Page 1 2J ENGINE RETURN TO: MAIN INDEX RETURN TO: SERVICE MANUAL INDEX GENERAL ENGINE TUNE-UP ENGINE OVERHAUL FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM STARTING SYSTEM CHARGING SYSTEM SST LIST SERVICE STANDARD SPECIFICATIONS...
Page 2 FOREWORD This repair manual describes the description. construction, trouble shooting, removal, disassem- bly, inspection and repair, assembly and installation of the various components of the 2J model engine equipped on the Toyota Forklift Trucks (Applicable Models. 5FD10 ~ 30 Series).
Page 3: Engine View
ENGINE VIEW 2J Engine KAH2-2 KAH1-15...
Page 4: Engine Performance Curves
ENGINE PERFORMANCE CURVES KAHM18 2J Engine Performance Curves KAHM19...
Page 5: Specifications
SPECIFICATIONS...
Page 6 ABBREVIATIONS GENERAL RULES OF SERVICING WORK PREPARATION BEFORE DISASSEMBLY 1 Prepare mechanic tools, necessary measuring instruments and SST before starting operation. 2 When disassembling a complicated assembly, put punch or matching marks at places not affecting the function to facilitate reassembly operation. When repairing an electrical system, start operation after disconnecting the cable from the battery negative terminal.
Page 7 STANDARD BOLT & NUT TIGHTENING TORQUE JUDGEMENT Standard bolt and nut tightening torques are not indicated: therefore tightening torque must be judged as below. 1. Find out the type of the bolt from the list below. Then, find the bolt tightening torque from the table. 2.
Page 8 STANDARD BOLT TIGHTENING TORQUE BAHS26 Precoated bolts (bolts and nuts coated with seal lock agent on threaded parts) 1. Do not use precoated bolts in any of the following cases: When a precoated bolt is removed. When a precoated bolt is moved as a result of tightening check, etc.
Page 9 -12-...
Page 10: Coolant Level Inspection
COOLANT LEVEL INSPECTION 1. Coolant level inspection Standard: The coolant level shall be between reser- voir tank FULL and LOW. No oil shall be mixed in the coolant. Inspecting the Coolant Level KAHS109 ENGINE OIL INSPECTION 1. Engine oil inspection Standard: The engine oil level shall be between F and L on the level gauge...
Page 11 CLOGGING WARNING SYSTEM INSPECTION 1. Inspection on vehicle Check that the air cleaner warning lamp on the instrument panel comes on when the key switch is set to ON and goes off when the engine is started. 2. Individual inspection Inspect the conduction when a neg- ative pressure is applied to the vac- Inspecting the Warning Lamp...
Page 12: Valve Clearance Inspection And Adjustment
Standard tension for measurement with tension gauge SST 09216-00020 Caution: Measure with the hook of the belt ten- sion gauge applied on the belt crest por- tion. Applying the Tension Gage F0676 2. V belt flexure adjustment Loosen alternator fixing bolt A and nut B.
Page 13 Measure the valve clearance of the valve shown in the figure. Inspection standard IN: 0.18 - 0.22 mm (0.0071 - 0.0087 in.) (hot) EX: 0.33 - 0.37 mm (0.013 - 0.015 in.) (hot) Rotate the crankshaft in the forward direction and bring No. 4 cylinder to the compression TDC.
Page 14 Inspect the idle speed. Standard 1.0 - 1.75 ton vehicle: 750 ± 25 rpm 2.0 - 3.0 ton vehicle: 700 ± 25 rpm 4. Adjust the idle speed. Loosen the lock nut and turn the ad- justing screw for adjustment. Standard 1.0 -1.75 ton vehicle: 750 ±...
Page 15: Injection Timing Inspection And Adjustment
INJECTION TIMING INSPECTION AND ADJUSTMENT 1. Adjust No. 1 cylinder to the compression TDC. Adjusting the TDC KAHS113 2.Remove the bolt at the rear end of the injection pump. Bolt LAD29-25 3. Set the SST and dial gauge. SST 09275-54010 4.
Page 16 (2) Loosen the pipe joints with the in- jection pump. 1 Injection pipe 2 Overflow pipe Loosing the pipes KAH3-7 (3) Loosen the injection pump mount- ing nut and lower bracket. Loosening the Pump Mounting Nut LAD29-32 (4) Move the pump body for adjustment If the measured value in step 4 is below the standard, move the pump in the direction of A in the...
Page 17: Compression Pressure Inspection
COMPRESSION PRESSURE INSPECTION Note: If output lowering or excessive oil con- sumption is perceived, or if the fuel con- sumption ratio is extremely poor, mea- sure the cylinder compression pressure. 1. Warm up the engine. Standard coolant temperature: Air Cleaner Connector KAG2-10 75 - 85°...
Page 18 1-10 INJECTION NOZZLE INSPEC- TION AND ADJUSTMENT 1. Inspect and adjust the injection pressure. Remove the injection pressure. Move the tester lever quickly to in- ject a few times to blow off the car- bon deposit at the nozzle orifice. Slowly push the tester lever to raise the pressure.
Page 19 CYLINDER HEAD AND VALVE SYSTEM 1. Cylinder head cover 12. Gasket 23. Valve rocker support No. 4 2. Caution plate 13. Rear plate 24. Adjusting screw 3. Oil filler cap 25. Push rod Cylinder head gasket 4. Gasket 15. Screw 26.
Page 20: Cylinder Head Removal
CYLINDER HEAD REMOVAL 1. Remove the fan, V belt and fan pulley. Set bolts Fan, V belt and fan pulley Fan, V Belt and Fan Pulley KAH2-20 KAH2-22 2. Remove the exhaust insulator Set bolts Exhaust insulator 3. Remove the injection pipes Injection pipe clamp Injection pipes (4 pcs.) Nozzle leakage No.
Page 21 6. Remove the water pump assy. Bypass hose Set bolts Alternator adjusting bar Water pump assy Water Pump Assy KAH3-21 7. Remove the glow plugs Glow Plugs KAH4-1 8. Remove the cylinder head cover. Set bolts Cylinder head cover w/gasket Cylinder Head Cover KAH4-2 9.
Page 22 Remove the intake manifold. Set nuts Intake manifold Gasket Intake Manifold KAH18-20 Remove the valve rocker assy. Loosen the lock nut and the valve adjusting screw. Evenly loosen support set bolts (10 pcs.) in the order shown in the figure and remove the bolts.
Page 23 14. Remove the cylinder head assy. (1) Loosen cylinder head set bolts (18 pcs.) sequentially in a few steps, a little each time, and remove them. (2) Cylinder head assy If removable is difficult, it may be pried with a screwdriver. Be careful not to damage the mating faces of the cylinder head and cylinder block.
Page 24: Cylinder Head Disassembly
CYLINDER HEAD DISASSEMBLY Remove the valve. SST 09202-43013 (1) Two retainer locks (2) Retainer (3) Valve spring Valve KAH4-28 (4) Oil seal Oil Seal KAH4-30 Caution: Removed parts shall be arranged cylin- der by cylinder. CYLINDER HEAD INSPECTION AND CLEANING Clean the piston and cylinder block top surfaces.
