1N Engine PDF

TOYOTA
REPAIR MANUAL
Jan., 1987
Pub.No.A M054E
FOREWORD
This repair manual has been prepared 10 provide information

covering general service repairs for the 1 N engines equipped
on the TOYOTA STARLET.
Apphcabte models. N P70 series
Please note that the pubhcat,ons below have also been prepa -
red as relevant service manuals 10 the components and system
,n this engine
Manual Name Pub No

Starlet New Cur Features
-
NCF021 E
All information in this manual 1s based on the latest product

information at the ume of pubhcat,on. However, spec1hcat1-
ons and procedures are subJect to change without notice.
TOYOTA MOTOR CORPORATION
•
TOYOTA 1 N ENGINE
REPAIR MANUAL
INTRODUCTION
ENGINE MECHANICAL ......
FUEL SYSTEM
COOLING SYSTEM
LUBRICATION SYSTEM
STARTING SYSTEM
CHARGING SYSTEM
SERVICE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
SST AND SSM
1995 TOYOTA MOTOR CORPORATION

All rights reserved. This book may not be re-
produced or copied. in whole or tn par, with
out the wrinen permission of Toyota Motor
Corporation.
IN -1
INT ROD UCT ION

Page
HOW TO USE THIS MANUA L ....... . ......... IN -2
IDENTIF ICATION INFORM ATION .. .. ......... IN-4
GENERA L REPAIR INSTRU CTIONS . . . . . . . . . . . IN-4
ABBREV IATIONS USED IN THIS MANUA L . . . IN- 7
IN-2 INTRO DUCT !ON- How to Use This Manua l
HO W TO USE THI S MA NU AL
n
To assist in findin g your way throug h this manua l, the Sectio
Title and major headin g are given at the top of every page.
to
An INDE X is provid ed on the 1st page of each sectio n
guide you to the item to be repaire d.
At the beginn ing of each sectio n, PREC AUTIO NS are given
n.
that pertain to all repair opera tions contai ned in that sectio
Read these precau tions before startin g any repair task.
TROU BLES HOOT ING tables are includ ed for each system
to help you diagno se the system proble m and find the cause.
y
The repair for each possib le cause is referen ced in the remed
colum n to quickl y lead you to the solutio n.
REP AIR PRO CED URE S

Most repair opera tions begin with an overvi ew illustra tion.
It
identif ies the compo nents and shows how the parts fit to-
gether .
Example:
~ - -- - - -Pressure Regulator
\] Valve
~ Piston
• Gasket
i
9 - - - - -
Spring
-Reta iner
• O-Ring
• Snap Ring
Oil Pump ~;l-- - Oil Strainer
195 (14, 19)

• Gasket
* Dra;n ~
P~
Oil Pan
I:
l kg -cm (ft- lb, N-m) Specified torque
• Non - reusable part
* Precoated part
LU0481
INTRODUCTION - How to Use This Manual 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 text tells how to perform the task and gives
other information such as specifications and warnings.
Example:
-------- Task heading: what to do
9. INSTALL GOVERNOR LINK

(a) Using SST, install the governor link with the two
support bolts and gaskets. Torque the bolts.
Torque: 115 kg -cm (8 ft-lb, 11 N -m) "'-
Illustration:
what to do and where SST 09260-54012 (09269-54040) ~
/ / Specification
Set part No. Components part NO.
(b) Check that the governor link moves smoothly after
assembly. ~
Detail text:
how to do it
This format provides the experienced technician within FAST

TRACK to the information needed. He can read the task head -
ings and only refer to the detailed text when he needs it.
Important specifications and warnings always stand out in
bold type.
REFERENCES
References have been kept to a minimum. However, when
they are required you are given the page to go to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text
in the applicable step. You never have to leave the procedure
to look up your specs. All specifications are also found in
Appendix A Specifications, for quick reference.
WARNINGS, CAUTIONS , NOTES:

• WARNINGS are presented in bold type, and indicate there
is a possibility of injury to you or other people.
• CAUTIONS are also presented in bold type, and indicate
there is a possibility of damage to the components being
repaired.
• NOTES are separated from the text but do not appear in
bold. They provide additional information to more effi -
ciently help you perform the repair.
IN -4 INTROD UCTION - Identifica tion Informati on, General Repair Instructio ns
IDEN TIFIC ATIO N

INFO RMA TION
ENGIN E SERIA L NUMB ER
The engine serial number is stamped on the left side of the
cylinder block.
IN0109
GENE RAL REPAIR

INST RUCT IONS
1. Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
2. During disassembly, keep parts in order to facilitate re -
assembly .
3. Observe the following :
(a) Before performin g electrical work, disconne ct the
cable from the battery terminal.
(b) If it is necessary to disconne ct the battery for in -
spection or repair, always disconne ct the cable from
the negative (-) terminal which is grounded to the
vehicle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight
up without twisting it or prying it.
(d) Clean the battery terminal posts and cable terminal
with a shop rag . Do not scrape them with a file or
such.
(e) Install the cable terminal to the battery post with the
nut loose and tighten the nut after installatio n. Do
not use a hammer or such to tap the terminal onto
the post.
( f) Be sure the cover for the positive ( + ) terminal is
properly in place.
4. Check hose and wiring connecto rs to make sure they are
securely and correctly connecte d.
5. Non -reusable Parts
(a) Always replace cotter pins, gaskets, 0 -rings and oil
seals etc. with new ones.
(b) Non-reus able parts are indicated in the compone nt
illustratio ns by the " • " symbol.
INTRODUCTION - General Repair Instructions IN-5
6. Precoated Parts
Precoated parts are the bolts. nuts. etc. Which are coated
w ith a seal lock adhesive at the factory.
(a) If a precoated part is tightened, loosened or caused
to move in any way, it must be precoated w ith the
specified adhesive.
(b) Recoating of Precoated Parts
Seal Lock Adhesive (1) Clean off the old adhesive from the bo lts, nut or
installation part threads.
IN0036
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
bolt or nut threads.
(c) Precoated part are indicated in the component illus-
trations by the "*" symbol.
7. When necessary, use a sealant on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
9. Use of special service tools (SST) and spec ial service
materials (SSM) may be required, depending on the na -
ture of the repair. Be sure to use SST and SSM where
specified and follow the proper work procedure. A list of
SST and SSM can be found at the back of this manual.
1 0. When replacing fuses, be sure the new fuse is the correct
amperage rating. DO NOT exceed the fuse amp rating or
use one of a lower rati ng.
11 . Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the
proper locat ions.
(a) If t he vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on the vehicle raised on one jack alone, even for a
small job that can be finished quickly.
12. Observe the following precautions to avoid d amage to

parts:
(a) To disconnect vacuum hoses, pu ll on the end, not
the middle of the hose.
(b) To pull apart electrica l connectors, pull on the con-
WRONG
==--=::::::;% ~- r✓ \~
\
.. CORRECT
IN0114
(c)
nector itself, not the wires.
Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused .
IN-6 INTR ODUC TION - General Repair Instru ctions
(d) When steam cleani ng an engine , protec t the air filter

and injecti on pump from water.
(e) Never use an impac t wrenc h to remov e or install
temp. switch es or temp. sensors.
(f) When check ing contin uity at the wire conne ctor,
insert the tester probe carefu lly to preven t termin als
from bendin g.
(g) When using a vacuu m gauge, never force the hose
onto a conne ctor that is too large. Use a step -down
adapte r instea d. Once the hose has been stretch ed,
it may leak.
13. After remov ing and reinsta lling the injecti on pump and
fuel hoses, clean off the fuel on engine compo nents. In
particu lar, be sure to check the radiato r hose and by- pass
hose, because deterio ration occurs easily if they come
into contac t with fuel.
....
INTRODUCTION - Abbreviations Used in This Manual IN- 7
ABBREVIATIONS USED IN THIS MANUAL

BTDC Before Top Dead Center
EX Exhaust
FIPG Formed in Place Gasket
IN Intake
MP Multipurpose
0/ S Oversize
PCV Positive Crankcase Ventilation
RH Right-hand
SST Special Service Tool
STD Standard
TDC Top Dead Center
U/ S Undersize
w/ With
w/ o Without
EM -1
ENGINE MECHANICAL
Pa g e
DIESEL ENGINE DIAGNOSIS . . . . . . . . . . . . . . . EM-2
DIESEL ELECTRICAL SYSTEM DIAGNOSIS . EM -1 0
ENGINE TUNE - UP . . . . . . . . . . . . . . . . . . . . . . . . . . EM -13
COMPRESSION CHECK . . . . . . . . . . . . . . . . . . . .
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . .
EM -24
EM -25
EM -37
m
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . EM -64
EM -2 ENGIN E MECH ANICA L - Diesel Engine Diagno sis
DIES EL ENG INE DIA GNO SIS

GENE RAL
. The injectio n pump is very rarely
Diesel engine problems are usually caused by t he engine or fuel system
the cause of fuel system problem s.
ssion, valve timing and other major

Before beginn ing fuel system tests, first check that the engine compre
systems are within specifi cation.
PREL IMIN ARY CHEC KS

running conditi on . If neces-
(a) Before perform ing fuel system checks, insure that the engine is in good
systems.
sary, first check the compre ssion, timing and major compo nents or
(b) Check the air fi lter and clean or replace it if necessary.
(c) Confirm that there is sufficie nt fuel in the tank.
elements. Only good-q uality diesel

(d) Check if the fuel is contam inated with gasolin e or other foreign
fuel should be used.
times.
(e) Bleed air from the system by pumpin g the priming pump 30 - 40
ary.
(f) Check for water in the fuel filter and fuel tank and drain as necess
the electrical system.

(g) If the engine will not crank or if it cranks slowly, first trouble shoot
ENGINE MECHANICAL - Diesel Engine Diagnosis EM-3
DIAGNOSIS
PRECAUTION:
1. The basic troubleshooting procedures for the diesel engine itself (valve clearance, compression,
bearings, valves, pistons, etc.) are the same checks you would make for a gasoline engine.
2. The repair of the injection pump requires considerable skill and use of a special test bench.
ENGINE WILL NOT CRANK
(Possible Cause) (Check Procedure and Correction Method)
1. LOOSE OR CORRODED Check cables from battery to starter and make

BATTERY CABLES necessary repairs.
12. DISCHARGED BATTERY I

I
Check alternator output and the drive belt.
Repair as necessary. (See page CH -4)
13. INOPERATIVE STARTER I

I
Check for battery voltage at starter terminals 30
and 50.
If Okay, see STARTING SYSTEM, page
(ST-7) for repair procedure.
ENGINE CRANKS SLOWLY-WILL NOT START

NOTE: Minimum cranking speed: 100 rpm Cold
150 rpm Hot
1. LOOSE OR CORRODED
BATTERY CABLES
I
2. DISCHARGED BATTERY Refer to items 1 and 2 of ENGINE WI LL NOT
CRANK.
I 3. IMPROPER ENGINE OIL lt ---- - ----1 Check engine oil.

If improper viscosity, drain and refill with oil of
viscosity recommended by manufacturer.
(See page LU -3)
- - - - -- - -
EM -4 ENGINE MECHANICAL - Diesel Engine Diagnosis
ENGINE CRANKS NORMALLY BUT WILL NOT START
( Possible Cause) (Check Procedure and Correction M ethod )
j 1. NO FUEL TO NOZZLE HOLDER l1-----1 Loosen any one injection pipe union nut from its
nozzle holder.
Crank the engine for approx. 5 seconds while confirming
t hat fuel is being discharged from the pipe.
If fuel is coming out, begin diagnosis from item 4.
If not, begin from item 2.
2. NO FUEL CUT SOLENOID With starter switch turned ON, check for fuel cut solenoid
operat ion noise (clicking sound) while repeatedly
OPERATION
connect ing and disconnecting fuel cut solenoid.
If no noise, check if there is battery voltage to the
solenoid when t he starter switch is ON.
If battery voltage is confirmed, fuel cut solenoid is faulty
and shou ld be replaced. If no voltage, refer to
ELECTRICAL DIAGNOSIS and make necessary repairs.
Disconnect inlet hoses to fuel fi lter and feed clean

3. NO FUEL INTO INJECTION
PUMP fuel from separate container directly into pump.
If engine starts, either the fuel filter or line between fuel
tank and filter is clogged and should be repaired
accordingly.
If engine still does not start (no fuel intake), check fuel
line between filter and pump.
If normal, pump is faulty and should be replaced.
NOTE: When feeding fuel directly into pum p,
keep container at sa me level as vehicle fuel tank.
4. INOPERATIVE PRE - HEATING With starter switch ON and the glow plug indicator
light illuminated, check t hat t here is voltage applied to
OPERATION
the glow plugs.
If not, refer to ELECTRICAL DIAGNOSIS and repa ir as
necessary.
5. FAULTY GLOW PLUG Check glow plug continuity (See page ST -4).
OPERATION If no continuity, a broken wire is indicated and glow
plug should be replaced.
6. FUEL LEAKAGE FROM Check for loose unions or cracks.

INJECTION PIPE If leaking, tighten to specified torque or, if necessary,
replace pipe(s).
7 . IMPROPER INJECTION Turn crankshaft pulley clockwise to where either

TIMING No. 1 or No. 4 piston is at TDC and, after releasing
cold start advance system, check plunger stroke with
SST. (See page EM-18)
SST 09275 -54010
Plunger stroke: 0.77 - 0.83 mm
(0.0303 - 0.0327 in.)
If not within specification, injection pump is
improperly adjusted.
NOTE: If crankshaft pulley is off more than 1 O°,
it cou ld indicate a jumped timing belt.
8. IMPROPER COLD START Measure timer piston stroke and fast idle lever
ADVANCE AND FAST IDLE opening angle with injection pump tester when cold
start advance is operated.
9. FAULTY NOZZLE OR Check nozzle with nozzle tester. (See page FU-6)
NOZZLE HOLDER Opening pressure: 135 - 155 kg/cm 2
(1 ,920 - 2,205 psi)
(13,239 - 15,200 kPa)
If not within specification, nozzle adjustment is
improper and pressure should be readjusted.
If pressure cannot be adjusted to specification, replace
nozzle holder assembly. (See page FU -8)
ROUGH IDLE WITH WARM ENGINE

-...
1. IMPROPER ADJUSTMENT With accelerator pedal released, check that adjusting
OF ACCELERATOR CABLE lever is in contact with idle screw. Also check if
accelerator cable is catching on something.
If necessary, adjust so lever is in contact with screw,
or make other required repairs.
12. IDLE SPEED TOO LOW I

I
Check the idle speed as specified below. (See page
EM-22)
Idle speed: 700 rpm
If not, adjust with idle adjusting screw.
NOTE: If less than specified, idling would
normally be rough .
, 3. FUEL LEAKAGE I Check for leaks at the pump connections, pump

I
distributive head bolts, nozzle holder and delivery
valve.
Tighten any loose connections to specified torque or
replace parts as necessary.
EM-6 ENGINE MECHANICAL - Diesel Engine Diagnosis
4. IMPROPER INJECTION Refer to item 7 of ENGINE CRANKS NORMALLY

TIMING BUT WILL NOT START, above.
5. IMPROPER OPERATION OF With engine idl ing, loosen t he injection pipe to each
NOZZLE OR DELIVERY VALVE cylinder in order, and check if the idle speed changes.
If no change, a faulty cylinder is indicated .
Check according to following procedure.
• Faulty Nozzle or Nozzle Holder
Check nozzle with nozzle tester. (See page FU - 6)
Opening presure: 135 - 155 kg /cm 2
(1,920 - 2,205 psi)
(13,239 - 15,200 kPa)
If pressure is not within specification, nozzle is faulty
and injection pressure should be readjusted. (See
page FU-8)
• Faulty Delivery Valve
If injection pressure is w ith specification, delivery va lve
is defective and should be replaced.
ENGINE SUDDENLY STOPS
11. ENGINE WILL NOT RE-START 1: -------1 Check to see if engine re-starts according to
prescribed procedure.
If not, refer to ENGINE CRANKS NORMALLY BUT
WI LL NOT START, above, and repair as necessary.
2. ROUGH IDLE If idle is not stable, refer to ROUGH IDLE WITH

WARM ENGINE and repa ir accordingly.
3. MALFUNCTION OF FUEL-CUT Refer to ENGINE CRANKS NORMALLY BUT WILL

SOLENOID NOT START, above, and check accordingly.
NOTE: No operation noise from the fuel cut
solenoid may be due to loose electrical
connections, so check connectors before
proceeding with further repairs.
Refer to item 3 of ENG INE CRANKS NORMALLY

4 . NO FUEL INTO INJECTION
PUMP BUT WILL NOT START, above. I
LACK OF POWER
NOTE:
1. First confirm that the air cleaner is not clogged or the engine overheating.
2. Not applicable if the customer desires an output power higher than specified for that vehicle.
For accuracy, adjust with a chassis dynamo.
1. IMPROPER ACCELERATOR With accelerator fully depressed, check that

CABLE ADJUSTMENT adjusting lever is in contact with maximum speed set
screw. (See page EM-22)
If not, adjust accordingly.
2. INSUFFICIENT Start engine, depress accelerator pedal to floor and

MAXIMUM SPEED check that maximum speed is as specified below.
(See page EM - 22)
Maximum speed: 5,800 ± 50 rpm
If not, adjust with maximum speed adjusting screw.
3. INTERCHANGED OVERFLOW NOTE: Overflow screw is marked "OUT" and

SCREW (OUT) AND INLET (NO has an inner jet. Although both fittings are
MARK) FITTING same size, they must not be interchanged.
, 4. FUEL LEAKAGE I Refer to item 3 of ROUGH IDLE WITH WARM

I
ENGINE.
, 5. CLOGGED FUEL FILTER I Disconnect inlet hose to fuel filter and feed clean fuel
I
directly into the pump.
If engine condition improves, fuel filter is clogged and
should be replaced. (See page FU-2)
NOTE: When feeding fuel directly into pump,
keep container at same level as vehicle fuel
tank.
If no increase in engine cond ition after replacing fuel
filter, check priming pump or perform other necessary
repairs.
, 6. IMPROPER INJECTION TIMING l>--------< 1

Refer to item 7 of ENGINE CRANKS NORMALLY
I BUT WILL NOT START.
7. FAULTY NOZZLE OR NOZZLE (

t - -- - - - - - t
HOLDER BUT WILL NOT START.
EM -8 ENGINE MECHAN ICAL - Diesel Engine Diagnosis
EXCESS IVE EXHAU ST SMOKE

NOTE:
1 . Confirm that the air cleaner is not clogged .
2. Confirm with the customer whether or not oil consumpt ion has been excessive.
( Possible Cause) (Check Procedure and Correction M eth od)
,, . IMPROPER INJECTION TIMING :-----1 Refer to item 7 of ENGINE CRANKS NORMALLY

BUT WILL NOT START.
NOTE: Black smoke indicates advanced timing
while white smoke indicates retarded timing .
Adjustmen ts should be made according ly.
12. CLOGGED FUEL FILTER

I
I
Refer to item 5 of LACK OF POWER.
NOTE: At high speed (2,000 - 3,000 rpm) , a
clogged filter tends to make the exhaust
smoke w hite.
3 . FAULTY NOZZLE OR NOZZLE Refer to item 9 of ENGINE CRANKS NORMALLY

HOLDER BUT WILL NOT START.
NOTE: Excessive exhaust smoke is often
caused by nozzle pressure being too low.
EXCESS IVE FUEL CONSU MPTION

NOTE: Confirm whether clutch slipping , brakes grabbing, tires wrong size or air filter clogged .
1 . FU El LEAKAGE Refer to item 3 of ROUGH IDLE WITH WARM

ENGINE.
I
12. IDLE SPEED TOO HIGH I
After sufficiently warming up engine, check that idle
speed is as specified below. (See page EM -22)
Idle speed : 700 rpm
If not, adjust with idle adjusting screw.
13. MAXIMUM SPEED TOO HIGH :- ----1 Start engine, depress accelerator pedal to floor and
check that maximum speed is as specified below.
(See page EM-22)
Maximum speed: 5,800 ± 50 rpm
If not, adjust with maximum speed adjusting screw.
, 4. IMPROPER INJECTION TIMING:- -- --< Refer to item 7 of EN GINE CRANKS NORMALLY

BUT WILL NOT START.
5. FAULTY NOZZLE OR NOZZLE

HOLDER
BUT WILL NOT START. l
ENGINE MECHANICAL - Diesel Engine Diagnosis EM -9
ENGINE NOISE WHEN WARM
(Clanking Noise with Excessive Vibration)
(Possible Cause ) (Check P rocedure and Co rrectio n Method )
1. COOLANT TEMPERATUR E TOO Check coolant temperat ure with coolant temp. '
LOW gauge.
If not sufficiently warm, thermostat is faulty and
should be replaced.
12. IMPROPER INJECTION TIMING 1: -------1

1
Refer to item 7 of EN GI N E CRANKS NORMALLY
BUT W ILL N OT START.
3. FAULTY NOZZLE OR NOZZLE

HOLDER
I
I
Refer to item 9 of ENG INE CRANKS NORMALLY
BUT WILL NOT START. I
ENGINE WILL NOT RETURN TO IDLE
(Possible Cause) (Check Procedure and Correct io n M ethod )
BINDING A CC ELERATOR CABLE :1- - ----1 Operate adjusting lever on top of injection pump
and check if engine returns to idle. (See page EM -22)
If so, accelerator cable is binding or improperly
adj usted and shou ld be repaired accordingly.
If engine does not return to idle, injection pump is
faulty and should be replaced.
ENGINE WILL NOT SHUT OFF WITH KEY
(Possible Cause) (Check Procedure and Correction M ethod)
IMPROPER FUEL C UT-SOLENOID Disconnect connector on top of fuel cut solenoid and
OPERATION check if engine stops.
If so, starter switch is faulty and should be repaired as
necessary or replaced.
If engine does not stop, either fuel cut solenoid is
faulty or there is interference by foreign particles.
Repair as necessary.
EM -10 ENGINE MECHAN ICAL - Diesel Electrical System Diagnosis
DIESE L ELECT RICAL SYST EM DIAGN OSIS

ENGINE DOES NOT START COLD
N_OTE: 1. Battery voltage at least 12 volts - starter switch OFF.
2. Engine c ranks normally.
3. Fusible link okay.
4. For voltage m a rked with an asterisk, check just as starter is turned ON be-
cause voltage c h anges with elapse of time.
1 . Super Glow System
YES Check if indicator light lights up with starter NO

switch ON.
Coo lant temp. at 2o·c (68°F) : 2 - 4 secs.
Check fuse
Starter switch OFF. I I
Fuse Blown
Fuse OK
Check for short
• Check for battery voltage to Check indicator circu it and repair
terminal 2 of pre-heating light bulb. if necessary.
timer with starter sw itch ON.
Bulb No Good
No Voltage
• Check that there is 0.2 - 1.0 V

between terminal 6 and 12.
I Replace bulb.
If faulty, repair glow plug current Bulb OK

sensor.
If okay, timer is faulty and should Check for battery voltage to terminal 3 of
be replaced. pre-heating timer connector (on wire harness side).
If okay, pre- heating timer is faulty and should be
replace.
Voltage Pre- heating Timer

6 5 4 3 2 1
• Check if voltage to terminal 1 of pre-
heating timer is terminated after engine
is started.
! NO
Start the engine and check if there is

voltage at terminal 9 of pre- heating
[ H
121110 9 7
]
ST0049
timer.
If faulty, repair charging system as
YES necessary.
If okay, timer is faulty and should be
Starter switch OFF.
I replaced.
! CONTINUE D ON PAGE EM-11

ENGINE MECHANICAL - Diesel Electrical System Diagnosis EM-11
CONTINUED FROM PAGE EM -10
• Place starter switch at ON and

check if current flow to terminal
5 of timer is in accordance
with coolant temperature I
(See graph on page ST- 5). No Voltage Pre-heating Duration is Quite
Different Than That Above
OK
I
Timer is faulty Disconnect water temperature sensor
and should be (left rear of engine) and check if
replace. pre-heating duration is approx. 70 or 130
• After completion of pre- seconds or, if connector is directly
heating, check for voltage grounnded, there is no continuity.
at terminal 5 again If okay, water temperature sensor
when starter switch is is faulty and should be replaced.
placed at ST. If not, timer is faulty and should
be replace.
Voltage No Voltage
Starter switch OFF.

