Toyota 1KS Repair Manual
  1. Manuals
  2. Brands
  3. Toyota Manuals
  4. Engine
  5. 1KS
  6. Repair manual

Toyota 1KS Repair Manual

Gen-set
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
CONFIDENTIAL
REPAIR MANUAL
Engine Model：1KS Gen-Set ENGINE

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 1KS and is the answer not in the manual?

Questions and answers

Related Manuals for Toyota 1KS

Summary of Contents for Toyota 1KS

  • Page 1 CONFIDENTIAL REPAIR MANUAL Engine Model：1KS Gen-Set ENGINE...

  • Page 2: Table Of Contents

    ・ PRECOAT BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON THREADS)0-11 ・ HANDLING THE FIPG (LIQUID GASKET) 0-11 1. TROUBLESHOOTING BEFORE TROUBLESHOOTING 1-02 1KS ENGINE GEN-SET SPEC. ECU WIRING DIAGRAM 1-04 1KS ENGINE GEN-SET SPEC. ECU TERMINAL ARRANGEMENT 1-05 DIAGNOSIS (SELF DIAGNOSIS FUNCTION) 1-06...
  • Page 3 CONTENTS 6. CYLINDER BLOCK INSPECTION AND REPAIR CHECKING CYLINDER BLOCK REPLACING CAMSHAFT BEARING REPLACING CAMSHAFT PLUG 7． ． ． ． CRANKSHAFT AND BEARINGS CHECKING CRANKSHAFT CHECKING MAIN BEARING CLEARANCES CHECKING CONNECTING ROD BEARING CLEARANCES CHECKING CRANKSHAFT END PLAY CHECKING CAMSHAFT 8.

  • Page 4: General

    0. GENERAL SPECIFICATIONS 0 - 2 HOW TO READ THIS MANUAL 0 - 3 OPERATING TIPS 0 - 3 STANDARD BOLT AND NUT TIGHTENING TORQUE JUDGMENT 0 - 8 PRECOAT BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON THREADS) 0 - 11 HANDLING THE FIPG (LIQUID GASKET) 0 - 11 0 - 1...
  • Page 5 SPECIFICATION Engine model Toyota 1KS Type Natural gas Cycle Number of cylinder and arrangement In-line 3cylinders, longitudinal arrangement Combustion chamber type Heron Type Valve mechanism ＯＨＶ, Gear drive Bore × Stroke 72.0×78.0 ㎜ Piston Displacement 0.952 Ｌ Compression ratio 12.0 Compression pressure 　MPa/400min...

  • Page 6: Operating Tips

    1． ． ． ． OPERATION PROCEDURE This manual describes detailed explanations of operational procedures, information, standards, and cautions with illustrations and pictures showing various componets of 1KS gas engine and how to operate them. 2． ． ． ． MATTERS OMITTED IN THIS MANUAL...
  • Page 7 When handling and moving the cylinder head ASSY or the cylinder block, always wear gloves and do not use your bare hands. GENERAL INSTRUCTIONS 1. For safe operation (1). Wear the correct safety gear (cap, safety goggles, gloves, safety shoes). (2).
  • Page 8 7. Position and orientation when reassembling (1). Reassemble each part with the same position and orientation from before it was disassembled (2). Reassemble the correct parts in the correct order, keeping to the specified standards (tightening torque, adjustment values etc. ). (Reassemble using the middle value within the range for tightening torque and adjustment values).
  • Page 9 ELECTRICAL PARTS INSPECTION 1. Always disconnect the battery plug before inspecting or servicing electrical parts. 2. Pay sufficient attention when handling electronic parts. (1). Never subject electronic parts, such as computers and relays, to impact. (2). Never expose electronic parts to high temperature or humidity.
  • Page 10 (2). Differences in results of measurement with circuit testers The circuit tester power supply voltage depends on the tester type : 1.5V, 3.0V and 6.0V The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage. Diode characteristics are shown in the figure to the left.

