Toyota 2H Repair Manual
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Toyota 2H Repair Manual

Toyota 2H Repair Manual

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TOYOTA
ENGINE
REPAIR
MANUAL
Nov., 1985

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Table of Contents

Troubleshooting

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Summary of Contents for Toyota 2H

  • Page 1 TOYOTA ENGINE REPAIR MANUAL Nov., 1985...
  • Page 2 Applicable models: series TOYOTA MOTOR CORPORATION A l l inform a t i o n contained in this manual is t h e most up-la-dale a l the lime o f publication. However, s p e c i f i c a t i o n s a n d pro­...
  • Page 3 S E R V I C E S P E C I FICATIO N S STANDARD B O L T TO RQU E S P E C I F I CATI O N S SST AN D S S M © 1986 TOYOTA MOTOR CORPORATION All rlgh'� reserved. This book reproduced or copied.
  • Page 4 I N - 1 INTRODUCTION Pag e HOW TO U S E T H I S M A N UAL I D E NTI FICATION I N F O R M A T I O N G E N E R A L R E P A I R I N S T R U C T I O N S I N -4 A B B R E VIATIO NS U S E D I N T H I S M A N U A L I N - 7...

  • Page 5: How To Use This Manual

    IN·2 I N T R O D U C T I O N How to Use This Manu al HOW TO USE THIS MANUAL To assist in finding your way through this manual. the Section Title and maj o r heading given at the of every page.

  • Page 6: Specifications

    How 10 Use This Manual INTRODUCTION IN-3 The procedures are presented in a step-by-step fOrmat: The illustration shows what to do and where to do it. • The task heading tells what to do. • The detailed texl tells to perform the task and gives •...

  • Page 7: Identification Information

    I N -4 I N T R O D U CTION I d e n t ifica tion I n f o rmation . General Repair Ins truc t i o n s I D E N TI F I CATI O N I N F O R M A TI O N E N G I N E S E RIAL N U M B E R The engine serial number i s s t a mped o n the left side o f the cylinder block...
  • Page 8 INTRODUCTION IN-5 Gene ral Repair Instructions Precoated Parts Precoated parts are the bolls, nuls, etc. Which are coated with a seal lock adhesive at the facto ry. If a precoated p a rt is ti htened, loosened or ca used move in any way, it must be precoated with t h e specified ad hesive Recoating of Precoatlng Parts...
  • Page 9 IN·6 INTRODUCTION General Repair I n s t ructions (d l When steam cleaning a n engIne, protect t h e a i r filter a n d injection p u m p from water. Never use a n i m pact wrench to remove or install t h er­ m o switches o r t h e rmo sensors.

  • Page 10: Abbreviations Used In This Manual

    IN-7 INTROD UCT I O N Abbreviations Used in This Manual ABB REVIATIONS U SED IN TH I S M A N U AL Air Conditioner Automatic Transmission ATDC After Top Dead Center Bottom Dead Center BTDC Before Top Dead Center EDIC Electrical Diesel Injection Control Exhaust...

  • Page 11: Engine M Echanical

    C O M P R E S S I O N C H E C K 12HI E M - 3 6 C O M P R E S S I O N C H E C K ( 1 2H·T1 E M - 3 6...

  • Page 12: Preliminary Checks

    Diesel E n g i n e Diagnosis E M - 2 E N G I N E MECHA N ICAL D I ES E L E N G I N E D I A G N O S I S G E N E R A L caused of fuel system...
  • Page 13 ENGINE ME CHANICAL EM-3 Diesel Engine Diagnosis PREC AUTI O N The basic trou bleshooting procedures for diesel engine (valve clearance, compression, bearings, valves, pistons. etc.) are the same checks you would make for a gasoline engine. The r epair of the injection pump requires consid erable skill and use of special t est bench.
  • Page 14 E M - 4 E N G I N E M E CHA N I C A L Diesel Engine Diag nosis E N G I N E C RAN K S N O R M A L L Y BUT W I L L NOT S TART (Possible Cause) (Check Procedure a n d C o r r e c t i o n M e thod) N O FUEL TO I N JECT I O N...

  • Page 15: Fuel Leakage

    ENGINE MECHANICAL EM-6 - Di esel Engine Diagnosis 8, IMPROPER INJECTION Check Ihe injection liming. (See page EM-23) Injection timing: ��: :�gg' ��H-T nol as spe c i f ied, injection t i m ing must be read­ justed. 9. FAULTY INJECTION NOZZLE Check the injec tion pressure w i t h nozzle lester.

  • Page 16: Improper Operation

    EM-S ENGINE MECHANICAL - Diesel Engine Diagnosis IMPROPER INJECTION Refer to item of ENGINE CRANKS NORMAU Y TIMING BUT WILL NOT START, above pipe 10 IMPROPER OPERATION With the engine idling. loosen the injection INJECTION NOZZLE OR each cylinder in order. and check if the idle speed D E LIVERV changes.

  • Page 17: Lack Of Power

    E NGINE MECHANICAL EM·7 esel Eng agnos LACK OF POWER NOTE' First check that the air is not clogged or the engine overheating. cleaner check Not applicable if the customer desires an output power higher than specified for that vehicle. is in contact with the For accuracy.

  • Page 18: Exc E S S I V E Fuel C O N Sum Ption

    EM-8 ENGINE MEC HANICAL - Diesel Engine Diagnosis EXC E S S I V E EXH A U S T SMOKE NOTE: ,. Check that the air cleaner is not clogged. Check with the customer whether or not oil consumption has been excessive. (Possible Cause) (Check Procedure and Correction Method) Refer...
  • Page 19 ENGINE MECHANICAL EM-9 Diesel Engine Diagnosis IMPROPER INJECTION TIMING Refer to item 8 of ENGINE CRANKS NORMALLY BUT WILL NOT START. FAULTY INJECTION NOZZ LE item 9 of Refer ENGINE CRANKS NORMALLY BUT WILL NOT START ENGINE NOISE WHEN WARM (Cranking Noise with Excessive Vibration) (Check Procedure and Correction Method)

  • Page 20: Operation

    Diesel Engine Diagnosis E M · 1 0 E N G I N E M E C H A N I C A L E N GIN E WILL NOT SHUT O F F W I TH STOP B UTTO N OR KEY (C heck Procedure and Corre c t i o n M e thod) (Possible Cause) Operate stop lever (adjusting leved on side of...

  • Page 21: Diesel Electrical Sy Ste M Diag N Osi S

    Diagnosis ENGINE ME CHANICAL EM-II f2Hl Diesel Electrical System [2H] DIESEL ELECTRICAL SY STE M DIAG N OSI S E N G I NE DOES NOT START COLD NOTE: Battery voltage at teast volts 24 volts) - ignition switch OFF.
  • Page 22 Diagnosis [2HI EM-12 ENGINE MECHANICAL Diesel Electrical System temperature Place ignition switch check current flow to terminal 5 of timer is in accordance Clnd with coolant Pre-healing Duration Quite (See Ti Thao on pag 5T -3!. r characteristics Diagram D"'''''' No Voltage is faulty and replaced.
  • Page 23 112H-TJ E N G I N E M E C H A N I C A L EM·13 Diesel Electrical System Diagnosis DIESEL ELECTRICAL SYSTE M DIAGNOSIS [12H- T] ENGINE DOES NOT STA RT WHEN C O LD volts NOTE: Battery voltage at least 1 2 (or 24 volts) - ign ition switch O F F .
  • Page 24 EM-14 EN G I N E M E CHANICAL 11 2H- D i esel E l e c t r i c a l S y s t e m D i a g n o s i s I N S P E C T C O N T R O L SECTION NOTE: Perform this inspec t i o n with the intake heater con nector f u lly connected.
  • Page 25 112H- TJ E N G I N E MECH A N I C A L Diesel Electrical System Diagnosis EM-1S CONTINUED FROM PAGE EM-14 T -91 When the ignition switch is lurned ON. D i d No . int ak e he ate r Replace the No.
  • Page 26 11 2H· TJ ·16 Diesel Electrical System Diagnosis E N G I N E M E C H A N I C A L EM·15 CONTINUED FROM PAGE With the engine started, does terminal of the Pre-heating have battery voltage for...
  • Page 28 E N G I N E M E C HA N I C A L E M · 1 8 f12H- Tl Turbocha r g e r Diagnosis ABN ORM AL N O I S E (Possible Cause) (C heck Procedure a n d Correction M e thod) TU RBOCHA R G E R HEAT I N S U LATOR C heck f o r loose, improperly Ins t a l led o r defo rmed R E S O N N A N C E...

  • Page 29: Tu R Bo C H A R G E R E L E C T R I C A L System D Ia G N O S I S

    EM - ' 9 E N G I N E M EC H A N I C A L T u rbocharger Electrical System Diagnosis ( 1 2 H � T l 1 0 ' TU R BO C H A R G E R E L E C T R I C A L SYSTEM D IA G N O S I S [ 1 2 H - TJ Troubleshooting of Turboc harger I n dicator L i g h t and W a r n i n g L i g h t Operation ���...

  • Page 30: I N S Pe C T I O N O F B Attery

    EM-20 E N G I N E M E C H A N IC A L - Engine u n e E N G I N E T U N E · U P I N S P ECTI ON O F E N G I N E COO LANT ( S e e steps a n d 2 o n page CO-3) I N S PECT I O N O F E N G I N E O I L...
  • Page 31 INS PECTION O F INJECT I O N NOZZ LES (See steps 4 to 6 on pages FU-4 and 5) 2H (See steps 6 to 8 o n pages F U - l 0 and 1 1 ) 1 2 H - T...