I Timer is faulty and
should be replaced.
• Place starter switch at ON

and check for voltage to glow
plug a few seconds later. No Voltage at All
Thereafter, voltage should
drop about 1 / 2. * Check for battery voltage at positive side of glow
plug current sensor ( Resister side).
If okay, replace sensor.
If no voltage, No. 1 glow plug relay is faulty and
should be replace.
(For component inspection, see page ST-3.)
OK
No 1 / 2 Voltage
Check glow plug for continuity. Thereafter
Continuity No Continuity
* Check for battery voltage to p lus side of resistor
Glow p lug Glow plug faulty (Intake manifold side).
okay. and should be If okay, replace resistor.
replaced. If no voltage, No. 2 glow plug relay is faulty
and should be replaced.
- EM -12 ENG INE MEC HAN ICAL - Diesel Electrical System
Diagnosis
2 . Fue l Cut Sole noid
With starter switc h ON, check for fuel

cut solen oid opera tion noise (click ing sound )
while repeatedly conne cting and
disco nnect ing fuel cut solen oid.
No Noise
Noise
I Fuel cut solen oid okay. I Check fuse.
Fuse OK Fuse Blown
Apply battery voltage Check for short

(12 volts) direct ly to circui t and repair
solen oid and check as necessary.
for noise.
Noise No Noise
Check wire harness Replace fuel cut

from fuse ( See page solen oid.
ST-2 to fuel
cut solenoid.
ENGINE MECHANICAL - Engine Tune- up EM-13
ENGINE TUNE-UP
INSPECTION OF ENGINE COOLANT
(See step 1 and 2 on page C0-3)
INSPECTION OF ENGINE OIL

(See step 1 and 2 on page LU-3)
INSPECTION OF BATTERY
(See step 1 on page CH-3)
INSPECTION OF DRIVE BELT

(See step 14 on pages EM -35. 36)
CLEANING OF AIR FILTER

(a) Remove the air filter.
(See step 1 on page EM -41)
(b) Visually check that the air filter element is not exces-
sively dirty, damaged or oily.
If necessary, replace the air filter element.
(c) Clean the element with compressed air.
First blow from the upper side thoroughly. Then
blow off the lower side of the element.
(d) Install the air filter.
(See step 14 on page EM-59)
INSPECTION AND ADJUSTMENT OF

VALVE CLEARANCE
NOTE: Check and adjust the valve clearance while the
engine is cold .
1. REMOVE CYLINDER HEAD COVER

(a) Remove the PCV hose.
(b) Remove the eight bolts and pull out the head cover
with the gasket.
2. MEASURE VALVE CLEARANCE

(a) Set the No.1 cylinder to TDC/ compression.
• Turn the crankshaft pulley and align its groove
with the timing pointer on the oil pump.
• Check that the valve lifters on the No.1 cylinder
are loose and valve lifters on the No.4 are tight.
If not, turn crankshaft one complete revolution.
EM -14 ENGINE MECHANICAL - Engine Tune- up
Front (b) Measure the clearance of half of the valves.

.. IN IN • Measure only those valves indicated in the figure.
• Record the measurements which are out of speci-
fication. They will be used later to determine the
) ~ required replacement shims.
Valve clearance (Cold):
)f.h')JO o Intake 0 .22 - 0 .28 mm (0.009 - 0.011 in .)
Exhaust 0 .27 - 0.33 mm (0.011 - 0.013 in.)
EX EX
EM3939
..
Front
IN IN
(c) Turn the crankshaft pulley one revol ution (360°)
and measure the other valves.
• Turn the crankshaft pulley one revolution and
align its groove and timing pointer on the oil
pump.
• Measure only the valves indicated in the figure.
EX EX
EM3940
3. ADJUST VALVE CLEARANCE

SST B (a) Using SSTs, press down the valve lifter with SST A
and hold the valve lifter down SST B.
SST 09248-5501 0
EM3713
(b) Remove the adjusting shim with a small screwdriver

and magnetic finger.
NOTE: For easy removal of the shim, when setting SST
B, set it on the lifter so there is a wide space in the
removal direction.
(c) Determine the replacement shim size by using the

following ( Formula or Chart) .
• Using a micrometer, measure the thickness of the
shim which was removed.
• Calculate the thickness of the new shim so the
valve clearance comes w ithin specified value.
T .. . ... Thickness of shim used
A .... .. Valve clearance measured
N ...... Thickness of shim new
Intake side:
N = T + (A - 0 .25 mm (0.0098 in.))
Exhaust side:
N = T + (A - 0 .30 mm (0.0118 in.))
ENGINE MECHANICAL - Engine Tune-up EM-15
Intake
Installed Shim Thickness (mm)
Measured
Clearance 0 ID 0 ID 0
ID r-- 0
ID 0 ID 0 ID 0 ID 0 ID 0 ID 0 ID 0 ID 0 ID 0 ID 0 ID 0 ID 0 ID 0 ID 0
ID r-- 0 N ID r-- 0 ID r-- 0 ID r-- 0 r-- 0
(mm)
0 N N N N
ID ID ID I{) <O <O <O <O r-- r-- r-- r-- CX) CX) 00 CX) m m m m 0
N ID
0 0 0 .... ....
N ID r--
N N N N N N N N N N N N N N N N N N N N C""i C""i C""i C""i C""i C""i C""i C""i C""i C""i C""i
.... ....0
N
N
N
ID r-- 0
N N (")
(") (")
0.000 - 0.025 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24
0.026 - 0.050 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26
0.051 - 0.075 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26
0.076 - 0.100 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28
0 101 - 0 125 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28
0.126-0.150 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30
0.151 - 0.175 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30
0.176 - 0.200 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32
0.201 - 0.219 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32
0.220 - 0.280
0.281 - 0.300 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.301 - 0.325 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.326 - 0.350 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.351 - 0.375 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.376 - 0.400 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.401 - 0.425 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.426 - 0.450 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.451 - 0.475 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.476 - 0.500 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.501 - 0.525 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.526 - 0.550 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.551 - 0.575 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.576 - 0.600 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.601 - 0.625 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.626 - 0.650 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.651 - 0.675 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.676 - 0.700 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.701 - 0.725 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.726 - 0.750 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.751 - 0.775 22 24 24 26 26 28 28 30 30 32 32 34 34
0.776 - 0.800 24 24 26 26 28 28 30 30 32 32 34 34
0.801 - 0.825 24 26 26 28 28 30 30 32 32 34 34
0.826 - 0.850 26 26 28 28 30 30 32 32 34 34
0.851 - 0.875 26 28 28 30 30 32 32 34 34
0.876 - 0.900 28 28 30 30 32 32 34 34 Shim thicknesses mm (in.)
0.901 - 0.925 28 30 30 32 32 34 34 Shim
Thickness !Shim
0.926 - 0.950 30 30 32 32 34 34 No. Thickness
No.
0.951 - 0.975 30 32 32 34 34 02 2.500 (0.0984) 20 2.950 (0.1161 )
0.976 - 1.000 32 32 34 34
04 2.550 (0.1004) 22 3.000 (0.1181 )
1.001 - 1.025 32 34 34
06 2.600 (0.1 024) 24 3.050 (0.1201 )
1.026 - 1.050 34 34
1.051 - 1.075 34 08 2.650 (0.1043) 26 3.100 (0.1220)
10 2.700 (0.1063) 28 3.150 (0.1240)
Intake valve clearance (cold):
12 2.750 (0.1083) 30 3.200 (0.1260)
0 .22 - 0 .28 mm (0.009 - 0 .011 in.)
14 2.800 (0.1 102) 32 3.250 (0.1280)
Example: . A 2.800 mm shim is installed and the
measured clearance is 0.450 mm. 16 2.850 (0.11 22) 34 3.300 (0.1299)
Replace the 2.800 mm shim with 18 2.900 (0.1142)
shim No. 22 (3.000 mm).
EM -16 ENGIN E MECHA NICAL - Engine Tune-u p
Exhau st
Installed Shim Thickness (mm)
Measured 0 I{) 0 I{) 0 I{) 0 I{) 0 I{) 0 I{) 0 I{) 0 I{) 0 I{) 0
0 0 I{) 0 I{) 0 I{) 0 I{)
r-- 0 r-- 0
Clearance 0
0
I{)
N
0
I{)
I{)
r-- 0
I{)
N I{)
(D
r-- 0 N I{) r-- 0CX)
(D r-- r-- r-- r--
N
cq
I{)
CX)
r-- 0a, N
CX)
I{) r-- 0
a, a, a, 0
N
0
I{)
q
r-- 0
0 ..... N..... I{)
..... .... N
~ N
I{)
N N (")
(mm) I{) I{) I{) ll')(D (D

N N N N N N N l"'i l"'i (") l"'i M l"'i l"'i M (") l"'i M l"'i M
N N N N N N N N N N N N N
0.000 - 0.025 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22
0.026 - 0.050 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24
0.051 - 0.075 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24
0.076 - 0.100 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26
0.101 - 0.125 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26
28
0.126 - 0.1 50 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26
02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28
0.151 - 0.175
02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30
0.176 - 0.200
22 22 24 24 26 26 28 28 30 30
0.201 - 0.225 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20
20 20 22 22 24 24 26 26 28 28 30 30 32
0.226 - 0.250 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18
20 22 22 24 24 26 26 28 28 30 30 32 32
0.251 - 0.269 02 02 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20
0.270 - 0.330
32 32 34 34
0.331 - 0.325 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30
26 28 28 30 30 32 32 34 34
0.326 - 0.350 04 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26
30 30 32 32 34 34
0.351 - 0.375 04 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28
28 30 30 32 32 34 34
0.376 - 0.400 06 06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28
06 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.401 - 0.425
32 34 34
0.426 - 0.450 08 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32
34
0.451 - 0.475 08 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34
10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.476 - 0.500
0.501 - 0.525 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.526 - 0.550 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.551 - 0.575 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.576 - 0.600 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.601 - 0.625 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.626 - 0.650 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.651 - 0.675 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.676 - 0.700 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.701 - 0.725 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.726 - 0.750 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.751 - 0.775 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.776 - 0.800 22 22 24 24 26 26 28 28 30 30 32 32 34 34
0.801 - 0.825 22 24 24 26 26 28 28 30 30 32 32 34 34
0.826 - 0.850 24 24 26 26 28 28 30 30 32 32 34 34
0.851 - 0.875 24 26 26 28 28 30 30 32 32 34 34
0.876 - 0.900 26 26 28 28 30 30 32 32 34 34
0.901 - 0.925 26 28 28 30 30 32 32 34 34
28 28 30 30 32 32 34 34 Shim thicknesses mm (in.)
0.926 - 0.950
0.951 - 0.975 28 30 30 32 32 34 34 $ him Shim Thickness
Thickness No.
0.976 - 1 .000 30 30 32 32 34 34 No.
1.001 - 1.025 30 32 32 34 34 02 2.500 (0.0984) 20 2.950 (0.1161 )
1 .026 - 1 .050 32 32 34 34 04 2.550 (0.1004) 22 3.000 (0.1 181 )
1.051 - 1.075 32 34 34
1.076 - 1.100 34 34 06 2.600 (0.1024) 24 3.050 (0.1201)
1 .101 - 1 .1 25 34 08 2.650 (0.1 043) 26 3.100 (0.1220)
10 2.700 (0 .1063) 28 3.150 (0 .1240)
Exhaus t valve clearan ce (cold) : 12 2.750 (0.1083) 30 3.200 (0.1 260)
0 .27 - 0 .33 mm (0.011 - 0.013 in.)
14 2.800 (0.1102) 32 3 .250 (0.1280)
Exampl e: A 2.800 mm shim is installe d and the
measur ed clearan ce is 0 .450 mm. 16 2.850 (0.1122) 34 3 .300 (0.1299)
Replace the 2.800 mm shim with 18 2.900 (0.1 142)
shim No. 20 (2.950 mm).
ENG INE MEC HAN ICAL - Engi ne Tune - up
EM -17
(d) Rech eck the valve clear ance .

(e) Adju st the valve clearance of the rema
ining cylin -
ders as requ ired.
4. INST ALL CYL INDE R HEA D COV ER

EM -18 ENGINE MECHANICAL - Engine Tune-up

INJECTION TIMING
1. REMOVE ENGINE UNDER COVER
2. INSTALL PLUNGER STROKE MEASURING TOOL

(SST) AND DIAL INDICATOR
(a) Remove the bolt and injection pump protector.
FU1683
(b) Remove the distributive head plug bolt and gasket

from the injection pump.
(c) Install SST and the dial indicator to the distributive

head plug hole.
SST 09275-54010
EM3693
3. SET NO. 1 OR NO . 4 CYLINDER TO ABOUT 25-30°

BTDC / COMPRESSION
Turn the crankshaft pulley clockwise so the pulley groove
is 25 - 30° from the oil pump pointer.
EM 3694
4. RELEASE COLD STARTING SYSTEM

(a) Using a screwdriver, turn the cold starting lever
counterclockwise about 20° as shown.
(b) Put a metal plate 8.5 - 10 mm (0.33 - 0 .39 in.) thick
between the cold starting lever and thermo w ax
plunger.
ENGINE MECHA NICAL - Engine Tune- up EM -19
5. CHECK INJECTI ON TIM ING

(a) Set the dial indicator at 0 mm (0 in.) .
(b) Recheck to see that the dial indicator remains at 0
mm (0 in.) while rotating the crankshaft pulley
slightly to the left and right.
- I
EM3695 EM3694
(c) Slowly rotate the crankshaft pulley clockwis e until

the pulley groove is aligned with the timing pointer.
(d) Measure the plunger stroke.
Plunge r stroke : 0 .77 - 0 .83 mm
(0 .0303 - 0 .0327 in.)
EM3696 EM3695
6. ADJUST INJECTI ON TIMING

(a) Loosen the four injection pipe union nuts on the
pump side.
(b) Loosen the four bracket bolts.
(c) Loosen the two injection pump mounting nuts.
EM 3935
EM-20 ENGINE MECHANICAL - Engine Tune-up
(d) Adjust the plunger stroke be slightly tilting the in-

jection pump body.
If the stroke is less than specification, tilt the pump to-
ward the engine.
If greater than specification, tilt the pump away from the
engine.
Plunger stroke: 0.77 - 0.83 mm
(0.0303 - 0 .0327 in.}
FU1823
(e) Tighten the two injection pump mounting nuts.

Torque: 195 kg-cm (14 ft-lb, 19 N·m)
EM3935
(f) Tighten the four bracket bolts.

Torque: 195 kg-cm (14 ft-lb. 19 N•m)
(g) Tighten all union nuts on the injection pipes.

Torque: 300 kg-cm (22 ft- lb, 29 N-m)
(h) Recheck the plunger stroke.
Plunger stroke: 0.77 - 0 .83 mm
(0.0303 - 0.0327 in.)
7. REMOVE METAL PLATE FROM COLD STARTING

LEVER
8. REMOVE SST AND DIAL INDICATOR

(a) Remove SST and dial indicator.
ENGINE MECHANICAL - Engine Tune-up EM -21
(b) Install the distri butive head plug bolt with a new
gasket. Torque the bolt.
T orque : 170 kg-cm (12 ft- lb, 17 N-m )
EM3692
9. BLEED AIR FROM FUEL LINE

Bleed air from the injection pipe be activating the starter
motor.
FU1788
10. INSTALL INJECTION PUMP PROTECTOR
FU1683
11 . START ENGINE AND C HECK FO R LEAKS
12. INSTALL ENGINE UNDER COVER

EM-22 ENGIN E MECH ANICA L - Engine Tune-u p
INSP ECTI ON AND ADJU STM ENT OF IDLE

AND MAX IMUM SPEE D
1. INITIA L COND ITION S:
(a) Air cleaner installed
(b) Engine coolan t normal operating temperature
(c) Accessories switch ed off
(d) Transmission in neutral
2. CONN ECT TACH OMET ER TO ENGIN E
3. DISCO NNEC T ACCE LERAT OR CABL E

Discon nect the accelerator cable from the injectio n
pump.
4. CHEC K AND ADJU ST IDLE SPEED

(a) Check that the adjusting lever is in contac t with the
idle speed adjusti ng screw.
If not, check if the air conditi oner switch is OFF or if
engine is running at normal operating temperature.
(b) Start the engine and check the idle speed.
Id le speed : 700 rpm
(c) Loosen the lock nut and adjust by turning the idle
adjusti ng screw.
(d) Securely tighten the lock nut and recheck the idle
speed.
5. CHEC K AND ADJU ST MAXI MUM SPEED

(a) Inspec t the engine maximum speed with the adjust -
ing lever fully depressed.
Maxim um speed: 5,800 rpm
CAUT ION: This check should be perfor med in as
short a time as possible.
ENGINE MECHANICAL - Engi ne Tu ne- up EM -23
(b) Remo ve the maximum adjusting screw wire.

(c) Loosen the lock nut and adj ust by turning t he max-
imum speed adjusting screw.
CAUTION : Perform adjustment at low rpm. and
t hen recheck at m axi mum speed. ·
(d) Securely tighten the lock n ut and recheck the maxi -
mum speed.
(e) Lock the maximum speed adjusting screw with the
wire.
6. CONNECT ACCELERATOR CABLE

(a) Connect the accelerator cable and adjust so there is
no slack in it.
(b ) Inspect to see that the adjusting lever is stopped by

t he maximum speed adjusting screw when the ac-
celerator pedal is depressed all the way.
7. DISCONNECT TACHOMETER

IDLE-UP SPEED
1. CHECK AND ADJUST IDLE- UP SPEED
(a) Turn the idle adjust knob to clockwise fully.
(b) Check t he idle- up speed.
Idle- up speed: 1,300 rpm
EM 3705
If not specification. turn the adjusting screw.

Idle- up speed: 1.300 rpm
NOTE: The adjusting screw is located above the accel -
eration pedal.
EM3706
Check
EM -24 ENG INE MEC HAN ICA L - Com pression
CO MP RE SS IO N CH EC K
oil or fuel
NOTE: If there is lack of pow er, excessive
cylin der com pres sion pres -
cons ump tion, measu re the
sure .
1. WA RM UP ENG INE
E
2. DIS CON NEC T FUE L CUT SOL ENO ID WIR
CON NEC TOR
3. REM OVE GLO W PLU GS

(See st ep 8 on pag es EM -42, 43 )
ire is not
SST (Ada pter) CAU TIO N : M ake sure the load w
-./ grou nde d.
GLO W
4. INST ALL SST (GA UGE ADA PTE R ) TO
PLU G MO UNT ING HOL E
SST 0999 2-00 024
EM 3716
5. MEA SUR E CYL IND ER COM PRE SSI ON

SST (Com press ion Gaug e) PRE SSU RE
to the SST
(a) Con nect SST (compression gaug e)
(gau ge adap ter).
SST 0999 2 -000 24
starter moto r,
5f4
(b) Whi le cranki ng the engi ne w ith the
measure the compression.
y to obta in
NOTE: A fully charged battery is necessar
engi ne revo lutio n of more than 250 rpm.
/I EM 3717 der.
(c) Repeat steps (a) and (b) for each cylin
j
Com pression pressure:

30.0 kg / cm (427 psi, 2,94 2 kPa )
2
M inim um pressure:
25.0 kg /cm (356 psi, 2,45 2 kPa )
2
Diff erence between each2 cyli nder:

)
Less t han 5 .0 kg /cm (71 psi , 490 kPa
cylin ders
(d) If the cylin der compression in one or more
engi ne oil into the
is low, pour a small amo unt of
hole and repeat
cylin der thro ugh the glow plug
low com pres -
steps (a) and (b) for the cylin der with
sion .
ces are
• If addi ng oil helps the com pres sion , chan
cylin der bore are
that the pisto n rings and / or
worn or damaged.
ing or
• If pressure stays low, a valve may be stick
be leaka ge past
seating improper ly, or t here may
the gasket.
6. INS TAL L GLO W PLU GS

(See st e p 7 on pag e EM -57)
E
7. CON NEC T FUE L CUT SOL ENO ID WIR
CON NEC TOR
ENGINE MECHANICAL - Timing Belt EM -25
TIMING BELT
COMPONENTS
Injection Pump Drive Pulley

Camshaft Timing Pulley
No. 2 Timing Belt Cover- - --1
1,200 (87,1 18) ,(},

-:::::
-, 1
~
Timing Belt
~ Tension Spring
·1'dler Pulley
Crankshaft Timing Pulley
Timing Belt Guide
No. 1 Timing Belt Cover
Crankshaft Pulley
kg -cm (ft- lb, N-m) I : Specified torque F6443
REMOVAL OF TIMING BELT

1. REMOVE DRIVE BELT
2. REMOVE NO.2 TIMING BELT COVER

Remove the clip, five bolts and the No.2 timing belt cover
with the gasket.
3. REMOVE GLOW PLUGS

(See step 8 on pages EM -42, 43)
NOTE: It is necessary to remove the glow plugs so that
the cra nkshaft will tu rn smooth ly and enable the belt to
be adjusted properly.
EM -26 ENGINE MECHANICAL - Timing Belt
4. SET N0.1 CYLINDER AT TDC /CO MPRESSION

Align the line mark of the camshaft timing pulley with the
cavity of the cylinder head by turning the crankshaft pul-
ley clockwise.
EM3719
5. REMOVE CRANKSHAFT PULLEY

(a) Install the SST to the crankshaft pulley.
SST 09213- 7001 0
(b) Using SSTs to hold the crankshaft pu lley, loosen the
pulley bolt.
SST 09213-70010 and 09330-00021
(c) Remove SSTs, pulley bolt and washer.
EM3720
(d) Using SST, remove the crankshaft pulley.

SST 09213- 31021
6. REMOVE N0.1 TIMING BELT COVER

Remove the three bolts and No.1 timing belt cover.
c-..__
r - - EM3722
7. REMOVE TIMING BELT GUIDE

ENGINE MECHANICAL - Timing Belt EM-27
8. REMOVE TIMING BELT

NOTE: If reusing the timing belt, draw a direction arrow
on the belt (in direction of engine revolution}, and place
matchmarks on the pulleys and timing belt.
(a) Using a screwdriver, remove the tension spring.

CAUTION: Do not pinch the tension spring with
pliers or such.
(b) Loosen the idler pulley bolt.
(c) Remove the timing belt from each pulley.
9. REMOVE CAMSHAFT TIMING PULLEY

(a) Using SST to hold the timing pulley, remove the
pulley bolt.
SST 09278-5401 2
CAUTION: Avoid turning the camshaft or the
valves will hit against the pistons.
(b) Using SST, remove the timing pulley.

SST 09950-20016
CAUTION: The pulley will spring out so be care-
ful not let if fall.
(c) Remove the woodruff key from the camshaft.
10. REMOVE INJECTION PUMP DRIVE PULLEY

(a) Using SST to hold the drive pulley, remove the pul-
ley nut.
SST 09278-54012
CAUTION: Do not use an impact wrench .
EM-28 ENGINE MECHANICAL - Timing Belt
(b) Using SST, remove the drive pulley.