Page 25 Clean the cylinder head combustion camber and bottom surface. Use a wire brush and remove carbon from combustion chamber. Use a scraper and carefully clean the head bottom surface and manifold mounting surface so as not to dam- age the cylinder head. Cleaning the Cylinder Head Bottom Surface KAH5-10 Clean the valve guide bush.
Page 26 Check racks in the cylinder head. Use red check (flaw detection with dye) check combustion chamber, intake port, exhaust port, head bottom surface and head top surface. Cylinder Head Red Check KAH15-16 Clean the valve Use a scraper and remove carbon deposit.
Page 27 2-10 Replace the valve guide bush. Use a vernier caliper and measure the protrusion of valve guide bush from the cylinder head top surface. Standard: 16.5 mm (0.6495 in.) Measuring the Valve Guide Bush Protrusion KAH4-34 Use the SST and drive out the valve guide bush combustion...
Page 28 2-11 Inspect the valve seat Thinly coat red lead on the valve face. Insert the valve into the valve guide bush and force it against the valve seat. Caution: Do not rotate the valve when it is in forced contact state. Check that the contacting with sat- Inspecting the Valve Contacting Point KAH5-18...
Page 29 2-12 Inspect the compression spring. Use a square and thickness gauge to measure the rectangularity at the top of each spring. Limit (IN and EX): 2.0 mm (0.079 in.) Valve Spring Rectangularly Inspection KAH5-20 Use a vernier caliper and measure the free length.
Page 30 2-13 Move the rocker arm as illustrated and measure the clearance between rocker shaft. If the clearance is excessive disas- semble and inspect the valve rocker arm. Inspecting the Valve Rocker Arm (2) KAH6-20 Disassemble the valve rocker assy. Shaft lock screw Valve rocker support Rocker arm Compression spring...
Page 31 2-14 Reassemble the valve rocker assy. Valve rocker support Valve rocker shaft Caution: When reassembling the val-ve rocker shaft, the screw set hole of the shaft shall be on the upper side. Valve rocker arm Compression spring Shaft lock screw Reassembling the Valve Rocker Assy KAH6-22 Inspect the push rod bend.
Page 32: Cylinder Head Installation
2-15 CYLINDER HEAD INSTALLATION Caution: ¦ Thoroughly clean the components to be installed. ¦ Coat engine oil on the sliding contact surface and rotating part. ¦ Replace the gaskets and oil seals with new ones. Valve Stem Oil Seal KAH6-1 Install the valves.
Page 33 2-16 CYLINDER HEAD ASSY INSTALLATION Install the cylinder head assy. Use a new cylinder head gasket and carefully install in the correct direc- tion. Cylinder head assy Coat engine oil on head bolts (18 pcs.) and uniformly tighten them in the sequence shown in the figure in a few steps.
Page 34 2-17 Install the valve rocker shaft assy. Valve rocker shaft assy. Coat engine oil on the rocker arm tip end and adjusting screw threaded portion. Engine Oil Coating Places F2663 After checking that the ball under the push rod is housed in the center of the valve lifter, temporarily tighten the adjusting screw.
Page 35 2-18 Install the exhaust manifold Gasket (Use a new one.) Exhaust manifold Set nuts T = 180- 240 kg-cm (13.1 - 17.5 ft-lb) Exhaust Manifold KAH19-5 Install the injection nozzle assy Nozzle seat gasket (use a new one.) Nozzle seat Nozzle Seat and Gasket KAH19-7 KAH19-8...
Page 36 2-19 Install the injection nozzle pipe. Injection Nozzle Pipe KAH19-14 Adjust the valve clearance. Set No. 1 cylinder to the compres- sion TDC. Adjust the valve clearance shown in the figure. Reference IN: 0.25 mm (0.0098 in.) EX: 0.40 mm (0.0157 in.) Setting to the Compression TDC KAHS114 Caution:...
Page 37 2-20 Install the water pump assy. Water pump assy w/ gasket Set bolt Install the alternator assy. Water Pump Assy KAH20-7 Install the fan pulley, V belt and fan. Fan pulley and V belt Set bolts V belt tension adjustment Standard: 8 - 13 mm (0.315 - 0.512 in) when pushed by 10 kg (22 lb)
Page 38: Timing Gear
2-21 TIMING GEAR 1. Engine hanger 10. Oil pump flange 19. Idle gear 2. Timing gear case 11. Oil pump drive gear 20. Idle gear shaft 3. Drive gear cover 12. Gasket 21. Camshaft timing gear 4. Pointer 13. Pump drive gear 22.
Page 39 2-22 TIMING GEAR COVER REMOVAL Set No. 1 cylinder to the compression TDC. Remove the fan, fan pulley and V belt. Remove the alternator. Fan, Fan Pulley and V Belt KAH2-20 KAH2-22 Remove the cylinder head cover w/ gas- ket. Remove the valve rocker assy.
Page 40 2-23 Remove the crank pulley. Set bolt Crank pulley SST 09213-60017 Crank Pulley KAH7-23 Remove the timing gear cover Set bolts Timing gear cover Timing Gear Cover KAH10-3 Remove the injection pump drive gear Set nut Injection pump drive gear SST 09213-60017 Injection Pump Drive Gear KAH10-11...
Page 41 2-24 Remove the oil pump drive gear assy. Oil Pump Drive Gear Assy KAH10-20 Measure the camshaft timing gear back- lash Use a dial gauge and measure the backlash between the camshaft tim- ing gear and crankshaft timing gear. Standard: 0.10 mm (0.004 in.) Limit: 0.30 mm (0.012 in.) Measuring the Backlash...
Page 42 2-25 Remove the oil pump assy. Set bolts Oil pump assy Gasket Oil Pump Assy KAH10-32 Remove the camshaft with camshaft timing gear. Thrust plate set bolt Camshaft with camshaft timing gear Caution: Do not damage the camshaft bearing. Camshaft w/ Camshaft Timing Gear KAH17-14 Remove the timing gear case subassy.
Page 43 2-26 TIMING GEAR INSPECTION AND REPLACEMENT Inspect the idle gear oil clearance. Use a cylinder gage and measure the idle gear inside diameter. Standard: 50.00 - 50.03 mm (1.9686 - 1.9698 in.) Use a micrometer and measure the idle gear shaft outside diameter. Measuring the Idle Gear Inside Diameter KAH15-4 Standard:...
Page 44 2-27 Measure the camshaft thrust clear- ance. Standard: 0.06 - 0.13 mm (0.0024 - 0.0051 in.) Limit: 0.3 mm (0.012 in.) Measuring the Camshaft Thrust Clearance KAH12-24 Use a micrometer and measure the outside diameter of the camshaft journal. Standard No.1: 47.16 - 47.18 mm (1.8568 - 1.8576 in.)