  • Page 32: A D J U St M E N T O F Valve C L E A R A N C E S

    E N G I N E M E C H A N I C A L Engine T u n e - u p A D J U ST M E N T O F VALVE C L E A R A N C E S WARM U P E N G I N E reach -norm a l Allow the engine .
  • Page 33 M a k e a n i n s pection D i p e with a inject ion p i p e as s h o w n . About in.) ( 1 2H-TI ( 1 . 9 7 REMOVE I N TA K E A I R C O N N ECTOR AND INTAKE...
  • Page 34 E N G I N E M E C HAN I C A L Engine T u n e - u p (2H AfT and 2 H - Align t h e m a r k s of t h e SlOp l e v e r a n d injec t' l on p u m p govemor h o u s i n g .
  • Page 35 E N G I N E M E C H A N I C A L E n g i n e Tu n e - u p EM-25 T i g h t e n t h e f o u r nuts hol ding t h e injection pump t o t h e retai n e r.
  • Page 36 E M -26 E N G I N E M E C H A N I C A L Engine T u n e - u p A D J U ST M E N T O F I D L E S P E E D A N D MAXI M U M S P E E D [ 2 H M IT] I N IT I A t C O N D I T I O N S Air c l e a n e r i n s l a l led...
  • Page 37 E N G I N E M E C H A N I C A L E n g i n e T u n e - u p EM-27 ( b ) S t a rt t h e engine. t h e D e p ress the accelerator ped a l a l l way.
  • Page 38 Tune-up E M - 2 S E N G I N E M E C H A N I C A L - E n g i n e ADJ U S T M E N T I D LE S PE E D AN D M AXI M U M S P E E D [ 2 H AfT a n d 1 2 H -TJ I N IT I A L C O N D I T I O N S ( a )
  • Page 39 E N G I N E M E C H A N I C A L Engine Tune-up E M · 2 9 Stan the engine. Depress the acce leralor pedal all the way. C h e c k t h e maximum speed . M a x i m u m speed: 4 , 1 70 r p m [ e )

  • Page 40: I N I T I A L C O N Ditions

    E M - 3 0 E N m N E M E C H A N IC A L E n g i n e T u n e - u p A D J U ST M E N T O F P O W E R S T E E R I N G I D LE - U P S E TT I N G S P E E D ! 1 2 H - T AfT] I N I T I A L C O N DITIONS Air cleaner i nstalled...

  • Page 41: Engine Mechani Cal

    - 3 1 ENGINE MECHANI CAL Engine Tune-up A D J USTM ENT O F AIR COND I T I O N E R I D L E - U P S ETT I N G S P E E D [ 2 H MIT] INI TIAL CONDITIONS Air cleaner installed Normal operating coolant t emperature...
  • Page 42 Engine Tune-up E M - 3 2 E N G I N E M E C H A N I C A L A D J U ST M E N T OF A I R C O N D I T I O N E R a n d 1 2 H -TJ I DLE- U P S ETTI N G S P E E D...
  • Page 43 E M - 3 3 I N S P ECT I O N O F I N TAKE S H UTTER [2H AfT] I N S PECT I N T A K E S H U T T E R AND ACTUATOR...
  • Page 44 E N G I N E M E C H A N I C A L - Engine T u n e - u p E M - 3 4 I N S PEC T I O N O F I N T A K E S H UTTER [ 1 2H -TJ I N S PECT INTAKE SHUTTER A N D ACTUATOR...
  • Page 45 E N G I N E M E C H A N I C A L Com pression Check [ 2 H l E M - 3 6 COM PRESS I O N C H E C K [2 H ] N O T E : I f there i s lack o f power, excessive o i l consump­...

  • Page 46: C O M P R E S S I O N C H E C K

    EM-36 ENGINE M E C H A N ICAL Compression C h e c k '1 2 H - T l C O M P R E S S I O N C H E C K [ 1 2 H - TJ NOTE: there is lack of power, excessive oil consump­...
  • Page 47 - Turbocharger E N G I N E M E C H A N I C A L I' 2H- E M - 3 7 T U R B O C H A R G E R [ 1 2 H - �...
  • Page 48 E M · 3 8 \ 1 2 H - E N G I N E M E C H A N I C A L TurbOCharger O N · V E H I C L E I N S PECT I O N OF T U R B OC H AR G ER I N S P E CT I N T A K E A I R S Y S T E M C h e c k f o r leakag e or...
  • Page 50 1 1 2 H - T J E M ·40 E N G I N E M E C H A N IC A L Turbocharger R E M O V A L O F TU R B O C H A R G E R ( S e e pa g e E M - 3 9 J D R A I N E N G I N E C O O L A N T (See p a g e C O - 3 l R E M O V E V A C U U M H O S E S .
  • Page 51 1 1 2H- Turbocharger E N G I N E M E C H A N ICAL E M - 4 1 R E M O V E HEAT I N S U LATORS Remove the five b o l t s a n d two heat i ns u l a tors.
  • Page 52 E N G I N E M E C H A N I C A L E M · 4 2 Turbocharger 1 1 2 H -T I Remove t h e four nuts h o l d i n g t h e turbocharger to t h e exhaust manifold.

  • Page 53: I N Sta Llat I O N O F T U R B Och A R G E R

    E N G I N E M EC H A N I C A L Turbocharger f 1 2H- TI EM·43 assembly. I N S PECT AXIAL PLAY O F I M P E L L E R W H E E L Insert a d i a l indica tor into t h e exhaust side.
  • Page 54 E M ·44 E N G I N E M E C H A N I C A L Turbocharger 1 1 2H- I N STALL O I L P I P E I n s t a l l a new gasket and t h e oil pipe with new t w o n u t s . D o not torque t h e n u t s y e t .
  • Page 55 700 kg-em E N G I N E M E C H A N I C A L Turbocharger ! 1 2 H - E M -45 I N STALL T U R B O C H A R G E R STAY Install the stay with the t h ree b o l t s .
  • Page 56 11 2 H -TI EM-46 E N G I N E M E C H A N ICAL Turbo c h a rger I N STALL I N T A K E A I R C O N N E CTOR 1 0 .

  • Page 57: Cylinder Head

    Cvlinder Head E N G I N E M E C H A N I C A L E M -47 C Y L I N D E R H E A D C O M P O N E NTS Grommet Glow Pl u g Connector C,lind., Head Cove'...
  • Page 58 ECHANICAL - Cylinder Head 1 2 H -T Washer Seal Cyl i n der Head Cover Gasket Val v e Rocker Shaft Assembly...

  • Page 59: Drain Engine C O O L A N T

    E N G I N E M E C H A N I C A L - Cylinder Head E M - 4 9 R E M O V A L O F C Y L I N D E R H E A D [ 2 H ) ( S e e p a g e E M -41) DRAIN ENGINE C O O L A N T (See page CO-3) R E M O V E PCV H O S E...
  • Page 60 E M · 5 0 E N G I N E M E C H A N I C A L - C y l i n d e r H e a d collar malOr. { b l R e m o v e t h ree b o l t s , and E D I C ( M IT (w/o E D I C S Y S T E M ) )
  • Page 61 E N G I N E M E C H A N ICAL Cylinder Head E M - 5 1 1 0 . S E PARATE E X H A U ST M A N I FO L D S Separate the I r o n t and rear e x h a u s t m a n i f olds.
  • Page 62 E M · 5 2 E N G I N E M E C H A N I C A L - C y l n d e Head 1 4 . R E M O V E P U S H RODS Remove t h e twelve push rods i n order.

  • Page 63: R E M O V A L Of Cyli N D E R H E A D

    E N G I N E M E C H A N I C A L C y l i nder Head E M - 5 3 R E M O V A L OF CYLI N D E R H E A D [ 1 2 H -TJ (See page E M - 4 8 1 R E M O V E T U R B O C H A R G E R (See s t e p s 1 to l O o n pages E M - 4 0 t o 4 2 )
  • Page 64 EM-54 E N G I N E M ECH A N I C A L Cylinder Head Remove t h e twelve nuts, plate washers, exhaust manifold and two gaskets. S E PARATE E X H A U S T M A N I F O L DS Separate the f r o n t and rear e x h a u s t mani foldS.
  • Page 66 E M - 5 6 E N G I N E M E C H A N I C A L Cylinder H e a d D I S A S S E M B L Y O F C Y L I N D E R H E A D 1 2 H- (See pag e E M - 4 7 1 ( See p a g e E M -4 8 1...
  • Page 67 E N G I N E M E C H A N I C A L Cylinder Head E M - 5 7 I N S P ECT I O N . C L E A N I N G A N D R E P A I R O F C Y L I N D E R H E A D COM P O N E NTS C L E A N T O P O F P I S T O N S A N D TOP O F BLOC K Tum the cra n k s h a f t and bring each piston...
  • Page 68 E N G I N E M E C H A N I C A L - E M · 5 8 linder Head I N S PECT C Y L I N D E R H E A D FOR FLAT N E S S Using a precision stra i g h t e d g e a n d feeler g a uge, measure the surfaces contacting the cylinder block and m a n i f o l d s for warpage.
  • Page 69 Head E N G I N E M E C H A N I C A L - Cylinder E M - 5 9 g a s k e t C L E A N V A L V E S Use a scraper.
  • Page 70 E M · 6 0 E N G I N E M E CH A N ICAL - C y linder Head Using a caliper g a u g e, measure ·the bushing bore diameter o f t h e cylinder head. the bushing bore diameter of the cylinder head i s more 1 4 .
  • Page 71 Head E N G I N E M E C H A N IC A L C y l i n d e r E M - 6 1 overall C heck t h e valve length. Standard overall lengt h : I n take 1 20.7 mm (4 .
  • Page 72 E N G I N E M E C H A N I C A L Cylinder H e a d 1 2H.T II 2H· T Intakel loto'. I f t h e seating is loa Iow a n the valve face. u s e Others 6 0 "...
  • Page 73 E N G I N E M E C H A N ICAL Cylinder Head E M · 63 1 4. I N S PECT ROCKER A R M A N D SHAFT Check the valve contacting surface of the rocker arm for wear.
  • Page 74 E M · 6 4 E N G I N E M E C H A N I C A L Cylinder H e a d • Using a m i c rometer. measure diameter of t h e ro c k er s h a f t R o c k e r s h a f t d i a m e ter: 1 8 .472 - 1 8 .493 m m (0 .