SST 09213-6001 7
CAUTION: The pulley will spring out so be care-
ful not to drop it.
11 . REMOVE IDLER PULLEY
12. REMOVE CRANKSHAFT TIMING PULLEY

Using SST, remove the timing pulley.
SST 09213-60017
ENGI NE MECH ANIC AL - Timing Belt
EM- 29
INSP ECT ION OF COM PON ENT S

NO ! 1. INSPECT TIMIN G BELT
CAUT ION :
~ ~ ~
• Do not bend, twist or t urn the be lt inside out.
• Do not a llow the belt t o come int o cont act w it h
~~ oil, wat er or steam .
~
• Do not utilize belt tensio n when instal l ing or
remo ving the set bolt of the cams haft ti m ing
EM0126 pull ey.
If t here are defect s as shown in the fig ures, check the
follow ing points and replace the timing belt if necessary.
(a) Premature part ing
• Check for proper installation.
• Check the timing cover gasket for damage and
prope r install ation.
EM 0127
( b) If the belt teeth are cracked or damaged, check to

see if the camshaft, water pump or oil pump is
locked .
EM0128
(c) If there is notice able wear or cracks of the belt face,

check to see if there are nicks on one side of the idler
pulley lock.
EM0129
(d) If there is wear or damage on only one side of the

belt, check the best guide and the alignm ent of each
pulley .
EM0130
EM-30 ENGIN E MECH ANICA L - Timing Belt
(e) If there is noticea ble wear on the belt theeth. check

the timing cover gasket for damag e and proper in -
stallatio n. Check for foreign material on the pulley
teeth.
EM0131
2. INSPE CT IDLER PULLEY

Check the turning smooth ness of the timing belt idler
pulley.
If necessary, replace the idler pulley.
EM3731
3. INSPE CT TENSI ON SPRIN G

(a) Check the free length of the spring.
Free length : 45 .55 mm (1 .7933 in.)
i.--- - - -45.55 mm- - --i

F1615
(b) Check the tension of the spring at the specified in-

stalled length.
Stand ard install ed tensio n:
6 .0 kg (13.2 lb, 59 N) at 52.7 mm (2.07 in.)
Minim um install ed tensio n:
5.4 kg (11.9 lb, 53 N) at 52.7 mm (2 .07 in.)
If the installe d tension is less than minimu m, replace the
tension spring.
ENGINE MECHANICAL - Timing Belt EM -31
INSTALLATION OF TIMING BELT

(See page EM -25)
NOTE: Remove any oil or water on the t iming pulleys
and keep it clean.
1. INSTALL CRANKSHAFT TIMING PULLEY

(a) Align the wood ruff key groove of t he timing pulley
with the woodruff key on the crankshaft.
(b) Using SST and a hammer, drive in the timing pulley.
SST 09214- 60010
2. INSTALL IDLER PULLEY

(a) Install t he idler pulley.
( b) Pry the idler pulley toward the left as far as it w ill go
and temporarily tighten it.
3. INSTALL INJECTION PUMP DRIVE PULLEY

(a) A lign the woodruff key groove of the drive pulley
with the woodruff key on t he drive shaft.
(b) Using SST to hold t he drive pulley, install and
torque t he pulley nut.
SST 09278 - 54012
Torqu e: 650 kg -cm (47 ft- lb, 64 N -m)
CAUTION : Do not use an impact wrenc h.
4. INSTALL CAMSHAFT TIMING PULLEY

(a) Install t he woodruff key to the groove of the
camshaft.
(b) Al ig n t he woodruff key groove of the timing pulley
w ith the woodruff key on the camshaft.
(c) Usi ng SST to hold t he timing pulley, install and
torque the pulley bolt.
SST 09278 -54012
Torque: 900 kg -cm (65 ft- lb, 88 N-m)
CAUTION : Avoid turning the camshaft or the
va lves will hit against the pistons.
EM-32 ENGINE MECHANICAL - Timing Belt
5. SET TIMING AND DRIVE PULLEYS

(a) Align the line mark of the camshaft timing pulley
with the cavity of the cylinder head.
(b) Align the grooves of the crankshaft timing pulley
with the protrusion mark on the oil pump.
CAUTION: When turning the crankshaft or
camshaft, the valves will hit against the pistons
so do not turn them more than necessary.
(c) Align the cavity of the injection pump drive pulley
with the line mark on the water pump.
EM 3735
6. INSTALL TIMING BELT

CAUTION: The engine should be cold.
NOTE: If reusing the timing belt, align the points
marked during removal (See step 8 on page EM-27 ) and
install the timing belt with the arrow pointing in the
direction of engine revolution.
(a) Place the timing belt on the camshaft timing pulley.
EM 3737
(b) Place the timing belt to the injection pump drive

pulley while holding the pulley stationary with a
wrench.
CAUTION: Be sure the timing belt is securely
meshed and not loose.
ENGINE MECHANICAL - Timing Belt EM- 33
(c) Place t he tim ing belt to t he water pump pulley, oil

pump drive pulley and crankshaft timing pulley.
CAUTION : Be sure the timing belt is securely
meshed and not loose.
EM4037
(d) Place the timing belt to the idler pulley.

CAUTION: Be sure the belt is not twisted or too
tight.
EM4036
(e) Pry the idler pulley toward the right far as it will go
and temporarily tighten it.
(f) Usi ng a screwdriver, install the tension spring.

CAUTION : Do not pinch the tension spring with
pliers ot suc h.
(g) Loosen the idler pulley bolt to where the idle pul ley
lightly moves wit h tension spring force.
7. CHECK VALVE TIMING

(a) Temporarily install the crankshaft pulley bolt.
(b) Turn t he crankshaft two revolutions to where the
line mark of the camshaft pul ley and t he cavity of the
cylinder head are again alig ned.
CAUTION : Always turn the crankshaft c lock-
wi se.
If t urned counter clockwise, there is possibility of the belt
EM3740
teeth becoming unmeshed and the best tension chang-
ing.
EM -34 ENGI NE MECH ANIC AL - Timing Belt
(c) After turnin g the cra.nkshaft, insure that each pulley

aligns with the marks as shown .
If the marks do not align, repeat the above procedure
from step 6.
EM3741
8. TORQ UE IDLER PULL EY BOLT

(a) Torqu e the idler pulley bolt.
T orque : 195 kg -cm (1 4 ft- lb, 19 N -m)
CAUT ION : While t ighte ning t he pulley bolt , do
not move the idler pulley brack et.
(b) Remove the cranks haft pulley bolt and washer.
9. INSTA LL BELT GUID E

Place the belt guide on the crankshaft timing pulley, fac -
ing the cup side outwa rd.
10. INSTA LL NO .1 TIMIN G BELT COVE R

Install the No.1 timing belt cover with the three bolts.
ENGINE MECHANICAL - Timing Belt EM-35
11 . INSTALL C RANKSHAFT PULLEY

(a) Align the woodruff key groove of t he crankshaft
pulley with t he woodruff key on the crankshaft.
(b) Using SST and hammer, drive in the cra nkshaft pul -
ley.
SST 09223 -4601 1
EM3743
(c) Install the washer, pulley bolt and SST to the

crankshaft pulley.
SST SST 09212 -70010
(d) Usi ng SST to hold the crankshaft pulley, torque the
pul ley bolt.
SST 09212 -70010 and 09330-00021
T orqu e: 1,200 kg-cm (87 ft- lb, 11 8 N -m )
12. INSTALL G LOW PLUGS

EM 3744 (See step 7 on page EM -57 )
13. INSTALL NO.2 TIMING BELT COVER

Install the No.2 timing belt cover and gasket with the clip
and five bolts.
14. INSTALL AND ADJUST DRIVE BELT

Drive belt deflection at 10 kg (22.0 lb, 98 N)
New be lt 6 - 7 mm (0 .24 - 0 .28 in.)
Used belt 8 - 11 mm (0 .32 - 0 .43 in .)
Crankshaft EM3745
(Reference)
Using SST, check the drive belt tension.
SST B
SST A 09216 -00020
SST B 092 16-00030
SST A Drive belt t ension: New be lt 45 - 55 kg
Used belt 20 - 35 kg
EC0003 EC0004
EM -36 ENGINE MECHANICAL - Ti ming Belt
NOTE:
CORRECT WRONG • "New belt" refers to a new belt which has never been
used.
Clearance • "Used belt" refers to a belt which has been used on a
running engine for 5 minutes or more.
• After installing the belt, run the engine for approx. 5
minutes and t hen recheck the deflection.
MA0035
15. INSPECT AND ADJUST INJECTION TIMING

(See pages EM -18 to 20)
Exha
Mani
Heat
Ex
Ir
Q
Ne
Pre
ENGINE MECHANICAL - Cyli nder Head EM-37
CYLINDER HEAD
COMPONENTS
Vacuum Pu m p - 4 ,-
T~---- • Gasket
f
PCV H o s e ~
140 (10. 14)

Intake Manifold
~ -- - - - Camshaft Bearing Cap
Camshaft
1
" -'ii
Air Filter o----SVhlim ~ Accelerator Wire
C l - - ave
u Lifter V s rac ket
~- valve Keepers
~Valve Spring Retainer
g - -Valve Spring
Exhaust
Manifold
Heat Insulator
• Gasket
Injection Pipes- - - -,
300 (22. 29) - - - ----{)'(
~
No.2 Injection Pump ~
Protector ~ @>
~ 1 sso (47. 64) 1
~ ~
Injection Nozzle
~~ Holder No. 1 Fuel Pipe
jkg -cm (ft-lb, N-m) j : Specif ied torque ~ Nozzle Seat
• Non-reusable part • Nozzle Gasket
* Precoated part EM4013
EM -38 ENGINE MECHANICAL - Cylinder Head
REMOVAL OF CYLINDER HEAD

(See page EM -37)
(See steps 1 to 8 on page EM -25 to 27)
2. REMOVE CAMSHAFT TIM ING PULLEY

3. REMOVE MANIFOLD STAY

Remove the two bolts and manifold stay.
4. REMOVE OIL DIPSTICK GUIDE MOUNTING

BOLT
(a) Remove t he oil d ipstick.
(b) Remove t he oil dipstick guide mounting bolt.
5. DISCONNECT N0 .1 OIL COOLER HOSE

Disconnect the No. 1 oil cooler hose from t he union.
6. REMOVE INJECTION PIPES

(a) Remove t he No. 2 injection pump protector.
ENGIN E MECH ANICA L - Cylinder Head
EM- 39
(b) Remove the injectio n pipe clamps.

(c) Discon nect both ends of the injectio n pipes from
the injectio n pump and nozzle holders.
7. DISCO NNEC T FUEL HOSE S

Discon nect t he two fuel hoses from the injectio n pump.
8. REMO VE WATE R INLET

(a) Remove the two nuts.
(b) Discon nect the water inlet hose from the water inlet
pipe.
(c) Remove the water inlet and gasket .
9. REMO VE ACCE LERAT OR WIRE BRAC KET
10. REMO VE WATE R PUMP MOUN TING BOLT

EM-40 ENGINE MECHA NICAL - Cylinder Head
11 . REMOV E CYLIND ER HEAD COVER

(a) Remove the PCV hose.
(b) Remove the eight bolts and cylinder head cover.
12. REMOV E CYLIND ER HEAD

(a) Gradually loosen and remove the ten head bolts in
three passes and in the numerical order shown.
CAUTIO N : Head warpage or cracking could re-
sult from removin g incorrec t order.
2 8 10 5 3
EM4041
EM3944
(b) Lift t he cylinder head from the dowels on the cylin-

der block and place the head on wooden blocks on
a bench.
CAUTIO N : Be careful not to damage the cylin-
der head and block surface of the head gasket
sides.
EM4067
NOTE: If the cyli nder head is difficult to lift off, pry with
a screwdriv er between the cylinder head and block and
block projectio n.
(c) Remove the cylinder head gasket.
ENGINE MECHANICAL - Cylinder Head EM-41
DISASSEMBLY OF CYLINDER HEAD

(See page EM- 37)
1. REMOVE AIR CLEANER CAP
Remove the four bolts, air cleaner cap and-air filter.
2. REMOVE EXHAUST MANIFOLD

(a) Remove t he eight bolts and exhaust manifold heat
insulator.
EM3948
(b) Remove the six bolts, two nuts, exhaust manifold

and gasket.
EM 3949
3. REMOVE INTAKE MANIFOLD

Remove the two bolts, two nuts, intake manifold and
gasket.
4. REMOVE VACUUM PUMP

Remove th'e two nuts, bolt, vacuum pump and gasket.
5. REMOVE NO.1 ENGINE HANGER
EM3952
6. REMOVE NO.1 FUEL PIPE AND WATER OUTLET

No. 1 Fuel Pipe
(a) Remove the two nuts, bolt, No.1 fuel pipe, water
out let and gasket .
(b) Disconnect the fuel hose from the No.1 nozzle leak-
age pipe.
Water Outlet
EM3953
7. REMOVE INJECTION NOZZLE HOLDERS

(a) Remove the four nuts, No.1 nozzle leakage pipe and
four gaskets.
EM3954
(b) Usi ng SST, remove the four injection nozzle hold-

ers.
SST 09268-64020
( c) Arrange t he injection nozzle holders in order.
(d) Remove the nozzle seats and nozzle gaskets.
8. REMOVE GLOW PLUGS

(a) Remove the current sensor cover and four grom-
mets.
(b) Remove the nuts, washer, No.2 glow plug resistor
insulator, current sensor and No.1 glow plug resis-
tor insulator.
EM3957
(c) Remove the nuts and glow plug connector.

(d) Remove the glow plugs.
9. REMOVE NO.2 ENGINE HANGER
EM3958
10. REMOVE UNION
EM3959
11. REMOVE CAMSHAFT

(a) Gradually loosen and remove the bearing cap bolts
from in three passes and in the numerical order
shown.
CAUTION: Loosen each cam bearing cap bolt a
little time.
(b) Remove the bearing caps and camshaft.
3 5
4 6 2
EM3960
EM4117
EM-44 ENGINE MECHANICAL - Cylinder Head
12. REMOVE VALVE LIFTERS WITH SHIMS

(a) Pull out the valve lifter with shim by hand.
(b) Arrange the valve lifters and shims in order.
13. REMOVE VALVES

SST
(a) Using SST, compress the retainer until the two
keepers can be removed.
SST 09202-43013
(b) Remove the two keepers and SST.
(c) Remove the retainer, spring and valve.
EM3962
,~e!
(d) Remove the oil seal.
i (e) Using a small screwdriver or magnet, remove the

spring seat.
@ (f) Arrange the disassembled parts in order.
IN
EX
1~
@
1
,i~
2 3 4 EM0025
14. REMOVE COMBUSTION CHAMBERS

(a) Insert a rod 4 mm in diameter into the glow plug
hole and tap out the combustion chambers.
(b) Arrange the combustion chambers in order.
EM 3963 F64 76
ENGINE MECHAN ICAL - Cylinder Head EM -45
INSPEC TION AND CLEANI NG OF

COMPO NENTS
1. CLEAN TOP OF PISTONS AND TOP OF CYLINDER
BLOCK
(a) Turn the crankshaft and bring each piston to top
dead center, scrape the carbon from the piston top.
(b) Remove all gasket material from the top of the block.
Blow carbon and oil from the bolt holes.
WARNING : Protect your eyes when using high
pressu re air .
2. CLEAN COMBUS TION CHAMBE R

Using a wire brush, remove all the carbon from the com -
bustion chambers.
CAUTION : Be careful not t o scrat c h the head
gasket contact surface .
3. REMOVE GASKET MATERIA L

Using a gasket scraper, remove all gasket material from
the head and manifold surfaces.
CAUTION : Be careful not t o scratch the sur-
faces.
4. CLEAN VALVE GUIDE BUSHING S

Using a valve guide brush and solvent, clean all the valve
guide bushings.
EM3846
5. CLEAN CYLINDE R HEAD

Using a soft brush and solvent, clean the head.
6. INSPECT CYLINDER HEAD FOR FLATNESS

Using a precision straight edge and thickness gauge,
measure t he surfaces contacting the cylinder block and
manifold for warpage .
Maximum warpage: 0 .2 mm (0.008 in.)
If warpage is greater than maximum, replace the cylinder
head.
EM3968
EM3969
EM3970
7. INSPECT CYLINDER HEAD FOR CRACKS

Using a dye penetrant, check the combustion chambers,
intake and exhaust ports, head surface and the top of the
head for cracks.
If a crack is found, replace t he head.
EM3971
8. CLEAN VALVES
(a) Use a gasket scraper to chip any carbon from the
valve head.
(b) Using a wire brush, clean the valve thoroughly.
EM0580
9. INSPECT VALVE STEM OIL CLEARANCE

EB (a) Using a dial gauge, measure the inside diameter of
the valve guide bushing.
Standard inside diameter: 6 .01 - 6 .03 mm
(0.2366 - 0.2374 in.)
EM3972 EM3847
(b) Using a micrometer, measure the diameter of the

-o-
1
valve stem.
Stem diameter:
Intake 5.970 - 5.985 mm
(0.2350 - 0.2356 in.)
Exhaust 5.965 - 5.980 mm
(0.2348 - 0.2354 in.)
(c) Subtract the valve stem measurement from the valve
guide bushing measurement.
EM2588 EM0798
Standard oil clearance:
Intake 0.025 - 0.060 mm
(0.0010 - 0 .0024 in.)
Exhaust 0.030 - 0.065 mm
(0.0012 - 0.0026 in.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in. )
Exhaust 0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the
valve and valve guide bushing.
10. IF NECESSARY, REPLACE VALVE GUIDE

90°C BUSHING
(a) Gradually heat the cylinder head to approx. 90°C
(194°F).
EM3973
(b) Using SST and hammer, drive out the valve guide
bushing.
SST 09201 -7001 0
(c) Using caliper gauge, measure the valve guide bush-

ing bore of the cylinder head.
EM3975 EM3845
Both intake and exhaust (d) Select a new valve guide bushing .
Bushing bore mm (in.) Bushing size If the valve guide bushing bore of the cylinder head is
more than 11 .02 mm (0.4339 in.), machine the bore to
10.993 - 11 .02
(0.4328 - 0.4339) Use STD the following dimension.
Over 11 .02 Rebored valve guide bushing bore dimension:

(0.4339) Use 0/S 0.05 11.043 - 11.07 mm (0.4348 - 0.4358 in.)
(e) Gradually heat the cylinder head to approx. 90°C

(194°F).
9.2 - 10.0 mm (f) Using SST and a hammer, drive in the new valve
guide bushing to where there is 9.2 - 10.0 mm
(0.362 - 0.394 in.) protruding from the cylinder
head.
SST 09201 -7001 0
EM3974 EM3687
(g) Using a sharp 6 mm reamer, ream the valve guide

bushing to obtain the specified clearance between
the bushing and new valve stem.
Standard oil clearance:
Intake 0.025 - 0 .060 mm
(0.0010 - 0.0024 in.)
Exhaust 0 .030 - 0 .065 mm
(0.0012 - 0 .0026 in.)
EM3976
11. INSPECT AND GRIND VALVES

(a) Grind the valves only enough to remove pits and
carbon.
(b) Check that the valves are ground to the correct valve
face angle.
Valve face angle: 44.5°
44.5°
EM0254 EM0180
(c) Check the valve head margin thickness.

Minimum margin thickness:
Intake 0 .9 mm (0.035 in.)
Exhaust 1.0 mm (0.039 in.)
If the valve head margin thickness is less than minimum,
replace the valve.
Margin Thickness
EM0181
ENGINE MECHA NICAL - Cylinder Head EM-49
~
(d) Check the valve overall length.
Standar d overall length: 91 .28 mm (3.5937 in.)
Minimu m overall length: 90.78 mm (3.5740 in .)
If the valve overall length is less than minimum, replace
Overall length the valve.
-
-
/ '----. EM2534
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface it with a grinder or
replace the valve.
CAUTIO N: Do not grind off more than the mini-
mum amount .
Minimu m overall length : 90.78 mm (3.5740 in.)
EM0373
12. INSPEC T AND CLEAN VALVE SEATS

(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.

Apply a thin coat of prussian blue (or white lead) to
the valve face. Install the valve.
Lightly press the valve against the seat. Do not ro-
\ tate the valve.
EM3978
(c) Check the valve face and seat for the following :
• If blue appears 360° around the face, the valve is
concentr ic. If not, replace the valve.
• If blue appears 360° around the valve seat, the
guide and seat are concentr ic. If not, resurface the
seat.
• Check that the seat contact is on the middle of the
.. Intake:
Exhaust:
valve face with the following width :
1 .2 - 1.6 mm (0.047 - 0.063 in. )
1.6 - 2.0 mm (0.063 - 0 .079 in.)
If not, correct the valve seat as follows:
• If seati ng is too high on the valve face, use 30°
and 45° cutters to correct the seat.
IN 1.2 - 1.6 mm
EX 1.6 - 2.0 mm
EM0185
• If seat ing is too low on the valve face, use 75° and
..
45° cutters to correct the seat .
IN 1.2 - 1.6mm
EX 1.6 - 2.0 mm EMoi as
(d) Hand - lap the valve and valve seat with abrasive
compound.
(e) Clean the valve and valve seat after hand - lapping.
EM 3979
13. INSPECT VALVE SPRINGS

Squareness- 1 (a) Using a steel square, measure the squareness of the
valve springs.
Maximum squareness: 2.0 mm (0.079 in.)
If squareness is greater than maximum, replace the valve
spring.
EM 2590
(b) Using calipers, measure the free length of the valve

spri ng.
Free length: 41 .52 mm (1 .6346 in. )
If not as specified, replace the valve spring.
EM 0801
(c) Using a spri ng tester, measure the tension of the

valve spring at the specified installed height.
Installed height: 34.16 mm (1 .3449 in.)
Standard installed tension:
18.41 kg (40.6 lb, 181 N)
Minimum installed tension:
17.49 kg (38 .6 lb, 172 N)
If the installed tension is less than minimum, replace the
spring.
EM0281
14. INSPECT CAMSHAFT

(a) Place the camshaft on V-blocks and measure the
circle runout at the center journal.
Maximum circle runout: 0 .02 mm (0.0008 in. )
If the circle runout is greater than the maximum, replace
the camshaft.
EM3980
(b) Usi ng a micrometer, measure the cam lobe height.