Page 45 2-28 Collar SST 09620-30010 Collar KAH13-5 Bearing SST 09420-23000-71 SST 09950-20017 Bearing KAH13-9, 10 Bearing SST 09608-35014 Collar SST 09608-35014 Bearing KAH11-17 Thrust plate Thrust Plate KAH11-18 -50-...
Page 46 2-29 Camshaft timing gear w/ bearing SST 09620-30010 Camshaft Timing Gear KAH11-20 (10) Slightly coat engine oil on the set bolts, and tighten the set bolt. SST 09278-54012 T = 3.0 - 4.5 kg-m (21.7 - 32.4 ft-lb) Set Bolt KAH11-24 Inspect the valve lifter.
Page 47 2-30 OIL PUMP DRIVE GEAR BEARING REPLACEMENT Remove the snap ring Snap Ring KAH15-13 Remove the drive gear with bearing. SST 09620-30010 Drive Gear w/ Bearing KAH15-14 Remove bearing No. 2. SST 09608-35014 Bearing No. 2 KAH15-16 Remove bearing No. 1 SST 09420-23000-71 SST 09239-40010 SST 09620-30010...
Page 48 2-31 Install bearing No. 1 Slightly coat engine oil on bearing No. 1 before installation. SST O9214-60010 Bearing No. 1 KAH15-27 Install bearing No 2 Slightly coat engine oil on bearing No. 2 before installation SST 09608-35014 Bearing No. 2 KAH15-29 Install drive gear SST 09411-41800-71...
Page 49 2-32 Slightly coat MP grease on oil seal lip. Coat engine oil on the outer circumfer- ence of the oil seal. Drive the oil seal into the timing gear cover. SST 09223-46011 Front Oil Seal KAHS6 -54-...
Page 50: Timing Gear Installation
2-33 TIMING GEAR INSTALLATION Install the crankshaft timing gear. SST 09370-20270-71 Slightly coat engine oil on the inside surface of the crankshaft timing gear before installation. Caution: Face the side punched with the match- ing mark outward. Crankshaft Timing Gear KAH18-30 Install the timing gear case subassy.
Page 51 2-34 Thrust plate Set bolt T = 3.0 - 4.5 kg-m (22 - 32 ft-lb) Idle Gear (2) KAH17-12 Measure the idle gear backlash. Standard: 0.10 mm (0.004 in.) Limit: 0.30 mm (0.012 in.) Measuring the Backlash KAHS7 Measure the idle gear thrust clear- ance.
Page 52 2-35 Align matching marks “0” on the crankshaft timing gear and camshaft timing gear. Matching Marks KAH17-15 Set bolt T = 1.5 - 2.2 kg-m (11 - 25 ft-lb) Specified Torque KAH17-16 Measure the camshaft timing gear backlash. Standard: 0.10 mm (0.004 in.) Limit: 0.30 mm (0.012 in.) Measuring the Backlash...
Page 53 2-36 Install the oil pan subassy Coat seal packing on the place shown in the figure and set the gas- ket to the oil pan Oil pan subassy Set bolts T = 0.5 0.8 kg-m (3.7 - 5.8 in-lb) Oil Pan Subassy KAH17-25 KAHS9 Install the injection pump assy.
Page 54 2-37 Install the timing gear cover subassy. Timing gear cover subassy Gasket Set bolts T = 1.5 - 2.5 kg-m (11 - 15 ft-lb) Timing Gear Cover KAH18-8 Install the crank pulley Crank pulley SST 09370-20270-71 Set bolt Crank Pulley KAH18-9 Remove valve lifters (8 pcs.) and install them to the original positions.
Page 55 2-38 Install the alternator assy Install the injection pipe Alternator Assy KAH3-18 Remove the valve push rod and install it at the original position. Valve Push Rod KAH4-12 Install the valve rocker assy. Valve stem cap Valve rocker assy Caution: Coat oil on the rocker arm tip end and adjusting screw threaded portion.
Page 56 2-39 Adjust the valve clearance Set No. 1 cylinder to the compres- sion TDC Adjust the valve clearance shown in figure. Note: 0.25 mm (0.0098 in.) 0.40 mm (0.0157 in.) Caution: Formal measurement shall be made in Setting the Compression TDC KAHS113 hot state.
Page 57: Cylinder Block
2-40 CYLINDER BLOCK 1. Gasket 9. Drain cock 17. Bolt 2. Valve push rod cover 10. Drain cock plug 18. Oil level gage guide 3. Cylinder liner shim 11. Tight plug No. 1 19. Straight plug 4. Oil level gage 12.
Page 58 2-41 1. Piston ring 7. Connecting rod bolt 13. Crankshaft sub-assy 2. Piston 8. Connecting rod cap 14. Crankshaft thrust washer 3. Piston pin 9. Bush 15. Key 4. Snap ring 10. Bolt 16. Crankshaft bearing 5. Connecting rod sub-assy 11. Crank pulley 17.
Page 59 2-42 CYLINDER BLOCK SUBASSY REMOVAL Remove the fan, V belt and fan pulley. Remove the water pump assy. Remove the cylinder head assy w/ mani- fold. Note: Cylinder Head Assy KAH4-21 See 2-3 CYLINDER HEAD REMOVAL for steps 1 - 3 above. Remove the oil filter assy w/ bracket Set bolt Oil filter assy w/ bracket.
Page 60 2-43 Crankshaft timing gear SST 09950-20017 Remove the oil pan subassy. Set bolt Oil pan subassy Gasket Crankshaft Timing Gear KAH8-11 Inspect the connecting rod thrust clear- ance. Use a dial gage or thickness gage and measure the thrust clearance Standard: 0.05 - 0.13 mm (0.00197 - 0.00512 in.)
Page 61 2-44 Place a plastigage on the crank pin, and install the bearing cap. T = 6.5 - 7.5 kg-m (48 - 54 ft-lb) Caution: Do not rotate the crankshaft during mea- surement. Setting the Press Gage EM1884 Measure after removing the bearing cap again.
Page 62 2-45 Remove the piston w/ connecting rod subassy. Connecting rod cap set nut Connecting rod cap Piston w/ connecting rod subassy Caution: ¦ Cover the bolt with vinyl tube. ¦ Do not mistake the combination of the piston w/ connecting rod and the bearing cap.
Page 63 2-46 Place a plastigage on the crankshaft journal and install the bearing cap. T = 9.8 - 11.2 kg-cm (71 - 81 ft-lb) Caution: Do not rotate the crankshaft during mea- surement. Setting the Press Gage EM1890 Remove the bearing cap for mea- surement.
Page 64: Cylinder Inspection
2-47 Arrange the bearing caps. bearings and thrust washers according to the mounting positions. Bearing Cap, Bearing, etc. KAH9-34 CYLINDER INSPECTION Clean the cylinder block Use a scraper and remove the gasket adhered to the cylinder block. Use light oil to clean each part of the cylinder block.
