150+ 150kg.cm
T.11S0+-1S0 a '
i
Mi
f -
T:250+ 50kg.cm
T:800+-100
-
f*
T:950-f 150kg.cm
h
Rack Assembly
T:625+ 75
/-
T: 800+-100
-
T:80(H- 100
Removal
.
8 Remove Assembly Attachemnt Bolts
Slightly Lower Unit
Yoke
/
/
/
7i < ,
9
t
I
I l
I
t
Dust Boot Body
Dust Boot
Steering System
Rack & Pinion Ovcrhual
Dust Cover
Oil Seal
Boot O - Snap
Snap Ring
Ring
Band Bearing ( Must be Replaced)
“
H / Pinion
/ Rack housing
^ j
Band
O Ring Boot
Boot Band
/
Hexagon - Boot W
j I asher
Nut Band Steering Rack
T: 400+ 50kg.eni
-
luide Clip Yoke (End)
Rack Guide
Spring Cap ipring A (N) T: 600+-100
Disassembly
Note: C se Service Tool Vise Holder Adapter 0%12 00012 000 - -
Dust Cover
.
6 Remove Compression Spring & Rack Guide Replace
Inspect for Cracks in Guide, Replace if Found O Ring
Worn
Oil Seal
-
7. lTse a Flate Head Driver ( ) and Pop Out
Oil Seed
r
Note: Oil Seal is ( Type K ) h
Snap Ring
Note: Use Service Tool #09631-87201-000 To
Remove Pinion
Tighten
-
Note: Bearing Con Not Be Re Used
Assembly
Housing Preperation
T
-
* *U i l
i
f fS
JL fe
/
Bushing
Needle Bearing Grease 1.0+ O.2Gram Grease
-
-
1.0+ 0.2Gram Grease
-
1. Slide Rack into Housing, Attach Back Washer
and New Snap Ring
.
2 Using a Press, Press on New Bearing
f Bearing
u
^
3. Attach New Snap Ring
Snap Ring
4. Use a Hard Plastic Hammer to Install Pinion
into Housing Assembly.
Oil Seal
Installer
.
6 Install New Oil Seal
Oil Seal Up S
Caution: Oil Seal Lip Must Be Covered W ith Minimum of
-
0.3+ 0.1g of Long Life Chassis Grease
New O Ring
Rack Guide
Wrench
10. Line Up Hexagon Nut W ith Ali gnment Mark
-
and Set Torque T:400+ 50kg.cm
Alignment
Mark
Torque W rench
11. Set Torque T: 12~T4kg.cm
Vi
\ r)
Tapper
Dust Cover
Knot HfcJhu Boot
13. Install New Boots and New Attachemnt luufflfflp
Bands r t
*
j Bands
B;mds
14. Attach End Yoke and Torque T: 600+-100kg.cin
15. Install in Vehicle
Steering System
Tie Rod Ends
-*- (!•)
-
® ( 2.) T: 475+ 75kg.cm
!
“
(2 - )
-
T: 475+ 75kg.cm
T: 450+-100
\
-
T: 450+ 100kg.cm
1. Cotter Pin
2. Castle Nut
3. Tie Rod (5.)
.
4 End: Tie Rod No 1 .
5. End: TieRodNo 2 .
Pstrt Numbers See Parts Page
=
( N ) Nut Manual Steering
=
(B) Bolt
WOJtt
90941
I [ -oi WOGOP )
Bushing
©
K
i
fUiS* 0 U 01. OOCHtJ
;
K
»4 < s< -OnCH -OOCKtl
s>
.
'>rx>4 *. ?&K ’ 0TJ0(!)
SOaiMMSeMXXHlt
W -
^ . /CffU OCOti!
I
aowt - rwarooom
Boots
S100, 110, 120, 130, 140 (MT, DX,LX, NGD,2S+$100YSMRS) # 45535-87509-000
S120, 130 DOHC +120 YZMQT 0YFMQT, S130YZMRS . #45535-87507-000
-
S100, 110 ( DECK YAN OLD) # 45535-87507 000 -
S120, 130 DOHC # 45535 87508 000 - -
Bearing
(ALL) # 90043-63147 000 -
Bushing
-
(.311) #90043 85163 000-
Note: Above Listed Parts Still Available at Time This Book Is Published
Steering System
Tie Rod End Parts
Cotter Pin
.
feW ?- iea V -COGtD ©
~
Dust Boot
-.
L H \ nd Screw
wxx • row «00 -
R Hand Screw
Dust Boot
Parts & Part Numbers Note: Some Parts May or May Not Be Available On Older Models
Suspension
Air ( kg.cm )
Vehicle Series Size F R
• 100P. SHOP
S 5.QG- Z 2-4
Moor , suor 5.00-12-6 2.0 2.1
sioocr. snocrr 145R 12
AT -
5.00 12 *
4 2.2 2.1
S 100V MT --
5.00 12 6 2.1 i
All 145R 12 2.4 2.6
- -
5.00 12 1 2, 4 2.1
SilOV - -
5.00 12 6 2.4 2.4
145R 12 2.4 2.6
143R12 2.4 2.4
Sidewall
.
1 Loosen Tie Rod End Lock Nut Look Nut
2. Measure Toe In
-
Specifications: (All) 0.0+ 1.0mm
Front
oB
Specifications
Caster:
-
3*08+ l ( Truck)
-
3*04+ l ( Van )
King Pin Degree 13*03+ ! -
=
Front Side Slip In 5mm ~ Out 5mm
Note: ( *) = Degree
Suspension
Strut Components
Torque: (kg.cm )
-
T:400+ 50
9
«
—- (1.)
T: 600+-100
( 4. )
-
T: 950+ 150kg.cm
Components Tool
1. Cover: Steering Dust Coil Spring Compressor
2. Support S /A: Front Suspension
3. Bushing
4. Seat Ay: Front Spring Upper
5. Bumper: Front Spring
6. Cover: Strut Dust
7. Spring: Coil Front
8. Front Strut Assembly -
P /N#09727 30020-000
Suspension
Front Strut Removal
Compressor
Installation
.
1 Compress Spring with Spring Compressor
2. Place Spring Onto Strut and Position as in
Diagram on Right
Spring Position
.
3 Coat Upper Bushing With Long Life Chassis Grease
Minimum Grease: O.Sg
Half Moon
Top
Note: Only New Nuts & Bolts Must be Used For
Assembly
Torque
-
Top Nut T: 600+ 100kg.cm
Support (2.) T: 400+ -50kg.em
Lower Strut Mount T: 950+ -150kg.cm
=
( N ) Nut -
T: 480+ 95kg.cm
(B ) = Bolt
(T:) =Torque
(3.) T:450+-100
. - .