Standard cam lobe height:
Intake 43.84 - 43.94 mm
(1 .7260 - 1 .7299 in.)
Exhaust 43.88 - 43.95 mm
(1.7276 - 1.7303 in.)
Minimum cam lobe height:
Intake 43.54 mm (1 .7142 in .)
Exhaust 43.58 mm (1.7157 in .)
If the cam lobe height is less than minimum, replace the
camshaft.
(c) Using a micrometer, measure the journal diameter.
Standard diameter: 26.979 - 26.995 mm
(1 .0622 - 1.0628 in.)
15. INSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the bearing caps and camshaft journal.
(b) Lay a strip of Plastigauge across each journal.
EM3983
(c) Place the bearing caps each journal w ith the arrows
Front • pointing toward the front and in numerical order
from the front side.
0 0
(8 8
0 0
EM3985
(d) Inst all and torque the cap bolts gradually in three
passes in the sequence shown.
Torque: 140 kg-cm (10 ft- lb, 14 N -m)
NOTE: Do not turn the camshaft while t he plastigauge
is in place.
4 2 6
3 5
EM3984
EM4117
(e) Remove the caps and measure the Plastigage at its

widest point.
Standard oil clearance: 0.037 - 0.073 mm
(0.0015 - 0.0029 in.)
Maximum oil clearance: 0.1 mm (0.004 in.)
If clearance is greater than maximum, replace the head
and / or camshaft.
(f) Clean out the pieces of Plastigage from the bearing
caps and journals.
16. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Clean and install the camshaft and bearing caps.
(b) Using a dial gauge, measure the trust clearance
while moving the camshaft back and forth .
Standard thrust clearance: 0.08 - 0 .18 mm
(0.0031 - 0 .0071 in.)
Maximum thrust clearance: 0.25 mm (0.0098 in.)
and/ or camshaft.
17. MEASURE VALVE LIFTER OIL CLEARANCE

(a) Using a micrometer, measure the diameter of the
valve lifter.
(1.3372 - 1.3376 in.)
EM 3988
(b) Using a caliper gauge, measure the inside diameter

of the cylinder head bore.
Standard inside diameter: 34.000 - 34.016 mm
(1.3386 - 1.3392 in.)
I
\ (c) Subtract the valve lifter measurement from the
cylinder head bore.
Standard oil clearance: 0 .024 - 0.050 mm
(0.0009 - 0.0020 in . )
Maximum oil clearance: 0 .10 mm (0.0039 in.)
and I or valve lifter.
18. INSPECT INTAKE AND EXHAUST MANIFOLDS

Using a precision straight edge and thickness gauge,
check the surfaces contacting the cylinder head for
warpage.
Maximum warpage: 0.2 mm (0.008 in.)
If warpage is greater than maximum, replace the mani -
fold.
EM3990
EM3992
EM3991
EM -54 ENGINE MECHAN ICAL - Cylinder Head
ASSEM BLY OF CYLIND ER HEAD

(See page EM-37)
NOTE:
• Thoroughl y clean all parts to be assembled.
• Before installing the parts, apply new oil to all sliding
and rotating surfaces.
• Replace all gaskets and oil seals with new parts.
1. INSTALL COMBUS TION CHAMBE RS

NOTE: If replacing a combustio n chamber, replace with
one having the same number as marked on the cylinder
head.
(a) Match the combustio n chamber knock pin with the

cylinder head notch.
(b) Using plastic-fac ed hammer, drive in the combus-
tion chamber.
NOTE: Combustio n chamber flange thickness
No. Combustion chamber flange thickness

1 4.95 - 4.98 mm (0.1949 - 0.1961 in.)
2 4.99 - 5.01 mm (0.1965 - 0.1972 in.)
3 5.02 - 5.04 mm (0.1976 - 0.1984 in.)
(c) Using a dial gauge, check the combustio n chamber

protrusion.
Combust ion chamber protrusio n:
Minus 0 .03 - Plus 0.03 mm
(Minus 0 .0012 - Plus 0.0012 in .)
2. INSTALL VALVES
(a) Install new oil seals on the valve guide bushings.
NOTE: Pushing down at the places shown in the illus-
tration .
(b) Rotate the oil seal to check that it is firmly installed.
(c) Lubricate and insert the valve in the valve guide
bushing. Check that the valves are installed in the
correct order.
EM4068
SST (d) Install the spring seat, spring and spring retainer on
the cylinder head.
(e) Using SST, compress the valve retainers and place
the two keepers around the valve stem.
SST 09202- 70010
(f) Unscrew the SST confirm proper fit of the keepers.
EM3962
(g) Using a plastic-faced hammer, lightly tap the valve

stem tip to assure proper fit.
3. INSTALL VALVE LIFTERS WITH SHIMS

(a) Install the valve lifters with shims on the valve stem
tips.
(b) Check the valve lifters and shims are installed in the
correct order.
(c) Check the valve lifters rotate smoothly by hand.
4. INSTALL CAMSHAFT
(a) Place the camshaft in the cylinder head.
(b) Apply MP grease to a new oil seal.
EM0050
(c) Install a new oil seal.

NOTE: Be careful not to install the oil seal slantwise.
(d) Apply seal packing to the No.1 bearing cap as

Seal Packing shown in the figure.
Seal packing: Part No.08826 - 00080 or
equivalent
NOTE: Install the No.1 bearing cap immediately after
applying the seal packing.
EM3997
(e) Place bearing caps each journal. (See step (c) on

page EM - 52)
(f) Gradually install and tighten the cap bolts in three
passes in the sequence shown.
Torque: 140 kg-cm (10 ft-lb, 14 N-m)
4 2 6
3 5
EM3984
EM4117
5. INSTALL UNION
Sealant (a) Clean the union threads and cylinder head union
hole of any sealant, oil or foreign material.
Remove any oil with kerosene or gasoline.
(b) Apply sealant to 2 or 3 threads of the union end.
Sealant: Part No. 08833 - 00070 or equivalent
NOTE: This adhesive will not harden while exposed to
air. It will act as a sealant or binding agent only when
applied to threads, etc. and air is cut off.
EM3998
(c) Install the union in the sequence shown in the fig -

ure.
EM3999
6. INSTALL NO.2 ENGINE HANGER

EM3958
7. INSTALL GLOW PLUGS

(a) Install and torque the glow plugs.
(b) Install the No.1 glow plug resistor insulator.

(c) Install the glow plug connector, current sensor,
No.2 glow plug resistor insulator, washer and nuts.
(d) Tighten the five nuts.
(e) Install the four grommets and current sensor cover.
8. INSTALL INJECTION NOZZLE HOLDERS

(a) Clean off all carbon deposits on the nozzle seats.
(b) Place four new gaskets and the nozzle seats in the
cylinder head.
(c) Using SST, install and torque the four injection noz -
zle holders.
SST 09268-64020
CAUTION: Over torquing could cause nozzle de-
formation and needle adhesion or other defects.
(d) Install the four new gaskets and nozzle leakage pipe
with the four lock nuts.
Torque the lock nuts.
Torque: 300 kg-cm (22 ft-lb, 29 N•m)
EM4001
d
EM - 58 ENG INE MEC HAN ICA L - Cyli nder Hea
1 FUE L PIP E
9. INS TAL L WA TER OUT LET AND NO.
No. 1 Fuel Pipe head.
(a) Install a new gasket to the cylin der
pipe with the
(b) Install the wate r outl et and No.1 fuel
two nuts and bolt.
nozzle leakage
( c) Con nect the fuel hose to the N o.1
pipe.
EM395 3
10. INS TAL L NO. 1 ENG INE HAN GER

}
Tor que : 195 kg- cm (14 ft-lb . 19 N-m
11 . INS TAL L VAC UUM PUM P

head .
(a) Install a new gasket to the cylin der
nuts and bolt
(b) Install the vacu um pum p with the two
in the sequ ence sho wn.
-m }
Tor que : 195 kg -cm (14 ft- lb, 19 N
12. INS TAL L INT AKE MA NIF OLD

der head.
(a) Pos ition a new gasket on the cylin
two bolt s and
(b) Install the intake man ifold with the
two nuts .
-m)
Tor que : 195 kg- cm (14 ft-lb , 19 N
EM3950
13. INS TAL L EXH AUS T MA NIF OLD

der head .
(a) Position a new gasket on the cylin
the two nuts and
(b) Install the exhaust man ifold with
six bolts.
-m}
Tor que : 400 kg -cm (29 ft-lb . 39 N
EM394 9
ENGINE MECHANICAL - Cyli nder Head EM-59
(c) Install t he exhaust man ifold heat insulator with the

eight bolts.
14. INSTALL AIR CLEANER CAP

Install the air filter and cap with the four bolts in t he
seq uence shown.
EM4014
EM -60 ENGINE MECHA NICAL - Cylinder Head
INSTA LLATI ON OF CYLIN DER HEAD

(See page EM-37)
1. INSTALL CYLIND ER HEAD
CAUTIO N : When installin g the cylinder head,
face the camsha ft key groove upward to prevent
interfere nce with the valve and piston.
EM4002
(a) Place a new head gasket over dowels on the cylin -

Gasket Selection der block.
Mark
NOTE: Use a gasket of the same thickness (make your
choice acoordin g to the thickness indentific ation number
on the gasket).
(b) Position the cylinder head over dowels on the block.
EM4003
2. TORQU E CYLIND ER HEAD BOLTS

NOTE:
• The cylinder head bolts are tighten in three progressive
steps.
• If any of the bolts break or deform, replace them.
• If the cylinder head bolts are to be replaced, use only
cylinder head bolts with a cavity in the head.
(a) Apply a light coat of engine oil on the threads and

under the cylinder head bolts.
(b) First, uniformly torque the eighteen cylinder head
bolts in several passes and in the seq uence shown.
Torque: 690 kg-cm (50 ft-lb, 68 N -m)
If any one of the bolts does not meet the torque specifi -
cation, replace the bolt .
(
EM 4004
EM3944
ENGINE MECHANICAL - Cylinder Head EM -61
(c ) M ark the front of t he top of head bolt w ith paint.

Paint Mark
•
Front
Cavity
(d) Tighten the ten head bolts 90° in t he numerical order

shown.
r (e) Then tig hten the bolts by an addit ional 90°.
(f) Check that the paint mark is now faci ng rearward.
3. INSTALL WATER PUMP MOUNTING BOLT

Torque: 195 kg -cm (14 ft- lb, 1 9 N -m )
EM3945
4. INSTALL WATER INLET

(a) Install a new gasket to the cylinder head.
(b) Connect the water inlet hose to water inlet pipe and
install the water inlet wit h the two nuts.
T o rq ue : 195 kg -cm (14 f t - lb. 19 N •m)
EM4118
5. CONNECT FUEL HOSES

Con nect the two fuel hoses to the injection pump.
EM4042
EM -62 ENGINE MECHA NICAL - Cylinder Head
6. INSTAL L INJECTI ON PIPES

(a) Con nect both ends of the injection pipes to the in-
ject ion pump and nozzle holder.
(b) Install the clamps holding the four injection pipes.
(c) Torque t he union nuts of the injection pipes.
Torque: 300 kg -cm (22 ft- lb, 29 N •m)
7. CONNE CT NO.1 OIL COOLER HOSE

Connect the No.1 oil cooler hose from the union.
8. INSTALL OIL DIPSTIC K GUIDE MOUNT ING BOLT

(a) Install and torque t he oil dipstick guide mounting
bolt.
Torque: 195 kg -cm (14ft- lb, 19 N -m)
(b) Install t he oil dipstick.
EM3942
9. INSTALL MANIFO LD STAY

Install the manifold stay with the two bolts.
Torque: 400 kg -cm (29 ft- lb, 39 N ·m)
EM3941
10. INSTALL CAMSH AFT TIMING PULLEY

11 . INSTALL TIMING BELT

(See steps 5 to 14 on pages EM -32 to 36)
12. ADJUST VALVE CLEARA NCE

(See pages EM - 13 to 17)
ENGINE MECHANICAL - Cylinder Head EM -63
13. INSTALL CYLINDER HEAD COVER

(a) Place t he head cover gasket on the head cover.
(b) Apply seal packing to two locations shown.
Sea l packing : Part N o. 08826-00080 o r
equivalent
(c) Place the head cover on the cylinder head and install
and torque the eight bolts.
T orque: 80 kg -cm (69 in.-lb, 7 .8 N -m )
(d) Install the PCV hose.
14. INSTALL ACCELERATOR WIRE BRACKET
15. INSPECT ANO ADJUST INJECTION TIMING

(See page EM- 18)
16. INSTALL NO. 2 INJECTION PUMP PROTECTOR

EM -64 ENGI NE MECH ANIC AL - Cylind er Block
CYL IND ER BLO CK

COM PON ENT S
~ - - - -- - + - --Pis ton Ring
~ 0 - - - P i s t o n Pin
• Snap Ring - - -0 QttJ
• Gasket
Wu______:::::::::::: so,,
Guide
RH Engine Mount ing
Straigh t Screw Plug
Oil Dipstic k _ _ -----"\.,
4a Flywhe el
900 (65. 88)
Bracket
Oil Hole Cover
~ Conne cting Rod
~---- --Be arin g
r\-o Conne cting Rod
~ C ap
See pages EM-90, 91
Dust Seal
• Oil Seal
Alterna tor
,,____,,,.,_:_, Rear Oil Seal Retainer
~
No. 1 Injectio n
Pump Protector ~ f/ • 0 - R~ng
°'6\) Water Inlet Pipe
Alterna tor Bracket
Water Temp. Switch
Oil Nozzle~
Crankshaft Bearing Cap,- - - - ~ 1--- -~1 600 (43. 59) I
!kg -cm (ft- lb. N-m) I : Specifi ed torque

• Non- reusable part
* Precoated part
L
ENGINE MECHANICAL - Cylinder Block EM -65
PREPARATION FOR DISASSEMBLY

1. REMOVE CLUTCH COVER AND DISC
4 2. REMOVE FLYWHEEL
EM3848
3. REMOVE REAR END PLATE AND DUST SEAL
4. INSTALL ENGINE TO ENGINE STAND FOR

DISASSEMBLY

(See steps 1 to 8 and 10 to 12 on pages EM -25 to
28)
6. REMOVE CYLIND.ER HEAD

(See st e ps 3 to 12 o n pages EM -38 t o 40)
7. REMOVE INJECTION PUMP

(a) Disconnect the No. 1 and No. 2 water by- pass
hoses from the injection pump.
(b) Remove the two bolts, nuts and injection pump.
8. REMOVE WATER PUMP

(See step 4 on page C0- 5)
EM-66 ENGIN E MECH ANICA L - Cyl inder Block
9. REMO VE WATE R INLET PIPE

(a) Discon nect the No. 2 oil cooler hose from the oil
cooler.
(b) Remov e the bolt.
(c) Discon nect the water inlet pipe from the cylinde r
block.
(d) Remove the O -ring .
10. REMO VE OIL FILTER

(See step 2 on page LU -4)
11 . REMO VE OIL COOL ER

(See step 2 on pages LU-11 , 12)
12. REMO VE NO.1 INJEC TION PUMP PROTE CTOR

Remov e the three bolts and No.1 injectio n pump protec-
tor.
EM4044
13. REMO VE WATE R TEMP . SENSO R
14. REMO VE OIL PRESS URE SWITC H

Using SST, remove the oil pressure switch .
SST 09816 - 3001 0
15. REMO VE RH ENGIN E MOUN TING BRAC KET

16. REMOVE ALTERNATOR BRACKET
EM3853
17. REMOVE Oil HOLE COVER PLATE

Remove the two bolts. oil hole cover plate and 0-ring.
18. REMOVE DRAIN COCK
19. REMOVE STRAIGHT SCREW PLU G

Remove t he plug and gasket.
20. REMOVE Oil PAN

( See step 2 o n page LU -6 )
21 . REMOVE Oil STRAINER

(a) Remove the two bolts and nuts.
(b) Remove the oi l strainer and gasket.
EM3858
EM -68 ENGI NE MEC HAN ICAL - Cylind er Block
22. REM OVE OIL REGU LATO R
23. REM OVE OIL PUM P

( See ste p 4 o n page LU -7 )
DISASSEMBLY OF CYLINDER BLOCK

(See page EM- 64)
1. REMOVE REAR OIL SEAL RETAINER
(a) Remove four bolts and rear oil seal retainer.
EM 3860
(b) Using a plastic-faced hammer, lightly tap the rear oil

seal retainer.
2. MEASURE CONNECTING ROD THRUST

CLEARANCE
Using a dial gauge, measure the thrust clearance while
moving t he rod back and forth.
Standard thrust clearance: 0 .08 - 0 .30 mm
(0.0031 - 0.0118 in.)
Maximum thrust clearance: 0 .40 mm (0.0157 in.)
connecting rod assembly and I or crankshaft.
3. MEASURE CONNECTING ROD OIL CLEARANCE

(a) Using a punch or numbering stamp, place the
matchmarks on t he rod and cap to ensure correct
assembly.
(b) Remove the rod cap nuts.

EM -70 ENGIN E MECHA NICAL - Cylinde r Block
(c)Using a plastic-f aced hammer, lightly tap the con-

necting rod bolts and lift the cap and lower bearing.
NOTE: Keep the lower bearing inserted with the cap.
(d) Cover the connec ting rod bolts with a short piece of
hose to protect the crankshaft from damage.
EM 3866
(e) Clean the crank pin and bearing.

(f) Check the crank pin and each bearing for pitting and
scratches.
If the crank pin or bearing are damage d, replace the
cranksh aft and replace bearing .
(g) Lay a strip of Plastigauge across the crank pin.

(h) Remove the short piece of hose.
(i) A lign the punche d marks on the rod and cap.

Install and torque the cap nuts.
(See step 9 on pages EM -90, 91)
NOTE:
• Do not turn the crankshaft.
• Apply a light coating of engine oil on the nut threads
and under the nut before installat ion.
ENGINE MECHANICAL - Cylinder Block EM-71
(j) Remove the rod cap. (See procedure (b) and (c).)
(k) Measure the Plastigauge at its widest point.
Standard clearance: 0.030 :-- 0.058 mm
(0.0012 - 0.0023 in.)
Maximum clearance: 0.08 mm (0.0031 in.)
bearings and/ or crankshaft.
(I) Completely remove the Plastigauge.
EM 3926
NOTE: If replacing the bearing, replace with one having

the same number as marked on the bearing cap.
There are t hree sizes of standard bearings supplied,
marked 1, 2 or 3 respectively.
mm (in.)
Big end inner Crank pin Bearing center

Size
diameter diameter wall thickness
1, 2 or 3
47.015 - 47.022 1 .488 - 1 .492
EM3869 1
(1.8510 - 1.8513) (0.0586 - 0.0587)
47.023 - 47.030 43.988 - 44.000 1.491 - 1.496
2
(1.8513 - 1.8516) (1.7318 - 1.7323) (0.0587 - 0.0589)
47.031 - 47 .038 1.496 - 1.500
3
(1 .8516 - 1.8519) (0.0589 - 0.0591)
4. PUSH OUT PISTON AND CONNECTING ROD

ASSEMBLIES
(a) Remove all the carbon from top of the cylinder.
EM 3870
(b) Cover the rod bolts with a short piece of hose to

protect the crankshaft from damage.
(c) Push out the piston and connecting rod assembly
and the upper bearing through the top of the cylin-
der block.
EM3866
EM-72 ENGINE MECHANICAL - Cylinder Block
NOTE:
• Keep the inserted bearing, connecti ng rod and cap
together.
• Arrange the piston and con necting rod assemblies in
order.
1 2 3 4
EM3871
5. MEASURE CRANKSHAFT THRUST CLEARANCE

Using a dial gauge, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.02 - 0.22 mm
(0.0008-0.0087 in.)
Maximum thrust clearance: 0 .3 mm (0.012 in.)
thrust washers as a set.
Over size thrust washer: 0/S 0.125, 0.250
EM 3927
NOTE: Thrust washer thickness:
STD 2.430 - 2.480 mm (0.0957 - 0.0976 in.)
O/S0.125 2.493 - 2.543mm(0.0981 - 0.1001 in.)
0.250 2.555 - 2.605 mm (0.1006- 0 .1026 in.)
6. MEASURE MAIN JOURNAL OIL CLEARANCE

(a) Gradually loosen and remove the bearing cap bolts
in three passes and in the numerical order shown.
4 8 10 6 2
3 7 9 5
EM 3872
EM 4006
ENGINE MECHAN ICAL - Cylinder Block EM-73
(b) Using the removed bearing cap bolts, pry the bear-
ing cap back and forth, and remove it with the lower
bearing and thrust washers ( No.3 journal only).
NOTE:
• Keep the lower bearing inserted with the cap.
• Arrange the caps and lower thrust washers in correct
order.
(c) Lift off the crankshaft.
EM3874
NOTE: Keep the upper bearings and upper thrust wash-
ers (for the No.3 journal only) inserted in the cylinder
block.
(d) Clean the journals and bearings.
Lower Upper
(e) Check the journals and bearings for pitting and
scratches.
If the journal or bearing is damaged, grind or replace the
crankshaft and replace the bearing .
EM3452
(f) Place the crankshaft on the cylinder block.

(g) Lay a strip of Plastigaug e across each journal.
(h) Install the main bearing caps in their proper loca -

tions.
(i) Apply a light coat of engine oil on the threads and
under the heads of the cap bolts.
(j) Torque the cap bolts in two or three passes and in
the sequence shown.
Torque: 600 kg -cm (43 ft-lb, 59 N ,m)
NOTE: Do not turn the crankshaft.
7 3 1 5 9
8 4 2 6 10
EM3875
EM4006
(k) Remove the bearing caps with the lower bearing

and lower thrust washers.
(See procedure (a) and (b))
(I) Measure the Plastigauge at its widest point.

Standard clearance: 0.020 - 0.051 mm
(0.0008 - 0.0020 in.}
Maximum clearance: 0.08 mm (0.0031 in.}
bearings and/ or grind the main journals.
(m) Completely remove the Plastigauge from the bear-
ings and journals.
NOTE: If replacing the standard bearing, replace with

one having the same number as marked on the bearing
cap.
0 0
There are three sizes of standard bearings supplied,
marked 1, 2 or 3 respectively.
mm (in.)
0
Cylinder block Main journal Bearing center
1, 2 or 3 Size
main journal bore diameter wall thickness
~ No. 1 - No. 5 Cylinder
Front Block Main Journal 54.036 - 54.044 2.005 - 2.008
EM3877 EM3460 1 (0.0789 - 0.0791)
(2.1274 - 2.1277)
54.045 - 54.052 49.985 - 50.000 2.009 - 2.01 2
2
(2.1 278 - 2.1280) (1.9679 - 1.9685) (0.0791 - 0.0792)
54.053 - 54.060 2.01 3 - 2.016
3 (0.0793 - 0.0794)
(2.1281 - 2.1283)
U/S 49.745 - 49.755 2.125 - 2.131
0.25 54.036 - 54.060 (1.9585 - 1.9589) (0.0837 - 0.0839)
UIS (2.1274 - 2.1283) 49.495 - 49.505 2.250 - 2.256
0.50 (1.9486 - 1.9490) (0.0886 - 0.0888)
7. REMOVE CRANKSHAFT
(a) Lift off the crankshaft.
Upper
]) ]) 00 [I ([ (b) Remove the upper main bearings and upper thrust
I~@;; washers from the cylinder block.

NOTE: Arrange the caps, bearings and thrust washers
in correct order.
Lower DD(O)Q(l
1 2 3 4 5 EM4007
ENG INE MEC HAN ICAL - Cylinder Block
EM -75
8. REM OVE OIL NOZ ZLES
9. REM OVE OIL DIPS TICK GUID E
EM4124
EM -76 ENGIN E MECHA NICAL - Cylinde r Block
INSPE CTION OF CYLIN DER BLOC K

1. REMOV E GASKE T MATER IAL
Using a gasket scraper, remove all gasket material from
the cylinder b lock surface.
2. CLEAN CYLIND ER BLOCK

Using a soft brush and solvent, clean the b lock.
3. INSPEC T CYLIND ERS

Visually inspect cylinder s for vertical scratches.
If deep scratches are present, rebore all four cylinder s.
(See page EM -85)
EM3882
4. INSPEC T CYLIND ER BLOCK WAR PAGE

Using a precisio n straight edge and thicknes s gauge,
check the surface contact ing the cylinder head gasket for
warpage .
M aximum w a rpage: 0 .1 mm {0 .004 in. )
If warpag e is greater than maximu m, replace the cylinder
block.
5. MEASU RE CYLIND ER BORE

(a) Using a cylinder microme ter, measure the cylinder
bore at position s A, B and C in the thrust and axial
directio ns.
Fo r sta nda rd siz ed piston
Standa rd d iamet er : 74.00 - 74.03 mm
{2 .9134 - 2.9146 in. )
M aximum diamet er: 74.23 mm (2.9224 in.)
Fo r Ove rsized piston (0 / S 0.50)
EM3880 Standa rd diamet er: 74.50 - 74.53 mm
EM3881
(2.9331 - 2 .9342 in .)
M aximum dia m eter: 74.73 mm (2 .9421 in.)
If the diamete r is greater than maximu m, rebore all four
1,2or3 cylinder s. If necessary replace cylinder block.
NOTE: Standar d Cylinder bore.
~ col
:o:o:au~
~ ®r o
Cylinder No.
1
Cylinder bore
74.000 - 74.010 mm (2.9134 - 2.9138 in.)
2 74.010 - 74.020 mm (2.9138 - 2.91 42 in.)
EM0086 EM5255 3 74.021 - 74.030 mm (2.9142 - 2.9146 in.)