Page 65 2-48 Inspect the valve lifter oil clearance. Use a micrometer and measure the valve lifter outside diameter. Standard: 22.170 - 22.190 (0.87237 - 0.87366 in.) Use a caliper gage and measure the inside diameter of the cylinder block lower bore. Standard: 22.200 - 22.221 mm Measuring the Valve Lifter Outside Diameter KAH15-3 (0.87405 - 0.87483 in.)
Page 66 2-49 Calculate the difference between the camshaft bearing inside diameter and camshaft journal outside diame- ter. Standard: 0.030 - 0.070 mm (0.0012 - 0.0028 in.) Limit: 0.1 mm (0.0039 in.) If the limit is exceeded, replace the bearing. If the camshaft journal shows an excessive scar or burning, grind the camshaft journal and replace the bearing with an U/S bearing.
Page 67 2-50 Install the camshaft bearing Caution: Since No. 2 and No. 3 bearings are the same in shape, measure the bearing inside diameter and install the larger one to No. 2 and smaller one to No. Bearing Types KAHS127 Surely align the bearing oil hole and cylinder block oil hole.
Page 68 2-51 CYLINDER LINER EXCHANGE If the cylinder liner inside surface is exces- sively scratched or if the wear limit is ex- ceeded, replace the cylinder liner. Use the SST and press to extract the cylinder liner from the cylinder block. SST 09218-46010 Cylinder Liner (1) KAHS116...
Page 69 2-52 PISTON CONNECTING DISASSEMBLY Caution: Removed pistons, piston rings and pis- ton pins shall be arranged so as not to change the combinations. Inspect piston movement. Move the piston back and forth and make sure that it moves smoothly Inspecting Piston Movement KAH13-14 If it is seized loose or heavy replace the piston sub-assy.
Page 70 2-53 Warm the piston to about 60°C. Heating the Piston EM1036 Use a brass bar and extract the pis- ton pin. Caution: Removed pistons, piston pins and con- necting rods shall be arranged for each cylinder. Piston Pin KAH13-20 Piston pin and Connecting Rod Inspection Carbon deposit in the ring groove shall be removed by using an old...
Page 71 2-54 Inspect the piston clearance. Use a cylinder gage and measure the minimum cylinder bore in the thrust direction. Measure the piston outside diameter and obtain the piston clearance. (See 2-53.) Standard: 0.11 - 0.13 mm (0.0043-0.0051 in.) If the standard is exceeded, replace the piston or cylinder block, or reborn the cylinder and use an O/S piston.
Page 72 2-55 1.111111 Inspect the piston ring gap. Push in the piston ring to deeper than the sliding contact surface by using the pis- ton, and measure the gap. Standard Compression ring No.1 0.25-0.45 mm (0.0098-0.0177 in.) Compression ring No. 2 0.20-0.35 mm (0.0079-0.0138 in.) Compression ring No.
Page 73: Crankshaft Inspection
2-56 CONNECTING ROD BUSH REPLACEMENT 1. Remove the bush Use the SST and press to remove the bush. SST 09222-66010 Use the SST and press to install the new bush. SST 09222-66010 Caution: Connecting Rod Bush EM1321 Align the oil holes of the connecting rod and bush.
Page 74: Rear Oil Seal Replacement
2-57 Use a micrometer and measure the crankshaft pin portion indicated in the figure. Standard: 54.98 - 55.00 mm (2.1647 - 2.1654 in.) Calculate the ovalness and taper. Limit ovalness and taper: 0.02 mm (0.000787 in.) Measuring the Crankshaft Pin Outside KAH12-14 If the standard and limit are exceeded or Diameter...
Page 75: Piston And Connecting Rod Installation
2-58 PISTON AND CONNECTING ROD INSTALLATION 1. Install the connecting rod. Use nozzle pliers and install one snap ring to the piston. Warm the piston to about 60 C. Warming the Piston KAHS21 Match the front marks of the piston and connecting rod.
Page 76 2-59 Use the piston ring tool and install the oil ring side rail. Adjust the oil ring expander and side rail to the illustrated positions. Use the piston ring tool and install compression rings No. 3, No. 2 and sequentially. with their punched marks facing upward.
Page 77 2-60 CYLINDER BLOCK INSTALLATION 1. Install the crankshaft bearing. Caution: Do not let oil adhere on the bearing outside surface (the surface in contact with the block and bearing cap). Install the upper bearing, with proper matching with the lock groove.
Page 78 2-61 2. Install the crankshaft. Coat engine oil on the crankshaft and bearing sliding contact surfaces Install the crankshaft bearing cap. with its front mark (arrow mark) in- dicating the front. Slightly coat engine oil on the threaded portion of the bearing cap Crankshaft Subassy KAHS31 mounting bolts and tighten them in...
Page 79 2-62 Install the bearing cap with its front mark on the front side, and slightly coat engine oil on the threaded por- tion. Checking the Front mark KAHS33 Alternately tighten the nuts left and right to the specified torque. T = 6.5 - 7.5 kg-m (48 - 54 ft-lb) 5.
Page 80 INJECTION NOZZLE ASSY 1. Holder & nozzle set 10. Nozzle retaining nut 2. Lock nut 11. Nozzle seat 3. Packing No. 1 ring 12. Nozzle seat gasket 4. Washer 13. Combustion chamber subassy 5. Washer 14. Nozzle leakage pipe No. 1 6.
Page 81 NOZZLE ASSY REMOVAL 1. Clean around the nozzle. 2. Remove the air cleaner connector. Set nuts and set bolts Air cleaner connector Air Cleaner Connector KAH2-10 3. Remove the injection pipe subassy. Injection Pipe Subassy KAH3-5 KAH3-7 4. Remove nozzle leakage pipe No. 1 Loosen the hollow screw.
Page 82 INJECTION NOZZLE INSPECTION AND ADJUSTMENT 1 . Inspect and adjust the nozzle injection pressure. Remove the injection nozzle. Quickly move the tester lever to cause injection a few times to blow off carbon deposit at the nozzle spout. Slowly push the tester lever to in- crease the pressure.
Page 83 NOZZLE ASSY DISASSEMBLY AND INSPECTION 1. Disassemble the nozzle. Use the SST and loosen the nozzle holder body. SST 09268-46021 SST 09268-46012 Caution: Never drop inside parts during disassem- bly. Nozzle Assy (1) KAHS38 Remove the following parts: 1 Nozzle holder body 2 Washer 3 Pressure spring 4 Pressure pin...
Page 84 Use a cleaning scraper and clean the nozzle seat. Cleaning the Nozzle Body (1) KAHS42 Use a cleaning needle to clean the injection hole in the nozzle body. Cleaning the Nozzle Body (2) KAHS43 Use a brass bush to remove the car- bon deposit from outside of the noz- zle body.
Page 85 4. Sinking test Wash the body and needle with clean light oil. Tilt the body by about 60° and pull out about 1/3 of the needle. Sinking Test (1) KAHS46 Release the needle and check if it smoothly sinks into the body due to its own weight.