(1 ) T:450+ i50kg cm
Q>
w
1. Nut
2. Washer (6. )
3. Nut
4. Washer
5. Rear Shock Absorber
6. Washer
7. Cushion
Replacement
.
5 Remove Upper Attachment Nut
.
6 Remove Shock and Replace New Unit
=
( N ) Nut
=
(W) Washer
=
(B) Bolt
T: 500+-50kg.cm -H
-
T: 400+ 100
T: 1040+ 160kg.cm
-
.
-
1. U Bolt
2 Bumper: Rear Spring
3. Pad: Spring Upper
.
4 Shackle S /A: Rear Spring
5. Leaf Spring
6. Bushings
.
7 Retainer: Spring Pad
8. Lower Spring Pad
Suspension
1. Shock Absorber
2. Rear Suspension Arm
3. Spring: Coil Rear
4. Seat: Rear Spring Upper
5. Seat: Rear Spring Lower
.
6 Bumper: Rear Spring
Removal
Here"''
-
T: 900+ 150kg.cm
9
© -
Nut (1) #90041 78042 000 -
Nut (3) #90041-79075-000 &
Bushing
Bumper
-
Bushing: (.311)#90043 86101 000 -
-
Coil (Truck)#48131 87564 000 -
-
( Van ) #48131 87566 000-
Suspension
Rear Leaf Spring Suspension Parts
=
( N ) Nut Part# -
Truck - Tan MT Deck-
=
( B) Bolt Part#
=
(W) Washer Part#
Shock Bushings
k t
TfHraCC
-
CO'XJCTJW COOi - j
- -
!M ' ta 7 tepco axHn
.^ OtTOO-OCS*!!
WV
Bumper
Truck #48341-87520 000 - Note: Available Parts listed to Left
-
Van #48341 87521-000
Bushings
- -
(All)#90043 85158 000
Shock Absorber
Van #48531-87592 000 -
-
Truck #48531 87593-000
(RH)
Knuckle
i
i o
(LH)
- Knuckle
^—
90t>4 l ?«O42’OCKX
^ o
(LH) Arm
i -
9oo4 jrn 7 is ocio( ij
-
SOSai TMSt OOOi!)-
- -
9004! 7WW 000(!| 9i (MtairK 000 *1
*X>*2-0 7 tO Xo; )
! ( i
-
916**> B!2MK>00(?1
Knuckle
-
(RH) #43211 87517 000 -
-
(LH) #43212 87513 000 -
BaH Joint Cover (ALL) #43345 87508-000 -
.Arm: Lower Suspension
( RH)
EFTS, EFGS, EFGS, EFZS, NTBO #48605-87519-000
-
Turbo#48605 87520 000
( LH)
-
EFTS, EFGS , EFGS, EFZS, NTBO #48606-87520-000
-
Turbo#48606 7521 000 -
Stabalizer Bar Grommet (All ) #48674-87505-000
Chapter 5
Brake System
T: Torquekg.cm
=
Front
I
Pedal
Master Cylinder
7.
1. Pin
.
2 Union Inlet
3. Grommet (Must Replace)
4. Master Cylinder Body
5. Bolt Set ( Lock)
6. Gasket (Must Replace)
7. C-Ring
8. Piston Assembly No.l
9. Piston Assembly No.2
10. O Ring
Brake System
Muster Cylinder Type & Rebuild
.
5 Use a Driver to Push Piston Forward,
Remove Set Bolt
Set Bolt
Brake System
Master Cylinder Rebuild
.
7 While Holding Pressure Forward Use
Snap Ring Pliers and Remove Snap
Ring .
Wood
Blocks
-
Note: ABS & Non ABS Are Not Interchangable
.
2 Coat Inside of Master Cylinder With Fresh
DOT Type 3 or DOT4 Brake Oil
-
Note: Never Re Use Gaskets & Grommets .ABS Type
Brake System
Master Cylinder Rebuild
P/ N: See Below
fOMl - 7 IZ 44HO)
*
. .
3cnf 4 < Myoix*' > Qt
.
Van (EFI, HX, ATM TBO)
-
Truck /Van ( TR ,MT,MTM, NTBO-HX) #44610 87519-000 #04443 87513 000
- -
-
# 44610 87520 000 #04443-87514-000
-
All Others - -
#44610 87519 000 #04443-87513 000 -
Brake System
Front Disk Brake System 2WD
Truck
\\ asher
-
P / N (All) 43512 87520-000
P /N (ALL 2-4WD)
- -
Bearing #90043 63221 000
T: 475+ -75kg.cm
Truck
T: 1150+-230kg.cm
- -
P / N (All) 43512 87520 000
T: 2000+ -200kg.cm
Truck Caliper
\ an Caliper
T: 475+-25kg.cm
^ (4.)
1. Pin: Cotter
2. Nut: Castle T: 2000+ ~200kg.cm Major Part Numbers
3. Drum
4. Spring: Shoe-Hold down Brake Shoe(s)
-
5. Pin: Shoe Hold Down Spring -
Brake Shoe No.l ( All ) 47420-87512 000
-
6. Spring: Tension
7. Spring: Tension
-
Brake Shoe No.2 (.411) 47430 87514 000
Note: Daihatsu Order Shoes Separately
8. Spring: Tension
.
9. Brake Shoe No l Wheel Cylinder Assembly
10. Brake Shoe No.2 Right Side
11. Strut
12. Parking Brake Lever
-- -
Normal: 47550 87509 000
ABS: 47550 87517-000
13. W heel Brake Cylinder
14. Catch: Automatic Adjuster Left Side
.
15 Lever: Automatic Adjuster - -
Normal: 47560 87509 000
16. Spring: Tension
17. Pin: Adjuster
ABS: -
47560 87520-000
!
}
1
Cable No.2
1. Cover; Parking Brake Lever -
Yan P / N # 46420 875X4-000
2. Lever Assembly Truck P / N # 46420-87507-000
.
3 Clamp
.
4 Cable No.l Cable No.3
.
5 Cable No.2 -
Yan P / N # 46430 87507 000-
6. Cable No.3 - -
Truck P / N # 46430 87506 000
Brake Svstem
-
T: 90+ 18kg.citv
fcj
Front
.
1 Bracket: Brake Actuator No.2
2. Bracket: Brake Actuator No.l
3. Actuator Assembly
.