  • Page 11: Standard Bolt And Nut Tightening Torque Judgement

    STANDARD BOLT AND NUT TIGHTENING TORQUE JUDGMENT Standard bolt and nut tightening torque Standard bolt and nut tightening torque are not indicated. Judge the standard tightening torque as shown below. 1. Determine the tightening torques of the standard seat hexagon head bolts, welded bolts and stud bolt by identifying the strength type in the table below, and checking the torque in the tightening torque table.
  • Page 12 Identification by part number Type Example of part number Shape 　9 1 6 1 1 - 4 0 6 2 5 Length(mm) : A Hexagon bolt Diameter(mm) : B Strength Type 　 9 2 1 3 2 - 4 0 6 1 4 Length(mm) : A Stud bolt Diameter(mm) : B...
  • Page 13 Identification by bolt shape (Hexagon flange bolt) Type 4.8T 6.8T 8.8T 10.9T 11.9T No mark Hexagon flange bolt No mark Tightening torque table Diameter Pitch Specified torque Strength type N･m ㎜ ㎜ 1.00 1.25 13.0 1.25 27.0 4.8T 1.25 50.0 1.50 78.0 1.50...

  • Page 14: Handling The Fipg (Liquid Gasket)

    PRECOATED BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON THREADS) 1. Do not use precoat bolts in any of the following cases: (1) When a precoat bolt is removed (2) When a precoat bolt is removed as a result of tightening torque check, etc.

  • Page 15: Troubleshooting

    1． ． ． ． TROUBLESHOOTING TROUBLESHOOTING TROUBLE SHOOTONG BEFORE TROUBLESHOOTING 1KS ENGINE GEN-SET SPEC. ECU WIRING DIAGRAM 1KS ENGINE GEN-SET SPEC. ECU TERMINAL ARRANGEMENT DIAGNOSIS (SELF DIAGNOSIS FUNCTION) ELECTRIC TROUBLE INSPECTION WATER TEMPERATURE SENSOR 1-13 INSPECTION ADAPTER 1-14 MECHANICAL TROUBLE...

  • Page 16: Before Troubleshooting

    BEFORE TROUBLESHOOTING CONNECTOR HANDLING Disconnect the battery plu before connectiong or disconnecting each connector or terminal. When disconnecting a connector, do not pull the wire harness but hold the connector itself and pull it after unlocking it. To connect, push the connector fully until it is locked in position.
  • Page 17 Short Circuit Check Short Circuit Check Short Circuit Check Short Circuit Check Disconnect the connectors at both ends the corresponding harness. Measure the resistance betwenn the corresponding connector terminal and frame. Be sure to inspect the connectors at both ends. 　...

  • Page 18: 1Ks Engine Gen-Set Spec. Ecu Wiring Diagram

    1KS ENGINE GEN-SET SPEC. ECU WIRING DIAGRAM Power delay relar Coil min.50Ω ECU delay power 1 ECU delay power 2 CONTROL Start / Stop UNIT BATTERY signal Signal Crank position sensor CRANK Power delay relay POSITION Crank position sensor SENSOR Water temp.

  • Page 19: 1Ks Engine Gen-Set Spec. Ecu Terminal Arrangement

    1KS ENGINE GEN-SET SPEC. ECU TERMINAL ARRANGEMENT No. I/O ITEM No. I/O ITEM 1 G ECU GND 1 N.C. N.C. N.C. N.C. N.C. N.C. 41 G Cranl position sensor GND N.C. N.C. N.C. N.C. N.C. N.C. N.C. 45 G Gain adjustm ent signal GND N.C.

  • Page 20: Diagnosis (Self Diagnosis Function)

    DIAGNOSIS (SELF DIAGNOSIS FUNCTION) General When the computer detects a problem in the system, the fault is indicated by lighting a warning lamp on the combination meter and displaying an error code, and fail-safe functions operate to ensure safety by stopping the engine or controlling the engine to a low speed. DIAGNOSIS DISPLAY METHOD The diagnosis code is displayed when turn ON the diagnosis switch of unit.
  • Page 21 ● ● ● ● ERROR CODE 09（ （ （ （ Water temp. sensor open abnormality） ） ） ） Related portion 47 Water temp. sensor GND Water Engine temp. 48 Water temp. sensor sensor Probable cause ① Water temp. sensor defect ②...
  • Page 22 ● ● ● ● ERROR CODE 25,26（ （ （ （ Fuel cut solenoid open abnormality） ） ） ） Related portion 27 Fuel cut solenoid 1 Fuel cut 34 ECU delay power solenoid 1 Engine 34 ECU delay power Fuel cut 11 Fule sut ssolenoid 2 solenoid 2 Probable cause...
  • Page 23 ● ● ● ● ERROR CODE 52～ ～ ～ ～ 59（ （ （ （ Step motor open abnornality） ） ） ） Related portion Connector color : Red 53　S/M +B1 64　S/M S1 60　S/M S3 Throttle motor 54　S/M +B2 6 6 6 6 5 5 5 5 4 4 4 4 59　S/M S2...
  • Page 24 ● ● ● ● ERROR CODE 70 （ （ （ （ Oil pressure abnormality） ） ） ） Related portion 23 Oil press. SW Oil press.SW Engine Probable cause ① Lubrication system defect ② Harness defect ③ Engine ECU defect Inspection 1: Lubrication system defect Inspection the oil pressure Inspection 2:...