Page 86: Injection Pump Assy
INJECTION PUMP ASSY Injection Pump Assy Components KAHM5 -92-...
Page 87 1. Adjusting lever 42. Drive gear 2. Return spring 43. Roller ring 3. Overflow screw 44. Coupling 4. O-ring 45. Coupling spring 5. Governor thrust washer 46. Cam plate 6. Adjusting lever shaft 47. Adjusting shim 7. Speed control spring 48.
Page 88: Specification
3-10 SPECIFICATION SERVICE STANDARDS -94-...
Page 89: Adjustment Standards
3-11 ADJUSTMENT STANDARDS 1. Adjustment conditions 2. Temporary adjustment (lever at FULL position) 3. Pump internal pressure adjustment (lever at FULL position) 4. Overflow rate inspection (lever at FULL position) 5. Timer adjustment (lever at FULL position) Note: The hystersis for each speed shall be within 0.3 mm (0.012 in.) -95-...
Page 90 3-12 6. Injection volume adjustment 7. Low speed lever setting -96-...
Page 91 3-13 INJECTION PUMP ASSY REMOVAL (ON VEHICLE) 1. Remove the battery and battery case. 2. Remove the fuel filter assy. 3. Disconnect the accelerator wire. 4. Disconnect the solenoid switch wiring. 5. Remove the injection pipe. Solenoid Switch LA01-20 6. Align the yellow marking on the crank shaft pulley with the pointer on the tim- ing gear cover.
Page 92 3-14 DISASSEMBLY Caution: Wash outside of the injection pump. Clean the work bench and workshop for operation. Always measure and record the pump injection volume characteristic before disassembly. If there is an adjustment error or part with defective function, comparison of the characteristics before and after disassembly enables detection of the defect cause.
Page 93 3-15 4. Remove the fuel inlet union. 5. Remove the governor shaft parts. Loosen the governor shaft lock nut, and use a hexagon wrench to loosen the governor shaft. SST 09260-54012 Caution: Be careful that the lock nut and governor shaft use left-handed screw.
Page 94 3-16 7. Remove the distributor head plug. Head plug SST 09260-54012 O-ring Removing the Head Plug KAD34-11 8. Remove the delivery valve. Delivery valve holder SST 09260-54012 Valve spring seat Valve spring Delivery valve and valve seat Valve gasket Removing the Delivery Vale Holder LAD34-12 Caution: Removed valves and valve seats shall...
Page 95 3-17 10. Remove the plunger. Plunger spring guide Plunger spring shim Plunger spring upper seat Plunger spring Spill ring Plunger spring lower seat Plunger upper plate Plunger lower plate Caution: Removing the Plunger LAD34-17 Carefully operate because the adjusting shim under the plunger. (Remained on the cam plate) Disassembling the Plunger Parts KAA2-23,26...
Page 96 3-18 12. Remove the cam plate and coupling. (1) Cam Plate (2) Plunger adjusting shim Removing the Cam Plate LAD34-20 (3) Coupling spring (4) Coupling Removing the Coupling LAD34-21 13. Remove the timer spring (1) Timer cover (2) Timer spring (3) Adjusting washers (2 pcs.) (4) O-ring Removing the Timer Spring...
Page 97 3-19 Push the timer slide pin to the center of the roller ring. Caution: Set the pawl of the drive shaft 90 off from the timer slide pin. Pushing out the Timer Slide Pin LAD34-25 Roller ring sub-ass’y Caution: ¡ Use long-nozed pliers and remove the roller ring carefully without tilting it.
Page 98 3-20 Disassemble the drive shaft (with gear). Drive shaft Drive gear Rubber joints (2 pcs.) Drive shaft washer Drive shaft Disassembling the Drive Shaft KAA15-22 Remove the feed pump related parts. Feed pump cover set screws Feed pump cover Liner Note: ¡...
Page 99 3-21 Remove the oil seal. SST 09612-65014 Note: Install the SST as illustrated, and drive out the oil seal by using a driving bar, etc. Removing the Oil Seal KAHS49 Remove the adjusting lever parts from the governor cover. Punch matching marks on the lever shaft and lever.
Page 100 3-22 INSPECTION Plunger When wear, scratch or discoloration at the plunger load part is perceived, replace the plunger, spill ring and distributor head as a set. Inspect the plunger sliding contact surface as follows: Slide the plunger 4 to 5 times in clean light oil.
Page 101 3-23 Inspect the height of four rollers with a dial gauge to check if disper- sion of the height is within the limit. Limit dispersion of roller height: 0.02 mm (0.00078 in.) If the limit is exceeded, change the roller positions. It is acceptable if dispersion becomes less than the limit.
Page 102 3-24 Fly weights Measure staged wear at the fly weight surface in contact with the washer. If the wear limit is exceeded replace four fly weights as a set. Depth wear limit A = 0.2 mm (0.0078 in.) Inspecting Wear of Fly Weight KAHS51 Feed pump Inspect the sliding contact surface.
Page 103 3-25 Pump housing Wear and damage at sliding contact surface of feed pump Damage at each threading Wear of housing bushing Fit the nut to the drive shaft as illustrated. Lightly shake the drive shaft in the wear direction (by a light push with a hand), and measure the wear amount with a dial gauge.
Page 104 3-26 ASSEMBLY Caution: ¡ The assembly procedure is roughly the reverse of the disassembly procedure, but the careful because there is a little difference in the sequence. ¡ The work bench and work shop be kept clean and pay careful attention to the operation. ¡...
Page 105 3-27 Spring guide T = 0.5 - 1.0 kg-m (3.7 - 7.2 ft-lb) Assembling the Adjusting Lever LAD38-6 Use the SST and install the pump hous- ing to the pump stand. SST 09245-54010 Assemble the oil seal. Note: Use a 22 mm box and drive in the oil seal to the end of the pump body.
Page 106 3-28 Rotor and blades Caution: Assemble the rotor and blades as ° shown in Figure. Install each blade with its grooved side facing inward (toward the rotor center). The rotor and blades shall slide smoothly. When replacing the feed pump, al- °...
Page 107 3-29 Install the roller ring. Insert the timer slide pin to the roller ring assy. Caution: Washers at rollers of the roller ring ° shall be set so that their curved sur- faces face outward. The slide pin shall be inserted fully to °...
Page 108 3-30 Install the following parts: O-ring Washer Timer spring Timer cover Caution: At least 0.5 mm (0.020 in.) thick washer shall be placed at each end of the spring. Install the coupling and cam plate. Coupling Install the cam plate with its pin di- Installing the Timer Spring KAHS58 rected toward the key groove of the...
Page 109 3-31 Plunger spring shim selection Measure dimension KF for free plunger spring length and obtain the plunger spring shim thickness by the following equation. Shim thickness mm (in.) = 5.8 (0.228) - dimension KF Caution: Use the plunger spring shims of the °...