4 Tube: No.l
5. Tube: No.2
6. Tube: No. 3
7. Tube: No.l
8. Tube: No S.
-
9. Two Way Valve
Brake Systems
ABS Front Speed Sensor
Rear Right
Rear Left
ABS Computer
/
/
Note: All ABS parts sire YIN Specific. Contact Parts Center for More Information
Brake System
ABS 2\YD Control Circuit Diagram
ABS 2WD
—-
Stop Lamp
nCr H' 1
— — —
Stop Lamp
Stop 10A Switch
cruo
5 I "G"
It 3' Sensor
Sf
-^ -
ro o
<r >
\j
- ^b
O
— .
Ptukiitg Bt tke Switch
;
?
ABS
Compmrr
10-
Gage K)A
i
i
——— rWMv
- O'
!
<
JS ( Check
Connector
I—
-nnwrw>
—
!
1 o i
^
ABS !
Actuator ! WW " <
£ *s
HRfWH Zt
CC
i Check !'• jj '
Lt Fuse ir& ' S^ ^ Speed
->
!
l
sV ^
r Sensors
T~~n \
i
&T
I
ABS
Relay
!y
;
\ aW
oJ \
'
<£g
4 O \ i
v
•j
6 !
A X
5 h
^
l \
i ii
.
^-
M on t
<A : .
B iltety
ABS System
a .
I>«« pF / L Mai 2
H| 1 A Testing Fuse
Brake Svstem
ABS 4VtD Control Circuit Diagram
ABS 4WD
Stop Lamp
ABS
Stop Lamp Computer
— u= —
Stop 10A
crvo
s
crsjz
Switch
ri' O - A
%
!
%
i
0i S<
¥ M"
g( —
^^—
-
r <>
G"
Sensor
3o
'
y 1
—- —
Low Brake Fluid
^ arniug SW
rC/'h (:
Parking; Brake Swifcli
Gage IOA
<r\A>
^ — y£+ -
•C "C (; •
——
ABS Warning Lamp
H"
— — i
—
VvV 0
— —4
-W 9 UyS
s© 4
0
:
Check
Connector
—
S
ABS I 'uwfir*
Acwtator |
!
—i h N h l '“'WW'
•
'TOTiP <i>
i
©I
0a ie
!
1
1)2
:0I
—-
ABS *
<V Q- Check
Fuse Speed
10A Sensors
T« I
r
s)-
1
ABS 1
Relay 52
i J ©5
f '
f 0E
4 A
4 #1 £< ! M
Y
S©
6 c
Center Diff-Lock SW
+•
L -z
1
|
xS O
^
t
2
D
j Battery
H 2WD 1
—
-n /4WD Switch 1
*
0
^=.d
u
n
0
^5 o
r«4
•» III I il
<
2
Chapter 6
Cooling System
Truck
EFNS
To Reserve Tank
Fan Motor
Oil FRONT
Cooler
Outlet
i
:
Fan Shroud
i
Lower
§
;
/ FRONT
/ I
:
i
i
/
To Reserve Tank
( Reserve Tank Hose)
Cooling System
Radiator & Components
EFTS Van
Upper Hose
Lower Hose
Motor
Radiator
Fait Shroud
Cooling System
Radiator Removal
AT Vehicle
i / \
A
Fan Relay
Note: If Fan Does Not Engage Replace Relay V Location
If Relay is Replaced And Still No
Engagement Replace Fan Motor Fan Relay Location #2
Use Diagrams on the Right For Relay Location
-
Van Truck
Relay Circuit
KJ
r
-
60 80 Ohm (20*C)
Cooling System
Radiator Thermo-Control Switch Test
-
1. Place Thermo Switch In Beaker and W arm to Required Temperature
2. Test Connectivity at Selecte Temperature Ranges Listed Below
Therm om eter
Truck (Carbureted)
-
Note: Never Re Use Thermostat Gasket
Housing
(Replace) &
Attachemnt Bolt
/
/
Attachment Screw
Cooling System
Thermostat Testing
-
Minimum Opening: 82 88+ -1.5*C
8mm Travel
Thermostat
-
Note: Do Not Re Use Gaskets Water
Pump
Cooling System
Parts: Water Pump
16271-87204-000
Internal Parts
. - -
EF-NS EF-ES , EF-TS S 100, S-110,S-120,S 130 Series Engines
-
Part# 16100 87592-000
EF-GS, EF ZS, EF RS Series Engines TR,DX, MX, HX, MXC
- -
-
Part# 16100 87231-000
Cooling System
Parts: Water Pump & Thermostat Housing
-
16271 87203-000
- -
16341 87700 000
90041-79052-000
1 16307-87203-000 - -
16321 87204 000 - -
1O307 87204 000
. -
EF-NS EF-ES, EF-TS S-100,S 110,S-120,S-130 Series Engines
Part# 16100-87592-000
EF-GS, EF-ZS, EF-RS Series Engines TR,DX,MX,HX,MXC
Part# 16100-87231-000
Cooling System
Parts: Radiator & Related EFNS
EFNS
Note: See End of This Chapter for Major Parts list Per Series
Cooling System
Parts: Radiator & Related EFGS
Note: See End of This Chapter for Major Parts List Per Series
Cooling System
Radiator Assembly
Engine .
.
:
-
'
:.
-
• Piston & Block Overhaul
• Engine Parts Replacement Including Oversize Pistons & Rings
• Engine Miscellaneous Guide Pins & Part Numbers
Engine
Engine Types
Engine
Engine Mounts
Torque: = kg.cm
-
T: 250+ 60
-
T: 195+ 35
-
T: 250+ 60
N.
S
v (B) T:195+ -35
(W /PTO) s
(4\TD)
T: 375+-7S
"i (2\YD)
T: 195+-35
Van /Atrai
(W /PTO)
( 4WD)
-
T: 250+ 60
Ki
T:19S+ 35-
-
T: 42S+ 75
Engine
Engine Mount Inspection
12.4mm+ 4 -
l
f
i
-
6mm+ 2.5
Right
JU
f 5mm+ -2
Center Mount
Smm+ -1
4WD A / T
^ Rein Mount
Engine
Engine Expoded View Component Diagram
'1
&
i 5r
'
. i
f
i
t BOST
'
Engine
Diagnostic Connectors
Diagnostic Connectors
Picture Part Number Use
-
09991-87604 000
Pickup Truck RPM
Harness Test Connector Adapter
09991-87705-000
Engine Control Harness Engine Circuit Testing
Test Adapter Connection
Engine Condition:
Before performing engine work it is
important to check oil condition. Oil
is the best indicator to the internal
condition of the engine.