  • Page 25: Troubleshooting When There Is No Error Code

    TROUBLESHOOTING WHEN THERE IS NO ERROR CODE Symptom Portion to be inspected Page for reference Cannot running of specified number of revolutions Speed adjustment VR 1-11 Ignition system 11-1 Cannot start ECU power system 1-11 (no starting combustion) Starter 10-1 Cannot start Speed sensor 1-12...
  • Page 26 ●Gain adjustment VR Probable cause Adjustment defect ① ② Gain adjustment VR or Harness defect ③ Engine ECU defect Inspection 1: Resolution hunting Adjustment defect Control hunting by adjust volume Inspection 2: Gain adjustment VR or Harness defect Gain adjustment VR and Harness inspection Engine ECU defect ●Speed sensor Probable cause...

  • Page 27: Electric Trouble

    ELECTRIC TROUBLE INSPECTION WATER TEMPERATURE SENSOR (1) Remove the water temperature sensor. (2) Use the circuit tester, measure the resistance value between the terminals according to temperature changes. Standard Temperature ℃ ℃ ℃ ℃ 2.45±0.24 0.322±0.032 Resistance kΩ (3) Install the water temperature sensor. Fig.1-Inspecting the water temperature sensor 1 - 13 CONFIDENTIAL...
  • Page 28 REMOVING ADAPTER 1. Remove two bolts and remove adapter Fig.1. NOTICE Remove the deposit and the foreign substance adhered in the adapter. Fig. 1 - Removing ADAPTER INSPECTION STEPMORTOR STEPMORTER STEPMORTER for throttle valve control for fuel control 1. A tester is attached between the combination terminals of the following table, and resistance is measured.

  • Page 29: Troubleshooting Mechanical Trouble

    TROUBLESHOOTING MECHANICAL TROUBLE The causes of engine faults are divided into 3 factors of gas engines. 3 Factors of gas engines 3 factors Main functional parts Good air-fuel mixture Mixer etc Good compression Engine body (Intake and exhaust valves, piston rings, cylinders etc.) Good ignition Ignition coil, spark plugs, resistive cord and ignition The basics are as described above, however, since insufficient maintenance also gives rise to faults.

  • Page 30: Engine Does Not Start Easily, Or Does Not Start At All

    【Point 1】 To test whether the fault is with the circuit to the starter motor, or with the starter motor itself. connect the starter motor directly to the battery with the 30 terminal and 50 terminal leads. If the starter motor turns, then the fault is in the circuit. If it does not turn, then the fault is in the motor.

  • Page 31: Cannot Accelerate Smoothly

    CANNOT ACCELERATE SMOOTHLY (INCLUDING HESITATION) Phenomenon Main places for inspection and adjustment 1. Spark plugs Ignition 2. Ignition timing 3. Ignition circuit 1. Intake and exhaust valve contact 2. Piston rings Compression 3. Piston 4. Cylinder INSUFFICIENT POWER OUTPUT (INCLUDING HUNTING) Phenomenon Main places for inspection and adjustment 1.

  • Page 32: Abnormal Combustion

    Places for inspection and adjustment when fuel consumption has become greater than previously Classification Main places for inspection and adjustment Ignition 1. Ignition timing Fuel 1. Mixer 1. Valve 2. Piston rings Compression 3. Piston 4. Cylinder Cooling 1. Coolant temperature 【Point 1】 【Point 1】...

  • Page 33: Abnormal Engine Noise, Or Noisy Engine

    Back fire Item Inspection content Check the operation and adjustment of parts that might make the air-sue mixture too lean. Fuel, intake system Air being sucked in from the intake manifold ・ Inspect to see whether the ignition timing is too retarded Ignition timing, ・...
  • Page 34 Noise that is often heard at a certain engine speed Probable cause Example of sound Notes The knocking sound is loud when the engine is cold, and grows quieter or stops as the engine warms up. Since aluminum alloy piston expand more than the cylinder, Side knocking of the ・...