Page 110 3-32 Carefully fit the distributor head and fix it by bolts. Caution: Turn the drive shaft and check if the ° plunger rotates. If the plunger does not rotate, carry ° out reassembly because the cam plate pin is not in the plunger groove. Installing the Head Temporarily KAHS63 Bring the plunger to the BDC posi-...
Page 111 3-33 Install the coupling spring. Installing the Coupling Spring LAD35-16 Install the cam plate. Caution: Install the cam plate so that its drive pin is aligned with the drive shaft key groove. Carefully prevent misalignment because it will cause incorrect injection sequence.
Page 112 3-34 Plunger shim (selected one) Caution: Do not coat grease on plunger shim. Install the assembled plunger parts as shown in the figure at right. Caution: Install the plunger so that the cam plate drive pin groove at the plunger leg. Installing the plunger LAD35-18 Install the governor lever.
Page 113 3-35 Distributor head set bolts T = 1.1 - 1.3 kg-m (8.0 - 9.3 ft-lb) Caution: Alternately tighten four bolts evenly. ° After tightening, operate the governor ° lever to check if the spill ring follows smoothly. Tightening the Head Bolts LAD35-22 Install the head plug.
Page 114 3-36 Install the solenoid. Install the O-ring to the solenoid. Solenoid T = 2.0 - 2.5 kg-m (14.5 - 18.0 ft-lb) Caution: When installing the solenoid, never for- get to install the piston and spring. Boot Installing the Solenoid LAD35-25 Assemble the governor shaft parts.
Page 115 3-37 Measure the thrust clearance of the weight holder with thickness gauge. If the standard is not satis- fied, adjust the clearance by chang- ing the adjusting washer thickness. Thrust clearance: 0.15 - 0.35 mm (0.0059 - 0.0137 in.) (Clearance on entire circumference) Note: Adjusting washer type Thrust Clearance of Weight Holder KAHS66...
Page 116: Airtightness Test
3-38 Governor shaft lock nut SST 09260-54012 T = 2.5 3.0 kg-m (18.1 - 21.6 ft-lb) Caution: The lock nut adopts left-handed screw. Tightening the Lock Nut LAD35-33 Install the governor cover. Hook the control spring on the gov- ernor cover. Caution: Install the control spring so that the open end of the hook is directed as shown in...
Page 117 3-39 ADJUSTMENT Adjustment Sequence Inspection and preparation before test Running-in Temporary adjustment Pump internal pressure adjustment Overflow rate inspection Pump Adjustment LAD36-11 Timer adjustment Full-load injection volume adjustment Adjustment of injection volume at start- Full-load injections volume check High speed lever setting Low speed lever setting Inspection and Preparation before Test 1.
Page 118 3-40 Inspect the valve opening pressure of the nozzle holder for the test. Valve opening pressure: 145 - 155 kg/cm (2062 - 2204 psi) Install the pump to the pump tester. Manually rotate the pump to check that it rotates smoothly. Installing the pump LAD36-1 Connect the high - pressure pipe and...
Page 119 3-41 Apply 14V to the fuel cut solenoid. Applying a Voltage to the Solenoid LAD36-9 Running-in Stabilize the fuel temperature at 40 - 45°C (104 - 113°F). Adjust the feed pressure of the pump tester to 0.2 kg/cm (2.8 psi). Run the pump at a low speed (about 300 rpm) and make sure that the air in the pump chamber had been bleed through the overflow pipe.
Page 120 3-42 Temporary Adjustment (Lever at FULL position) Temporary adjustment of full-load stan- dard injection volume Measure the injection volume at a pump speed of 1000 rpm. If the standard is not satisfied, adjust the injection volume by turning the full load set screw. Standard: Adjusting the Full-load Standard Injection LAD36-22...
Page 121 3-43 Overflow Rate Inspection (Lever at FULL position) Measure the overflow rate at a pump speed of 1200 rpm. l l l l l Standard: 20 - 35 l (5.28 ~ 9.24 US gal/H) Caution: Always use the overflow screw attached to the engine.
Page 122 3-44 Full-load injection Volume Adjust- ment (lever at FULL position) Measure the injection volume at a pump speed of 1000 rpm. If the standard is not satisfied, make adjustment by turning the full load set screw. Standard: 7.8 - 8.2 cc/200 st. 1 cyl. (0.48 - 0.49 cu-in./200 st.1 cyl.) Deviation: 0.6 cc (0.036 cu-in.) or Adjusting the Full-load Injection Volume...
Page 123 3-45 Full-load Injection Volume Check Check that the full-load standard injec- tion volume under the conditions in the following table satisfies the standard. If not, make adjustment by turning the full load set screw. Standard: Adjusting the Full-load Standard Injection Volume LAD36-22 If the deviation does not satisfy the stan-...
Page 124 3-46 Low Speed Lever Setting Free the adjusting lever. Adjust the injection volume by turning the idle set screw so that it satisfies the standard. Standard Note: Tightening the screw increases the injec- tion volume. Low Speed Lever Setting LAD 36 - 24 Check after Adjustment Upon completion of adjustment, cut off voltage supply to the fuel cut solenoid and check that injection ceases.
Page 125: Installation
3-47 INSTALLATION 1. Install the injection pump assy w/ bracket. (1) Insert the shaft of the infection pump assy into the drive gear. Caution: Make sure that the pump assy key posi- tion is the same as that before removal. Timing Mark KAH17-34 (2) Align the timing marks on the pump...
Page 126 3-48 FUEL FILTER ASSY Fuel filter assy Level warning switch sub-assy Cap sub-assy O-ring Fuel filter sub-assy Drain cock O-ring Fuel Filter Assy Components KAHM7 -132-...
Page 127 3-49 REMOVAL 1. Remove the fuel filter assy. (1) Disconnect the sedimenter sensor wiring. (2) Disconnect the fuel hose. (3) Set bolt (4) Fuel filter assy Fuel Filter Assy LAO6-2 LA06-4 DISASSEMBLY Caution: Thoroughly drain fuel from the filter be- fore disassembly.
Page 128 3-50 2. Level warning switch assy (1) Check continuity between terminals when the float is fully raised. Inspecting the Level Warning Switch Assy KAHS75 KAG16-19 Reassembly Install the fuel filter sub-assy to the cap sub-assy. (1) O-ring (2) Fuel filter sub-assy SST 09228-64010 T = 150- 200 kg-cm (11 - 14.6 ft-lb)
Page 129 COOLING WATER INSPEC- TION AND EXCHANGE COOLING WATER INSPECTION 1. Inspect the cooling water level. (1) Make sure that the cooling water level is between FULL and LOW in the radiator reservoir tank. 2. Inspect the cooling water quality. (1) Make sure that the cooling water is Resevoir Tank KAHS109 free from any oil or other contami-...
Page 130 THERMOSTAT ASSY REMOVAL Drain about half of cooling water. 2. Disconnect the radiator inlet hose at the water outlet. 3. Remove the fan shroud set bolts (3 pcs. on the outlet side). Water Outlet LA06-33 4. Remove the water outlet. (1) Set bolts (2) Water outlet 5.