660cc Engine
1 BOM
Engine
Diagnostic Connectors
Diagnostic Connectors
Picture Part Number Use
-
09991-87604 000
Pickup Truck RPM
Harness Test Connector Adapter
09991-87705-000
Engine Control Harness Engine Circuit Testing
Test Adapter Connection
Engine Condition:
Before performing engine work it is
important to check oil condition . Oil
is the best indicator to the internal py '
Ji
EF-ES
-
BTDC 5+ 2 /850 RPM
EF TS -
-
BTDC 10+ 2 /900 RPM
Idle Settings
-
EF NS Series
-
use RPM gage SST Pn# 09991 87604-000
Engine
Timing Belt System Components
=
(B) Bolt
=
(N ) Nut
=
(\\ ) VTasher
'
T:300+ -60
Torque=(Kg.cm )
See Inside Box
T: 400+ -80
-
: 1000+ 160
I j
.
12 Remove Timing Mark Cover and Useing a Long Screw -T~ M
.
Driver, put it Threw Sevice Hole #2 Wedge it into the . - N
.
Ring Gear to Prevent Movement Remove Crankshaft
Pulley.
.
13. Remove Timing Belt Cover & Gasket Do Not Re-Use
Ip - 's
Gasket.
.
14 Remove Timing Belt Pulley Flange
Belt Conditions
Belt Cracking
Damaged
Uneven Wear
Belt Seperation
-
Note: Never re use a timing belt. Used belts will fail if a new tensioner
has been installed
Engine
Timing Belt Tensioner
Belt Guard
F Mark
——
Tensioner
(joMI/ Injector
Granshaft Timing '
' Punch Mark
Belt Pulley
Engine
Timing Belt Assembly
Attach Tensioner
Timing Belt
Tensioner
Bolt
#91612-81040-000(1) FRONT
- -
EF NS, EF ES, EF-TS Part # 13514-87282-000
EF-ES - -
Part #13514 87283 000
-
EF GS, EF-ZS,EF-RS Part#13514-87215-000
-
EF NS ,EF-ES,EF-TS -
Part#13514 87283-000
T:=Torque Kg.Cin
*= 1: EF-NS, EF-TS
*=2: EF-ES
Cylinder Head
- .
T: 550+ 50kg cm
Head Gasket
Block
-
Note: Gaskets Cm not be Re Used
VAN
Caution: Fuel Lines are Under High Pressure
Always Use Caution FP Relay
XT
Removal
1. Remove Timing Belt (See Previous Section )
2. Remove Air-Cleaner Hose
3. Disconnect Accelerator Cable
4. Disconnect Engine Main Harness
5. Disconnect Fuel Hose Line
6. Disconnect Vacuum Lines
7. Disconnect Water Hose
8. Fuel Pump and EGR Valve (EF-NS)
Engine
Head Gasket Continued
.
9 Remove Intake Manifold Assembly
.
10 Remove Engine Side Under Cover LH
Disconnect Front Exuast Head Pipe
( If Turbo-Charged Remove TB Assembly)
.
12 Remove Valve Cover Assembly s: .6 A
13. Remove All Remaining Attachment Bolts
14. Carefuly Remove Cylinder Head
Bolt Pattern
EF-ES #11115-87215-000
Note: Clean All Surfaces Thoroughly E-GS , EF-ZS #11115-87217-000
Check for Surface Cracks or Other EF-NS, EF-TS #11115-87210-000
visable Damage. If Cracks are Located
All Others # 11115-87219-000
.
replace with New Parts Cylinder Heads
Can Not Be Repaired . Valve Cover Gasket
Part Number(s)
EF-ES #11213-87208-000
EF-NS, EF-TS #11213-87206-000
-
All Others # 11213 87211-000
Engine
Cylinder Head Gasket Assembly
Torque Sequence
. .
3 Torque Head Bots To: 550+-50( Kg Cm )
Use Diagram on Right For Torque Sequence
§' 2 % r
7. Attach Exhaust
Torque: 495+-75(KG.CM)
.
19 Assembel Tinting Belt
( See Previous Chapter) Accelerator Cable
.
22 Start Engine and Check Timing
Engine
Head & Valve Cover Gaskets
#900-H -05I044K>0
/
#90041-05074)00( 2)
-
-
(A)#90041~I6433 000(4)
-
(B) #90041 16385 000(4)
i
*
i
S,
'
-
90041 103834)00(2 )
-
90041 164204)00(5)
Head Gasket
EFGS-EFZS-EFRS Shown
-
90042 501904)00
-
90042 501904)00(1)
-
90042 501904)00
900414)1600-000
-
90042 060644)00
-
90048 010384)00
Oil Seal
-
90042 540594)00
Steoi OilSej
Part # 90043-11277-000
Engine
Oil Pump System
—
SST Special Service Tool
Sped al Service Tools
Picture of Tool Part Number Part Name Use
IS -
09032 00100-000
Gasket Scraper Oil Pan Gasket Removal
is
0 -
09608 87302-000
Oil Seal Replacement
©©© CCXD Seal Set (Drive)
=
B Bolt
=
N Nut
—
T: Torque kg.cm
B T: 195+-39
-
B T:80+ 16
-
T:250+ 50-
1. Power Train Brakcet
2. Clutch Housing Cov er
5. Oil Pan
6. Oil Strainer
7. Oil Strainer Gasket
8. Oil Pump Assembly
9. Oil Pump Gasket
Pre-Steps
.
A Drain Oil
.
B Remove timing Belt ( Previous Section)
.
1 Remove Power Train Braket
(See Diagram on the Right)
- -
EF Series Gasket PN: 15149 87203 000 ;
8. Remove Pump
.
9 Attach New Pump Assembly
.
Torque to: 200+-40( kg cni)
10. Attach Strainer
i
T: 105+ -25kg.cm
(6 )
(5 )
1. Ring "O"
2. Attachment Screw
3. Cover, Oil Pump
4. Gear, Oil Pump Drive
5. Cotter Pin
.
6 Oil Pump Relief Retainer
7. Valve Compression Spring
8. Valve Oil Pump Reief
9. Seal, Type "T" Oil
Engine
Oil Pump Overhaul
.
1 Remove "O" Ring
2 . Remove Srews
3. Remove Oil Pump Cover
4. Remove Oil Pump Drive Gear
.
5 Remove Cotter Pin
Cottei Pin
.
6. Remove Inner Parts Relief Spring
Relief Valve & Retainer
.
1 Check Oil Pump Drive Gears
Mark
3. Body Clearance
( Between Rotor and Body)
See Diagram to die Right
.