CD Thrust (b) Difference between measurements A B and C is

Direction greater than taper limit.
Front . . · 1
w Ax1a
r,i'\ Taper limit: 0.02 mm (0.0008 in.)
Direction (c) Difference between the thrust and axial measure-
ments is greater than out-of-round limit.
A 10 mm
1-------'--'-- -h- (0.39 in.) Out-of -round limit: 0.02 mm(0.0008 in.)
B
6. REMOVE CYLINDER RIDGE

If the wear is less than 0.2 mm (0.008 in.), use a ridge
reamer to machine the top of the cylinder.
EM3870
DISASSEMBLY OF PISTON AND

CONNECTING ROD ASSEMBLIES
1. CHECK FIT BETWEEN PISTON AND PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as set.
2. REMOVE PISTON RINGS

(a) Using a piston ring expander, remove the compres-
sion rings.
(b) Remove the two side rails and oil ring expander by
hand.
NOTE: Arrange the rings in the correct order.
EM -78 ENGINE MECHANICAL - Cylinder Block
3. DISCONNECT CONNECTING ROD FROM

PISTON
(a) Using snap ring pliers, remove the snap ring.
EM3885
(b) Gradually heat the piston to approx. 80°C (176 °F).
Approx.
80°C
EM3886
(c) Using a brass bar and a hammer, lightly tap out the
piston pin from the piston.
NOTE:
• The piston and pin are a matched set.
• Arrange the pistons, pins, rings, connecting rods and
bearing in correct order.
1 2 3 4
EM3888
INSPECTION OF PISTON AND

CONNECTING ROD ASSEMBLIES
1. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the
piston top.
EM 3889
ENGI NE MEC HAN ICAL - Cylind er Block
EM -79
---- (b) Using a groov e clean ing tool or broke n ring, clean
the ring groov es.
EM 3890
(c) Using a soft brush and solve nt, thoro ughly clean the
piston .
CAU TION : Do not use a wire brush . j
2. MEA SURE PIST ON CLEA RANC E

(a) Using a micro meter , measure the piston diame ter
at
right angle s to the piston pin cente r line, 50 mm
(1.97 in.) from the piston head.
Pisto n diam eter:
STD 73.95 5 - 73.98 5 mm
(2.91 16 - 2.912 8 in.)
0 I S 0 .50 74.45 5 - 74.45 8 mm
(2.93 13 - 2.931 4 in.)
EM3892 (b) Meas ure the cylind er bore diame ter in thrust direc-
tions. (See page EM -77)
1, 2 or 3
(c) Subtr act the piston diame ter meas ureme nt from
the
o c:::,~o cylind er bore diameter measurement.
c:::, o
Stan dard oil clear ance :
oo oo oo oo q 0 .035 - 0 .055 mm (0.00 14 - 0.002 2 in.)
ID n n .o ~ Maxi mum oil clear ance : 0 .10 mm (0.00 39 in.)
o ~ OG ~ 0 If the oil cleara nce is greater than maxim um, replace
all
Front • W---1,2 3
~
or
EM5255
four piston s and I or rebore all four cylind ers.
NOTE: Even when the oil cleara nce is greate r than
maxim um, if may be possi ble to achie ve stand ard
oil
F6495
cleara nce simpl y by choos ing a stand ard piston with
a
narro wer diameter.
mm (in.)
Piston No. Piston Diameter Cylinder Bore
1 73.955 - 73.965 74.000 - 74.010

(2.911 6 - 2.9120 ) (2.913 4 - 2.9138 )
2 73.966 - 73.975 74.010 - 74.020

(2.912 0 - 2.9124 ) (2.913 8 - 2.9142 )
73.976 - 73.985 74.021 - 74.030
3
(2.912 4 - 2.9128 ) (2.914 2 - 2.9146 )
EM-8 0 ENGI NE MECH ANIC AL - Cylind er Block
3. INSPE CT CLEA RANC E BETW EEN PISTO N RING

LAND AND NEW PISTO N RING
(a) Install the No. 1 ring to the piston and, using a
thickness gauge, measure the No. 1 ring clearance
betwe en the ring land and new piston ring when the
ring is flush with the piston surface.
No. 1 ring cleara nce:
0 .04- 0 .08 mm (0.001 6 - 0.0031 in.)
EM4120 EM4009
(b) Using a thickness gauge, measure the No. 2 and oil

ring clearances betwe en the ring land and new pis-
ton ring.
No. 2 ring cleara nce:
0 .04 - 0 .08 mm (0.001 6 - 0.0031 in. )
If not within specif ication , replace the piston.
EM3893
4. INSPE CT PISTO N RING END GAP

(a) Insert the piston ring into the cyli nder.
Top of
Cylind er Block (b) Using a piston , push the piston ring a little beyon d
the bottom of the ring travel to the follow ing depth
from the top of the cylind er block.
120 mm Depth : 120 mm (4.72 in.)
EM3894
(c) Using a t hickness gauge, measure the end gap.

Ring end gap:
No.1 STD 0 .23 - 0 .36 mm (0.00 91-0.0142 in .)
Limit 0 .96 mm (0.037 8 in.)
No.2S TD 0 .40 - 0 .55 mm (0.01 57-0. 0217 in.)
Limit 1.05 mm (0.041 3 in.)
Oil STD 0.10 - 0 .60 mm (0.00 39-0. 0236 in .)
Limit 1.20 mm (0.047 2 in.)
If the clearance is greater than maxim um, replace the
EM2552
piston ring and/ or piston .
If the clearance is greater than maxim um even with a new
piston ring, rebore the cylind er and use an O / S piston
ring.
CAUT ION: Do not file the ring end .
5. CHEC K PISTO N PIN FIT

At 80°C (176°F), the pin shou ld be able to be pushed
into the piston with your t humb.
If the pin can be install ed at a lower temperature, replace
the piston and pin.
EM3895
6. INSPECT CONNECTING RODS

(a) Using a rod aligner, check the connecting rod align-
a ment.
e • Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting
rod assembly.
EM3896 EM0288
• Check for twist.

Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting
rod assembly.
NOTE: If replacing the connecting rods, replace the
same number of connecting rod bearings as that of new
connecting rod caps.
EM3897 EM0290
(b) Inspect connecting rod bolts.

• Fix a nut to each of the connecting rod bolts
threads and check that the nut can be turned by
hand to the end of the threads.
• If a nut can not be moved all the way down the
threads, measure the compressed thread outer di-
ameter with a measuring gauge.
• If the location of this area cannot be judged by
PH+-- ----.---- 15 mm visual inspection, use the dimension locations in
,,___ __,'- (0.59 in.)
EM3899 the illustration and measure the outer diameter.
(0.3094 - 0.3150 in.)
Minimum diameter: 7.60 mm (0.2992 in.)
If the measurement is not within specifications, replace
either the nut or connecting rod bolts.
(c) Measure the oi l clearance between the rod bushing

and piston pin.
• Using a dial gauge, measure the inside diameter
of the rod bushing.
Standard inside diameter: 23.511 - 23.523 mm
(0.9256 - 0.9261 in.)
EM3898
• Using a micrometer, measure the diameter of the

piston pin.
(0.9252 - 0.9257 in.)
EM 0227
• Subtract the piston pin diameter measurement

from the inside diameter of the rod bushing.
Standard oil clearance: 0.007 - 0.015 mm
(0.0003 - 0.0006 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the clearance is greater than maximum, replace the rod
bushing.
REPLACEMENT OF ROD BUSHING

1. REMOVE ROD BUSHING
Using SST and press, remove the rod bushing from the
connecting rod.
SST 09222 -66010
2. INSTALL NEW ROD BUSHING

Using SST and press, install the bushing to the connect-
ing rod.
SST 09222-6601 0
Oil Hole NOTE: Align the bushing oil hole with the connecting
rod oil hole.
EM2983
3. HONE NEW BUSHING AND CHECK PIN FIT IN

CONNECTING ROD
(a) Hone the new bushing and check that the oil clear-
ance is within standard specification.
Standard clearance: 0.007 - 0.015 mm
(0.0003 - 0.0006 in.)
(b) Check the pin fit at normal room temperature. Coat
the pin with engine oil and push the pin into the rod
with thumb pressure.
EM0291
INSPECTION OF CRANKSHAFT
1. MEASURE CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V - blocks.
(b) Using a dial gauge, measure the circle runout at the
center journal.
Maximum circle runout : 0.06 mm (0.0024 in.)
If the circle runout is greater than the maximum, replace
the crankshaft.
EM3901
NOTE: Use a long spindle on the dial gauge.
2. INSPECT MAIN JOURNALS AND CRANK PINS

(a) Using a micrometer, measure the diameter of the
main and crank pin journal.
Standard main journal diameter:
49.985 - 50.000 mm (1.9679 - 1 .9685 in.)
Standard crank pin diameter:
43.988 - 44.000 mm (1 .7318 - 1.7323 in.)
EM3903
EM3902
(b) Measure t he journals for out-of-round and taper as

shown.
Maximum taper: 0 .02 mm (0.0008 in.)
Maximum out-of- round : 0 .02 mm (0.0008 in.)
If taper and out-of -round are greater than maximum, re-
grind(main journal only) or replace the crankshaft.
EM0315
3. GRIND AND HOME MAIN JOURNAL

Grind and hone the main journals to the undersized f in -
ished diameter.
Main journal finished diameter:
UIS 0 .25 49.745 - 49.755 mm
(1.9585 - 1.9589 in.)
0 .50 49.495 - 49.505 mm
(1.9486 - 1.9490 in.)
REPLACEMENT OF OIL SEALS

1. REPLACEMENT OF FRONT OIL SEAL
(a) Using a screwdriver, remove the oil seal.
(b) Apply MP grease to a new oil seal.

(c) Using SST, install a new oil seal.
SST 09214-60010
CAUTION : Drive in the oil seal to a depth of 0.5

0.5 mm
mm (0.020 in.) from the oil pump body edge.
2. REPLACEMENT OF REAR OIL SEAL

(a) Using a screwdriver, remove the oil seal.
- (b) Apply MP grease to a new oil seal.

(c) Using SST, install a new oi l seal.
SST 09223-41020
NOTE: Be careful not to install the oil seal slantwise.
EM3907
ENGINE MECHANICAL - Cyl inder Block EM -85
BORING OF CYLINDERS
NOTE:
• Bore all four cylinders for the oversized piston outside
diameter.
• Replace the piston rings with ones matching the pis-
tons.
1. SELECT OVERSIZED PISTON

Oversized piston diameter:
0 / S 0 .50 74.455 - 74.485 mm
(2.9313 - 2.9325 in. )
2. CALCULATE DIMENSION TO BORE CYLINDERS

(a) Using a micrometer, measure the piston diameter at
a right angle to the piston pi n center line, 50
mm(1 .97 in.) the piston head.
EM3892
(b) Calculate the size each cylinder is to be rebored as

follows.
Size to be rebored = P + C - H
P = piston diameter
C = piston clearance
0 .035 - 0.055 mm (0 .0014 - 0.0022 in. )
H = allowance for honing
Less than 0 .02 mm (0 .0008 in.)
3. BORE AND HONE CYLINDERS TO CALCULATED

DIMENSIONS
Amou nt of honing: 0.02 mm (0.0008 in.) maximum
CAUTION : Excess honing will destroy t he fin -
ished rou ndness.
EM-86 ENGIN E MECHA NICAL - Cylinder Block
ASSE MBLY OF PISTO N AND

CONN ECTIN G ROD
1 . ASSEM BLE PISTON AND CONNE CTING ROD
(a) Install a new snap ring on one side of the piston pin
hole.
EM4122
(b) Gradually heat the piston to approx. 80°C (176°F).
(c) Align the notch on the piston with the protrusi on on

the connec ting rod and push the piston pin in with
your thumb.
(d) Install the new snap ring on the other side of the pin.
0
EM 3909
2. INSTAL L PISTO N RINGS

(a) Install the oil ring expander and two side rails by
hand.
~ EM3884
(b) Using a piston ring expander, install the two com-

Tor 1N pression rings with the code mark facing upward .
~ /]Tor 2N
r. (, I
I
~
~ NS0013 EM 3883
No. 1 Compression No. 2 Compression (c) Position the piston rings so that the ri ng ends are as
Ring Ring shown.
Upper Side
Lower Side CAUTION : Do not align the end gaps.
Rail Rail
Front
+
Expander
EM3910
ASSEMBLY OF CYLINDER BLOCK

(See page EM -64)
NOTE:
• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply new eng ine oil to all
sliding and rotating surfaces.
• Replace all gaskets O- rings and oil seals with new
parts.
1. INSTALL OIL NOZZLES

To rque : 80 kg-cm (69 in.-lb, 7 .8 N •m)
2. INSTALL MAIN BEARINGS

Install the bearing in the cylinder block and bearing caps.
CAUTION: Install the bearing with the oi l ho le in
the block.
3. INSTALL UPPER THRUST WASHERS

Install the upper thrust washers on the No.3 main bearing
cap position of the block with the oil grooves facing
outward.
4. PLACE CRANKSHAFT IN CYLINDER BLOCK.
\ v. Y Qil Gr.oove
~ . J ~L _ ""' EM3913
5. INSTALL MAIN BEARING CAPS

NOTE: Each bearing cap is numbered.
(a) Install the lower thrust washers on No.3 bearing cap
with the oil grooves facing outward.
ENGI NE MEC HAN ICAL - Cylind er Block
EM-8 9
Front • (b) Install the main bearing caps in their prope r loca
-
tions.
EM4129
(c) Apply a light coat of engin e oil on the thread s and

under the heads of the cap bolts.
(d) Instal l and torqu e the cap bolts in two or three
passes and in the sequence show n.
To rque: 600 kg -cm (43 ft-l b. 59 N -m)
(e) Check that the crank shaft turns smoo thly.
(f) Check the crankshaft thrust clearance.
7 3 5 9
8 4 2 6 10
EM 3875
EM4006
6. INST ALL BEAR INGS

(a) Install the bearings in the conne cting rods and rod
caps.
(b) Lubric ate the face of the bearings with clean engin
e
oil.
EM 3915 EM 3916
7. INST ALL PIST ON AND CON NECT ING ROD

ASSE MBLI ES
(a) Cover the rod bolts with a short piece of hose
to
prote ct the crank shaft from damage.
(b) Lubric ate the cylind er bore and rod journa ls with
clean engin e oil.
(c) Using a piston ring compressor, push the correctly

numbered piston and connecting rod assembly into
each cylinder w ith the front mark of the piston fac-
ing forward.
EM3918 EM 3919
8. INSTALL CONNECTING RO D CAPS

(a) Match the numbered cap with the numbered con-
necting rod .
(b) Install the cap w ith the front mark facing forward.
9. TORQUE CONNECTING ROD CAP NUTS

NOT E:
• The Connecting rod cap nuts are tighten in two pro-
gressive steps.
• If any of the cap bolts break or deform, replace them.
(a) Apply a light coat of the engine oil under the nuts.
(b) First, alternately torque the cap nuts in several
passes.
If any one of t he nuts does not meet the torq ue specifica-
tion, replace the bolt.
EM3921
(c) M ark the front side of t he top of cap nut with paint.
Paint Mark
..
Front
EM3922
7 ENGINE MECHANICAL - Cylinder Block
(d) Torque the cap nuts by an additional 90°.

EM -91
(e) Check that the paint mark is now facing sideward.

(f) Check that the cra nkshaft turns smoothly.
(g) Check the rod thrust clearance.
(See step 2 on page EM-69 )
EM3923
Seal Packing POST ASSEMBLY

1. INSTALL REAR OIL SEAL RETAINER
(a) Apply seal packing to the oil seal retai ner as shown
in the fig ure.
Seal packing: Part No. 08826-00080 or
equivalent
NOTE: Cleaning and applicati on of seal packing to the
installation surface is the same as for the oil pan.
I EM4010 I However, use a nozzle cut to 2 mm (0.08 in.)
(b) Install t he oil seal retainer with the four bolts.
Torque the four bolts.
Torque: 80 kg-cm (69 in.-lb, 7.8 N -m)
2. INSTALL OIL PUMP

(See step 2 on page LU -9 )
3. INSTALL OIL DIPSTICK GUIDE

Install the oil dipstick guide w ith the mark facing right-
ward.
i·:' '~''
EM4011
4. INSTALL OIL REGULATOR

T orque: 250 kg -cm (18 ft - lb, 25 N -m)
5. INSTALL OIL STRAINER

(a) Place a new gasket on the cylinder block.
(b) Install the oil strainer with the two bolts and nuts.
(c) Torque t he bolts.
Torque: Bolt 120 kg-cm (9 ft- lb, 12 N •m)
Nut 80 kg -cm (69 in.-lb, 7.8 N -m )
6. INSTALL OIL PAN

7. INSTALL STRAIGHT SCREW PLUG

(a) Install a new gasket to t he plug.
(b) Install and torque t he plug.
Torque: 250 kg -cm (18 ft-lb, 25 N -m )
8. INSTALL DRAIN COCK

(a) Clean t he drain cock threads and cylinder block
drain cock hole of any sealant or foreign material.
(b) Apply sealant to 2 or 3 threads of the drain cock end.
Sealant: Part No. 08833-00070 or equivalent
NOTE: This adhesive wi ll not harden while exposed to
air. It w ill act as a sealant or binding agent only when
EM3925
(c) Install and t ighten t he drain cock.
9. INSTALL OIL HOLE COVER PLATE

(a) Install a new 0 - ring to the cyli nder block.
(b) Install and torq ue the oil hole cover plate with the
two bolts.
Torque: 195 kg -cm ( 14 f t -lb, 19 N -m)
10. INSTALL ALTERNATOR BRACKET

Torque: 400 kg -cm (29 ft-lb, 39 N -m)
EM 3853
11. INSTALL RH ENGINE MOUNTING BRACKET

Torque: 440 kg -cm (32 ft- lb, 43 N -m)
..---
EM3855
12. INSTALL Oil PRESSURE SWITCH

(a) Clea n the threads of sealant foreign material.
(b) Apply sealant t o 2 or 3 threads of the switch end.
NOTE: This adhesive will not harden while exposed to
air. It will act as a sealer or bindi ng agent only when
Sealant: Part No. 08833- 00080 or
Sealant equivalent
EM4125
(c) Using SST, install the oi l pressure switch.

SST 09816- 3001 0
13. INSTALL WATER TEMP . SENSOR

(a) Install a new gasket to t he water temp. sensor.
(b) Install and torque the water temp. sensor.
EM 3851
14. INSTALL NO.1 INJECTION PUMP PROTECTOR

Install t he No.1 inject ion pump protector with the three
bolts.
EM4044
ENGINE MEC HANICAL - Cylinder Block EM -95
15. INSTALL OIL COOLER

(See steps 1, 2 o n page LU - 13)
16. INSTALL OIL FILTER

(See st ep 2 on page LU -4 )
17. INSTALL WATER INLET PIPE

(a) Install a new O-ring to the water inlet pipe.
{b) Insert the water inlet pipe to the cylinder block.
(c) Install and tighten the bolt.
(d) Connect the No. 2 oil cooler hose to the oil cooler.
18. INSTALL WATER PU MP

(See step 1 on page CO- 5 )
19. INSTALL INJECTIO N PUMP

(a) Align the matchmarks on the injection pump and
water pump.
(b) Temporarily install the mounting bolts and nuts.
NOTE: Torque the mounting bolts and nuts to specifi -
cation after adjusting the injection timing.
(c) Connect the No. 1 and No. 2 water by -pass hoses to

the injection pump.
20. SELECT CYLINDE R HEAD GASK ET

NOTE:
• If only replacing the gasket, use a gasket of the same
thickness (make your choice accoriding to the thick-
ness indentifica tion number on the gasket).
• If replacing the cylinder block, pistons, connecting
rods, or crankshaft, use the following procedures to
make the cylinder head gasket selection.
Gasket Selection Mark
F6519
Measuring tip (a) Clean the cyli nder block with solvent.
(b) Using a dial gauge, measu re t he amount of piston
protrusion at all cylinders from at the upper surface
of the cylinder block.
L;;/4 ( c) Measuring is to be done at two points for each
--- Protrusion
cylinder, as shown in the illustration.
~ unt
NOT E:
• Change the dial gauge measuring tip to that
M shown in the illustration.
• Make certain t hat the measuring tip is vertical to
the cylinder block surface when taking the mea -
Front .,. surements.
( d ) From the piston protrusion measurements taken
from each cyl inder, calculate the average amount
and select the appropriate gasket using the table
below.
Selection Amount of piston Head gasket

mark protrusion• (mm) thickness (mm)
X Measuring Points F6517
F6509 1 0.65 - 0.75 (0.0256 - 0.0295 in.) 1.45 (0.0571 in.)
2 0.76 - 0.85 (0.0299 - 0.0335 in.) 1.55 (0.0610 in.)
3 0.86 - 0.95 (0.0339 - 0.0374 in.) 1.65 (0.0650 in.)

• (average from the eight measuring points)
( e) Next , calculate the average p iston protrusion for
each of the cylinders and w it h the gasket selected in
(d ) and com pare. If the average protrusion of even
one cylinder exceeds the limit for the gasket se-
lected in ( d), rep lace with t he next size gasket.
Limit: 1 Selection mark 0 .80 mm (0.031 5 in.)
EM4043
Limit: 2 Selection mark 0 .90 mm (0.0354 in.)
21 . INSTALL CYLINDER HEAD

(See steps 1 to 9 on pages EM -60 t o 62)

(See steps 1 to 3 a nd 5 to 14 on pages EM - 31 t o 35 )
23. REMOVE ENGINE FROM ENGINE STAND
24. INSTALL DUST SEAL AND REAR END PLATE

Torque: 50 kg-cm (43 in.-lb, 4 .9 N .m)
EM3849
ENGI NE MECH ANIC AL - Cylind er Block
EM -97
25. INSTA LL FLYW HEEL ON CRAN KS HAFT

Sealan t (a) Clean the set bolt threads and cranks haft bolt holes
of any sealant, oil or foreign material.
Remove any oil with kerosene or gasoline.
(b) Apply sealant to 2 or 3 threads of the bolt end.
Seala nt: Part No. 08833 -0007 0 o r equiv alent
NOTE : This adhesive will not harden while exposed to
\ 8613S
air. It will act as a sealer or bindin g agent only when
applie d to threads, etc. and air is cut off.
(c) Install the flywhe el on the cranks haft.

Torqu e the bolts to the specified torque in two or
three passes in the sequence shown .
3
T orqu e: 900 kg-cm (65 ft-lb, 88 N -m )
5
4
Y-- EM3848
26. INSTA LL CLUT CH DISC A ND COVER

NOTE: If necessary, inspec t the clutch unit before in -
stallat ion.
27. INSPE CT AND ADJU ST INJEC TION TIMIN G

(See page EM -18)
FU -1
FUEL SYSTEM
NOTE: For troubleshooting procedures, refer to DIE-
SEL ENGINE DIAGNOSIS {EM Section) .
Page
REPLACEMENT OF FUEL FILTER . . . . . . . . . . . FU - 2
FUEL FILTER WARNING SWITCH ........... FU - 3
INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . FU -4
INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . FU -12 Iii]
FU-2 FUEL SYSTEM - Replacement of Fuel Filter
REPLACEMENT OF FUEL FILTER

1. DISCONNECT FUEL FILTER WARNING SWITCH
CONNECTOR
2. DRAIN FUEL FROM FUEL FILTER

NOTE: Put a suitable contai ner or shop towel under the
fuel filter.
FU1776
3. REMOVE FUEL FILTER

(a) Using SST, remove the fuel filter with t he gasket.
SST 09228 -6401 0
FU1777
(b) Using pliers, remove the fuel filter warning switch

with the 0 -ring.
CAUTION : Be careful not t o dam age t he warn -
ing switch .
FU1778
4. INSTALL NEW FUEL FILTER

(a) Install a new 0-ring to the fuel filter warning switch.
(b) Apply fuel to t he 0-ring of the fuel filter warning
switch.
(c) Install the fuel filter warn ing switch to the fuel filter
by hand.
FU1779
(d) Apply fuel to t he gasket of t he new fuel filter.