  • Page 35: Excessive Engine Oil Consumption

    EXCESSIVE ENGINE OIL CONSUMPTION A classification of oil consumption by the main phenomena is as follows 1. Oil loss via the piston ring This is when the oil that lubricates the cylinder walls gets into the combustion chamber. After the engine has warmed up, after left idling or operated at about 1000 rpm for 4 to 5 minutes, if the engine is raced, alarge amount of white-purple exhaust is output for the first 30 to 60 seconds, thereafter tending to become less.

  • Page 36: 2． ． ． ． Cylinder Head & Valve

    Section2 CYLINDER HEAD　 　 　 　 &　 　 　 　 VALVE Section Contents Page REMOVE CYLINDER HEAD DISASSEMBLE CYLINDER HEAD INSPECT AND REPAIR CYLINDER HEAD VALVE GUIDES VALVES DISASSEMBLE ROCKER ARM SHAFT ASSEMBLE ROCKER ARM SHAFT ASSEMBLE CYLINDER HEAD 2-10 INSTALL CYLINDER HEAD 2-11 ADJUST VALVES...
  • Page 37 REMOVE CYLINDER HEAD 1. Remove Eｘｈａｕｓｔ　Manifold Exhaust　Manifold Fig.1-Remove Exhaust　Manifold 3. Remove Intake Manifold 4. Remove Ignition plug and tube Ignition plug and tube Use an ignition plug wrench and remove ignition plugs (3pcs.) and ignition plug tube (3 pcs.) Intake 　Manifold Fig.2-Remove Intake　Manifold 5.
  • Page 38 7. Remove Valve rocker shaft assy Valve Stem Cap (1) Nut (3 pcs.) , Washer (3 pcs.) (2) Remove the valve rocker shaft ASSY. (3) Remove the Valve Stem Cap 8. Remove Valve push rod NOTE Mark push rods so that they may be reassembled in their original position.
  • Page 39 1. Remove Valve (1) Set the Valve Spring Compressor to the valve to compress the valve spring, and remove two retainer locks. Fig.7-Remove the valve (2) Remove spring retainers, springs, seats, valve and oil seal. NOTE Remove parts shall be arranged orderly for each cylinders.
  • Page 40 3. Check Valve guide bush (1) Use a caliper gauge and measure the inside diameter of the valve guide bush. LIMIT 6.10mm If the limit is exceeded, replace the valve guide bush Fig.11-Check the valve guide bush inside diameter Remove valve guide bushing if required. (1) Use bushing driver, SST**-**-**, press out valve guide bushing from combustion chamber side.
  • Page 41 (2) Measure valve stem diameter at specified distance from end of valve, as shown in Fig.15. LIMIT IN: 5.952mm EX: 5.948mm 35mm If the limit is exceeded, replace the valve Fig.15-Measure Valve Stem Diameter 7. Check Valve and valve seat contact (1) Thinly coat red lead on the valve face (2) Insert the valve into the valve guide bush.
  • Page 42 (3) Use a compound and lap the valve (4) After lapping, use red lead and check that the valve contact is uniform on the whole circumference CAUTION Thoroughly remove the compound after valve lapping Fig.19-Lapping the valve 9. Inspect valve stem cap for wear. Replace if cap is worn recessed.
  • Page 43 DISASSEMBLE ROCKER ARM SHAFT Remove snap rings from ends of rocker arm shaft. Remove set screw from center rocker arm support. Disassemble rocker arm assembly. Note position of all components. SET SCREW SPRING ROCKER ARM SUPPORT, VALVE ROCKER WASHER SNAPRING SHAFT, VALVE ROCKER Rocker Arm Components (1) Snapring removal (2 pcs.)
  • Page 44 ASSEMBLE ROCKER ARM SHAFT Oil all components before assembling. Small grooves in rocker shaft next to oil holes must face down. Assemble rocker arm components, noting order of assembly as shown in Fig. Note position of three thrust washers. Install set screw in center rocker arm shaft support. SET SCREW(1) SPRING(2) ROCKER ARM(6)
  • Page 45 ASSEMBLE CYLINDER HEAD 1 ．HEAD, CYLINDER 2 ．GASKET, SYLINDER HEAD 3 ．CAP, VALVE STEM 4 ．LOCK, VALVE SPRING RETAINER 5 ．RETAINER, VALVE SPRING 6 ．SPRING, COMPRESSION 7 ．VALVE 8 ．SEAT, VALVE SPRING 9 ．SEAL, VALVE STEM OIL 10 ．BUSHING, VALVE GUIDE 11 ．ROD, VALVE PUSH 12 ．SHAFT ASSY, VALVE ROCKER 13 ．BOLT, STUD (T=12Nm)
  • Page 46 NOTE: ・ Thoroughly clean the parts to be assembled. ( F ) ・ Coat engine oil on the sliding contact and rotating ( E ) ( D ) surface. ・ Replace the gaskets and oil seals with new parts. ( C ) ( B ) 2.
  • Page 47 3. Lubricate push rods with engine oil then install with recessed end up RECESSED END UP Fig.29-Install Push Rods 4. Install Valve rocker shaft ASSY (1) Install CAP, VALVE STEM at its original position before removal. (2) Install the valve rocker shaft ASSY to the cylinder head.
  • Page 48 2. Vallve clearance adjustment (1) Loosen the lock nut and turn the adjusting screw for adjustment. Standard： ： ： ： IN 0.25± ± ± ± 0.05mm (Cool engine) EX 0.25±0.05mm (Cool engine) (2) Tighten the lock nut and recheck the valve clearance T = 11 Nm Fig.33-Adjust Valve Clearances With No.