4 Lighltv Lubricate With Grease
7. Install Pump
Cotter Pin
Engine
Oil Pump Parts
Oil Pump
. -
G isket#15197 87202 4)00
O Ruin
'
*-
900 3 01135-000
-
Oil Seal Tv)>e T #90043 11284 000 -
IfOlll $-
j
6V -
915JU-80010 000
/
-
90041 79059-000
-
#90041-58019 000
900 2
*- 501514)00
Oil Seal
-
#90043 11284-000
Cortei Pm
- -
90041 16414 000
Note: At This Time Only Part listed Above Are Available At Dealer Level
Engine
Oil Filter
Oil Filter
Denso
Tokyo Roki
- - -
EF Series S100 S110 S120 S130
- -
PN: 15601-87204 000 or PN: 15601-87703 000
-
09032-00100 000 Gasket Scraper
s u
s 09221-87206-000 Piston Pin Remover
Stand
T
- -
09221 87207 000 Piston Pin Remover
Bar
Torque=Kg.cm
Rings
Rod Piston & Pin
Main Bearing
Gasket
-
T:570+ 60kg.cm
T:80+ -16kg.cm
-
Bolts T:80+ 15
Oil Pan
T:250+ -SOkg.cm
Engine
Pistons & Block
Mark Piston
i
/
.
1 Remove Piston Rings with Pliers
// \\ /
i
I
Ring Pliers
A
SST09221-S7207-000
Piston Pin
.
2 If Piston Pins are to be Removed Use
Special Service Tools Listed Above
-
SST 09221-87200 000
, Thrust
\/
Clvlinders (Drank
i
1. Using The Diagram Measure The
Cylinder Roundness Minimum 6 i
Positions -f lOnun
Center
Limits: Between 68.00mm to 68.03mm
-t 10mm
Engine
Pistons 8c Block
.
2 Use a Cylinder Gage & Check Points
.
3 Clean out Piston Groves Using an Old
Ring or Use Ring Groove Cleaner Tool
5. Piston Measurment
=
Limit 67.965~ 67.995
11.5mm
Note: Measure From 11.5mm Down
as in the Diagram on the Right
Engine
Pistons & Block
Front
!i
i
/ j@3\ Piston M;trk
EF-NS & EF-ES
!
i
i «; 1
!
> Cylinder dnnpfl Piston tOnterl i
i68.00 mm 68.010mm ~ 67.965nnn ~ 67.975mm
2 68.010 miu ~ 67.020 mm 67.965nnn ~67.985mm
3 68.02 Onuu ~ 68 030m in Block ID
- 67.995mm ~ 67.995mm
J* i
EF-TS i
bf "
EF-TS
Clearenoe Limit
*< i
* \ - 5 - 0.005
0.01 o .n
v> 2 -
0.015 0 . Uivi 0.31
Engine
Pistons & Block
Limit: 0.07mm
-
Clearance: 0.020 mm 0.044mm
i
Engine
Pistons & Block
^ Spacer
Face
No. 1
Up Mark
No. 2
2
Engine
Pistons & Block
Ring Installation:
No.l & No.2 Rings Must
be 180 Degrees Opposite. Front Rear
Direction
Piston Intallation
S100-S110-S120-S130
—
N Made byKPR
=
R Made bv Riken
MhD BYM<CO
- -
» W041 "02<<1 000( 2)
-
<XKM2 M02' 000-
- - .)
9Il>li 60$12 OCK)(|
9« -
m -0513'J (KK>il ) ‘<MM2-Sil52-00 (Wj|
- -
y(HUl 05015 «KK 0}
'
*- -
900 2 53003 000
*- \
-
900 2 53003 000
- -
2 50073 000
*- -
900 2 50122 000
- -
90042 50122 000
- -
92122 60610 000
- -
90041 79104 000
Chapter 8
• Starter
• Starter Circuit & Specifications
• Alternator
• Charging Circuit & Specifications
Starter
Solenoid
Starter
Removal
Bajterv
A: w.
/ (+ )
Solenoid
!. Jack Up Vehicle
-
2. Disconnect Battery ( +) and ( ) terminals
3. Remove Starter Attachment Bolts ( 2)
4. Slide Back and Remove Solenoid Terminal Connector
and ( +) Battery Cable Connection from Solenoid
Starter
Starter Circuit & Specifications
Circuit
MT
AT Vehicle
Ignition Switch
A
AM60A 7
^
2.0sq (Van )
-1.05sq (Truck EFI)
0.85sq (Truck Garb)
Zff Starter Relay
t
Battery ] TO
I
a n
i
—flN
Nuetral Saftey Switch
\
Starter
P
F- j
Specifications
=
(B ) Bolt
Torque: kg.cm
Removal
Charging Circuit
8r
IG Switch ( 1G 1 )
IG
Engine>l0A
l 4B
AM 60A Gage 10A £
L !L IF
1
A
2.0sq (Tan )
l.Osq ( Truck EFI)
0.85 (Truck Garb)
f
/
1C i
// iL7? 'WPC
I Q
|
- -J
t Battery L
i
Alternator Unit
ll IC Regulator
Battery Charge Indicator Lamp
Specifications
Truck: EFNS
EFES (T) & EFNS(Van)
12v 40A
J2v 50A
15, 000
15, 400
14.2
13.6
- 14.8
-14.4
-
EFES(T AT) EFES ( V MT)
EFES ( V-AT) EFTS
- 12v 55A
12v 60A
18,000
18,000
13.6
13.6
-14.4
- 14.4
Chapter 9
Fuel System
• Carburetor Assembly
• Carburetor Removal & Replacement
• Carburetor Setting and CO HC Levels
• Carburetor Component Diagram
• Fuel Filter & Part Numbers
• Fuel Tank & Components (Truck) Base Carbureted
• Fuel Tank & Components (Van) Base Carbureted
• EFI Fuel Injection
• EFI Fuel Injection Components & Parts Location
• Engine Control Computer Connector Pin Guide
• Fuel Pump: Mechanical (Head Type), & Electric (Body or Tank)
• Fuel Lines EFNS (Truck)
• Fuel Lines: EFES
• -
Fuel Lines: Turbo Vehicle
• Fuel Lines: EFNS (Van)
• Fuel Lines: EFES (Van) Fuel Injected
Fuel Svstem
Carburetor Assembly
Accelerator Cable
Air Cleaner Hose \\ ater Bypass No.4
\ Water Bypass No.3 Witter Bypass No 1.
\
\
Carb Assembly
Fuel Hose
_ Vacuum
T ; 135 r 11
Riser Panel
.
3 Disconnect Air Cleaner Duct Hose
Connector
Fuel Svstem
Carburetor Installation
.
-I Connect Fuel Vapor Hose
.
7 Disconnect The Following: Water Bypass Hoses,
Mounting Bolts.
8. Remove Carburetor, Place Cover Over Intake
Opening.