Page 131: Water Pump Assy
WATER PUMP ASSY Water outlet housing Water pump cover Thermostat Gasket Gasket Water pump seal set Water pump pulley seat Water pump rotor Water pump bearing Water pump body Water pump retaining wire Gasket Water Pump Components KAHM8 -138-...
Page 132 REMOVAL 1. Remove the fan, fan pulley and V belt. (1) Open the engine hood. (2) Loosen the alternator adjusting bolt. (3) Fan set bolts (4) Fan (5) Fan pulley and V belt Fan, Fan Pulley and V Belt KAH2-20 KAH2-22 2.
Page 133 2. Remove the pulley seat. SST 09235-60010 Pulley Seat KAHS77 3. Use a press and the SST to remove the water pump rotor. SST 09239-40010 Water Pump Rotor KAHS78 4. Remove the water pump bearing. (1) Heat the water pump cover assy to about 85°C.
Page 134 ASSEMBLY 1. Remove the water pump bearing. (1) Heat the water pump body to about 85°C. Heating the Water Pump Cover KAHS81 (2) Use a press and the SST for press fitting until alignment of the bearing outer race end surface and pump cover end surface.
Page 135 (2) Use a press for press fitting until alignment of the rotor end and bear- ing shaft end surface. Rotor (2) KAHS85 4. Install the pulley seat (1) Use a press and install the pulley seat. Press fitting margin: From pulley mounting surface to pump body end surface 64.7 mm (2.55 in.)
Page 136: Oil Pump Assy
OIL PUMP ASSY Oil pump assy Oil pump drive shaft gear Oil pump body Straight pin Oil pump cover Oil pump shaft Plug Driven shaft key Relief valve spring Oil pump drive gear Oil pump relief valve Shaft snap ring Gasket Oil Pump driven gear Oil strainer sub-assy...
Page 137: Oil Pressure Inspection
OIL PRESSURE INSPECTION Remove the oil pressure switch, and install the oil pressure gauge. 2. Measure the oil pressure. Standard: At idling speed 0.5 kg/cm (7.1 psi) or above At 2400 rpm 3.5 kg/cm (49.8 psi) or above REMOVAL 1. Set the engine assy to the engine stand. 2.
Page 138 DISASSEMBLY Caution: Wash the oil pump assy with light oil before starting disassembly. 1. Remove the oil strainer sub-assy. (1) Set bolts (2) Oil strainer sub-assy 2. Remove the oil pump cover. Oil Strainer Sub-assy KAH15-35 (1) Set bolts (2) Oil pump cover Oil Pump Cover KAH14-4 3.
Page 139 4. Remove the drive and driven gears. (1) Put matching marks on the drive and driven gears. Matching Marks KAH14-5 (2) Driven gear Driven Gear KAH14-7 (3) Pump drive shaft gear Caution: Use a drill to cut off the caulked portion of the straight pin.
Page 140: Relief Valve Disassembly
REASSEMBLY The reassembly procedure is the reverse of the disassembly procedure. Caution: When assembling the pump drive shaft gear, be sure to caulk both ends of the straight pin. Tighten the pump cover set bolts to the specified torque. T = 0.5 -1.0 kg-m (3.65 - 7.3 ft-lb) Pump Cover KAH14-11 RELIEF VALVE DISASSEMBLY...
Page 141: Oil Filter Assy
OIL FILTER ASSY Oil filt. Union Oil filter bracket Oil pump sub-assy Gasket Union Oil pressure switch Oil Filter Components KAHM10 -149-...
Page 142 ENGINE OIL AND OIL FILTER REPLACEMENT 1. Drain engine oil (1) Oil filler cap (2) Oil pan drain plug (3) Engine oil 2. Remove the oil filter element. SST 09228-44011 3. Install the oil filter element. Draining Engine Oil LA07-3 (1) Remove dirt and foreign matters from the mounting surface on the engine side.
Page 143: Preheating System
PREHEATING SYSTEM CIRCUIT DIAGRAM Preheating System Circuit Diagram KAHM11 -152-...
Page 144 GLOW PLUG REMOVAL AND INSPECTION 1. Remove the glow plug. (1) Screw grommet (2) Connecting nut (3) Wire harness (4) Glow plug connector (5) Glow plug 2. Inspect the glow plug Inspect the glow plug continuity. Glow Plug LA06-19 Standard: Continuity shall exist.
Page 145 If any abnormality is found by inspec- tions in steps 1 and 2, replace the pre- heating timer. (1) Instrument panel set screws (6 pcs) (2) Disconnect the preheating timer connector. (3) Instrument panel w / preheating timer Intrument Panel W/ Preheating Timer LA08-23 LA08-12 (4) Set bolt...
Page 146: Starting Motor Assy
STARTING MOTOR ASSY Starting motor assy Magnet switch assy Idle gear clutch roller Commutator end frame sub-assy Contact tip sub-assy Idle gear retainer Brush holder sub-assy Packing Housing assy Yoke assy Contact plunger sub-assy Magnet switch return spring Brush Plate Steel ball Armature assy Lead wire...
Page 147 Caution: The starting motor assy removal and in- stallation described here are operations on the vehicle. REMOVAL Disconnect the lead from the battery negative - terminal. Remove the wire harness. (1) Nuts Wire Harness F4998 (2)Disconnect the wire harness from terminal 30.
Page 148 Remove the end frame. (1) Screws (2 pcs) (2) End frame End Frame KAHS93 Remove the brushes. (1) Raise the positive + side brush spring with longnose pliers. Caution: Carefully operate so as not to damage the brush and commutator. Brush KAHS94 Remove the armature assy.
Page 149 Remove the clutch assy. Clutch Assy KAHS97 Remove the steel ball Caution: Do not lose the steel ball. Steel Ball KAHS98 Remove the idle gear. Idle Gear KAHS99 Remove the retainer and rollers. Caution: Carefully prevent the retainer and rollers from falling.
Page 150 11. Remove the coil spring. Coil Spring KAHS101 -159-...
Page 151 6-10 INSPECTION Armature coil ground test (1)Inspect the continuity between the commutator and armature coil. Standard: No continuity Armature Coil (1) Z5260 Armature coil short-circuit test (1) Use an armature tester. Rotate the armature with a thin steel strip ap- plied parallel with the armature.
Page 152 6-11 (2) Inspect the outside diameter. Standard: 36 mm (1.42 in.) Limit: 35 mm (1.38 in.) Measuring the Commutator Outside Diameter Z5257 (3) Inspect the undercut depth between segments. Standard: 0.7 - 0.9 mm (0.028 - 0.035 in.) Limit: 0.2 mm (0.00787 in.) Undercut M5044 Field coil open-circuit test...
Page 153 6-12 Brush inspection Inspect the contact surface rough- ening and brush length. Standard: 20.5 mm (0.81 in.) Limit: 13.0 mm (0.51 in.) Caution: Measure the brush length at the center (concave portion). Wrap sand paper around the com- Brush ST0017 ST0018 mutator for correction of the contact surface and for a new brush.