  • Page 75: E N G I N E Mechanical

    M a x im u m warpa g e : tnlake 0.60 m m 10. 0 1 9 7 in.) E x haust 1 2H -T IFront a n d read 0.30 m m 10.01 1 8 in.1 (Read (Front) 0.30 m m (0.0 1 1 8 in.)

  • Page 76: Install V A L V E S

    E M - 6 6 E N G I N E M E C H A N I C A L C y l i n der Head ASS E M B L Y O F C Y L I N D E R H EA D (See page E M -4 7 ) 2 H ( S e e p a g e E M -481 1 2 H -T N O T E :...
  • Page 77 E N G I N E M E C H A N I C A L - C y l i n der Head E M - 6 7 the valve f��mer, Using a p l a s t i c - faced h lightly tap �.

  • Page 78: I N St A L Lati O N Of C Y L I N D E R H E A D

    E M - 5 8 E N G I N E M E C H A N I C A L C y l i n d e r Head [ 2 H ] I N ST A L LATI O N OF C Y L I N D E R H E A D (See page E M ·...
  • Page 79 ENGINE MECHA N I C A L Cylinder Head EM-69 INSTAll C Y L INDER HEAD COVER Install a new gasket to the cylinder head cover. I nstall the cylinder head cover with the fo u r seal washers and cap nuts. 70 k g ·...
  • Page 80 Head C y l i n d e r E M - 7 0 E N G I N E M E C H A N I C A L C e l Assemble the fronl and rear m a n i f olds. INSTAll E X H A U S T M A N I F O L D S I n s l a l l new s i x g a s k e t s and t h e e x h a u s l m a n i f O l d s w i t h the t w e l v e plate wash ers and new n u l s .
  • Page 81 E N G I N E M E C H A N I C A L - C y l i n der Head E M - 1 0 . [MIT Iwl E D I C S Y S T E M l l with I N S T A L L E D I C MOTOR I n s t a l l the E D I C m o t o r...
  • Page 82 E M · 7 2 E N G I N E M E C H A N I C A L C y l i n d e r H e a d 1 4 . I N S T A L L I N J EC T I O N N O Z Z L E S (See sleps 1 to 3 on page E M - B ) 1 6 .
  • Page 83 E N G I N E M E C H A N I C A L C y l i n d e r Head E M - 7 3 I N S T A L L A T I O N O F C Y L I N D E R HEAD [ 1 2 H -T] (See page EM -48) I N S TALL C Y L I N D E R H E A D l a )
  • Page 84 - Cylinder Head E N G I N E M E C H A N I C A L E M - 74 I N S T A L L C Y L I N D E R H E A D COVER ew 9 askel to the cylind coveo.
  • Page 85 E N G I N E M E C H A N I C A L Cylinder Head E M - 7 6 (e ) Assembly t h e front and rear manifoldS. I N S TALL E X H A U S T M A N I F O L D S f a) Install n e w two gaskets a n d t h e exhaust manifolds with the twelve p l a t e washers and new n u t s .
  • Page 86 E M - 7 6 E N G I N E M E C H A N I C A L C y l i n d e r H e a d 1 1 . I N S T A l l F U E L F I L T E R A S S E M B L Y t a l I n S liI l I t h e...

  • Page 87: T I M I N G G E A R S

    A N D C A M S H A FT C O M P O N E N T S 2 H ( w i o PS AiC) Timing Gear Cover Crankshaf. P 2H (wi P " G . " Co",, • lorque •...
  • Page 88 E N G I N E M E C H A N I CAL E M - 7 8 T i m i n g G e a rs and C a m S h a f t R E M O V A L O F T I M I N G G EARS A N D C A M S H A F T E M - 7 7 ) ( S e e p a g e...
  • Page 89 E N G I N E M E C H A N ICAL T i m i n g Gears and C a m s h a ft E M · 7 9 R E M O V E C R A N K S HA F T P U L L E Y l a ) Using SST a n d a mm s o c k e t wrench.
  • Page 90 E M · S O E N G I N E M E C H A N I C A L T i m i ng G e a r s and C a m S h a l l C H E C K B A C K L A S H O F A U T O M A T I C T I M E R D R I V E 1 0.
  • Page 91 E N G I N E M E C H A N IC A L - Ti m i n g Gears and Camshaft E M · S l 1 2 . REMOVE C A M S H A FT T I M I N G GEAR A N D C A M S H AFT A S S E M B LY I s } Remove t h e t w o b o l t s holding t h e t h r u s t plate to t h e...
  • Page 92 E M · 8 2 T i m i n g G e a r s a n d C a m s h a f t E N G I N E M E C H A N IC A L 1 6 .
  • Page 93 E N G I N E M EC H A N ICAL - T i m i n g Gears and C a m s h a f t E M -8 3 I N SP E C T I O N OF T I M I N G G E A R S A N D C A M S H AFT I N S P E C T C A M S H AFT P lace the c a m s h a f t on V - blocks and.
  • Page 94 E M · 8 0 E N G I N E M E C H A N I C A L - Timing Gears and C a m s h a ft Using a feeler g a u g e . measure the thrust clea ri'lnce between the t h rust pla t e and camshaft.
  • Page 95 E N G I N E M E C H A N I C A L T i m i n g Gears and C a m s h a f t E M - a s R E P L AC E M E N T O F C A M S H A F T (OR C A M S H A F T T I M I N G G EA R ) R E M O V E C A M S H A F T "...
  • Page 96 E M-86 E N G I N E M E C H A N I C A L - T i m i n g Gears a n d C a m s h a f t R E P L A C E M E N T O F A U T O M A T I C T I M E R D R I V E G E A R [ 1 2 H -T] REMOVE DRIVE G E A R nt t h e t i mer hub in a...
  • Page 97 E N G I N E M EC H A N IC A L Timing Gears and Camshaft E M - B 7 REPLACE M E NT O F C R A N K S H A F T F R O N T O I L S E A L R E PLACE C R A N K S H A F T F R O N T O i l S E A L There a r e t w o methods...
  • Page 98 E M - S S E N G I N E M E C H A N ICAL T i m i n g G e a r s and C a m s h a f t I N STALLAT I O N O F TI M I N G G E A RS A N D CA M S H A FT (See page E M - 7 7) I N S T A L L C R A N K S H AFT TIMING GEAR...
  • Page 99 E N G I N E M E C H A N I C A L Timing Gears and Ca m s h a f t E M - 8 9 l a l I N STALL NO. 2 I D L E G E A R "...
  • Page 100 e t h e boils. E M - 9 0 E N G I N E M E C H A N I C A L T i m i n g Gears a n d C a m s h a f t Inst311 and 3 7 5 k g - e m ( 2 7 37 N ' m)
  • Page 101 E N G I N E M E C H A N ICAL T i m i n g G e a rs and Camsh a f t E M - 9 1 1 2_ I N S T A L L T I M I N G G E A R C O V E R i w/D PS Dr A/C] "A,"...
  • Page 102 1 7 . I N S T A L L V A L V E R O C K E R S H A F T A S S E M B L Y ( S e e s t e p s 2 to o n p a g e s E M - S 8 a n d 69) 2H ( S e e s teps 2 to o n pages E M - 7 3 a n 74) 1 2 H·T...
  • Page 103 Ti ming Gears and C a m s h a f t E N G I N E M EC H A N I CAL - E M - 9 3 20. I N STALL A N D A D J UST DRIVE B E LT (See page C H - 6 ) 2 1 .
  • Page 104 E M · 9 4 Block - C y l i n d e r 0 , . '" ",. C Y L I N D E R "" 9 1 2 H-T ";n9 (0 ; 1 " 9 C O M P O N E NTS •...
  • Page 105 (See p a g e s E M -40 to 4 2 ) R E M O V E I N J ECTION P I P E S ( See page F U - 3 ) 2H (See page F U - 9 and 1 0) 1 2 H-T...
  • Page 106 E N G I N E M E C H A N I C A L E M - 9 6 - C y l i n d e r B l o c k 1 3. R E M O V E C O N N E CTING ROD CAPS AND C H E C K O I L C L E A R A N C E ( a ) U s i n g...
  • Page 107 E N G I N E M E C H A N I C A L - C y l i nder Block E M - 97 lay a stnp of Plasligage across the crank pin. Inslall the connecting rod c a p . (See age E M - 1 1 6J ft-Ib.
  • Page 108 NOTE: c a p E N G I N E M E C H A N I C A L C y l i n der B l o c k • Keep the beari n g s . c o n n e c t i n g r o d a n d t o g e t h e r .
  • Page 110 E M - l 00 E N G I N E M E C H A N I C A L - C y l i nder B l o c k I N S P E CT I O N O F C Y L I N D E R B L O C K R E M O V E G A S K ET MATE R I A L U s i n g a ga sket scraper, remove a l l t h e g a s k e t m a t e r i a l from t h e c...

  • Page 111: Remove Piston R I N G S

    E M- l 0 1 E N G I N E M E C H A N I C A L Cylinder arock R E M O V E C Y L I N D E R R I D G E fO.008 I f t h e w e a r is less than 0.2 m m i n .