  • Page 49: Timing Gear　 　 　 　 &　 　 　 　 Gearcase

    Section3 TIMING GEAR　 　 　 　 &　 　 　 　 GEARCASE Section Contents Page REMOVING TIMING GEAR COVER AND GEARS CHECKING GEARS REMOVE GEAR CASE REPLACE TIMING GEAR COVER OIL SEAL ASSEMBLE TIMING GEAR CASE AND GEARS 3 - 1 CONFIDENTIAL...

  • Page 50: Removing Timing Gear Cover And Gears

    REMOVING TIMING GEAR COVER AND GEARS 1. Engine oil draining 　　 (1) Prepare a container for drained oil (2) Remove the oil pan plug to drain the engine oil Fig.1-Draining the engine oil 2. Remove Oil pan (1) Remove 20 set bolts and 4 set nuts. (2) Insert the blade of the SST between the oil pan and cylinder block, and cut the sealant to remove the oil pan.

  • Page 51: Checking Gears

    Remove timing gear cover (1) Remove set bolts (12pcs), and set nats (2pcs) cover (2) Discard timing gear cover gasket. NOTE Carefully prevent the timing gear cover and timing cgear case installation surface from any damage. Fig.5-Removing the timing gear cover Remove oil pump drive gear.

  • Page 52: Remove Gear Case

    3. Hold idler gear as shown and check gear backlash between camshaft timing gear and idler gear using dial indicator, Fig.9. Camshaft timing gear backlash must not exceed 0.2 mm. NOTE Idler gear must not turn while checking. Fig.9-Checking Camshaft Timing Gear Backlash REMOVE GEAR CASE (1) Remove camshaft thrust plate set bolt (2) Remove 5 set bolts...
  • Page 53 2. Install timing gear case with new gasket. Install camshaft retainer, Fig.13. NOTE It may be necessary to rotate oil pump drive to engage oil pump rotors. NOTE Position camshaft retainer so that center hole does not interfere with camshaft. Note position, length and number of bolts as shown.
  • Page 54 7. Install timing gear cover with new gasket. Use 12 bolts and 3 nuts and install the timing gear cover with a new gasket in-between. M6×30mm(9pcs) T = 8Nm M6×55mm(3pcs) T = 8Nm M6 Nut(2pcs) T = 8Nm Fig.17-Installing Timing Gear Cover 8．...

  • Page 55: Flywheel　 　 　 　 &　 　 　 　 Retainer, Oil Seal

    Section4 FLYWEEL　 　 　 　 &　 　 　 　 RETAINER, OIL SEAL Section Contents Page REMOVING PAN AND FLYWHEEL REMOVE REAR SEAL RETAINER REPLACING OIL SEAL INSTALLING REAR SEAL RETAINER AND FLYWHEEL 4 - 1 CONFIDENTIAL...
  • Page 56 REMOVING PAN AND FLYWHEEL 1. Remove Oil pan (see section 3) Lock 2. Remove Flywheel (1) Install flywheel holder (2) Remove the pulley bolt (3) Remove set bolts (6pcs) Inspect flywheel for cracks or damage. Inspect flywheel ring gear for worn, chipped or cracked teeth. If ring gear is worn or damaged the flywheel must be replaced.
  • Page 57 INSTALLING REAR SEAL RETAINER AND FLYWHEEL 1. Install rear seal retainer with new gasket. (1) Use 6 bolts install the Oil seal retainer with a new gasket in-between. Fig.5-Installing Seal Retainer 2. Install flywheel. NOTE FLYWHEEL Use new 6 bolts or apply sealant to used flywheel HOLDER bolts.