(e) Install the fuel filter to the fuel filter bracket by hand.
FU1780
C
FU EL SYSTEM - Replacem ent of Fuel Filter, Fuel Filter Warning Switch
FU -3
5. CONNE CT FUEL FILTER WARNIN G SWITCH

CONNE CTOR
6. CHECK FOR FUEL LEAKS

Using a priming pump, fill with fuel and check for leaks.
FU1781
FUEL FILTE R WAR NING

SWIT CH
INSPE CTION OF FUEL FILTER WARN ING
SWITC H
1. REMOV E FUEL FILTER WARNIN G SWITCH
( See page FU -2)
2. INSPEC T WARNIN G SWITCH

Ohmmeter (a) Check that there is continuit y between terminals
when the warning switch is ON (float up) .
'[ n (b) Check that there is no continuit y between terminals
when the warning switch is OFF (float down) .
I~ If operation is not as specified , replace the warning
switch.
11
FU1682
3. INSTAL L FUEL FILTER WARNIN G SWITCH

(See page FU -2)
FU-4 FU EL SYSTEM - Injection Nozzle
INJECTION NOZZLE
COMPONENTS
300 (22, 29) I--- - - - · ~~

Fuel Return Pipe ~ (, ~ /, ©
~ --( ---
II '--'~~ V © '<-:_
~ ~ ~ @ ---T I-,
I 650 (47, 64) ~1-----'---- - -~ ~ @ V / 1
\_ ~ ~ ~ ~ , ~ F u ell Hose
@ ~ ~ - - -Injection Nozzle Holder
@ ~ ~
@ ~
~ •- - - - Nozzle Seat
•
f
Nozzle Gasket
['-'J'<- -1 300 (22, 29)
1--- -lnjection Pipe
Pump Protector
\kg - cm (ft-lb, N-m) I : Specified torque

• Non - reusable part FU1782
REMOVAL OF INJECTION NOZZLE

HOLDERS
1. REMOVE INJECTION PIPES
(a) Remove the bolt and injection pump protector.
FU1683
(b) Disconnect both ends of the injection pipes from

the injection pump and injection holders.
FUEL SYSTEM - Injection Nozzle FU -5
2. REMOVE FUEL RETURN PIPE

(a) Disconnect the fuel hose from the return pipe.
(b) Remove the four lock nuts and return pipe with the
four gaskets.
3. REMOVE INJECTION NOZZLE HOLDERS

(a) Using SST, remove the four injection nozzle hold -
ers.
SST 09268 -64010
(b) Arrange the injection nozzle holders in order.

(c) Remove the nozzle seats and nozzle gaskets.
2 3 4
FU0299
FU -6 FUEL SYSTEM - Injection Nozzle
TEST OF INJECTION NOZZLE HOLDERS

1. INJECTION PRESSURE TEST
(a) Pump the handle several times to flush out nozzle
fittings, then tighten the fittings.
WARNING : Do not place your finger over the
nozzle injection hole.
(b) Install the nozzle holder to the injection nozzle hand
tester and bleed air from the union nut.
FU0142
(c) Pump the tester handle a few times as fast as possi-
ble to discharge the carbon from the injection hole.
( d) Pump the tester handle slowly and observe the pres-
sure gauge.
(e) Read the pressure gauge just as the injection pres -
-----
sure begins to drop.
Opening pressure kg / cm 2 (psi, kPa)
Reused nozzle 135-155 (1,920- 2,205, 13,239-15,200)
New nozzle 145-155 (2,062 -2,205, 14,220-15,200)
FU01 43
NOTE: Proper nozzle operation can be determined by a
swish ing sound.
If the opening pressure is not within specification, disas-
semble he nozzle holder and change the shim in the top
of the pressure spring . (See page FU - 8) .
Adjusting shim thickness mm (in.)

(:\Os,
~a
~
.s;:;:PV
Adjusting Shim
0.900 (0.0354)
0.925 (0.0364)
0.950 (0.0374)
1 .275 (0.0502)
1.300 (0.0512)
1.325 (0.0522)
1 .650 (0.0650)
1.675 (0.0659)
1.700 (0.0669)
1.725 (0.0679)
0.975 (0.0384) 1.350 (0.0531)
FUl 686
1.000 (0.0394) 1 .375 (0.0541) 1.750 (0.0689)
1.025 (0.0404) 1 .400 (0.0551) 1.775 (0.0699)
1 .050 (0.0413) 1.425 (0.0561) 1.800 (0.0709)
1.075 (0.0423) 1.450 (0.0571) 1.825 (0.0719)
1.100 (0.0433) 1.475 (0.0581) 1 .850 (0.0728)
1.125 (0.0443) 1.500 (0.0591) 1 .875 (0.0738)
1.150 (0.0453) 1.525 (0.0600) 1.900 (0.0748)
1.175 (0.0463) 1.550 (0.061 0) 1.925 (0.0758)
1.200 (0.0472) 1.575 (0.0620) 1.950 (0.0768)
1 .225 (0.0482) 1 .600 (0.0630)
1.250 (0.0492) 1 .625 (0.0640)
NOTE:
• Varying the adjusting shim thickness by 0.025 mm
(0.0010 in.) changes the injection pressure by about
3.5 kg/ cm 2 (50 psi, 343 kPa).
• Only one adjusting shim should be used.
• If adjusting the opening pressure, use the specification
for a new nozzle.
(f) There should be no dripping after injection.
FU0144
FUEL SYSTEM - Injection Nozzle FU-7
2. LEAKAGE TEST
While maintaining pressure at about 10 - 20 kg / cm 2
(142 - 284 psi, 981 - 1,961 kPa) below open ing pres -
sure (adjust by tester handle), check that there is no
dripping for 10 seconds from the injection hole or around
the retaining nut.
Good
•
Faulty
If the nozzle drips within 10 seconds, replace or clean
and overhaul the nozzle assembly.
FU1687
Good 3. SPRAY PATTERN TEST

Ex. Austria (a) The injection nozzle should shudder at a certain
pumping speed between 15 - 60 times (old nozzle)
or 30 - 60 times (new nozzle) per minute.
(b) Check the spray pattern during shuddering.
If t he spray pattern is not correct during shuddering, the
nozzle must be replaced or cleaned .
..
''
Austria
FU1890
FU1 889
Faulty
Ex. Austria
u '
Austria
u I
FU1891
FU1871
FU - 8 FUE L SYS TEM - Injec tion Nozzle
CO MP ON EN TS
Nozzle Hold er Body
Pressure Sprin g
Dista nce Pipe
Nozz le Holde r Retai ning Nut
Adjus ting Shim
Pressure Pin
Nozzle Asse mbly
FU1686
DIS ASS EM BLY , CLE ANI NG AN D TES T OF

INJ ECT ION NO ZZL E HO LDE R
DER
1. DISA SSE MBL E INJE CTIO N NOZ ZLE HOL
ning nut.
SST
(a) Usin g SST, unsc rew the nozzle hold er retai
SST 0926 8-64 010
nozz le
CAU TION : Whe n disa ssem bling the
r part s.
hold er, be care ful not to drop the inne
pin, dis-
(b) Remove the pressure sprin g, shim , pressure
FU1688
tance piece and nozzle assembly.
2. NOZ ZLE CLE ANIN G

wash the
(a) Use a wood en stick and brass brush to
nozzles. Wash in clean diese l fuel.
ces with
NOT E: Do not touc h the nozz le mati ng surfa
your fingers.
\- - - ~ ~
FU1689
FUEL SYSTEM - Injection Nozzle FU-9
(b) Use a wooden stick to remove any carbon adhering

to the nozzle needle tip.
( c) Remove the carbon from the exterior of the nozzle

body (except lapped surface) with a brass brush .
FU1691
Ex. Austria Austria ( d) Inspect the seat of the nozzle body for burns or
corrosion.
(e) Inspect the nozzle needle tip for damage or corro-
sion.
If any of these conditions are present, replace the nozzle
assembly.
FU1785 FU1877
3. SINKING TEST
(a) Wash the nozzle in clean diesel fuel.
NOTE: Do not touch the nozzle mating surfaces wit h
your fingers.
(b) Tilt the nozzle body about 60 degrees and pu ll the
needle out about one third of its length.
FU1692
(c) When released, the needle should sink down into

the body vent smoothly by its own w eight.
( d) Repeat this test, rotating the needle slightly each
time.
If the needle does not sink freely, replace the nozzle
assembly.
FU1693
FU -10 FUEL SYSTEM - Inject ion Nozzle
ASSEMBLY AND INSTALLATION OF

INJECTION NOZZLE HOLDERS
Retaining Nut
(See page FU -8)
'11>~~ 1. ASS EM BLY INJECTION NOZZLE HOLDERS
(j)© (a) As shown in the figure, assemble t he injection noz-
,<\\~ . zle and fi nger tig hten the retaining nut.
~ 0-»
'
FU1686
( b) Using SST, torque the retaining nut.

SST 09268-64010
CAUTION : Over torquing could ca use nozzle de-
SST formation and needle adhesion or other defects.
2. PERFORM PRESSURE AND SPRAY PATTERN

TEST (See page FU -6)
/ FU1694
3. INSTALL INJECTION NOZZLE HOLDERS

(a) Place four new gaskets and the nozzle seats in the
cyli nder head.
(b) Using SST, install and torque t he four nozzles.
SST 09268-6401 0
Torque: 650 kg-cm (47 ft- lb, 64 N-m)
CAUTION : Over torquing could cause nozzle de-
formation and needle adhesion or othe r defect s.
4. INSTALL FUEL RETURN PIPE

(a) Inst all four new gaskets and the return pipe with the
four lock nuts.
(b) Connect t he fuel hose to the return pipe.

FUEL SYSTEM - Injection Nozzle FU -11
5. INSTALL INJECTION PIPES

(a) Connect both ends of the injection pipes to the in -
jection pump and nozzle holder.
(b) Torque the injection pipe union nuts.

(c) Install the injection pump protector with the bolt.
FU1683
6. BLEED INJECTION NOZZLES

(a) Loosen all union nuts of the injection pipe on the
nozzle holder side.
(b) Crank t he engine to bleed the air and force out the
fuel from the injection pipe.
(c) Tighten t he injection pipe union nuts.
Torque: 300 kg -cm (22 ft - lb, 29 N-m)
FUl 788
7. START ENGINE AND CHECK FOR FUEL LEAKS
8. CHECK ENGINE IDLE SPEED AND MAXIMUM

SPEED (See page EM - 22)
FU-12 FUEL SYSTEM - Injection Pump
INJECTION PUMP
COMPONENTS
No. 2 Timing Belt Cover
Injection Pump Drive Pulley

,~
r
'
.,JI Injection Pump .
~,P.,J.f----- - l
~
~
300 (22, 29)
d)
Pump Protector
r~~
Timing Belt
Pump Bracket
195 (14, 19)

1,200 (87, 118)
!kg-cm (ft- lb, N-m) I : Specified torque FU1789
REMOVAL OF INJECTION PUMP

1. DRAIN COOLANT
2. DISCONNECT ACCELERATOR CABLE FROM

INJECTION PUMP
3. REMOVE TIMING BELT AND INJECTION PUMP

DRIVE PULLEY (See pages EM - 25 to 28)
4. DISCONNECT FUEL CUT SOLENOID

CONNECTOR
5. DISCONNECT FUEL INLET AND OUTLET HOSES
FU1695
FUEL SYSTEM - Injection Pump FU -13
6. DISCONNECT WATER BY- PASS H OS ES
7. REMOVE FOUR INJECTION PIPES

(See st ep 1 o n page FU -4 )
8. REMOVE INJECTION PUMP

(a) Before removing the injection pump, check if the
matchmarks are aligned.
If not, place new matchmarks for reinstallation.
(b) Remove the four bolts and bracket.
FU1791
(c) Remove the two nuts and then remove the injection
pump.
CAUTION : Do nut ho ld or carry t he pump by the
adjusting lever.
FU 1792
COMPONENTS
, ~- - -- - - Overflow Screw
~ • Gasket
Return Pipe
~ • Gasket
I
I
)
Governor Cover- -- - - -----1-..
I
I
• 0 - Ring C>
Inlet Pipe <§) Speed Control Spring
2-5o_(_i_·2-5~, ,W
l
1
- I
~")(J' ~ ' - - -- -- Spring Seat
(D,>1>''1) I
Damper Spring
e-- • Gasket- - -
L-----
I ----
Fuel Inlet Hollow Screw---r':::..,,....---1=1

1 375 (21. 37) 1 Thermo wax
!kg -cm (ft- lb, N-m) I:

Specified torque
• Non-reusable part FU1793
COMPO NENTS (Cont'd )
Governor Sleeve
Flyweight Holder
Fuel Cut Solenoid
Timer Cover - - Lock Nut
Timer Adjusting Screw
• Non-reusab le part FU l 794

FU -16 FU EL SYSTEM - Injection Pum p
DISASSEMBLY OF INJECTION PUMP

(See pages FU -14 and 15)
1. MOUNT INJECTION PUMP TO STAND (SST) FOR
DISASSEMBLY
SST 09241 -76022 and 09245-5401 0
SST
2. REMOVE WOODRUFF KEY FROM DRIVE SHAFT
3. REMOVE TWO FUEL PIPES

FU1795
4. REMOVE ADJUSTING LEVER
5. REMOVE THERMO WAX

) Remove the three bolts, thermo wax and O- ring.
6. REMOVE DASH POT ADJUSTING SCREW

,J-
./
~
7. REMOVE FULL LOAD SET SCREW
8. REMOVE GOVERNOR COVER

(a) Using an allen wrench, remove the four bolts.
(b) Disconnect the speed control spring from the spring

Damper Spr~
seat and then remove the spring seat and damper
spring.
~) (c) Remove the governor cover with the gasket.
Spring Seat
Speed Control ·
Spring
FU1798
9. REMOVE FUEL CUT SOLENOID

(a) Discon nect the lead wire from the fuel cut solenoid.
FU1697
FUEL SYSTEM - Injection Pump FU-17
(b) Remove the fuel cut solenoid, spring and valve.
FU1698
10. REMOVE GOVERNOR SHAFT AND FLYWEIGHT

HOLDER
(a) Remove the governor shaft lock nut by turning it
\, clockwise.
FU0445
(b) Using an allen wrench, remove the governor shaft.

(c)Hold the flyweight holder subassembly and screw
out the governor shaft clockwise.
NOTE: Be careful not to drop the two washers into the
pump housing.
11 . REMOVE DISTRIBUTIVE HEAD PLUG

Using SST, remove the distributive head plug.
SST 09260-54012 (09262- 54010)
FU1879
12. REMOVE FOUR DELIVERY VALVE HOLDERS

(a) Using SST, remove the four delivery valve holders,
springs and spring seats.
SST 09260- 54012 (09269-54020)
(b) Remove four delivery valves and gaskets.
FU-18 FUEL SYSTEM - Injection Pu mp
NOTE:
• Do not touch the sliding surfaces of the delivery valve
with your hand.
• Arrange the delivery valves, springs and holders in or-
der.
13. REMOVE D ISTRIBUTIVE HEAD BOLTS

Using an alien wrench, remove the four head bolts and
connector clam p.
FU1881
14. REMOVE DISTRIBUTIVE HEAD

Remove the distributive head and following parts:
( 1 ) Lever support springs
! (2)t (2) Plunger spring guides

(3) Plunger spring shims
~ (3}~
(4) -.;, (4) Upper spring seats
1( 1 5
FU0163
(5) Plunger springs
15. REMOVE PUMP PLUNGER

~ (1) Using SST, remove the pump pl unger and plunger ad -
~ (2}
justing shim with the following parts:
~ (3) ( 1 ) Spill ring
(4) (2) Lower spring seat
fr- Plunger (3) Upper plunger plate
(4) Lower plunger plate
- Shim
(5) Plunger adjusting shim
FU0164
SST 09260- 54012 (09269-54030)
NOTE: Do not touch the sliding surfaces of the pump
plunger with your hand.
16. REMOVE GOVERNOR LINK

Using SST, remove the two support bolts and governor
link.
SST 09260- 54012 (09269-54040)
FU1700
FUEL SYSTEM - Injection Pump FU - 19
17. REMOVE FACE CAMPLATE AND COUPLING

~ Remove the face camplate, spring and coupling.
~
'
FU0166
18. REMOVE ROLLER RING AND DRIVE SHAFT

(a) Remove the timer clip and stopper pin.
(b) Push on the slide pin as shown.
(c) Push the drive shaft and remove the roller ring.
FU0169
NOTE:
• Be carefu l not to drop the rollers.
• Do not alter the position or assembly of the rollers.
FU0170
(d) Remove the drive shaft with the governor drive gear.
(e) Remove the drive shaft washer.
FU1734
FU -20 FUEL SYSTEM - Injection Pump
19. REMOVE TIMER

(a) Loosen the timer adjusting screw lock nut.
(b) Remove the two timer covers and 0-rings.
(
FU0167
(c) Remove the following parts:

(1) Spring
(2) Piston
(3) Sub-piston
(4) Timer adjusting screw lock nut
(5) Timer adjusting screw
(6) 0 -ri ng
20. REMOVE FUEL FEED PUMP

(a) Remove the two screws.
(b) Using a piece of wire, remove the feed pump cover.
(c) Remove the feed pump rotor, four blades and liner.
CAUTION :
• Be ca reful not to interchan ge the blade posi-
tions.
• Be ca reful not to damage to the pump body.
21. REMOVE REGULAT OR VALVE

Using SST, remove the regulator valve.
SST 09260- 54012 (09262 -54020)
FU0173
22. REMOVE FUEL INLET HOLLOW SCREW

INSPECTION OF INJECTION PUMP

COMPONENTS
NOTE: Do not touch the sliding surfaces of the pump
plunger and delivery valves.
1. INSPECT DELIVERY VALVES

(a) Pull up the valve and close the hole at the valve seat
bottom end with your thumb.
When the valve is re leased, it should sink down
quickly and stop at the position where the relief ring
closes the valve seat hole.
If defective, replace the valve as a set.
I
FU0175 FU0179
(b) Close the hole at the valve seat bottom end with
your thumb.
Insert the valve into the valve seat and press down
with your finger. When your finger is released , the
valve should rise back to its original position .
Replace if defective.
FU0177 FU0176
(c) Remove your thumb from the valve seat hole.