  • Page 112: C L E A N Piston

    E M - 1 02 E N G I N E M E C H A N ICAL C y l i n d e r Block G r a d u a l l y heut the p i s t o n to a p p r o x . 60�C ( 1 4 0 "...
  • Page 113 E N G I N E M E C H A N I C A L Cylinder Block I c l U s i n g solvent and a b r u s h , thoroughly clean t h e p i s t o n .
  • Page 114 E N G I N E M E C H A N I C A L Cylinder B l o c k EM - l 04 I NS P E C T PISTON R I N G END G A P Insert t il e ton ri ng into t h c y l i nder bore.
  • Page 115 E N G I N E M E C H A N I C A L - der B l o c k EM - l 06 C heck f o r twist. • M a x imum twist: 0.05 10.0020 i n .
  • Page 116 Block. E M - 1 06 EN GINE MECHANICAL Cylinder INSTA L L NEW CONNECTING ROD e U S HING oil holes o f A l i g n lhe the b u s h i n g and c o n n e c t i n g rod. U s i n g SST and a press, press i n the b u s h i n g .
  • Page 117 a l l s i x E N G I N E M E C H A N I C A L C y l i n d e r Block E M- 1 0 7 Repl ace BO R I N G O F C Y L I N D E RS N O T E : •...
  • Page 118 E M - l 0 8 E N G I N E M E C H A N I CAL Cylinder B l o c k INS P E C T I ON AND RE P A I R O F CRAN K S H A F T I N S PECT C R A N K S H A F T F O R R U N O U T ( a ) P lace t h e c r a n k s h a f t on V - b l o c k s .
  • Page 119 E N G I N E M E C H A N I C A L Cylinder Block E M - l 0 9 I N SP E C T I O N A N D REP A I R C A M S H A F T B E A R I N G S A N D C A M S H A F T I N S PECT C A M S H A F T O I L C L E A R A N C E...
  • Page 120 E M - 1 1 0 E N G I N E M E C H A N I C A L Cylinder Block IF N E C E S S A R Y . REPLACE C A M S H AFT B E A R I N G S R e m o v e e x pansion plug Using SST a h a m mer, lap...
  • Page 121 E N G I N E M E C H A N I C A L - Cylinder Block EM - l 1 1 Check camshaft oil c learance (See page E M - 1 09J I nstall expansion p lug Apply l i q u i d sealer to the expansion plug surface of the cylinder block.
  • Page 122 E M - 1 1 2 E N G I N E M E C H A N I C A L C y l i n der Block R E P L A C EM E N T O F C R A NK S H A FT REAR O I L S E A L a r e t w o m a n d 8 ) 1 0...

  • Page 123: A S S E M B L E Piston A N D C O N N Ecti N G Rod

    E N G I N E M E C H A N I C A L E M · 1 1 3 Cylinder Block AS S E M B L Y OF P I S T O N A N D C O N N ECT I N G R O D ASS E M B L I E S A S S E M B L E PISTON A N D C O N N ECTI N G ROD I n s tall...
  • Page 124 E M- 1 1 4 E N G I N E M E C H A N I C A L Cylinder Block Using a piston ring expander. i nstall the twO com­ pressl"on r i n g s w i t h t h e code m a r k facing upward. NO.

  • Page 126: I N Stall C O N N E C T I N G Rod Caps

    E M - 1 1 6 E N G I N E M E C H A N I C A L Cylind er Block Apply a l i g h t c o a l o f the engine oil on the threads and u n d e r the bolt heads of the main bearing caps.
  • Page 127 E N G I N E M E C H A N I C A L C ylinder B l o c k E M - 1 1 7 Apply l i g h t coat o f e n g i n e o i l o n the t h reads and under t h e nuts of t h e connec t i n g rod cap.
  • Page 128 E M - 1 I 8 E N G I N E M E C H A N I C A L C y linder Block 1 6 . [M!TI INSTALL F L V W H E E L t h e a n d ( a ) A p p l y a l i g h t c o a t O f e n g i n e o i l o n...

  • Page 129: Fuel System

    I N J E C T I O N N O Z Z L E S F U - 9 I N J E C T I O N NOZZLES [ 1 2H-T 1 F U - 1 6 F U E L FE...

  • Page 130: R E P L Ac E M E N T O F F U E L F I Lt E R

    F U E L S Y S T E M F U - 2 Replacement o f Fuel F i l t e r R E P L AC E M E N T O F F U E L F I LT E R REPLACE F U E L F I L T E R Using S S T .

  • Page 131: I N J Ecti O N N O Z Z L Es

    F U - 3 Injection NOzzles [2H] I N J ECTI O N N O Z Z L ES R E M O V A L A N D T E S T O F I N J E C T I O N...
  • Page 132 F U E L [ 2 H I F U - 4 S Y S T E M - I n j e c t i o n N o z z l e s R E M O V E I N J E C T I O N N O Z Z L E S SST, U s i n g r e m o v e t h e six n o z z l e s , s e a l s and g a s k e t s...

  • Page 133: Leakage Test

    F U E l SYSTEM 1 2 H I Inje c t i o n N o z z l e s F U - 5 I f t h e opening pressure i s n o l within specification, dis­ assemble the n o z zl e and c h a n g e t h e adjusting s h i m o n the top of the pressure spring.

  • Page 134: Nozzle C L E A N I N G

    1 2 H J F U - 6 F U E L S Y S T E M Iniection Nozzles C O M PONENTS D I SAS S E M B L Y , CLEANING AND TEST O F I N J E C T I O N N O Z Z L E D I S A S S E M B L E I N J ECTION N O Z Z L E SST, U s i n g...
  • Page 135 F U E L S Y S T E M [ 2 H ] I n j e c t i o n N o z z l e s c a r b o n a U s i n g a wooden s t i ck, r e m o v e t h e erin...
  • Page 136 F U - 8 F U E L S Y S T E M Iniection N o z z l es [ 2 H ) A S S E M B L Y OF I N J E C T I O N N O ZZLES {See page F U - 6 1 A S S E M B L E I N J ECT I O N N O Z Z L E S { a l...
  • Page 137 F U E L S Y S T E M Injection Nozzles 1 1 2 H - T l F U - 9 I N J E CTI O N N O Z Z L E S [ 1 2 H -TJ REMOVAL A N D TEST O F I N J E C T I O N N O Z Z L E S •...
  • Page 138 1 2H-Tl FU - 1 0 F U E L S Y S T E M I njection N o z z l e s R E M O V E I N J ECTION P I P E S L o o s e n t h e union nuts t h e six injection pipes.

  • Page 139: S P R A Ypattern T E S T

    F U E L S Y S T E M [ 1 2 H . T 1 I n j e c t i o n N o z z l e s F U · 1 1 I I t h e o p e n i n g pressure i s not w i t h i n spec i f i c a t ion. d i s · a s s e m b l e t h e n o z z l e a n d c h a n g e t h e a d j u s t i n g s h i m o n t h e l O P of t h e press u r e s p r i n g .
  • Page 140 1 1 2H- Tl F U - 1 2 F U E L S Y S T E M Shim Injection N o z z l e s C O M P O N E N T S Adj u S l i f'l g ",,, "...
  • Page 141 F U E L S Y S T E M Injec t i o n Nozzles ( 1 2H- T \ F U - 1 3 f b ) U s i n g a w o o d e n s t ick, remove t h e c a r b o n adhering t o t h e n o z z l e needle l i p .
  • Page 142 F U E L SYSTEM F U · 1 4 Injec t i o n N o z zl e s 1 1 2 H · T I ASS E M B LY O F I N J EC T I O N N O Z Z L E S ( S e e page F U ·...
  • Page 143 Injection F U E L S Y S T E M - 11 2 H - TI N o z z l e s F U - 1 5 I N ST A L L H E A T E R PIPES Connect the t h r e hoses.

  • Page 144: F U E L Feed P U M P

    F U - 1 6 F U E L SYSTEM d P u m p Fuel F U E L FEED P U M P R E M OVAL A N D TEST O F F U E L F E E D PU M P Fuel 1 2 H-T I n l e t...

  • Page 145: Discharge Test

    F U E L SYSTEM Fuel Feed P u m p " F> S U CT I O N TEST Mount the feed pump on t h e pump lester. � C on n e c t a suction p i p e with the followi n g specifica­ tions: P i pe inner d i a meter: 8 mm (0.
  • Page 146 F U - 1 8 F U E L SYSTEM F u e l Feed P u m p C O M P O N E N TS • Gasket -- -- -- --t@ spri n 91-- -- -- -- --lI· Check.
  • Page 147 F U E L S Y ST E M - Fuel Feed P u m p FU - 1 9 R E M O V E F E E D P U M P TAPPET a li i Remove the snap ring, and p u l l t h e lappet NOTE: Since the push rod i s precisely f i l led i n t o the feed...
  • Page 148 - F u e l P u m p F U - 2 0 F U E L S Y S T E M Feed I N S TALL F E E D P U M P PI STON Install t h e piston. spring, a new gasket and t h c h a m ber p l u Torq u e :...

  • Page 149: Automatic Timer

    A U T O M A T I C T I M E R R E M O V A L O F A U T O M A T I C TI M E R Automatic Timer Set Key 1 2H-T Specified torque...