Installation
Rubber
EF-ES
James Note: Idle Curcuit Trouble is 99% of the Time the ISC Valve
ISC is Connected to ECU (Rotary ISC) (RSO & RSC Connection)
EF-TS
EF-TS Series
Using a SST connector Pn#09991-87604-000
attach tachometer.
Set Idle to 900+-50 RPM
CO-HC Levels
EF-NS ( Use Mixture Screw to Adjust)
Idle CO-HC Level
CO 1.5+-1.0% to -0.5%
HC 900 PPM (Parts Per Million) or Less Throttle Ad Screw A , s -
;
;
Note: Ahvay Remove Fuel Relay When Changing Fuel Filter ( FI Engines)
Note: Fuel Pumps Olun Renting 0.2~3.0 Ohm
- -
EF-ES, EF TS, S100-S110-S120-S130 Part# 23300 S7508-000
- -
EF-ES, S100 S110 (Truck ) Part# 23300-87509 000 -
- -
EF-NS, EF-GS, S100-S110-S120 S130 (Truck) Part# 23300 87502 000 -
EF-NS (Van ) Part# 23300-87510 000-
Fuel System
Fuel Tank EF-NS-EF-ES (Truck )
Fuel Ga * je (Sendet )
I
/
Vent
Tube
$
/
Return l
Line j Gasket
/
Gasket
Hose Charcoal
Caniste #1
Breather Tube
$
' p
5
i
i F
? /
-
i
T
Torque =( kg.cm )
Fuel System
Fuel Tank Components EF-NS EF-ES - - EF-TS (Tiui)
—
Torque ( kg.ein )
= -
Note: * Parts Not Re usable
Miiin Fuel
Hose Fuel #1
Gasket
Fuel Return I
T:195+-25kg.cm
Inlet Hose gb
— * Washer
T:65+-35kg.cm
Fuel Tank
Fuel System
Fuel Injection
Torque: T = kg.cm =
Note: * Must Be Replaced if Dissasembled
T:35kg.cm
Injector ©
Fuel Line
Injector Cover
© T:-100+-50
/
/
,T:195+-J>9
—
Hose Pressure Regulator
O Ring
*
Rail Assemby
Injector Seat
Note: Fuel Injection System Is Controlled by The On-Board Computer. The Special
Adapter Cable Listed Below is Required to Check System Funtions .
This Adapter Can Also Bypass Fuel Pump Circuit. The Unit Connects Under
Drivers Side Steering Wheel Panel
Mechanics Note: 90° o of EFI Problems are "Dead Injectors" or Air Leaks. Use a
Stethoscope and Listen if Injector is Operating or Not . If Not
Check Connetor for Signal or Not..Also Spray a Bit of Carburetor
Cleaner Near Injectors and Notice For Idle Speed Change If Idle .
Increases or Decreases An Air or Vacuum Leak Has Been Detected.
No Injectors Are Operating Change Computer.
Fuel System
Fuel Injection Component Location
Charge Temp
TPS Sensor
Distributor
Speed Sensor
Test Connector
Fuel Pump
EF-ES
Ignition Coil
Oxygen Sensor
Engine Control ECM
-
ISC VSV
Speed Sensor
Charge
Temp Sensor /
Ignition Coil
Test Connector
Fuel Pump
Oxygen Sensor
EF-ES
#10! Injector
RPM Sensor
Speed Sensor
FC
1CI
^ ) FUEL Pump Relay
. Ignition Coil
RSOI
Rotary ISC Valve
RSCI
ACUP( Idle Up VSV
Pressure Sensor — Y)PIM
Oxygen Sensor IOX
ALTMi Alternator Cut Signal
Water Temp Sensor — [ 3 ) THW
A/C Temp Sensor 6
J ACEV AMP© A/C AMP (AC cut out Signal)
Throttle Sensor >VTH
w(i; - Diag Lamp
VF< -VF Monitor
|
27 26 25 24 23 2a ai 20 19 18 17 16 15 14 13 12 11 lo 9 6 7 ! 6 5 4 3 2 1
54 53 52 51 50 49 48 47 46 45 44 43 42 41
JAO |
39 38 37 M 35 34 33 32 31 30 29 28
ECU Computer
Connector Pin Guide
Fuel System
Fuel Pump
r Connector
'Pump Unit
Mount
Puinp Gasket Pushrod
Bracket
Pump Unit'
Note; See Following Pages For Vehicle Specific Tank Mount Location
Fuel System
Fuel lines Diagram EF-NS
Truck
-Fuel Tank
JSH• - fi
a
Fuel
Return Fuel Pump
Fuel
Main 1
m
os
Charcoal
Canister
!
1
!c
•tl
K't©
Carburator :;V \ '
t t*- to
Fuel Fliter
Fuel System
Fuel Line Diagram EF-ES
Truck
Fuel Injected Vehicle
Fuel Tank
Wrnmmk
Fuel Return Fuel Pump
j?sT!
jy «J
Fuel Main
mi
Charcoal Canister
Fuel Filter
Fuel System
-
Speci al Turbo Charged Vehicle
Fuel Tank
Fuel Pump
Return Line
Charcoal
Canister Fuel Rail
Fuel
Main
Fuel System
Fuel Lines Diagram EF -NS
Carbureted Vim
Fuel Tank
Fuel Return
Jy / \ \
Charcoal
Canister
u
Fuel
Main Carbitrator
Line
Fuel Pump
Fuel
Filter
Fuel System
Fuel Lines Diagram EF ES -
Fuel Injected Van
Fuel Tank
m
Charcoal
Canister
"
^
Kp
m • VFuei Pump
Fuel Return
s-:
m
0"\
Fuel Mai \ )
1
line \ PS
\\
a
3
v, ^
m
Fuel Filter
Chapter 10
Charcoal Canister
( Outer Vent )
D
i i3
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Fuel Tank
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Yokohama Motors [English]
Switch
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/ Temp Operated Valve
Choke
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—
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Outer Vent V«rh e
Check Valve
-
EX Temp Overheat
f
:
Warning light
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2 . Exlianst Temp
Sensoi
Emission Control
EF-NS (Truck )
EGR Port
EGR Fuel Pomp
ahe AD Port
Vacuum Switch Charcoal TVSV
Canister N
' Air Filter
Beige Port
Throttle Position
Yellow
Brown
--
' Accelerator Cable
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Vacumu Switch ,
Ni -
AC Eqniped Vehicl VSV
Emission Control
EF-NS (Van)
Check
Modulator Take Orange
I
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Distributor m n< \
A
Fuel Pinup
A
AD Port
EGR Valve e Black
!