  • Page 58: Cylinder Block Disassembly

    Section5 CYLINDER BLOCK DISASSEMBLY Section Contents Page ENGINE STAND CYLINDER BLOCK DISASSEMBLY 5 - 1 CONFIDENTIAL...

  • Page 59: Engine Stand

    ENGINE STAND An automotive type engine stand is recommended when complete engine disassembly is required. See drawings below for dimensions to make an engine stand mounting fixture. 5 - 2 CONFIDENTIAL...

  • Page 60: Cylinder Block Disassembly

    CYLINDER BLOCK DISASSEMBLY 1. Remove cylinder head. See Sec. 2. 2. Remove oil pan, oil pick up tube, timing cover, gears and gear case. See Sec. 3. 3. Remove flywheel and rear seal retainer. See Sec. 4. 4. Remove valve lifters. a.
  • Page 61 8. Remove crankshaft. a. Remove crankshaft thrust washers (#3 mainbearing). b. Remove upper main bearings from saddles and place with respective bearing caps. Fig.5-Removing Crankshaft 5 - 4 CONFIDENTIAL...

  • Page 62: Cylinder Block Inspection And Repair

    Section 6 CYLINDER BLOCK INSPECTION AND REPAIR Section Contents Page CHECKING CYLINDER BLOCK REPLACING CAMSHAFT BEARING REPLACING CAMSHAFT PLUG CHECKING CYLINDER BLOCK Remove all traces of sealant and gasket material from mounting surfaces. Inspect cylinder block for damage, cracks and stripped threads. Inspect cylinder bores for damage or scores.
  • Page 63 3. Check cylinder bores for wear, Fig.3. Standard Bore Size: Model Series： φ72.00-72.030 mm a. Measure cylinder bore in 6 points at right angles as shown, Fig.3. b. If cylinder bore is worn more than 0.075 mm or more than 0.035 mm out of round, it must be resized.
  • Page 64 2 Install camshaft bearing, Fig. 7. a. Use camshaft bearing driver, SST. SST=09215-87802-000 NOTE Notch on camshaft bearing must face out. Be sure oil hole in bearing is aligned with oil hole in cylinder block. Fig.7-Installing Cam Bearing REPLACING CAMSHAFT PLUG 1 Remove rear camshaft plug, Fig.8.
  • Page 65 4. Remove timing gear oil nozzle, Fig.11. Fig.11-Removing Oil Nozzle 5. When re-installing oil nozzle, oil hole must be positioned at 45°angle, pointing towards idler gear, Fig.12. Fig.12-Installing Oil Nozzle 6 - 4 CONFIDENTIAL...

  • Page 66: 7． ． ． ． Crankshaft And Bearings

    Section 7 CRANKSHAFT AND BEARINGS Section Contents Page CHECKING CRANKSHAFT CHECKING MAIN BEARING CLEARANCES CHECKING CONNECTING ROD BEARING CLEARANCES CHECKING CRANKSHAFT END PLAY CHECKING CAMSHAFT CHECKING CRANKSHAFT Inspect crankshaft journals for grooves or signs of scoring. If found, crankshaft must be re-ground or replaced.
  • Page 67 3. Check crankshaft timing gear teeth for damaged teeth, Fig. 3. NOTE See Section 3 for procedure to check crankshaft timing gear for wear. If crankshaft timing gear teeth are damaged or worn, the crankshaft must be replaced. Fig.3-Checking Timing Gear CHECKING MAIN BEARING CLEARANCES If main bearings show signs of flaking or scoring, bearings must be replaced.
  • Page 68 CHECKING CONNECTING ROD BEARING CLEARANCES If connecting rod bearings show signs of flaking or scoring, bearings must be replaced. Connecting rod bearings and crankpin journals must be clean and free of oil. 1. With upper bearing assembled to connecting rod, install connecting rod.
  • Page 69 CHECKING CAMSHAFT 1. Measure camshaft lobe height, Fig. If lobes are not to specification, replace the camshaft. Intake and Exhaust: STD: 30.065-30.135 mm Reject: 29.965 mm Fig.11-Checking Camshaft Lobes 2. Measure camshaft journals, Fig. 12. STD: Front - 35.959-35.975 mm Reject: 35.890 mm STD: Center - 35.910-35.955 mm...