  • Page 150: R E M O V E Drive B E Lt

    F U - 2 2 F U E L S Y S T E M A u t o m a t i c T i m e r R E M O V E DRIVE B E LT R E M O V E FAN A N D WATER P U M P P U L L E Y (See p a g e C O - 6 ) R E M O V E C R A N K S H A FT P U L L E Y A N D T I M I N G G E A R COV E R...
  • Page 151 A u t o m a tic T i m e r F U - 2 3 C O M P O N E N TS Orive Gear We ghl Timer Spnng (Inner! 1 2H-T Gear Drive (with Frange) Timer H u b...
  • Page 152 (2H). springs and adjusting s h i m s . R e m o v e t h e timer w e i g h t s from t h e l i m e r hub.
  • Page 153 Y S T E F U - 2 6 F U e l S - A u t o m a t i c T i m e r I N S P E C T I O N O F AUTOMATIC T I M E R I N S PECT T I M E R S P R I N G S Using c a l i pers.
  • Page 154 F U · 2 6 F U E L S Y S T E M - Automatic Timer onto the T u rn a n d p u s h t h e drive gear timer h u b . ( 2 H l , (g ) Using a s c rewdriver.
  • Page 155 2 . 7 1 ,400 1 . 680 0 - 5 .00 less 1 2H-T 1 ,4 5 0 0 . 5 0 o r 1 . 7 00 5 . 5 - 6 . 5 0 ( b ) D i s assemble t h e a u t o m a t i c t i m er.
  • Page 156 Install t h e washer { 1 2H-Tl and round n ut. Torque the round nut. 7 5 0 kg - e m ( 6 4...
  • Page 157 F U E L S Y S T F U - 2 9 R E M O V A L O F I N J ECTI O N PU M P Injection P u m p (A/T) • Gask.et 1 2H - T Injection Pump Re,ainer...
  • Page 158 F U - 3 0 f U E L S Y S T E M I nj e c t i o n P u m p R E M O V E ' N J ECTION P I P E S (See s t e p on page F U - 3) (See steps...
  • Page 159 F U - 3 1 Inje c t i o n Pump F U E L S Y STEM R E M O V E I N J ECTION P U M P ( a l Remove the b o l t h O l d i n g the i nj e c l i o n p u mp s l a y .
  • Page 162 F U - 34 - Injection Pump F U E L S Y S T E M C O M P O N E N T S (Cont'd) Governor (2H AfT) Cover . O-Ring P l a t e e ",...
  • Page 166 F U - 3 8 F U E L S Y S T E M - I n j e c t i o n P u m p R E M O V E C O N T R O L RACK L E V E R S R e m o v e b o l l .
  • Page 167 [ 2 H AfT 1 2H -TJ (See page F U - 3 3 and 34) 2H AIT (See pag e F U · 3 3 and 35) 1 2 H - T M O U N T P U M P A S S E M B L Y TO SST (STA N O )
  • Page 168 D I S A S S E M B L E F U L L - L O A D STOPPER H O U S I N G A S S E M B L Y (2H A m Dis a s s e m b l e t h e following p a r i S :...
  • Page 169 F U E L SYSTEM - Injection P u m p F U - 4 1 &--- 1 1 31 E - r i n g , w a s h e r a n d c o n n e c t i n g p i n ( 1 0) thrust ( 1 1 ) Two l O C k n u t s , No.
  • Page 170 S Y S T E M F U - 4 2 F U E L Injection P u m p �c) U s i n g a s m a l l screwdriver . p u s h o u t the s u pp o r t i n g lever shaft.
  • Page 171 F U E L S Y ST E M Injection Pump C H E C K T H R U S T C L E A R A N C E O F S T E E R I N G L E V E R U s i n g a f e e l e r g a u g e , measure the t h r u s t clearance b e t ­...

  • Page 172: Fuel System

    F U E L SYSTEM F U - 44 I n j e c t i o n P s h a B o l t a n d washers l e v e r g level t h r u s t Return spr ( 1 0! T h r u s t...
  • Page 173 FUEL SYSTEM ection Pump F U ·45 1 5 . D I S A S S E M B L E F L O A T I N G lEVER A S S E M B L Y R e m o v e t h e following parts: ( 1 ) E-ring (2 )
  • Page 174 R e m o v e t h e 11 2H M I T I Remove t h e thrust washer and t h e f l y w e i g h t a s s e m ­...
  • Page 175 F U E L S Y S T E M Injection P u m p F U · 4 7 I c l U s i n g a d i a l i n d i c a t o r , measure t h e t h r u s t clearance between t h e flyweig h t and c a m s h a f t b u s h i n g .
  • Page 176 F U -48 FUEL SYSTEM - I njection P u m p 26. C H EC K T H R U S T C L E A R A N C E OF STOPPER A R M U s i n g d i a l indicator, m e a s u r e t h e t h r u s t...
  • Page 178 F U - 6 0 F U E L S Y S T E M Injection P u m p R E M O V E PLATE P L U G S S I X Remove t he p l a t e p l u g s . R E M O V E C A M S H A F T A N D G O V E R N O R H O U S I N G 1 1 2 H - T J T u r n t h e c a m s h a f t ,...
  • Page 179 Remove t h e two screws a n d gaskets o f t h e c a m s h a f t c e n l e r bearing. 1 1 2H- T I t h e camshaft tog e t h e r...
  • Page 180 F U - 5 2 F U E l S Y S T E M - I i on P u m p S L I D I N G R E S I STA N C E O F C O N T R O L R A C K C H E C K s p r i n g t e n s i o n gauge, m e a s u r e h e s l i d i n g resis­...
  • Page 181 (a ) Remove the three lock plates. Using SST, remove the delivery valve hold er, C · ring ( 1 2H-Tl. stopper 1 1 2 H - n . s p ring a n d gasket 1 1 2 H ­...
  • Page 182 F U - 54 F U E L S Y S T E M Injection P u m p 12HI. U s i n g S S T , remove t h e d e l i v ery v a l v e a n d g a s k e t SST 0 9 2 6 0 - 4 7 0 1 0 109 2 7 1 - 7 60 1 1 1 with N O T E :...
  • Page 183 F U E L S Y S T E M Injec t i o n Pum p F U - 5 5 INS PECT I ON INJECTION P U M P N O T E : l a u c h Do n o t t h e s l i d i n g s u rfaces o f t h e p u m p...
  • Page 184 36.8 ( 1 . 4 4 9 ) 4 9.4 1 1 . 9 4 1 0. 2 (OA02) 24,0 (0.9 4 5 ) 2 3 . 8 (0 9 3 7 1 1 2H-T 1 9 8 (0.780) 49.4 " .945) 1 0.
  • Page 185 F U E L F U - 5 7 S Y S T E M Injection P u m p Measure the clearance between the push rod flange a n d HAC body. Clear a n c e : 0 . 1 - 0 . 3 mm ( 0 . 0 0 4 - 0.0 1 2 in.1 a t sea l e v e l t h e c l e a r a n c e is not w i t h i n specifi c a t i o n , a d j u s t w i t h t h e a d j u s t i n g screw.
  • Page 186 , p r e s s o u t the outer race. SST 0 9 2 60-4 7 0 1 0 (09 2 8 6 - 7 6 0 1 1 1 2H 0 9 2 8 6 - 7 8 0 1 0 1 2 H - T ( b l U s i n g S S T a n d a press, press in a new outer race.
  • Page 187 SST 0 9 2 6 0 - 4 70 1 0 109 2 8 6 - 7 6 0 1 1 1 U s i n G S S T and a press. press i n a new outer race. SST 09608- 1 20 1 0 109 6 0 8-000401 [2H M !Tl B E A R I N G REPLACE OF S P E E D CONTROL S C R E W I n s l a l l new g a s k e t s .
  • Page 188 F U E L S Y S T E M F U - 60 Injection P u m p AS S E M B LY OF I N J E C T I O N P U M P Asse m b ly o f P u m p Body pag e s F pages (See...
  • Page 190 F U E L S Y S T E M - F U - 6 2 Injec t i o n Pump Align t h e d riving face e lappet wi th the groove Con trol Sleeve of the pump h o u s i n g . A l i g n t h e d r i v i n g f a c e of the p l u n g e r with the g r o o v e the c o n t r o l sleeve.
  • Page 191 I N S TA L L G O V E R N O R H O U S I N G A N D C A M S H A F T 1 1 2H- T ) Insert t h e c a m s h a f t t o g e t h e r with t h e bearing a s shown.