EGR Port TVSV
X Brown
Jets o !
rrv
Charcoal Canister Beige Poi' t^' A|r Filter
Yellow
Green A Section
Vacuum Switch
Vacuum
Switch
B Section
F
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By
AC Equiped Vehicle
Emission Control
EF-ES Series
Charcoal Canister
S7ZZ
Fuel Tank
Thoftle
Sensor
Surge Tank
1
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02 Seusor
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Injector
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Catalytic
Convertor
5
(S Exhaust
7 Temp
3V
V5 Computer Sensor Relay
T
Check
n
Speed
Sensor Pump
——
Power Fuel
Ignition Coil Pump jljt (
Relay
www.yokohamamotors.com
[English] Exhaust Temp
Overheat Warning
Lamp (Dashboard )
Emission Control
EF-ES ( Truck )
-BYT
) Only
To Vacuum Tank
Presure
Regulator
Check Valve
(4\VD)
Pressure Sensor
.Throttle Body
Air Cleaner
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fi \ AC Vehicle
AC Fast Idle
/
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To Charcoal Canister [English]
Emission Control
EF-ES (Van)
4WD Only
To Vacuum Tai
Li,
Pressure
•' Regulator
Pressure
Sensor i
II AC Fast Idle
'dr di /
Tlirottle Body f — f
1
To Charcoal
Canister
Air Cleaner
Emission Control
-
EF TS Series
YTV
Gray
Black
Air Cleaner
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7
AB Valve
35
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Check Valve !
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Pressure
Regulator
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VSV
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Pressure
Sensor Check Valve
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Orange
To Charcoal
Canister
Chapter 11
2WD-4WD
Differentials-Driveshaft (s)-Axels
- .
(3 ) ( 4 )
.
(15 )
( 44 )
/( 12.)
1. Union
2. Plug
3. Seal: Oil
4. Cover: Differetial Clutch Case
5.0 Ring
6. Case: Clutch
.
7 Tube
8. Snap Ring
9. Thrust W ashers 26. Sloted Pin
.
10 Sleeve: Clutch 27. Shaft: Pinion 43. Shim
11. Piston: Differential Lock Clutch 28. Shaft Gear 44. Differential Carrier
12. Seal: Oil Type S 29. Side Gears
13. O Ring 30. Thrust W asher
14. Pin: Sloted 31. Case
15. Seal: Oil Type S 32. Nut
16. Snap Ring 33. Washer
17. Hub: Clutch 34. Flange
18. Front Diff Cover 35. Seal: Type T Oil
19. Diff Bearing Cap 36. Pinion: Drive
.
20 Shim 37. Bearing
21. Bearing 38. Shim
22. Ring Gear 39. Spacer
23. ( LH) Case: Ring Gear Housing 40. Front Bearing
24. ( RH) Case: Ring Gear Housing 41. Outer Race
25. Thrust Washer 42. Outer Race
Differential
Front Differential Flange Oil Seal Replacement
Tools
%
Puller: Oil Seal gfgr 53
#09308-10010-000
T: 1200+-200kg.em
Attach Here
1. Lift Up Vehicle
2. Remove Driv e Shaft
. -
3 Attach Special Tool (Flange Holder) as in
.
Diagram on Right Hold onto Holder and
Use Breaker Bar to Remove Attachment Nut
Flange
Note: Nut Must Be Replaced Holder
.
5 Remove Oil Seal and Discard
Torque: = kg.cm
=
(B) Bolt
=
( N ) Nut
-
T: 775+ 75kg.cm
=
(\V ) Washer
T: 425+ 75-
(2)
T: 250+ 60 -
5 -
T:425+ 75 V
-
T:425+ 75kgem
ft] (1)
( 4) f -
T: 475+ 75
9 *
J
-
T: U50+ 150kg.cm
T: 950+-150
-
T: 950+ 150 '
— K
f —
>4 T: 475+ 75-
-
T: 950+ 50kg.cm
50
o
Q
r\T
1
o
t/ U
( 4) T: 1200+-200
(2) T: 850+-50
.
1 Cap: Bearing 13. Outer Race: Front
2. Case Assembly 14. Outer Race: Rear
3. Shim 15. Shim
4. Nut 16. Carrier Case
5. Washer 17. Bearing
6. Flange Assembly 18. Ring Gear
7. Seal: Oil Type T 19. Shaft: Differential Pinion
8. Pinion: Differential Drive 20. Pinion Gear
9. Bearing: Tappered Lower 21. Side Gear
10. Shim 22. W asher: Side Gear Thrust
11. Spacer
12. Bearing: Tappered Lower
Differential
Rear Differential W / Diff-Lock Option
( 4) T: 1200+ 200 -
1. Cap: Bearing .
13 Outer Race: Front
2. Case Assembly 14. Outer Race: Rear
3. Shim 15. Shim
.
4 Nut 16. Carrier Case
5. Washer 17. Bearing
6. Flange Assembly 18. Ring Gear
.
7 Seal: Oil Type T 19. Shaft: Differential Pinion
8. Pinion: Differential Drive 20. Pinion Gear
.
9 Bearing: Tappered Lower .
21 Side Gear
.
10 Shim 22. Washer: Side Gear Thrust
11. Spacer
12. Bearing: Tappered Lower
Differential
Tools
Flange Holder - -
#09330 87301 000
Seal Installer -
#09635 20010-000
1. Flange Assembly
2. Oil Seal Type T
-
T: 1200+ 200kg.cm
Replacement
.
6 Attach Flang Holder Tool and Use a
Torque Wrench to Set to Specification
-
Torque: 1200+ 200kg.cm
7. Install Driveshaft
-
Note: Majority of Diff Lock Problems are Vacuum Related
=
(R ) Bolt Removal
1. Lift Up Vehicle
Attachment .
2 Remove ( 2) Vacuum Hoses
Point 5. Remove ( 4) Attachment Bolts
Note: Sensor Equipped Disconnet
Connector
Actuator
T: 185+ -35kg.cm
Installation
Line Up These Two
.
1 Clean Surfaces
2. Attach New Gasket
3. Use Diagram on Right to Line Up Arm
and Slot
-
4. Attach Bolts & Torque: 185+ 35kg.cm
5. Check Differential Oil and Add if Low
-
OIL: SAE 90W (API GL5)
Capacity: 1.3 Liters
Vacuum Ports
Actuator Testing
L Remove Actuator
Rear Differential
Driveshaft
Diff-Lock Switch
(Brown) £ M
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Rear Axel Clutch Hub
\
\ x 1
\i
VSV 2
l r-
J
1 st
2
yRevj T/M
72r
To
Intake P P VSV 1
/
Manifold
Vacuum vIG Switch
“
. W
\
7
CheckValve ( Gray) Actuator
- f - Battery ( A) Chamber
\
Fuse Box (B) Chamber
i 20A Heater Fuse
Note: Common Problems 1. Check Valv e 2. Leak in Hose 3. Vacuum Port Switched
Caution: Never Spray Carburetor Cleaner in Vacuum Lines! Check Valve and
Actuator Diaphragm Will Be Destroyed
=
Torque: kg.cm
=
(B) Bolt
CN
(B)T:457+ 75
!