The valve should close completely by its own
weight.
Replace if defective.
NOT E: Before using a new valve set, wash off the rust
prevention compound with light oil or gasoline.
Then re- wash with diesel fuel and perform the above
~~~ tests.
~U0178
2. INSPECT PUMP PLUNGER, SPILL RING AND

DISTRIBUTIVE HEAD
(a) Tilt the spill ring (distributive head ) slightly and pull
out the plu nger.
(b) When released, the plunger shou ld sink down
smoothly into the spill ring (distributive head) by its
own weight.
(c) Rotat e the plunger and repeat the test at various
positions.
If the plunger sticks at any po~ition, replace the parts as
FU0180
a set.
(d) Insert the governor link ball pin into the spi ll ring
and check that it moves smooth ly without any play.
FU0181
3. INSPECT ROLLER RING AND ROLLERS

Using a dial indicator, measure the roller height.
Roller height variation : 0 .02 mm (0 .0008 in. )
If not within specification, replace the rol ler ring and
roller as a set.
4. INSPECT PLUNGER SPRINGS FOR

Squareness SQUARENESS
Using a steel square, check the squareness of the plunger
springs.
Maximum squareness: 2.0 mm (0.079 in.)
If one spring is out of square more than the maximum,
replace both springs.
EM2590
5. INSPECT SPRING LENGTH

Using calipers, measure the free length of each spring.
Spring length mm (in.)
Delivery valve
Plunger spring
spring
Standard 24.4 (0.961 ) 30.0 (1.181)
Minimum 23.5 (0.925) 29.5 (1.161)
FU1702
If the length is less than minimum, replace the spring.
6. INSPECT FUEL CUT SOLENOID

(a) Con nect the solenoid valve body and terminal to the
battery terminals.
(b ) You should feel the click from the solenoid valve
when the battery power is connected and discon -
nected.
e If the solenoid valve is not operating properly, replace it.
FU0184
FUEL SYSTEM - Inject ion Pump FU -23
7. ADJUST PLU NGER SPRING SHIM

(a) Install the following parts to the distributive head.
(1) Two pl unger spring guides
(2) Two upper spring seats
(3) Two plu nger springs
(4) Lower spring seat
(5) Upper plunger plate
FU0186
(7) Pump plunger
NOT E: Do not assemble the plunger spring shims at
this time.
(b) Using calipers, measure clearance A indicated in the

figure.
(c) Determine the shim size by using the following for-
mula and chart.
New shim thickness = 5.8 - A
A . .. . Plunger position measured
Shim selection chart mm (in.)
Measured Shim Measured Shim

FU0187 FU0188 clearance thickness clearance thickness
More than 0.5 4.3 - 4.5 1.5

5.3 (0.209) (0.020) (0.169 - 0.177) (0.059)
5.0 - 5.2 0.8 4.0 - 4.2 1.8

(0.196 - 0.205) (0.031) (0.157 - 0.165) (0.071)
4.8 - 4.9 1.0 Less than 3.9 2.0
(0.189 - 0.193) (0.039) (0.154) (0.079)
4.6 - 4.7 1.2

- -
(0.181 - 0.185) (0.047)
NOTE:
• For a measurement between listed sizes, use the next
larger size. Ex. If thickness is 1.1 mm (0.043 in.) by
calculat ion, use a 1 .2 mm (0.047 in.) shim.
• Select two shims which have the same thickness.
FU -24 FUEL SYSTE M - Injection Pump
8. IF NECES SARY, REPLA CE OIL SEAL

(a) Using a screwdr iver, push out the oil seal.
CAUTI ON: Be care ful not to damag e t o the
pump body.
FU1703
(b) Apply M P grease to the lip of a new oil seal.

(c) Using a socket wrench , drive in the oil seal until its
surface is flush with the pump housing .
FU- 25
FUE L SYS TEM - Injec tion Pum p
AS SE MB LY OF INJ EC TIO N PU MP
(See pag e FU- 14 and 15)
1. INST ALL FUE L INLE T HOL LOW SCR EW
Torq ue: 375 kg -cm (27 ft- lb, 37 N -m)
2. INST ALL REG ULA TOR VAL VE

valve .
Usin g SST, insta ll and torq ue the regu lator
SST 092 60-5 401 2 (092 62- 5402 0)
)
Torq ue: 90 kg -cm (78 in .-lb, 8.8 N-m
3. INST ALL FUE L FEED PUM P

(a) I nstal I the Ii ner, roto r and four blades.
I
(b) Che ck that the liner and blades are
corre ct direc tion, as show n.
facin g in the
I
.
(c) Check that the blades mov e smo othly
FU0451
scre ws and
(d) Insta ll the pum p cove r with the two
chec k that the roto r mov es smo othly .
the cove r is
NOTE: Check that the fuel outle t hole of
align ed with the liner.
4. INS TAL L DRI VE SHA FT

t as show n.
(a) Insta ll the drive gear on the drive shaf
FU01 92
drive gear .
(b) Install new two joint rubbers into the
haul ing.
NOTE: Replace the joint rubb er whe n over
FU0193
FU -26 FU El SYSTEM - Injection Pump
(c) Position the notch of the feed pump rotor upward.
FU1705
(d) Install t he woodruff key and drive shaft washer on

the drive shaft and insert the drive shaft assembly
Drive Shaft
Washer into the pump housing.
1
/-~ &
FU0194
(e) Check that the drive shaft turns without catching.
5. INSTALL TIMER PISTON

(a) Apply No. 50 Denso grease to the timer piston .
(b) Install the sub-piston in the timer piston .
FU1706
(c) Insert the t imer piston into the pump housing.

FU -27
FUEL SYST EM - Injecti on Pump
Slide Pin 6. INSTA LL ROLLER RING

(a) Install the slide pin, four rollers and washers on the
roller ring.
{b) Check that the roller is facing the flat surface of the
washer.
(c) Install the roller ring in the pump housi ng.
(d) Carefully push down the slide pin and install the
stoppe r pin and clip.
(e) Install a new 0-ring and the flat timer cover with the
two bolts.
(f) Install a new 0-ring and the timer adjust ing screw .
(g) Install a new 0 -ring, the spring and other timer
cover, two bolts and adjust ing screw lock nut.
7. ADJU ST PLUN GER ADJU STING SHIM

{a) Install the coupli ng and campl ate.
NOTE : Do not assemble the coupli ng spring .
FU0199
(b) Clean the adjusting shim and contacting surface

area.
(c) Using SST, install the used adjusting shim and
pump plunger.
SST 09260-54012 (09269-54030)
(d) Check that the notch on the pump plunger is
aligned with the camplate pin.
(e) Install the distributive head with the four bolts.

Torque the bolts.
CAUTION: Be careful not to damage the pump
plunger.
(f) Using calipers, measure clearance B indicated in the

figure.
(g) Determine the shim size by using the following for-
mula and chart.
New shim thickness = T + (B - 3.3)
T ... Thickness of shim used
B ... Plunger position measured
Shim selection chart

Measured clearance (mm)
2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 - 3.4 3.5 3.6 3.7 3.8 3.9 4.0 4.1 4.2 4.3 4.4
1.9 - - - - - - - - - - 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.9
2.0 - - - - - - - - 1.9 - 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.9 -
2.1 - - - - - - - 1.9 1.9 - 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.9 - -
2.2 - - - - - - 1.9 1.9 2.0 - 2.4 2.5 2.6 2.7 2.8 2.9 2.9 - - -
2.3 - - - - - 1.9 1.9 2.0 2.1 - 2.5 2.6 2.7 2.8 2.9 2.9 - - - -
2.4 - - - - 1.9 1.9 2.0 2.1 2.2 - 2.6 2.7 2.8 2.9 2.9 - - - - -
2.5 - - - 1.9 1.9 2.0 2.1 2.2 2.3 - 2.7 2.8 2.9 2.9 - - - - - -
2.6 - - 1.9 1.9 2.0 2.1 2.2 2.3 2.4 - 2.8 2.9 2.9 - - - - - - -
2.7 - 1.9 1.9 2.0 2.1 2.2 2.3 2.4 2.5 - 2.9 2.9 - - - - - - - -
2.8
1.9 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6
- - - - - 2.9 - - - - -
1.9 2.0 2.1 2.2 2.3
2.9 2.4 2.5 2.6 2.7
- - - - - - - - - - -
Example: 2.5 mm (0.098 in.) shim installed. Measured clearance is 3.0 mm (0.118 in.).
Replace with 2.2 mm (0.087 in.) shim.
Plunger adjusting sh im 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
thickness mm (in.) (0.075) (0.079) (0.083) (0.087) (0.091) (0.094) (0.098) (0.102) (0.106) (0.110) (0.114)
(h) Install a new shim and recheck clearance B.

B: 3 .3 ± 1 mm (0.130 ± 0 .039 in .)
FU0453
( i) Remove the distributive head and the following
~
parts with SST:
( 1 ) Pump plunger I
(2) Plunger adjusting shim
t SST (3) Camplate I

e SST 09260- 54012 (09269-54030)
~.
8. INSTALL CAM PLATE
Key Groove (a) Face the key groove of the drive shaft upward.
di)
-......_
, \1y (&)
~ ' V
FU0492
(b) Install the coupli ng spring and camplate with the

camplate pin facing toward the governor cover side.
FU0205 FU0454
9. INSTALL GOVERNOR LINK

(a) Using SST, install the governor link with the two
support bolts and gaskets. Torque the bolts.
Torque: 115 kg-cm (8 ft- lb, 11 N •m)
SST 09260- 54012 (09269-54040)
(b) Check that the governor link moves smoothly after
assembly.
FU1708
10. INSTALL PUMP PLUNGER

Shim
(a) Place t he selected plunger adjusting shim on the
center of the camplate.
NOTE: Do not apply grease to the shim.
FU0207
(b) Install the following parts to the pump plunger:

(2) Upper plunger plate
(3) Lower spring seat
(2)~ (4) Spill ring
NOTE: Face the spill ring with the hole side toward the
~ (1) lower seat.
(3)
FU1709
(c) Using SST, install the pump plunger and plunger

springs.
SST 09260-54012 (09269- 54030)
FU0209
(d) Check that the camplate pin and plunger notch are
aligned.
(e) Check that the spill ring hole and governor link ball
pin are aligned.
FU1710
11 . INSTALL DISTRIBUTIVE HEAD

(a) Apply No. 50 Denso grease to the following parts
and install them to the distributive head:
(1) Plunger spri ng guides
(2) Plunger spring shims
(3) Upper spri ng seats
( 4) Lever support springs
(5) New O-ring
FU0210 FU021 1
FUEL SYSTE M - Injection Pump FU -31
(b) Install the distribu tive head.

CAUTI ON : Be careful not to damag e the pump
plunge r.
FU0212
(c) Install and torque the four bolts and wire connec tor
bracket.
Torque : 120 kg -cm (9 ft- lb, 12 N -m )
FU1881
12. INSTAL L FOUR DELIVE RY VALVE HOLDE RS

(a) Install four new gaskets and the valves into the dis-
tributive head.
(b) Install the spring seats and spri ngs into the delivery
valve holders.
(c) Using SST, install and torque the delivery valve
holders.
/< SST 09260- 54012 (09269 -54020 )
FU1711 Torqu e: 500 kg -cm (36 ft - lb, 49 N -m)
13. INSTAL L DISTRI BUTIVE HEAD PLUG

(a) Install a new 0-ring on the head plug.
(b) Using SST, install and torque the head plug.
SST 09260- 54012 (09262 -54010 )
Torque : 700 kg -cm (51 ft - lb, 69 N -m)
FU1879
14. INSTAL L GOVER NOR SHAFT AND FLYWE IGHT

HOLDE R ASSEM BLY
(a) Install the four flyweig hts, washer and governo r
sleeve on the flyweigh t holder.
NOTE: Replace the four flyweigh ts as a set.
FU1800
(b) Install a new 0-ring to the governor shaft.

(c) Put the flyweight holder subassembly, flyweight
washer and adjusting washer into the pump hous-
ing.
(d) Install the governor shaft through the adjusting
washer, flyweight washer and flyweight holder sub-
assembly.
(e) Turn the governor shaft counterclockwise with an
alien wrench.
FU1799
NOTE: The governor shaft has LH threads.
15. CHECK FLYWEIGHT HOLDER THRUST

CLEARANCE
Using a feeler gauge, measure the flyweight holder thrust
clearance.
Thrust clearance: 0 .15 - 0 .35 mm
(0.0059 - 0.0138 in.)
FU021 7
If the thrust clearance is not w ithin specification, adjust

with a governor gear adjusting washer.
Adjusting
Governor gear adjusting washer thickness mm ( in.)
Washer
1.05 (0.0413) 1.65 (0.0650)
1.25 (0.0492) 1.85 (0.0728)
1.45 (0.0571)
FU1801
16. ADJUST PROTRUSION OF GOVERNOR SHAFT

(a) Using calipers, measure the protrusion of the gover-
nor shaft.
Protrusion: 2.0 - 2.5 mm (0.079 - 0.098 in.)
If the protrusion is not within specification, adjust by
turning the governor shaft with an allen wrench.
NOTE: The governor shaft has LH threads.
(b) Install and torque the lock nut while holding the
governor shaft with an alien wrench.
FU0458
17. INSTALL FUEL CUT SOLENOI D

(a) Install a new 0 - ring on the fuel cut solenoid.
(b) Install the valve and spring.
(c) Install and torque the fuel cut solenoid.
Torque: 225 kg -cm (16 ft- lb. 22 N -m)
FU1698
(d) Con nect the lead wire to the fuel cut solenoid.
(e) Install the lead wire connector to bracket.
FU1697
18. INSTALL GOVERN OR COVER

(a) Install a new gasket into the groove of the governor
cover.
(b) Install the damper spring and spri ng seat. and con -
nect them with the control spring.
NOTE: Install the damper spring as shown.
CAUTION : Never install the governor cover
without removing the full load set screw and dash
pot adjusting screw .
FU1712 FU1798
(c) Using an allen wrench, install the four bolts.
19. INSTALL FULL LOAD SET SCREW
20. INSTALL DASH POT ADJUSTI NG SCREW
21 . INSTALL THERMO WAX

Install a new 0 - ring and thermo wax with two bolts.
22. INSTALL ADJUSTI NG LEVER
FUl796
23. PERFORM AIR TIGHT TEST

(a) Install a bolt to the overflow port.
(b) Connect an air hose to the fuel inlet pipe and place
the injection pump into diesel fuel.
(c) Apply 1.5 kg/ cm 2 (21 psi, 147 kPa) of pressure and
confirm that there are no leaks.
2
(d) Next check t hat there are no leaks w ith 5.0 kg / cm
(71 psi , 490kPa) of pressure applied.
FU1803
24. INSTALL TWO FUEL PIPES
25 . INSTALL WOODRUFF KEY ON DRIVE SHAFT

FUEL SYSTEM - Injection Pump FU - 35
ADJUSTMENT OF INJECTION PUMP

1. PRE-TEST CHECK AND PREPARATION
(a) The specifications for test nozzle and nozzle holders
are as follow s.
Test nozzle: DN 12 SD 12 {NIPPONDENSO)
Test nozzle holder va lve opening pressure:
145 - 155 kg -cm 2
{2,062 - 2,205 psi, 14,220 - 15,200 kPa)
FU1713
(b) Check the accuracy of the tachometer.

Allowable e rror: ± 40 rpm
FU1804
(c) Install the angle gauge stand.

(d) Mount the injection pump body on the pump tester.
NOT E: Place a mark on the key groove portion of the
cou pling.
(e) Insta ll an injection pipe with the following specifi-

cations.
Outer diameter: 6 .0 mm {0 .236 in. )
Inner diameter: 2 .0 mm (0.079 in. )
Length: 840 mm (33.07 in. )
Minimum bending radius:
More than 25 m m (0 .98 in. )
FU 1872
Fuel Inlet Pipe (f ) Connect the fuel inlet pipe with an adapter.
Adapter
FU1806
(g) Remove the overflow screw and fuel return pipe.

(h) Install the overflow hose with the overflow screw.
NOTE: Always use the overflow screw installed on the
pump to be adjusted.
(i) Remove the timer cover with t he two screws.

(j) Install the inner pressure gauge w ith the timer mea -
suring device.
Part No. 95095-10220 and 95095-10231
(NIPPON DENSO)
NOTE: Bleed the air by the air bleed screw.
Inner Pressure Gauge Fuel Pressure Gauge
Nozzle and Holder
@1) @1) Adjust;ng Valve
p--- ---J, '~-----~, "~-----------, I

I
I
I
I
Measuring
Cylinder
~
I:)
Fuel Feed
Pump
I
I
r--~----- --1
Fuel Tank
FU1884
(k) Apply about 12 volts of DC power to the fuel cut

solenoid.
CAUTION:
>- 1. When applying voltage to the solenoid, position
ai -- the battery as far away from the solenoid as
~I
..,
possible so that a spark does not occur.
2. When connecting the battery cable, connect
the solenoid side first.
FU1885 FU0233
(I) The pressure for feeding fuel to the injection pump

should be 0.2 kg / cm 2 (2.8 psi, 20 kPa) . The fuel
40 - 45•c temperature for pump testing should be 40 - 45
~C(104 - 113°F) .
FU171 4 FU1873
(m) Install an angle gauge to the stand and set it to the

adjusting lever.
(n) Secure the adjusting lever fully on the maximum
speed side.
(o) Check the installation direction of the camplate.

( 1 ) Disconnect the injection pipe from the position
marked "C" on the distributive head.
(2) Using SST, remove the delivery valve holder.
SST 09260-54012 (09269-54020)
(3) Check that fuel is flowing out when the mark is

in the position shown in the figure.
If not, it is improperly assembled.
(4) Disassemble and change the camplate position
180° in the opposite direction.
NOTE: At this time, disconnect the fuel cut solenoid
wire harness.
FU1808
(5) Using SST, install the delivery valve holder.

SST 09260-54012 (09269 -54020)
(6) Connect the injection pipe.
(p) Bleed the air from the injection pipes.
FU1716
(q) Race the injection pump for 5 minutes at 2,000 rpm.

CAUTION: Check that there is no fuel leakage or
abnormal noise.
,-- I '
FU1874
NOTE:
• Measure the volume of each injection cylinder with a
measuring cylinder.
30 Seconds
• Before measuring the injection volume first hold the
cylinder tilted for at least 30 seconds to discard all the
fuel.
------- FU1717 FU0239
2. PRE- SETTING OF FULL LOAD INJECTION

VOLUME
(a) Set the adjusting lever to maximum position.
(b) Adjust the injection volume with the full load set
screw.
No. of
Pump revolution Inject ion volume
measuring
(rpm) cc (cu in.)
strokes
FU1886 6.2 - 6.6 (0 .38 - 0.40)
1,300 200
NOTE: The injection volume will increase about 3 cc

(0.18 cu in.) with each 1 / 2 turn of the screw.
2Q
FUEL SYST EM - Injecti on Pump

FU-39
/ 3. PRE- SETTING OF MAX IMUM SPEE D

(a) Set the adjust ing lever to maxim um positio n .
(b) Adjus t the injecti on volum e with the maxim um ad -
justing screw.
Pump revolut ion No. of

measu ring Injectio n volume
(rpm) cc (cu in.)
strokes
FU1875
2,900 200 1 .6 - 2.8 (0.10 - 0.17)
4. MEAS URE PUMP INNE R PRES SURE

Measu re the pump inner pressure at the below - listed
rpm.
Pump revolut ion

(rpm) Inner pressure kg / cm 2 (psi, kPa)
500 2.4 - 3.0 (34 - 43, 235 - 294)

2,900 7.6 - 8.2 (108 - 117, 745 - 804)
FU1874
• If the pressure is low, adjust by lightly tappin g the

regula tor valve piston while watch ing the pressure
gauge .
• If the pressure is too high or if the regula tor valve was
tapped in too far, the regula tor valve must be replaced.
FU0244 FU0245
5. MEAS URE OVER FLOW VOLU ME

Measu re the overfl ow volum e at the below listed rpm .
Pump revolut ion

(rpm) Overflo w volume cc /min. (cu in./mi n.)
2,900 392 - 845 (23.9 - 51 .6)
NOTE : Alway s use the overfl ow screw install ed on the

pump to be adjust ed.
FU1876
6. RELEASE COLD STAR TING SYST EM FOR NEXT

INSPE CTIO NS
Using a screw driver, turn the cold start lever counte r-
clockw ise and put a metal plate of 8.5 - 10 mm (0.33 -
0.39 in.) in thickn ess betwe en the lever and therm o wax .
NOTE : Keep the cold startin g system released until all
measurements and adjust ments are finishe d.
FU1810
7. CHECK AND ADJUST TIMER

(a) Set the timer measuring device at zero.
(b) Measure the piston stroke at the below listed rpms.
Pump revolution Piston strokes

(rpm) mm (in.)
700 0.20 - 1.20 (0.0079 - 0.0472)

1,300 2.37 - 3.37 (0.0931 - 0.1327)
2,300 6.06 - 7.06 (0.2386 - 0.2780)
FU1719
2,900 7.70 - 8.70 (0.3031 - 0.3425)
NOTE: Confirm that the hysteresis is within 0.3 mm

(0.012 in.)
If any stroke is not within standard, adjust with the
TIMER ADJUSTING SCREW.
NOTE: The stroke will decrease with turn to clockwise
and increase with turn to counterclockwise.
FU1811
8. MEASURE AND ADJUST FULL LOAD INJECTION

VOLUME
(a) The adjusting lever angle for the adjustment below
should be as shown in the figure.
Adjusting lever angle
A (Maximum speed side) B (Idle speed side)
plus 42 - 52 • Minus 5 - Plus 5°
FU1812
(b) Measure the full load injection volume.
Pump No. of
Injection volume Remarks
Adjusting lever angle revolution measuring
cc (cu in)
(rpm) strokes
1,300 6.2 - 6.6 (0.38 - 0.40) Adjust
Plus 42 - 52° 500 200 5.1 - 5.8 (0.31 - 0.35)

-
2,600 6.1 - 6.8 (0.37 - 0.41)
If any injection volume is not at standard value, adjust

with the FULL LOAD SET SCREW.
NOTE: The injection volume will increase about 3 cc
(0.18 cu in.) with each 1 /2 turn of the screw.
FU1886
/ 9. ADJUST MAXIMUM SPEED

Maximum Speed Adjusting Screw
Adjust to the standard value with the MAXIMUM SPEED
ADJUSTING SCREW.
No. of Injection volume

Adjusting Pump revolution measuring Remarks
lever angle (rpm) cc (cu in.)
strokes
2,900 1.6 - 2.8 (0.10 - 0.17) Adjust
Plus 42 - 52° 2,800 200 4.2 - 5.8 (0.26 - 0.35)
-
3,100 Less than 1.5 (0.09)
10. INSPECT INJECTION VOLUME

Measure the injection volume for each pump rpm .
No. of Injection volume Variation limit

Adjusting Pump revolution measuring Remarks
lever angle (rpm) cc (cu. in.) cc (cu. in.)
strokes
Basic full -load
1,300 6.2 - 6.6 (0.38 - 0.40) 0.4 (0.02 )
injection volume
Plus 42 - 52° 200 Volume during

100 6.6 - 11.4 (0.40 - 0.70) 1.2 (0.07 ) starting
500 5.1 - 5.8 (0.31 - 0.35) -
0.5 (0.03)
2,600 6.1 - 6.9 (0.37 - 0.42) -
If the injection volume at 100 rpm is not within specifica -

tion; replace the governor sleeve plug .
(1) Using SST and press, remove the sleeve plug

subassembly.
SST 09236-00101 (09237 - 00070)
FU1813
(2) Remove the E-ring, stop ring, bearing and sleeve

plug.
9 - - -s1eeve Plug
f i l _ Bearing
~
@ - - Stop Ring
@ - -E-Ring
FU1814
(3) Select the head thickness of the sleeve plug.

Head Thickness
Governor sleeve plug head thickness mm (in.)
3.0 (0.118) 3.7 (0.146)

3.1 (0.122) 3.8 (0.150)
3.2 (0.126) 3.9 (0.154)
3.3 (0.130) 4.0 (0.157)
3.4 (0.134) 4.1 (0.161)
3.5 (0.138) 4.2 (0.165)
3.6 (0.142)
FU1815
NOTE: Lengthening the plug 0.1 mm (0.004 in.) will

increase injection volume by 0.6 cc (0.04 cu in.).
If the variation limit exceeds specification, replace the
delivery valve.
(4) Install the sleeve plug, bearing, a new stop ring and
a new E-ring.
£ 1 - -sieeve Plug
13--Bea,;ng
S - - stop Ring
@ - - -E-Ring
FU1814
(5) Using a hand press, install the sleeve plug sub-

assembly.
FU1816
11 . ADJUST IDLE SPEED

(a) Loosen the dash pot adjusting screw fu lly.
(b) Adjust the injection volume with the IDLE SPEED

ADJUSTING SCREW.
Pump No. of
Injection volume
revolution measuring Remarks
cc (cu in.)
(rpm) strokes
500 q = 0.5 - 1.5 (0.03 - 0.09) Adjust
1,000
350 q plus 5 - 9 (0.31 - 0.55) -
(c) Adjust the injection volume with the DASH POT

ADJUSTING SCREW.
NOTE: The stroke will decrease with turn to clockwise
and inc rease with turn to counterclockwise.
Pump No. of
Injection volume
revolution Measuring
cc (cu in.)
(rpm) strokes
500 1,000 q plus 0.7 - 1.2 (0.04 - 0.07)
(d) Adjust the injection volume with the IDLE SPEED

ADJUSTING SCREW.
Adjusting Pump revolution No. of measuring Injection volume

lever angle (rpm) strokes Remarks
cc (cu in.)
Minus 5° - Plus 5° 350 1,000 8.75 - 12.25 (0.53 - 0.75) Adjust
12. ADJUST COLD STARTING SYSTEM

(a) Remove the overflow screw and check the fuel tem-
perature in the fuel pump.
Fuel temperature: 15 - 35°C (59 - 95 °F)
(b) Set the woodruff key on the pump drive shaft in a
vertical or horizontal position.
(c) Set the scale of the timer measuring device to zero.
(d) Check the adjusting lever opening angle and con-
sider this angle as zero.
(e) Remove the metal plate put between the cold start-
ing lever and thermo wax.
(f) Torque the cold starting lever clockwis e to approx.

50 kg-cm (43 in.-lb, 4 .9 N-m) and keep the lever
tightened for about 10 seconds. Then release the
torque.
(g) M easure the timer piston stroke.

If not within specifica tion, adjust with the timer adjusting
screw.
NOTE: Screw in for stroke decrease.
~ Fuel Temperature
Timer Adj usting F ("C)
Screw FU1820 FU 1860
13. POST ADJUST MENT CHECK

(a) Check that injection stops when the fuel cut so-
lenoid harness is removed .
Pump revo lution : 100 rpm
(b) Check the adjust ing lever movemen t.

Adjust lever angle: 42° - 52°
FU1821
(c) Lock the maximum speed adjusting screw and full

Maximum Speed Adjusting Screw load set screw with the wires as shown in the figure.
FU1822
FU El SYSTEM - Injection Pump FU-45
INSTALLATION OF INJECTION PUMP

(See page FU - 12)
1. INSTALL INJECTION PUMP