  • Page 192: Fuel System

    F U - 6 4 F U E L SYSTEM Injection P u m p 1 2 H ) I e ) I n s e r t t h e c a m s h a f 1 . ( f ) Using p l a s t i c - f a c e d h a m mer, t a p i n t h e bearing...
  • Page 193 Injection F U E L S Y S T E M P u m p F U - S S a n d 1 0 . R E M O V E S S T FROM T A P P E T S E R V I C E H O L E S T u r n t h e c a m s h a f t .
  • Page 194 F U - 6 6 F U E L S Y S T E M - Inlec t i o n P u m p Adj u s t m e n t o f P P R E - T E S T C H E C K A N D P R E P A R A T I O N h o ld e "...
  • Page 195 F U E L F U - 6 7 S Y S T E M Iniection P u m p I n s t a l l an Injection pipe w i t h the f o l l o w i n g specifica- lions.
  • Page 196 F U · 68 F U E L S Y S T E M Injection P u m p N O T E • M e a s u r e the v o l u m e o f each i n j e c t i o n c y l i n d e r w i t h a measuring cylin der.
  • Page 197 S O C F U E L S Y S T E M I njection P u m p F U · S9 U sing SST, set the No 1 l a ppel to position , and then set the d i a l gauge on t h e N O . 1 l a ppet. S S T 0 9 2 6 0 ·...
  • Page 198 - Injec t i o n Pump U - 70 F U E L S Y STEM Adj u s t i n g s h i m thickness t ' d in.) 0.60 ( 0 . 0 2 3 6 i n . ) 0 .
  • Page 199 5 3 10. 2 5 - 0 . 3 2 1 0.6 (0.041 8 . 0 (0.3 1 5 ) (0.4 4 5 ) 2H MIT 1 , 1 00 2 0 0 8 . 2 - 9.2 (0.50 - 0 . 5 6 ) 6 10.04)
  • Page 200 On.) F U - 7 2 F U E L S Y S T E M I njection P u m p Cont'd (Ot hers) Injec t i o n vol u m e of V a riation C o n t ro l r a c k Measuring I t e m pos i t i o n...
  • Page 201 F U E L S Y S T E M Injection P u m p F U - 7 3 Assembly of Governor [ 2 H M IT] F U - 32) (See page I N S T A L L STOP AND A D J U S T I N G L E V E R S Install the following parts: ( 1 1 Return spring...
  • Page 202 F U - 7 4 F U E L S Y S TEM Injection P u m p I N S T A L L S P E E D C O N T R O L S P R I N G A N D G O V E R N O R C O V E R I n s t a l l t h e f o l lowi ng parts: ( 1 )
  • Page 203 Adj u s t m e n t of G o v e r n o r [2H M IT] Governor C h a r a c t e c r i s t ic D ia g r a m...
  • Page 204 F U - 7 6 F U E L S Y ST E M Injection P u m p C H E C K A I R - T I G H T O F V AC U U M C H A M B E R S e t t h e p u m p speed a t 600 rpm.
  • Page 205 Inject i o n P u m p F U E L S Y S T E M F U - 7 7 A d j u s t G o v e r n o r M a i n Spring Measure the control rack p o s i t i o n .
  • Page 206 F U E L SYSTEM I njection Pump F U - 7 8 SST, Using adjust b y turning idling spring c a p - t h e s u l e . 0 9 2 60-470 1 0 10 9 2 8 2 - 7 6 0 1 01 A D J U S T TOTAL I N J EC T I O N V O L U M E Operate t h e adjusting lever i n several limes i n order to s t a bilize t h e i njection p u m p...
  • Page 207 FU-79 F U E L S Y S T E M Injection P u m p I N S T A L L A N D S E A L P A RTS Seal t h e following paris with new seal wire a n d lead seal: ( 1 ) [w/o HAC)
  • Page 208 · F U E L S Y S T E M Injec t i o n P u m p a n d A s s e m b l y o f G o v e r n o r [ 2 H AfT 1 2 H ·...
  • Page 210 Pump jointing f U E L S Y STEM Injection F U -82 i n . l specification, ( b ) A d j u s t the t h r u s t clearance the iointing bolt. Using a feeler g a u g e, measure t h e t h rust clearance between the bolt a n d flywe i g h t .
  • Page 211 F U E L S Y S T E M I n j ection P u m p F U - 8 3 1 2 . I N STALL FLOAT I N G L E V E R A S S E M B L V I n s t a l l t h e f l o a t i n g l e v e r a s s e m b l y w i t h t h e E-ring.
  • Page 212 F U - 8 4 F U E L S Y S T E M I nj e c t i o n P u m p ( 1 2) N o . 2 a d j u s t i n g lever Torque : 8 .
  • Page 213 F U E L S Y S T E M Injection P u m p F U - B 5 Apply liquid sealer on the threads and under I h e screw p l u g heads. Install the two screw plugs, Torq u e : 1 20 m ( 9 ft-Ib.
  • Page 214 F U - S 6 F U E L SYSTEM I njection P u m p Preset t h e full S l O p c a m position w i t h the No. 1 and NO. 2 a d a ptor screws . D i s t a n c e : Approx.
  • Page 215 8 6 kg-em ( 7 4 i n .- I b . 8 . 3 N ' m) l B. [2H AITl I N S T A L L F U LL-LOAD S T O P P E R H O U S I N G A S S E M B L Y...
  • Page 216 Injection Pump F U - S S F U E L S Y S T E M PS O R A / C ] I N S T A L L I D L E - U P A C T U A T O R...
  • Page 217 F U E L S Y STEM Injection P u m p F U - S9 a n d 1 2H - Adju stment of Governor G overnor Characteristic D iagram 2H AfT ed.u m ontro • • 1 1 . 3 1 1 , 3 1 1 .
  • Page 218 F U E L S Y S T E M F U - 9 0 Injection P u m p 2H AJT Coyer P l a t e page PRE-TEST C H E C K A N D PREPARATION (See...
  • Page 219 3 4 0 B.6 - 9.2 ( 0 . 3 3 9 - Idle adjusting screw washers 1 2H- Idle 6.9 - 8.3 (0. 2 7 2 - 0 . 3 2 7 1 Adjusting n u l or 6.0 - {0.
  • Page 220 F U - 9 2 F U E L S Y S T E M I n j e c t i o n P u m p C A U T I O N : T o insure t h a t there i s n o interference between the •...
  • Page 221 F U · 9 3 0 . 2 7 F U E L SYSTEM Injection P u m p ADJUST M E D I U M SPEED CONTROL 1 1 2 H · T I A p p l y (3.9 p s i , of pressure k g - c m �...
  • Page 222 A D J U ST M A X I M U M S P E E D kPa) 01 1 1 2H-TJ A p p ly 0 . 2 7 k g -cm2 (3 .9 psi, 26 pressure t o the b o o s t c o m p e n s a t o r .
  • Page 223 . P u m p rpm 1 1 2H -TI 9 . 8 - 1 0 . 4 (0.386 - 0.409) A D J U ST BOOST C OM P E N S ATO R 0 .
  • Page 224 1 5 6 . 0 - 1 7 4.0 1 9 . 5 2 1 0 . 6 2 1 2H All A d j u s t by t u r n i n g f u l l - l o a d s t o p p e r s c re w .
  • Page 225 Pump rpm mm (inJ position 2,0 (0,079) or less Idle 1 2H-T 7 , 5 ( 0 , 2 9 5 ) or less Idle 1 2 . INSTALL CAP N U T AND COVER PLATE OF F U L L · LOAD STOP PER H O U S I N G 1 3 .
  • Page 226 F U - 9 8 F U E L S Y STEM Injection P u m p I N ST A L L A T I O N O F I N J ECTI O N P U M P (See page F U o 2 9 ) I N S T A l l PARTS 1 2 H J...
  • Page 227 INSTALL V A C U U M H O S E S [2H MIT ( w i E D I C S Y S T E M I I INSTALL C O N NECTING ROD O F E D I C MOTOR...

  • Page 228: Cooling System

    C O - I CO OL I NG S Y S T E M Page C O - 2 T R O U B L E S HOOTING CHECK A N D REPLA C E M E N T O F E N G I N E COOLANT C O - J CO-4...

  • Page 229: Troubleshooting

    CO-2 COOLING S Y S T E M T r o u bl e s h O o t i n g T RO U B L E S H OOTI N G Possible cause Remedy Page Problem ose or missing condenser E n g i n e overh e a t s F a n bell l o...

  • Page 230: Check E N G I N E Coolant Q U A Lity

    C O O L I N G S Y S T E M Check a n d Replacement of E n g i n e C o o l a n t C O - 3 C H E C K A N D R E P L AC E M E N T OF E N G I N E C O O L A N T C H E C K E N G I N E COOLANT L E V E L AT R E S E R V E "lOW"...

  • Page 231: R E M O V A L O F Water P U M P

    Pump CO-4 COO L I N G SYSTEM Water WATE R P U M P R E M O V A L O F WATER P U M P F a n Drive Belt �Ulley • Gasket Fluid Coupling wi. "0;' w •••...

  • Page 232: Remove Water P U M P

    Waler P u m p C O O L I N G S Y S T E M C O - 5 D R A I N E N G I N E COOLA N T (See p a g e C O - 3 1 R E M O V E D R I V E B E LT R E M O V E FAN A N D WATER P U M P P U l l E Y Coup l i n g ]...
  • Page 233 CO·6 COO L I N G S Y S T E M - Water P u m p • Seal W i , e R e t a i o i O � Water Pump Cover Rotor Water Pu Cover •...
  • Page 234 S Y ST E M - Water P u m p COO L I N G C O - 7 R E M O V E ROTOR Using a n d press. press t h e shaft of the bearing and remove I he rolor.
  • Page 235 Water ( S e e CO-8 COOLING SYSTEM Pump A SS E M B L Y O F WATER P U M P heat p a g e C O - G ) N O T E : Always a s s e m b l e t h e waler p u m p wdh new s e a l set and water b e a r i n g .
  • Page 236 CO - 9 C O O L I N G S Y S T E M Water P u m p ( b l Using a p r e s s , p r e s s in t h e rotor. I N S T A L L P U L L E Y S E A T U s i n g S S T and a press, press in t h e seat to a d i s ­...

  • Page 237: I N Sta L L A T I O N O F Water P U M P

    CO· , o C O O L I N G S Y S T E M Water P u m p I N STA L L A T I O N O F WATER P U M P iSee page c o ·.) I N S T A L L W A T E R P U M P t h e...

  • Page 238: R E M O V A L O F T H E R M Ostat

    C O O L I N G S Y S T E M Therm o s t a t CO - l l T H E R M O STAT R E M O V A L O F T H E R M OSTAT D R A I N E N G I N E COOLANT (See p a g e C O ·...
  • Page 239 CO - 1 2 C O O L I N G S Y S T E M T h e r m o s t a t R a d i a t o r I N S TA L L A T I O N O F T H E R M O S TAT PLACE T H E R M O STAT I N WATER I N L E T I N S TALL W A T E R O U T L E T Install...

  • Page 240: Lubrication System

    L U - l L U B R I C AT I O N S Y S T E M Page L U - 2 T R O U B L E S H OO T I N G O I L P R E S S U R E C H E C K L U - 3 R E P L A C E M E N T O F E N G I N E O I L l U ·...
  • Page 241 L U - 2 L U B R I C A T I O N S Y S T E M Troubleshooting TR O U B LE S H O O T I N G Page Problem Possible Remedy c a u s e Cylinder head, c y l i n d e r b l o c k or oil p u m p Repair as necessary Oil l e a lo: a ge...
  • Page 242 L U B R ICATION S Y S T E M Pressure C h e c k L U - 3 O I L P R E S S U R E C H E C K C H E C K E N G I N E O I L Q U A L I TY C h e c k t h e o i l for deterioration.
  • Page 243 Engine l U - 4 l U B R I C A n O N S Y S T E M R e p l a c e m e n t o f Oil a n d O i l F i l t e r R E P L AC E M E N T OF E N G I N E O I L A N D O I L F I LTER D R A I N E N G I N E O I L...