  • Page 70: Piston, Rings And Connecting Rod Inspection And Assembly

    Section 8 PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY Section Contents Page DISASSEMBLE PISTON AND CONNECTING ROD CHECKING PISTON AND RINGS CHECKING PISTON PIN AND CONNECTING ROD ASSEMBLE PISTON AND CONNECTING ROD ASSEMBLE PISTON RINGS TO PISTON DISASSEMBLE PISTON AND CONNECTING ROD 1.
  • Page 71 CHECKING PISTON AND RINGS If the cylinder bore is to be resized there is no reason to check the piston as a new oversized piston will be used. If the cylinder is not going to be resized and the piston shows no signs of scoring, the piston should be checked.
  • Page 72 2. Check piston pin bearing, Fig. 7. a. Replace if greater than 17.98 mm or 0.01 mm out of round. Fig. 7 -Checking Piston Pin Bearing 3. Check crankpin bearing end of connecting rod for out of round, Fig. 8. a.
  • Page 73 2. To insert Stopper in the bottom of Support. a. Turn on the ID mark of the piston. b. Piston and guid NO.2 keep to support. Press fit the piston pin to guide No.1 hit stopper. After assembly, shake from side to side and holding the Piston and Connecting rod make sure that Connecting rod is free to swing Fig.11 -Assembling Piston/Connecting Rod...

  • Page 74: Cylinder Block Assembly

    Section 9 CYLINDER BLOCK ASSEMBLY Section Contents Page INSTALL CRANKSHAFT INSTALL PISTONS AND CONNECTING RODS GENERAL ASSEMBLY 1 INSTALL TIMING GEAR CASE, CAMSHAFT AND GEARS GENERAL ASSEMBLY 2 INSTALL CRANKSHAFT Install main bearings in cylinder block, Fig. 1. NOTE Upper bearing has an oil groove and oil holes. 1.
  • Page 75 3. Install crankshaft with gear facing front of cylinder block, Fig. 3. Take care not to damage journals or bearings. a. Install crankshaft shims on #3 main bearing web with grooves facing out. b. Lubricate journals with engine oil. Fig. 3 -Installing Crankshaft 4.
  • Page 76 GENERAL ASSEMBLY 1 1. Install gasket, oil pick-up tube and strainer, Fig. 7. a. Torque bolts to 8.0 Nm Fig. 7 - Installing Oil Pick-Up 2. Install gasket and rear seal retainer, Fig. 8. a. Torque bolts to 6.0 Nm Fig.
  • Page 77 2. Install timing gear case with new gasket. NOTE: It may be necessary to rotate oil pump drive to engage oil pump rotors. Note position, length and number of screws as shown, Fig. 11. a. M6 x 28 mm : 4 b.
  • Page 78 7． Tighten 5 bolts M10×29mm(1pcs) T = 41Nm M8×45mm(2pcs) T = 25Nm M8×20mm(1pcs) T = 19Nm Fig.15-Torque Screws 8. Install timing gear cover with new gasket. Use 12 bolts and 3 nuts and install the timing gear cover with a new gasket in-between. M6×30mm(9pcs) T = 8Nm M6×55mm(3pcs)
  • Page 79 GENERAL ASSEMBLY 2 1. Lubricate tappets with engine oil and install in cylinder block. 2. See Section 2 for install 9 - 6 CONFIDENTIAL...