Page 154 6-13 Bearing inspection and replacement The bearing shall move smoothly without any abnormality when it is rotated with a finger force. No abnormal sound shall be heard when rotated quickly. Replace the bearing if any abnor- mality is found. Inspecting the Bearing CO842 CO843 Use the SST and remove the front...
Page 155 6-14 Inspect the continuity between ter- minal 50 and the magnet switch body. Standard: Perfect continuity Inspecting the Magnet Switch Assy (2) ST0111 REASSEMBLY Install the steel ball. Coat grease on the steel ball and place it in the clutch shaft hole. Steel Ball ST0044 Install the starting motor housing assy.
Page 156 6-15 Install the armature assy. Coat grease on the armature bear- ing, and install the armature to the starting motor yoke. Armature Assy ST0237 Install the brush holder. Raise the brush spring with a screw- driver, and install the brush holder to the starting motor yoke.
Page 157 6-16 Connect the C terminal lead. Connect the lead wire to the C ter- minal with a nut. C Terminal Lead ST0347 STARTING MOTOR ASSY INDIVIDUAL INSPECTION Caution: Each test shall be completed in a short time (3 to 5 seconds). Pull-in-test Make sure that the pinion gear comes out when the connection is...
Page 158 6-17 No-load test Firmly fix the starting motor with a vise, etc. Use a thick lead wire for the no-load test because a big current flows in the lead. Read the ammeter when the indica- tion is stabilized. Standard: 90A or less No-load Test ST0352 INSTALLATION...
Page 159 -168-...
Page 160 ON-VEHICLE TEST Inspect the specific gravity of the battery fluid. Standard: 1.26 - 1.28 (at 20°C) Inspect the battery terminals. Inspect the V belt Inspect the fuses Inspecting the Battery Fluid Specific Gravity KAHS106 Inspect the wiring status. Check abnormal sound. Check abnormal sound generation from the alternator while the engine is running.
Page 161 ALTERNATOR ASSY Pulley set nut Wave washer Pulley Rectifier end frame Terminal bush Drive end frame Front bearin Rectifier holder Retainer IC regulator Brush holder (w/cover) Rotor Rear bearing Rear end cover Bearing cover Brush Alternator Assy Components KAHM13 -171-...
Page 162 CIRCUIT DIAGRAM Alternator Circuit Diagram KAHM14 -172-...
Page 163 Caution: The alternator assy removal and installa- tion described here are on-vehicle oper- ations. REMOVAL Disconnect the battery negative - ter- minal. Disconnect the alternator wiring. Alternator Assy KAHS107 Loosen the V belt Remove the alternator assy. DISASSEMBLY Remove the terminal insulator. Remove the rear end cover.
Page 164 Remove the rectifier sub-assy. Terminal screws (4 pcs.) at four places of stator coil Straighten the terminals. Rectifier sub-assy Rectifier Sub-assy KAH21-21 Remove the pulley. Set the alternator pulley to a vise. Caution: Always use mouth pieces for clamping with the vise. Set nut (Use a 22 mm socket wrench.) Pulley...
Page 165 Separate the drive end frame and rotor assy. Use a press and remove the rotor assy from the end frame. Caution: Carefully operate to prevent damage to the bakelite at the rear tip end of the rotor assy. Rotor assy KAH22-14 Remove the rear bearing.
Page 166 INSPECTION Rotor assy inspection No. 1 (coil open- circuit test) Measure the resistance between two slip rings. Standard: 3.0Ω Ω Ω Ω Ω or less Inspecting the Rotor Assy (Coil KAH22-15 Open-Circuit Test) Rotor assy inspection No. 2 (coil ground Test) Measure the insulation resistance between the slip and rotor core.
Page 167 Rectifier sub-assy inspection Test the continuity using the kΩ Ω Ω Ω Ω range of a multimeter. Standard: Perfect continuity in one direction and no continuity in the other direc- tion when tested with polarity change. Caution: See the figure at right for the rectifier Rectifier Sub-assy KAH21-33 circuit.
Page 168 7-10 IC regulator diode inspection Test the conduction of the diode be- terminals B and F with a mul- timeter set to the kΩ Ω Ω Ω Ω range. Standard: Conduction in one direction and no conduction in the other direction when tested with polarly change be- tween terminals B and F.
Page 169 7-11 4. Assemble the drive end frame sub-assy and rear end frame sub-assy. (1) Straighten the stator coil terminal. (2) Rear end frame sub-assy (3) Set bolts (2 pcs.) (4) Set nuts (2 pcs.) T = 55 kg-cm (4 ft-lb) Rear End Frame Sub-assy KAH22-7 5.
Page 170 7-12 9. Install the rear end cover (1) Rear end cover (2) Screws (3 pcs) Rear Cover KAH21-4 INSTALLATION The installation procedure is the reverse of the removal procedure. Caution: After alternator installation, always ad- just the V belt flexure. (See 1-4.) -180-...
Page 171 SST (SPECIAL SERVICE TOOLS) -182-...
Page 172 -183-...
Page 173 -184-...
Page 174 -185-...
Page 175 -186-...
Page 176 SERVICING REFERENCE VALUES PERIODIC MAINTENANCE SPECIFICATIONS ENGINE ASSEMBLY CYLINDER HEAD -188-...
Page 177: Valve Spring
VALVE GUIDE BUSHING VALVE SPRING VALVE -189-...
Page 178 VALVE ROCKER SHAFT AND ROCKER ARM VALVE LIFTER AND PUSH ROD MANIFOLD CYLINDER BLOCK -190-...
Page 179 CRANKSHAFT FLYWHEEL -191-...
Page 180: Piston And Piston Ring
CONNECTING ROD AND BEARING PISTON AND PISTON RING -192-...
Page 181 TIMING GEAR AND IDLE GEAR CAMSHAFT AN BEARING -193-...
Page 182: Injection Pump
FUEL NOZZLE & NOZZLE HOLDER INJECTION PUMP -194-...
Page 183 INJECTION PUMP ADJUSTMENT 1. Adjustment conditions 2. Temporary adjustment (at full lever position) 3. Pump internal pressure adjustment (at full lever position) 4. Overflow volume inspection (at full lever position) 5. Timer adjustment (at full lever position) Note: Hysteresis must be less than 0.3 mm (0.012"), at all speeds. -195-...
Page 184 9-10 6. Injection Volume Adjustment 7. Low speed lever set -196-...
Page 185 9-11 LUBRICATION OIL PUMP LUBRICATING OIL CAPACITY AND KIND COOLING RADIATOR THERMOSTAT -197-...
Page 186: Engine Electrical
9-12 ENGINE ELECTRICAL ALTERNATOR STATOR -198-...
Page 187: Starter Relay
9-13 STARTER RELAY GLOW PLUG PREHEATING TIMER TEMPERATURE SENSOR -199-...
Page 188: Tightening Torques
9-14 TIGHTENING TORQUES -200-...
Page 189 9-15 -201-...

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