  • Page 244: Oil Pump

    Pump N O T E - O i l ILLlUJ IB R ICATIDN S Y S T E M L U - 5 O I L P U M P cie��:d the P U M P R E M O V A L O F O I L �...
  • Page 245 L U - 6 L U B R ICATION S Y S T E M O i l P u m p D R A I N E N G I N E O i l (See page L U -41 R E M O V E D R I V E B E L T R E M O V E FAN A N O WATER P U M P P U l l E Y (See page C O - 5 )
  • Page 246 C A U T I O N : • Do not use SST for the t i m i n g gear case side and rear o i l seal retainer side. (2H) • Be careful not to damage the o i l flange.
  • Page 247 LU-8 .L uU HB R I C A T I O N Body ear Case) �:�i � �� • Non-re u sable part relief D I SAS S E M B LY O F O I L P U M P E L i E F REMOVE VALVE...
  • Page 248 L U B RICATION SY S T E M - O i l P u m p LU-9 I N S P E CT I O N O F Oil PU M P I N SPECT R E L I E F VALVE C o a t t h e valve w i t h engine oil a n d check t h a t i t falls s m o o t h ly i n t o t h e valve h o l e by its own weight.
  • Page 249 L U - l 0 O i l Pump L U B R I C A T I O N SYSTEM R E P L AC E M E N T D R I V E S P L I N E R E M O V E D R I V E S P L I N E Remove t h e t w o s e t keys .
  • Page 250 L U B RICATION S Y S T E M O i l P u m p A S S E M B L Y O F OIL P U M P (See page l U - 8) I N S T A L L D R I V E A N D D R I V E N ROTO RS Insert the drive and d r i v e n rotors i n t o the oil p u m p b o d y with t h e f a c i n g t h e o i l p u m p c o v e r side.
  • Page 251 L U - 1 2 L U B R ICATION SYSTEM P u m p " 2 H , Tj I N S T A L L STI F F E N I N G PLATE (a ) Remove any oil packing m a t e ri a l a n d b e careful n O t to drop any oil on the contacting surfaces o f the stiffen­...
  • Page 253 L U B R I CATION S Y S T E M L U - 1 4 O i l P u m p I N S T A L L N O . 2 I D L E R G E A R "l "...
  • Page 254 L U B R I C A T I O N S Y STEM Oil Cooler and Relief Valve l U - 1 6 O I L CO O L E R A N D R E LI E F VALVE C O M P O N E NTS .
  • Page 255 L U - 1 6 L U B R I C A T I O N SYSTEM O i l Cooler and Relief V alve R E M O V A L OF O I L C O O L E R AND R E L I E F V A L V E ! S e e p a g e L U ·...

  • Page 257: Relief Valve

    SYSTEM - ( S e e page - 1 8 O i l C o o l e r R e l i e f V a l ve L U B R I C A T I O N I N ST A L L A T I O N OF O I L C O O L E R A N D a n d O - r i n g s .
  • Page 258 I N STAll I N J E CTION P U M P ISee p a g e s F U · 9 8 and 99) (2H MiT (wi EDIC S Y S T E M I ) I N S T A L L EDIC MOTOR...

  • Page 259: O I L N O Z Z L E S A N D C H E C K V A L V E S

    l 1 2 H - T I L U - 2 0 N o z z les a n d C h eck V a l v e s L U B R I C A T I O N S Y S T E M O I L N O Z Z L E S A N D C H E C K V A L V E S [ 1 2 H - C O M P O N E N T S...
  • Page 260 L U BRICATION S Y STEM Oil N o z z l e s and C h e c k Valves [ 1 2 H - T) L U - 2 l R E M O V A L O F O I L N O Z Z L E S A N D C H EC K V A L V E S { S e e page L U -201...
  • Page 261 N o z z l e s a n d L U - 2 2 L U B R ICATION S Y S T E M C h e c k V a l v e s 1 1 2 H - T l I N STALLATI ON O F O I L N O Z Z L E S A N D C H E C K V A L V E S ( S e e p a g e lU -201...

  • Page 262: Starting System

    P R E - H E A T I N G SYSTEM 1 2 H J ST -2 P R E - H E A T I N G S Y S T E M 1 1 2H -TJ ST-8...
  • Page 263 START I N G S Y S T E M P r e - h eating System [2HI P R E - H E AT I N G SYSTE M [2H] S u per G l ow Type [Europe, Austra l i a and Ca nada]...

  • Page 264: I Ns P E C T I O N O F C O M Po N Ents

    Pre- heating System ! 2 H I STA R T I N G S Y S T E M ST - 3 I NS P E C T I O N O F C O M PO N ENTS Pre-heati ng T i m e r LOCATIO N , H J 6 0 c o w l on t h e passenger side.
  • Page 265 ST·4 P r e - h eating S y s tem [2HI ST ARTING SYSTEM N o . 1 G low Plug Relay LOCATION : On t h e f e n d e r a p r o n i n t h e e n g i n e compart­ ment.
  • Page 266 Pre- h e a t i n g S y s t e m 1 2 H I STARTI N G S Y S T E M S T - 5 I N S P E C T R E L A Y O P ERATION Apply ballery vol t a g e across t e r m i n a l s E a n d g.
  • Page 267 1 2H l S T - 6 START I N G S Y STEM P re - h e a ti n g S y s t e m Water T e mperature S e n sor lem­ I N SPECT WATER T E M P E R A T U R E S E N S O R...
  • Page 268 S T A R T I N G SYSTEM Pre-heating System ! 2 H ] S T - 7 F i x e d Delay Type [Ge n e r a l Destinations] S Y S T E M C I R C U I T Fuse 7.SA GLOW...
  • Page 270 P r e - h e a l i n g System 1 1 2H - STA R T I N G S Y S T E M ST-9 TIMER CHARACTERISTIC D I A G R A M 1 2V Type 24V Type �...

  • Page 271: Troubleshooting

    T r o u b l e s h o o t i n g . S t a r t i n g S y s t e m C i r c u i t ST- 1 0 STA R T I N G S Y S T E M T R O U B L ES H OOT I N G Page...
  • Page 272 S ta n e r STARTI N G SYSTEM ST· 1 1 START E R C O M P O N E N TS Housing S t a r t e r • Non·reusable parT O I S A S S E M B L Y O F STARTER A N D A R M A T U R E R E M O V E F I E L D F R A M E A S S E M B L Y...
  • Page 273 ST· 1 2 STARTING S Y S T E M - Starter R E M OV E S T A R T E R H O U S I N G . C L U TC H A S S E M B LY A N D G E A R R e m ove the t h ree screws.
  • Page 274 STA R T I N G S Y S T E M S t a r t e r I N S P EC T I O N OF STAR T E R A r m a t u re C o i l ohmmeter, IN S P E CT COM M U TA T O R F O R O P E N C I RC U I T U s i n g a n...
  • Page 275 ST- 1 4 START I N G S Y S T E M S l arter I N S PECT U N D E R C U T D E PT H C h e c k t h a t the u n d e rC u t d e p t h i s clean a n d free of f or e i g n malerials.
  • Page 276 STA R T I N G S Y S T E M - S ta rter ST- 1 5 H o l d e r B r u s h I N S P E CT I N S U L A T I O N O F B R U S H H O L D E R ! + ) ( - l U s i n g a n o h mmeter, check t h a t t h...
  • Page 277 S t a r l e r ST- ' 6 S T A R T I N G S Y S T E M U s i n g S S T a n d a press, press i n a new h o n i beari n g . S S T 0 9 2 8 5 - 7 60 ' 0 Using a press.
  • Page 278 STARTI N G S Y S T E M Starter ST- 1 7 AS S E M B l Y O F STARTER page (See S T - l l ) N O T E : Use h i g h - te m p e f a t u re grease to l u b ricate the bearings a n d gears when assembling t h e s t a rt er.
  • Page 279 ST A R T I N G S Y S T E M - S ta rt ST - 1 8 Assemble s t a rter housing a n d m a g n e t i c s w i t c h with t h e two screws.
  • Page 280 START I N G S Y S T E M - S t arter ST - 1 9 P E R F O R M A N C E T E S T O F STARTER CAUTI O N : T h e se tests must be performed within 3 seconds to a v o i d burning out the coil, P E R F O R M P U L L - I N TEST...
  • Page 281 ��G S tarter Relsy ST A R T I N G SYSTEM ST-20 STARTER RHA Y L O C AT I O N " On t h e fender aprOn in the engine compart· /TIent I N S P ECTION O F START E R R E L A Y M G .
  • Page 282 E LEC T R I C A L D I E S E L I N J E CT I O N C O N T R O L ( E D I C ) S Y S T E M [2H M IT E D I C System) ]...
  • Page 283 ST-22 STARTI N G S Y S T E M Electrical Diesel Injection Con trol ( E D I C I System A f t e r Starting ( D r i v e Position) A f t e r s t a r l i n g the e n g i n e, t h e p u m p a d j u s t i n g lever should be positioned to the drive p o s i t i o n .
  • Page 284 OV E R I N .I E CT I O N M A G N ET [2H M /T (w/o E D I C System) ] O N - V E H I C L E I N S P E C T I O N I N SPECT C O N N E C T I N G W I R E L E N G T H W h e n the i g n i t i o n switch i s turned t o ' ·...
  • Page 286 - Precautions Troubleshooting C H - 2 C H A R G I N G S Y ST E M P R E C A U T I O N S that t h e b a t tery cables are c o n nected correct term i n a l s .

  • Page 287: C H A Rg I N G Syste M C I Rc U I T

    Charging System Circuit C H A R G I N G S Y S T E M C H · 3 C H A RG I N G SYSTE M C I RC U I T H J 6 0 . 6 1 Series [w/o IC R e g u la torl F u sible Link Bat tery...
  • Page 288 System CH-4 C H A R G I N G SYSTEM C h arging Circuit C H A RG I N G S Y S T E M C I R C U I T (Cont'd) Type)] H J 6 0 , 6 1 S e r i e s [wI R e g u la t o r ( 2 4 V Fusible link...
  • Page 289 Charging System Circuit C H A R G I N G S Y ST E M C H - 5 C H A RG I N G S Y S T E M C I RC U I T (Cont'd) S e r i e s R e g u l a tor) H J 7 5...

  • Page 290: O N - Ve H I C L E I N S P E Ct I O N

    C H A R G I N G S Y S T E M - On-Vehicle I n s p e c t i o n C H - 6 O N - VE H I C L E I N S P E CT I O N C H E C K B A T T E R Y S P E C I F I C G R A V I T Y lei) C h e c k the s p e c i f i c g r av i t y o f e a c h c e l l .
  • Page 291 C H A RG I N G S Y S T E M On-Vehicle Insp ction C H - 7 ( e ) ( O t h e r s ) Check the d e belt deflection b y pressing o n the belt at t h e p o i n t s indicated in f i g u re with ( 22.0 Ib,...
  • Page 293 C H A R G I N G S Y S T E M O n - Ve h i c l e I spec C H - 9 I f t h e voltage reading is l e s s standard v o l t ag e , check term i n a l F r a nd...
  • Page 294 CH · 1 0 C H A R G I N G S Y S T E M - A l t e r n a t o r A LT E R N AT O R R e g u l a t o r R e C l d , e , 10,ul.
  • Page 295 C H A R G I N G SYST E M Alternator C H - " D I S A S S E M B L Y O F A L T E R N A T O R ( S e e p a g e C H · l 0) R E M O V E VAC U U M P U M P Remove t h e t h ree bolts, v a c u u m p u m p a n d C·ring.