  • Page 80: Ignition System

    Section 10 IGNITION SYSTEM Section Contents Page REMOVE AND INSTAL ADAPTER 10-2 INSPECT SPARK PLUG 10-2 INSPECT IGNITION COIL 10-3 CAM POSITION SENSOR REMOVAL, INSPECTION AND INSTALLATION 10-3 WATER TEMPERATURE SENSOR INSPECTION 10-4 IGNITION SYSTEM PARTS Ignition sysytem consists of three main component parts. 1．Cam position sensor of a permanent magnet and Camshaft rotor for ignition signals 2．Igniter which controls ignition timing based on the signal from cam posision sensor 3．Ignition coil prepared for every cylinder...
  • Page 81 REMOVING ADAPTER REMOVING ADAPTER REMOVING ADAPTER REMOVING ADAPTER 1. Remove two bolts and remove adapter Fig.1. NOTICE Remove the deposit and the foreign substance adhered in the adapter. Fig. 1 - Removing ADAPTER INSTALLING ADAPTER INSTALLING ADAPTER INSTALLING ADAPTER INSTALLING ADAPTER 1.
  • Page 82 Terminal　2nd (-) INSPECT IGNITION COIL INSPECT IGNITION COIL INSPECT IGNITION COIL INSPECT IGNITION COIL 1. Use the circuit tester, measure the resistance value between the 1st terminal (+) and (-). Terminal　1st (+) Standard： ： ： ： 2.52 - 3.08 Ω (20℃ ℃ ℃ ℃ ) 2.
  • Page 83 3. Cam position sensor installation (1) Coat clean engine oil on the O ring. (2) Set Cam position sensor to the engine, tighten 1 set bolt. Torque bolt to 8.0 Nm. O ring Fig.11-Installing the cam position sensor 　 　　　 10 - 4 CONFIDENTIAL...

  • Page 84: Lubrication System

    Section 11 LUBRICATION SYSTEM Section Contents Page DESCRIPTION 11-2 CHANGE OIL 11-2 CHECK OIL PRESSURE 11-2 DISASSEMBLE GEAR CASE, REMOVE OIL PUMP 11-3 11 - 1 CONFIDENTIAL...
  • Page 85 DESCRIPTION 1KS engine use a full pressure lubrication system with an oil filter. The gear driven oil pump draws oil from a screened oil pickup in the oil pan and pumps the oil through the oil filter. The filtered oil flows through oil galleries in the cylinder block and is distributed to the main bearings, connecting rod bearings, camshaft bearings and rocker arm shaft.
  • Page 86 DISASSEMBLE GEAR CASE, REMOVE OIL PUMP 1. Remove GEAR CASE. See Sec. 3. 2. Inspect rotors for wear or damage, Fig. 3. NOTE: If pump rotors are worn or damaged, replace the gear case. Fig. 3 - Inspect Rotors 3. Remove and check pressure relief valve assembly, Fig.

  • Page 87: Starter System

    Section 12 STARTER SYSTEM Section Contents Page STARTER CURRENT DRAW TEST 12-1 STARTER CURRENT DRAW TEST Important: When making the starter current draw test make sure that all parasitic load is removed from the engine and that engine has the correct viscosity oil. Engine temperature should be at least 21°...
  • Page 88 Testing Starter NOTE: To prevent engine from starting, remove Resistive cord. The DC Shunt must be installed on the negative (-) terminal of the battery, Fig.2. 1. Attach RED meter test lead to RED post terminal on shunt. 2. Attach BLACK meter test lead to BLACK post terminal on shunt.

  • Page 89: Sensor System

    Section 13 SENSOR SYSTEM Section Contents Page CAM POSITION SENSOR REMOVAL, INSPECTION AND INSTALLATION 13-2 WATER TEMPERATURE SENSOR INSPECTION 13-2 13 - 1 CONFIDENTIAL...
  • Page 90 CAM POSITION SENSOR REMOVAL, INSPECTION AND INSTALLATION 1. Cam position sensor removal (1) Remove one set bolt, and remove cam position sensor. Remove one set bolt, and remove cam position sensor. Removing cam position sensor 2. Inspection of Cam position sensor (1) Measure the resistance between 2 terminals using circuit tester.

  • Page 91: Special Service Tool

    Section 14 SPECIAL SERVICE TOOL ILLUSTRATION PART NO. PART NAME 09201-87801-000 VALVE GUIDE BUSHING REMOVER 09201-87802-000 VALVE GUIDE BUSHING REPLACER 09202-87802-000 VALVE SPRING REPLACER 09210-87701-000 FLYWHEEL HOLDER 09221-87206-000 PISTON PIN REMOVER & REPLACER 09221-87207-000 09213-87801-000 CRANKSHAFT PULLEY REPLACER 14 - 1 CONFIDENTIAL...
  • Page 92 ILLUSTRATION PART NO. PART NAME 09215-87801-000 CAMSHAFT BEARING REMOVER 09215-87802-000 CAMSHAFT BEARING REPLACER TIMING GEAR COVER OIL 09223-87801-000 SEAL REPLACER REAR OIL SEAL REPLACER 09223-87802-000 14 - 2 CONFIDENTIAL...

Table of Contents