-
I
.1
Front Driveshaft
-
T:425+ 75kg.cm
Removal
'
•
T
.
1 Lift Vehicle
2. Use Yellow Paint and Mark Present
Position of Flange and Yoke. This
Mark Will Be Used for Installation
Guidence.
\
Mark With Yellow
Paint
Driveshaft
Front Driveshaft Removal
3. Support Differential
.
4 Remove the ( 5) Bolts Supporting the Rear
Left Carrier Support Bracket as Seen in the
Right Side Diagram
-
5. Pull Back Driveshaft 5 iOcm and Move Front
Portion to Left Side of Vehicle. Pull Driveshaft
Forward and Remove From Vehicle. Oil From
Transfer Case May Leak Out, Place a Bucket
Under Transfer Case
.
7 Universal Joint Test: Follow the Diagram on Right
and Test All Direction Movement. If Failure
Replace Universal Joint.
Driveshaft
Front Driveshaft Installation
-
9. Torque Driveshaft: 475+ 75kg.cm
Dail Gage
.
1 Raise Vehicle
2. Use Yellow Paint and Mark Driveshaft Position
3. Remove Attachment Bolts
.
4 Slie Driveshaft Forward (Front of Vehicle) and
Lower Out
u VJ
6
.
5 Use a Dail Gage and Inpect Driveshaft Round Out- U -Joint
Limit: 1.0mm
Adapter j #09257-87201-000
Adapter #09515-21010-000
Axel
Rear Axel Removal
\(N) T: 400+-100kg.cm
T: 2200+-400kg.cm
1. Cotter Pin
2. Drum S / A: Brake
3. Back Plate (Dust Shield)
4. Spacer
5. Shaft Assembly: Rear Axel
6. Wheel Bearing
7. Oil Seal: Type T
Axel Remov al
.
6 Use Slide Hammer and Screw On Attachment,
Pull Axel
-
Note: Bearing Can Not be Re Used
.
8 Use Oil Seal Puller and Slide Hammer to Pull
Out Oil Seal
Note: Oil Seal Can Not be Re-Used
Assembly
!!
11. Use a Press and Press On New Bearing
Adaptei
.
14 Make Sure Grease Applied to Area Noted on Right
t
i
'
i
i
!
I
I
v4
.
1 Boot Attachment Bands
.
2 Circle Clip
.
3 DOJ Assembly
4. Snap Ring
5. Ball Retainer Cage Assembly
6. Boot
7. Boot Bands
8. Boot
Axel
Front Axel Rebuild
- -
1. Use ( ) Screwdriver and Un Clip Boot
Bands.
2. Remove All Old Grease
.
3 Use (-) Screwdriver and Remove Retainer
Clip
.
5 Remove Snap Ring
Axel
Front Axel Rebuild
-
6. Attach Service Tool #09950 20017-000
7. Remove Cage Bearing Assembly
Inspection
5
Axel
Front Axel Rebuild
Assembly
-
4. Attach C Clip
5. Pack Boots with Minimum 65grams
Of High Temp Long Life CY Joint
Grease
=
(B) Bolt
(W)= Washer
=
( N ) Nut 2\\ D Driveshaft
f 94512-01000-000( 4) Washers
4WI) Driveshafts
90041-01359-000( 4) ( B)
Front
U-Joint
Wheel Bearing!s)
@ Q) 2WD Hub
411 #43431-87503-000 ( Non ABS )
.
0 4BS #43401-87502-000
&
4WD Front
Disk ( Brake )
Castle Nut#90041-71053-000( 1)
Wheel Bearing(s)
Front
W heel Bearing
(JU1) #90043-63221-000
#D
Right Hand Left Hand
Assembly
Band &
d? e0
% 0
Inboard
so,
o Outboard
Joint Set
-
Left Hand (All) #43404 87591 000 -
-
Right Hand (All) # 43404 87592-000
Band Set
( All ) #04438-87518-000
W heel Bearing
Oil Seal
Oil Seal
(All) -
#90043 11312 000-
Rear Brake Drum
-
S100, S110, S120, S130 # 42403 87514 000 -
S140 -
#42403 87516 000 -
S120 SJL30 ( TBO) ABS #42403-87515 000
, -
Stud Bolts
(All) -
#90049 12044 00 -
Bearing: Wheel
S110, S130 #90043-63230 000 -
-
S100, S120, S140 #90043 63236 000 -
Chapter 12
Clutch System
=
Example: 214 2WD Non-Turbo Van
'
Clutch System
Clutch Cable
Components
(5) ./
Cover
Replacement & Adjutment
l!
1. Remove Clutch Housing Cover (Dust) It
.
2 Remove Cable Clamp
Installation
.
—
9 Set Cable Free Play
Limit: 15 25mm
—
Clutch Pedal Deck Height
Limit: 139 149mm
Clutch System
Clutch Specialty Tools
1. Pressure Plate
2. Clutch Disk
3. Bearing
4. Bearing Retainer
5. Clutch Fork
.
6 Spring: Release Fork
7. Pivot Support
Limit: 0.10mm
Note: Inspect Flywheel Ring Gear Teeth. If
Teeth Are Missing or Worn Replace
.
5 Measure Rivet Depth
Limit: 0.3mm
-
Clutch Disk Round Out Limit:1.0mm
Installation
.
1 Replace or Install Release Bearing and Grease
as Noted on Right
-
Use High Temp Long life Chassis Grease
Clutch System
Clutch Installation
.
2 Attach Release Bearing Hub Clip to
Release Fork as in Diagram to Right
Crease ONI A
'
.
6 Use Aligninet Tool And Line Up Disk
Tool
Clutch System
Clutch Assembly & Parts
.
7 Attach Pressure Plate Over Clutch Disk and Place Alignment Tool Between
8. Install (6) Pressure Plate Attachement Bolts and Torque in Order Lited Below
Torque Order
. -
9 Torque Pressure Plate Bolts to T: 185+ 35kg.cm
.
10 Remove Alignment Tool
11. Install Transmission!
Parts
. - -
Release Bearing Ret liner Clip (All) #31232 87505 000
Pressure Plate
-
S120, S130 OVZM #31210 87237 000 -
S100, S110, S120, S130, S140 #31210-87526-000
Clutch Disk
-
(Universal) #31250 87560-000