  • Page 296: Charging System

    R e m ove C H - 1 2 C H A R G I N G SYSTEM A l te r n a t o r [ w / I C R E G U LA T O R I R E M O V E B R U S H H O L D E R A N D R E G U LATO R the sc rew, d i s c o n n e c t...
  • Page 297 C H A R G I N G S Y S T E M - Allerna t o r C H · 1 3 Remove the drive end frame t o g e ther w i t h the rotor. NOTE: necessary.

  • Page 298: I N S Pecti O N O F Alte R N A T O R

    CH - 1 4 C H A R G I N G S Y S T E M Alternator I N S PECTI O N O F ALTE R N A T O R Rotor INSPECT ROTOR F O R O P E N C I R C U I T U s i n g a n o h m m e t e r .
  • Page 299 C H A R G I N G SYSTEM A l t e r n a t o r C H - 1 5 B r u s h e s I N S PECT E X P O S E D B R U S H L E N G T H U s i n g a scale.
  • Page 300 A l t e r n a t o r C H - 1 6 C H A R G I N G S Y S T E M Bearings I N S PECT F R O N T B E A R I N G C h e c k that the beari ng is n o t ro u g h o r worn.
  • Page 301 C H A R G I N G SYSTEM A l ternator C H - 1 7 Place the two terminal insulators on the positive ( + ) s t u d s of the rectifier holder. Connect the lea d wire of the condenser on the posi­ t ive stud of t h e rec t i l ier holder.
  • Page 302 C H - 1 8 C H A R G I N G S Y S T E M Alternator S l ide lhe f a n , pulley a n d spring washer onto t h e rotof s h a f t . (d ) I nSlall the n u l 9 0 0 k g - e m ( 6 5...
  • Page 304 C H - 2 0 C H A R G I N G S Y S T E M A l l e r n a t o r I N S T A L L B R U S H H O L D E R C O V E R Regulator] [w/o P l a c e t h e i n s u l a t o r w a s h e r on t e r m i n a l...

  • Page 305: A Lternator Regulator

    C H A R G I N G SYSTEM Allernator Regulator C H · 2 1 A LTERNATOR REGULATOR [W/o R e g u lator] I N S P ECT I O N O F A LT E RN A T O R R E G U LATO R LOCATI O N : On the l e f t fender a p r o n in the engine com­...
  • Page 306 terminals C H - 2 2 C H A R G I N G S Y S T E M Alternator R e g u lator Measure the res i s t ance between B a n d Resista nce (Voltage re lay) : A t r e s t Infinity P u l l e d i n...
  • Page 307 ( 1 2V C H A R G I N G S Y S T E M C h a rg e l i g h t Relay {w/ I C Regulator Type)] C H · 2 3 C H A R G E L I G H T R E LAY Type ) ] ( 1 2 V I C R e g u l ator...
  • Page 308 C H - 2 4 C H A R G I N G S Y S T E M C harge L i g h t R e l a y ( w I I e Regulator (24V Type)] C H A RG E L I G HT R E LAY [wi IC Regulator (24V Type) ] I N S P E C T I O N OF C H A R G E L I G H T R E L A Y L O C AT I O N :...

  • Page 309: I G N I T I O N M A I N R E La Y

    Serie s 1 C H A R G I N G S Y S T E M I g n i t ion M a i n Relay I H J 6 0 , 61 C H - 2 5 I G N I T I O N M A I N R E LA Y Ser ies] [ H J 6 0 , 6 1...

  • Page 310: Service Specifications

    A · 1 S E RV I C E S P E C I F I C AT I O N S P a g e E N G I N E M E C H A N I C A L A ·...

  • Page 311: E N G I N E M E C H A N Ical

    S p e c i f i c a t i o n s A ·2 S E R V I C E S P E C I F I C A n O N S Engine Mechanical Healer) HJ6D. :o.el:es 1 5 .4 1 6 .3...
  • Page 312 - Engine Mechanical S E R V I C E S P E C I F I C A T I O N S A - 3 Specifications ( C o n t ' d ) Engine {evolution a t 2 5 0 rpm C o m pression pressure PSI,...
  • Page 313 A· 4 S E R V I C E S P E C I F I C A T I O N S Mechanical Engine Specifications (C o n t ' d ) I n t a k e and Manifold surface warpage limit 0.50 mm...
  • Page 314 S E R V I C E S P E C I F IC A T I O N S E n g i n e Mechanical A - S Specifications (Cont'd) T i m i n g Gear Gear backlash Autom atic t i m e r drive gear S T D 0.0 5 0 - 0 .
  • Page 315 A - 6 E n g i n e Mechanical SE RVICE S P E C I F I C A T I O N S S p e c i f i cations ( C o n t ' d ) g a p piston No 1...
  • Page 316 Fuel hose x Injection p u m p 1 1 2 H - T ) ' 2 5 Glow p l u g x Cylinder head (2H) 4 5 0 C a m s h a f t t i m i n g g e a r...
  • Page 317 Inje c t i o n nOlzie N o z z l e type DN·N D O S D N O 1 7 7 thickness (2H) N o z z l e S e e A - 2 o p e n i n g pre<;'>ure...
  • Page 318 System S E R V I C E S P E C I FiCAT I O N S Specifications (Cont'd) F u e l A - 9 io n nonle Pressure adjusting shi m thick n e s s 1 .4 2 5 0.05 6 1 1 1 2 H ·...
  • Page 319 3.1 - 3 . 6 HAC push rod Stroke (wI HA C ) 0. 1 2 2 - 0 . 1 4 2 in. Clockwise as seen 2H AiT eCli on pump drive side Direction o f ro t a t io n...
  • Page 320 . ) o r le Delivery valve spring f r e e le g t h 1 2H · T 1 .4 4 9 i n . 3 6 . 8 m m 0 . 7 8 0 i n .
  • Page 321 0. 1 5 8 - 0. 1 9 7 . 1 2 H 800st compen sator p r essure drop ! 1 2H s e c o n d s or m o r e distance ( C o o r d ) F u l l-load stopper p r e ·...
  • Page 323 S y s t e m Meas uring Injection Pump cc leu Fuel A- 1 4 S E R V I C E S P EC I F I C A T I O N S I nj e c t i o n Pump Adjustment (Pump Bod y ) (Co nt' d ) 0 7 5 ) 1 2 H-T M/T Injection volume...
  • Page 324 S E R V I C E S P E C I F ICATIONS Fuel I nj e c t i o n P u m p A dj u s t m e n t (Governor 2H M IT) ( C o n t ' d ) Total injection...
  • Page 325 - Fuel System A - I S SERVICE SPECIFICATIONS I nj e c t i o n Pump Adjustment (Governor 2 H AIT 1 2 H - T) (Co nt' d) (inJ M e d i u m speed R a c k pos ition Adjusting Pump rpm c o n t ro l (Con r d )
  • Page 326 -I b Nozzle holder retaining n u l N o z z l e holder body 7 0 0 , 2H-T 3 5 0 Injection n o z z l e Cylinder h e a d 1 2 H - T...

  • Page 327: Lubrication System

    A - I S - Lubrication SERVICE S P E C I F I C A T I O N S System L U B R ICATION S Y S T E M S p e c i f i c a t i o n s Engine capac i l Y - 6.0 kgicm·...
  • Page 328 Pre-healing Light lime syste m 2H (Super glow rype) a t 20"C ( 6 8 "' F ) Approx. 2 s e c o n d s 2 H (Fixed d e l a y t y p e l 1 5 - , 9 .

  • Page 329: S Ta N D A R D B O Lt To R Q U E S P E C I F I C At I O N S

    B - 1 S TA N D A R D B O LT TO R Q U E S P E C I F I C AT I O N S Page STA N DARD BOLT TORQUE S P E C I F I CATI O N S . 8 - 2...
  • Page 330 B -2 STANDARD BOLT TORQUE S P E C I F I C A T I O N S STA N DARD B O LT T O R Q U E S P E C I F I C A T I O N S H O W T O D E TE R M I N E B O L T STRENGTH �...
  • Page 331 STA N D A R D BOLT T O R Q U E S P E C I F I C A T I O N S 8 · 3 SPE C I F I E D TORQUE FOR S T A N D A R D BOLTS T o r q u e s p e c i f i c a t i o n s Diameter C l a s s...
  • Page 332 C - 7 S S T AND S S M Page SST ISPECIAl S E R V I C E . TOOLS) S S M I S P E C I A l SE RVICE M A T E R I A LS)
  • Page 333 SST A N D S S M SST (Special Service Tools) SST (S P ECIA L S E RV I C E TOOLS) N O T E : C l a s s i f ication SST required for vehicle inspections a n d minor repa irs and m u l t i p u rpose SST.
  • Page 334 SSM - Section A N D SST (Special Service Tools) SST (S P E C I A L S E R V I C E TOOLS) (Cant'd) Classi fication • Part Name Part No. • Il lustra tion � (Nutl (092 1 6-00140) (P'I'II •...
  • Page 336 SST (Special Service Tools) SST A N D SSM C - 5 SST (S P E C I A L S E R V I C E TOOLS) ( C o nt'd) S e c t i o n Classification (Plunger Spring •...
  • Page 337 SST AND S S M S S T (Special S e rvice Tools) SST ( S P E C I A L S E R V I C E TOOLS) (Co nt'd) Section Classification Part N a me Part No. (1 n I 6 ChOnCamShOft) Belring •...
  • Page 338 SSM (Special Service Materials) SST A N D S S M C - 7 S S M ( S P E C I A L S E RV I C E M A T E R I A L S ) P a r t Name e t c .

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