(a) Align the matchmarks on the injection pump and
water pump.
(b) Temporarily install the mount nuts.
NOTE: Torque the mount bolt and nut to specification
after adjusting the injection timing .
FU1823
(c) Install the bracket with t he four bolts.

2. INSPECT AND ADJUST INJECTION TIMING

(See page EM -20)
FU1791
3. INSTALL FOUR INJECTION PIPES

(See steps 5 on pages FU -11)
4. CONNECT WATER BY-PASS HOSES
5. CONNECT FUEL INLET AND OUTLET HOSES
6. CONNECT FUEL CUT SOLENOID CONNECTOR
I
7. INSTALL INJECTION PUMP DRIVE PULLEY AND

TIMING BELT {See page EM -31 to 36)
8. CONNECT ACCELERATOR CABLE TO INJECTION

PUMP
9. REFILL WITH COOLANT

{See step 3 on page CO -3)
10. REFILL INJECTION PUMP WITH FUEL

Operate the priming pump until you feel more resistance.
FU1781
11. BLEED INJECTION NOZZLES

(a) Loosen all union nuts of the injection pipe on the
nozzle holder side.
(b) Crank the engine to bleed the air and force out the
fuel from the injection pipe.
(c) Tighten the injection pipe union nuts.
Torque: 300 kg-cm {22 ft- lb, 29 N •m)
FU1788
12. START ENGINE AND CHECK FOR FUEL LEAKS
13. CHECK ENGINE IDLE SPEED AND MAXIMUM

SPEED {See page EM -22)
14. RECHECK COOLANT LEVEL

CO -1
COOLING SYSTEM
Page
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . CO-2
CHECK AND REPLACEMENT OF ENGINE
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-3
WATER PUMP .............................. CO-4
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-6
RADIATOR .. .. .. . . .. . .. .. . . . .. . . . . . . . . . . . . . CO-7
ELECTRIC COOLING FAN .. .. .. . . .. .. . .. .. .. CO-13
m,1
C0 -2 COOLING SYSTEM - Troublesho oting
TROU BLES HOOT ING

Problem Possible cause Remedy Page
Engine Check coolant Replenish coolant C0- 3

overheats Alternator drive belt loose or missing Adjust or replace belt EM -35, 36
Radiator plugged or cap faulty Check radiator or cap C0- 7
Radiator hose plugged or rotted Replace hose
Dirt leaves, or insects on radiator Clean radiator C0- 7
Hoses, water pump, water outlet housing, Repair as necessary C0 - 7
radiator, heater, core plugs or head gasket
leakage
Thermostat faulty Check thermostat C0-6
Water pump faulty Replace water pump C0 -4
Electric cooling system faulty Inspect electric cooling system C0 - 13
Injection timing retarded Reset timing EM-18
Cylinder head or block, cracked or plugged Repair as necessary
NOTE: The thermostat on the 1 N engine is equipped with a by- pass valve. Therefore, if the engine tends
to overheat, removal of the thermostat would have an adverse effect, by causing a lower cooling efficiency.
COOLING SYSTEM - Check and Replacement of Engine Coolant C0-3
CHECK AND REPLACEMENT OF

ENGINE COOLANT
1. CHECK ENGINE COOLANT LEVEL AT RESERVE
TANK
The coolant level should be between the "LOW" and
"FULL" lines.
If low, check for leaks and add coolant up to the " FULL"
line.
C00471
2. CHECK ENGINE COOLANT QUALITY

There should be no excessive deposits of rust or scales
around t he radiator cap or radiator fill er hole, and the
coola nt shou ld be free from oil.
If excessively dirty, replace the coolant.
C00472
3. REPLACE ENGINE COOLANT

(a) Remove t he radiator cap.
(b) Drai n t he coolant from the radiator and engine drain
cocks.(The engine drain cock is at right rear of cylin-
der block.)
Drain Cock J C00473

(c) Close the drain cocks.
(d) Fill the system w ith coolant.
Use a good brand of ethylene -glycol base coolant,
mixed according to the manufacturer's direct ions.
Coolant capac ity (w / Heater) :
5 .7 liters (6.0 US qts, 5.0 lmp.qts)
(e) Install the radiator cap.
(f) Start the engine and check for leaks.
(g) Recheck the coolant level and refill as necessary.
C0-4 COOLING SYSTEM - Water Pump
WATER PUMP
COMPONENTS
--
CO0482
REMOVAL OF WATER PUMP

(See steps 1 to 8 on pages EM-25 to 27)
2. REMOVE INJECTION PUMP PULLEY

3. REMOVE INJECTION PUMP SET NUTS
CO0474
COOLING SYSTEM - Water Pump C0- 5
4. REMOVE WATER PUMP

(a) Remove the eight bolts.
(b) Using a plastic-faced hammer, lightly tap the water
pump and remove the water pump.
INSPECTION OF WATER PUMP

INSPECT WATER PUMP BEARING
Check that the water pump bearing operat ion is not
rough or noisy.
If necessary, replace the water pump
CO0476
INSTALLATION OF WATER PUMP

(See page C0-4)
1. INSTALL WATER PUMP

(a) Apply seal packing to the water pump.
Seal pac king: Part N o.08826-00100 or equivale nt
NOTE: Cleaning and application of seal packing to the
i nstallation surface. However, use a nozzle cut to 2 mm
Seal Packing coo466
(0.08 in.) .
(See page LU - 10)
(b) Install the water pump with the eight bolts.

Torque: 195 kg-cm (14 ft- lb, 19 N-m )
CO0475
2. INSTALL INJECTION PUMP SET NUTS
3. INSTALL INJECTION PUMP PULLEY


( See steps 5 to 14 on pages EM - 32 to 36)
n ,o m
C0-6 COOLING SYSTEM - Thermosta t
THER MOST AT
REMOV AL OF THERM OSTAT
REMOVE THERMO STAT
(a) Remove the two nuts.
(b) Remove the water inlet and thermostat from the
water inlet housing.
( c) Remove the gasket from the thermostat.
INSPEC TION OF THERM OSTAT

NOTE: The thermostat is numbered with the valve
opening temperature.
(a) Immerse the thermostat in water and heat the water
gradually.
CO0384
(b) Check the valve opening temperature and the valve

lift.
If the valve opening temperature and valve lift are not
within the following specificatio ns, replace the ther-
mostat.
Valve opening t emperat ure: 80 - 84°C
(176 - 183°F)
V a lve lift: M ore than 8 m m (0.31 in.) at 95°C
(203°F)
C00385
(c) Check that the valve spring is tight when the ther-
mostat is fully closed.
If not closed, replace the thermostat.
INSTAL LATION OF THERM OSTAT

1. PLACE THERMO STAT IN WATER INLET
(a) Install a new gasket to the thermostat.
(b) Install the thermostat and water inlet with the jiggle
valve upward.
2. INSTALL WATER INLET

Install and torque the two nuts.
Torque: 195 kg-cm (14 ft- lb, 19 N •m)
CO0477
I
~
COOLING SYSTEM - Radiator C0-7
RADIATOR
CLEANING OF RADIATOR
Using water or steam cleaner, remove any mud or dirt
from the radiator core.
CAUTION: If using high pressure type cleaner,
be careful not to deform the fins of the radiator
co re. For example, keep a distance of more than
40 - 50cm (15.75-19.69in.) between the radiator
co re and cleaner nozzle when the cleaner nozzle
pressure is 30 - 35 kg / cm 2 ( 427 - 498 psi, 2,942 -
3.432 kPa).
INSPECTION OF RADIATOR
Radiator Tester
1. CHECK RADIATOR CAP
Using a radiator tester, pump the tester until the relief
va Ive opens.
Check that the valve opens between 0.75 kg/cm 2 (10.7
psi, 74 kPa) and 1.05 kg/cm 2 (14.9 psi, 103 kPa).
Check that the pressure does not drop rapidly when the
Radiator Cap pressure on the cap is below 0.6 kg / cm 2 (~.5 psi, 59
C00034 kPa).
If either check is not within limits, replace the cap.
2. CHECK COOLING SYSTEM FOR LEAKS

(a) Fill the radiator with coolant and attach a pressure
tester.
(b) Warm up the engine.
(c) Pump it 1.2 kg/cm 2 (17.1 psi, 118 kPa) , check that
pressure does not drop.
If the pressure drops, check for leaks from the hoses,
Radiator Tester radiator or water pump. If no external leaks are found,
check the heater core, block and head.
C0 -8 COOLING SYSTEM - Radiator
DISASSEMBLY OF RADIATOR
COMPONENTS
• 0 - Ring - - - - - -- ----c.s..
Core - - - - - - - ---------1
• 0 - Ring - -- - - - -----'. . .<:. .

• Tank Plate - - - - - - - ( : . . _~
• Non - reusable part CO0467
1. REMOV E TANK PLATE

6 4 5 (a) Raise the claws of the tank plates with SST in the
numerical order shown in the figure.
SST 09230-0001 0
I I } 8 NOTE: Be careful not to damage the core plate.
2
F1581
Fl 582 CO0041
COOLING SYSTEM - Radiator CO -9
(b) Pull the tank plates outward.
F1583
2. REMOVE TANK AND O - RING

(a) Pull the tank upward.
(b) Remove the O-ring.
i----- Core
F1584
ASSEM BLY OF RADIAT OR

(See page CO-8)
1. INSPECT CORE PLATE
Core Plate Core Plate Inspect the core plate for damage.
NOTE:
• If the sides of the core plate groove are deformed,
reassem bly of the tank will be impossible . Therefore,
first correct any deformatio n with pliers or like object.
• Water leakage will result if the bottom of the core plate
Core groove is damaged or dented. Therefore, repair or re -
place if necessary.
C00443
2. INSTALL NEW O- RING AND TANK

t ll NOTE:
• Clean the tank and core plate.
F1679
C0-10 COOLING SYSTEM - Radiator
• Inspect the 0 - ring for twists.
C00317
3. INSTALL TANK PLATE

Tank Plate Install the tank plates from both ends in the direction of
the arrows. Insert to where the portions shown by the
arrows contact with the tank.
F1586
4. STAKE CLAW OF TANK PLATE

~-~ '
~ HIGH C5 (a) Set the punch of SST to "LOW".
SST 09230-0001 0
b LOW c~
C00315
(b) Stake the claws of the tank plates with SST in the
numerical order shown in the figure.
SST 09230-000 1 0
F1581
CAUTION : If the bottom of the core plate is

staked with the SST on the guide block stopper, it
may result in water leakage.
SST 09230-000 10
COOLING SYSTEM - Radiator C0-11
Tank Plate
Punch
SST
Guide Block
Stopper CO0043 CO0046
NOTE:
• Stake with just enough pressure to leave a mark on the
claw. The staked plate height ( H) should be as fol-
lows:
Plate height: 9 .18 - 9 .53 mm (0.3614 - 0.3752 in.}
• Do not stake the areas protruding around the pipes,

brackets or tank ribs.
F1588
• The points shown in the illustration cannot be staked

with the SST. Use a pl iers or like object and be careful
@ II • )DI~[] 11 11)) not to damage the core· plates.
F1581
85801
5. INSPECT FOR WATER LEAKS

(a) Tighten the drai n plug.
(b) Plug the inlet and outlet pipes of the radiator with
SST.
SST 09230-0001 0
(c) Using a radiator tester, apply pressure to the radia -
tor.
Test pressure: 1 .8 kg /cm 2 (26 psi, 177 kPa}
CO0106 Fl 590 (d) Inspect for water leaks.
C0-12 COOLING SYSTEM - Radiator
NOTE: On radiator with resin tanks, there is a clearance

between the core plate and tank plate where a minute
Tank
amount of air will remain , giving the appearance of an air
leak when the radiator is submerged in water. Therefore,
before performing the water leak test, first switch the
;1,--a-Core Plate
radiator around in the water until all air bubbles disap-
Clearance Ar-~- -Tank Plate pear.
CO0035
6. PAINT TANK PLATES

NOTE: If the water leak test checks out okay, allow the
radiator to completely dry and then paint the tank plates.
COOLING SYSTEM - Electric Cooling Fan C0- 13
ELECTRIC COOLING FAN

ON-VEHICLE INSPECTION
Low Coolant Temperature
(below 83°C (181 °F))
1. TURN IGNITION SWITCH ON
Check that the fan is stopped.
F1592 83648
If it does not, c heck the fan relay and temp. switch, and
check for a separated connector or severed wire between
t he relay and temp. switch.
2. D ISCONNECT TEMP . SWITCH CONNECTOR

Check that the fan rotates.
If it doesn't, check t he fa n relay, fan motor, engine main
relay and fuse, and check for a short circuit between the
fan relay and temp. switch.
3. CONNECT TEMP . SWITCH CONNECTOR

Disco~
C0479 B3650
High Coolant Temperature

(above 93°C (199°F))
4. START ENGINE
(a) Raise engi ne coola nt temperature to above 93°C
(199°F).
(b) Check that the fan rot ates.
(c) Check that the fan stops when coolant temperature
is below 83°C (181 °F).
C00090
If it doesn't replace the temp. switch .
Above 93°C No continuity INSPECTION

OD
1. INSPECT TEMP . SWITCH
NOTE: Located on the water inlet housing.
(a) Using an ohmmeter, check that t here is no continu -
ity when the coolant temperature is above 93°C
(199°F).
C00101
Below 83°C (b) Check that there is continuity when the. coolant
Continuity temperature is below 83°C (181 °F).
OD
If contin uity is not as specified, replace the temp. switch.
C00102
C0- 14 COOLI NG SYSTE M - Electric Cooling Fan
2. INSPEC T ENGIN E MAIN RELAY

Engine Main Relay
NOTE: Located in the engine compar tment relay box.
Inspec t Relay Contin uity

Continu ity No Continui ty
(a) Using an ohmmeter, check that there is continu ity
DD DD between terminals 1 and 2.
1°1: [? r: (b) Check that there is no continu ity between terminals

3 and 4.
If continu ity is not as specified, replace the relay.
' - - - - - ~ BE0375
Inspec t Relay Operat ion

(a) Apply battery voltage across termina ls 1 and 2.
(b) Using an ohmmeter, check that there is continu ity
between termina ls 3 and 4.
If operatio n is not as described, replace the relay.
B£0376
3. INSPEC T COOLI NG FAN MOTO R RELAY

Cooling Fan Relay
NOTE: Located in the engine compar tment relay box.
CO0481
Inspec t Relay Contin uity

(a) Using an ohmmet er, check that there is continui ty
between termi nals 1 and 2.
(b) Check that there is continu ity between terminals 3
and 4 .
Coninuit y
n If continu ity is not as specified, replace the relay.
C00103
COOLING SYSTEM - Electric Cooli ng Fan C0-15
Inspect Relay Operation

_ _____,EB
(a) Apply battery voltage across terminals 1 and 2.
(b) Check that there is no continuity between terminals
2 CD
Battery 3 and 4.
No continuity If operation is not as described, replace the relay.
fl
4
CO0104
4. INSPECT FAN MOTOR

(a) Connect battery voltage to the fan motor connector.
(b) Check to see that the motor rotates smoothly and
current is as follows:
Current: 6 .8 - 7.4 A
LU-1
LUBRICATION SYSTEM
Page
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . LU -2
OIL PRESSURE CHECK........ . ............. LU -3
REPLACEMENT OF ENGINE OIL
AND OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . LU -4
OIL PUMP AND PRESSURE
REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . LU-6
OIL COOLER AND RELIEF VALVE ........... LU -1 1
LU -2 LUBRICATION SYSTEM - Troubleshoot ing
TROUBLESHOOTING
Probl em Possib le ca use Rem edy Page
Oil le~kage Cylinder head, cylinder block or Repair as necessary

oil pump body damaged or
cracked
Oil seal faulty Rep lace oil seal EM-84
Gasket faulty Rep lace gasket
Low oil pressure Oil leakage Repair as necessary

Pressure regulator valve faulty Replace pressure regulator LU -6
va lve
Oil pump faulty Replace oil pum p LU -6
Poor engine oil quality Replace engine oil LU -4
Crankshaft bearing faulty Replace bearing EM -64
Con necti ng rod bearing faulty Replace bearing EM -64
Oil filter clogged Replace oil filter LU-4
High oil pressure Pressure regulator valve faulty Replace pressure reg u lator LU - 6
valve
LUBRICATION SYSTEM - Oil Pressure Check LU-3
Recommended Viscosity (SAE) OIL PRESSURE CHECK

1. CH ECK OIL QUALITY
Check the oil for deterioration, entry of water, discoloring
or thinning.
If the oil quality is poor, replace it.
·c-2s Use API grade CD or better and recommended viscosity
•F- 20
oil.
TEMPERATURE RANGE ANTIC IPATED BEFORE
NEXT OIL CHANGE
LU0312
2. CHECK OIL LEVEL

The oil level should be between the "L" and "F" marks on
the dipstick.
If low, check for leakage and add oil up to the "F" mark.
EM1759
3. REMOVE OIL PRESSURE SWITCH

Using SST, remove the oil pressure switch.
SST 09816- 30010
4. INSTALL OIL PRESSURE GAUGE
5. START ENGINE
Start the engine and warm it up to the normal operating
temperature.
LU0460
Oil Pressure Gauge

6. MEASURE OIL PRESSURE
Oil pressure:
At idle speed More than 0.5 kg /cm 2
(7.1 psi, 49 kPa)
At 3,000 rpm 2.5 - 6.0 kg/ cm 2
(36 - 85 psi, 245 - 588 kPa)
NOTE: Check for oil leakage after reinstalling the pres -
sure switch. (See step 12 on page EM - 94)
LU0470
LU-4 LUBRICATION SYSTEM - Replacement of Engine Oil and Oil Filter
R "'-<> REPLACEMENT OF ENGINE OIL

AND OIL FILTER
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil dipstick.
(c) Remove t he oil drain plug and drain the oil into a
container.
LU0486
2. REPLACE OIL FILTER

(a) Using SST, remove the oil filter.
SST 09228- 10000
(b) Inspect and clean t he oil filter installation surface.

(c) Apply clean engi ne oil to the gasket of a new oil
filter.
(d) Lightly screw in the oil filter until you feel resistance.
(e) Then, usi ng SST, tighten the oi l filter an extra 3/4
turn.
SST 09228-10000
LU0006 LU0485
3. FILL WITH ENGINE OIL

(a) Clean and install the oil drain plug with a new gas-
ket. Torque the drain plug.
Torque: 250 kg - cm (18 ft- lb, 25 N -m )
LUBR ICATIO N SYSTE M - Replacement of Engine Oil and Oil Filter
LU-5
(b) Fell the engine with new oil, API grade CD or better.
Capac ity:
Drain and refill -
w / o Oil filter cha nge
3 .1 liters (3.3 US qts, 2 .7 lmp.q ts)
w / Oil filter chang e
3 .8 liters (4.0 US qts, 3.3 lmp.q ts)
Dry fill-
4.2 liters (4.4 US qts, 3.7 lmp.q ts)
(c) Install the oil filler cap with the gasket.
(d) Install the oil dipstic k.
4. STAR T ENGIN E AND CHEC K FOR LEAKS
5. RECH ECK OIL LEVEL

Recheck the engine oil level and refill as necessary.
EM1759
LU-6 LUBRICATION SYSTEM - Oil Pump and Pressure Regulator Valve
OIL PUMP AND PRESSURE REGULATOR VALVE

COMPONENTS
~ 1--- - - -- Pressure Regulator

lif Valve
• Gasket t') Piston
; Spring
• O-Ring
S ,___- - - - -Retai ner
• Snap Ring
Oil Pump
Di-- -Oil Strainer
• Gasket
D,a;n ~
• Non -reusable part Oil Pan

* Precoated part LU0481
REMOVAL OF OIL PUMP AND PRESSURE

REGULATOR VALVE
NOTE: When repairi ng the oil pump, the oil pan and
strainer should be removed and cleaned.

(See steps 1 to 8 on pages EM -25 to 27)
2. REMOVE CRANKSHAFT TIMING PULLEY

(See st e p 12 on page EM -28)
3. REMOVE OIL PAN

(a) Remove the two nuts and twelve bolts.
(b) Insert t he SST blade between the cylinder block and
oil pa n, cut off applied sealer and then remove the
oil pan.
SST 09032-001 00
NOTE:
• Do not use SST for the oil pump body side. If neces-
sary, use a screwdriver.
• When removing t he oil pan, be careful not to damage
the oil pan flange.
LUBRICATION SYSTEM - Oil Pump and Pressu re Regu lator Valve LU-7
4. REMOVE PRESSURE REGULATOR VALVE

ASSEMBLY
5. REMOVE Oil PUMP

(a) Remove the five bolts and tension spring pin.
(b) Using a plastic -faced hammer, carefully tap off the

oil pump.
(c) Remove t he oil pump body and 0- ring.
LU0487
LU -8 LUBRICATION SYSTEM - Oil Pump and Pressure Regulator Valve
INSPECTION OF OIL PUMP

1. INSPECT BODY CLEARANCE
Using a thickness gauge, measure the clearance between
the driven rotor and pump body.
Standard clearance: 0 .10 - 0 .1 7 mm
(0.0039 - 0 .0067 in.)
Maximum clearance: 0 .20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil
,___ _ _ _ _ _ _ _ _ _ _ _ _Lu_o4
_e,, pump.
2. INSPECT TIP CLEARANCE

Using a thickness gauge, measure the clearance between
both rotor trips.
Standard clearance: 0.05 - 0 .15 mm
(0.0020 - 0 .0059 in.)
Maximum clearance: 0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil
pump.
LU0462
3. INSPECT ROTOR PROTRUSION ( Refe rence)

Using a dial gauge and flat block, measure the side clear-
ance as shown.
Standard protrusion: 5.00 - 5.08 mm
(0.1969 - 0.2000 in .)
LU0475
INSPECTION OF PRESSURE REGULATOR

1. DISASSEMBLE PRESSURE REGULATOR VALVE
(a) Using snap ring pliers, relT)ove the snap ring.
(b) Remove the retainer, spring and pressure regulator
valve piston.
LU0106
2. INSPECT PRESSURE REGULATOR VALVE

Coat the valve piston with engine oil and check that it
falls smoothly into the valve hole by its own weight.
If necessary, replace the valve.
3. ASSEMBLE PRESSURE REGULATOR VALVE

(a) Insert the pressure regulator valve piston, spring and
retainer.
(b) Using snap ring pliers, install the snap ring.
L U0144
LUBRICATION SYSTEM - Oil Pump and Pressure Regulator Valve LU - 9
INSTALLATION OF OIL PUMP AND

PRESSURE REGULATOR VALVE
(See page LU-6)
1. REPLACE CRANKSHAFT FRONT OIL SEAL,
IF NECESSARY (See step 1 on page EM-84)
Seal Packing 2. INSTALL OIL PUMP ASSEMBLY

(a) Apply seal packing to the oil pump body as shown
in the figure.
Seal packing : Part No.08826-00080 or equivalent
NOTE: Cleaning and application of seal packing to the
installation surface is the same as for the oil pan.
However, use a nozzle cut to 2 mm (0.08 in.)
LU0463
(b) Place a new O-ring into the groove.

Sealant (c) Apply sealant to the three bolts as shown in the
figure.
Sealant: Part No. 08833-00070 or equivalent
NOT E: This adhesive will not harden while exposed to
air. It wi ll act as a sealant or binding agent only when
B6135
~/ (d) Install the oil pump with the five bolts and tension
- \
spring pin.
Tesion Spring
Pin
_)
0 : Precoat Bolt
3. INSTALL PRESSURE REGULATOR VALVE

LU - 10 LUBRIC ATION SYSTEM - Oil Pump and Pressure Regulato r Valve
4. INSTALL OIL PAN

(a) Remove any old packing material and be caref ul not
to drop any oi l on the contacti ng surfaces of the oil
pan and cylinder block.
• Using a razor blade and gasket scraper. remove all
the packing ( Fl PG) material from t he gasket sur-
faces.
• Thorough ly clea n all components to remove all
t he loose material.
• Clean both sealing surfaces with a non - residue
solvent.
Seal Packing
CAUTIO N : Do not use a solvent which will af -
fect the pai nted surfaces.
b (b) Apply seal packing to the oil pan as shown in the
figu re.
b
Seal packing : Part No.0882 6-00080 or equivale nt
,. B t Seal diamete r:
a 6 - 7 mm (0.24 - 0 .28 in.)
. ·~ B
b 3 - 4 mm (0.12 - 0 .16 in.)
B+-+ B LU0483 Install a nozzle t hat has been cut to a 3 mm (0.12
in.) or 6 mm (0.24 in.) opening.
NOTE: Avoid applyi ng an excess amount to the sur-
face. Be especiall y careful near oil passages .
• Parts must be assembled withi n 15 minutes of
applicatio n. Otherwis e, the seal packing black
must be removed and re-applie d.
• Immediat ely remove nozzle from t ube and rein-
stall cap.
(c) Install the oi l pan with the two nuts and twelve
bolts.
Torque: 80 kg -cm (69 in .-lb, 7 .8 N -m )
5. INSTAL L TIMING BELT

(See steps 5 to 14 on pages EM - 32 to 36 )
6. INSTALL CRANK SHAFT TIMING PULLEY

LUBRICA TION SY STEM - Oil Cooler and Relief Valve LU -11
OIL COOL ER AND RELIEF VALV E

COMPO NENTS
~ , - - -- - - -- - -Clip
\--- -- - -- -No. 3 Oil Cooler Hose
Oil Cooler
Oil Cooler Relief Vavle
1,700 (123, 167)
,--- - - -No. 2 Oil Cooler Hose
700 (51, 69)

I kg -cm (ft- lb, N·m) I: Specified torque Oil Filter
• Non-reusab le part LU0482
REMOV AL OF OIL COOLER AND RELIEF

VALVE
1. REMOVE OIL FILTER
2. REMOVE OIL COOLER

(a) D isconnect t he No .2 an d N o .3 o il cooler h oses.
LU0476
LU - 12 LUBRICATION SYSTEM - Oil Cooler and Relief Valve
(b) Using SST, loosen the nut.

SST 09229-55010
(c) Remove the nut and oil cooler.
(d) Remove t he 0-ring.
3. REMOVE RELIEF VALVE

Using SST, remove the relief valve.
SST 09229-55010
INSPECTION OF OIL COOLER AND RELIEF

VALVE
1. INSPECT OIL COOLER
Check the oil cooler for damage or clogging.
F6277
2. INSPECT RELIEF VALVE

Check the relief valve for scoring or wear.
Tape
LU0478
LUBRICATION SYSTEM - Oil Cooler and Relief Valve LU-13
INSTALLATION OF RELIEF VALVE AND

OIL COOLER
1. INSTALL RELIEF VALVE
Using SST, install and torque the relief valve.
SST 09229-55010
Torque: 1,700 kg-cm (123 ft-lb, 167 N-m)
LU0479
2. INSTALL OIL COOLER

(a) Install a new 0-ring to the oil cooler.
(b) Apply clean engine oil to the 0 - rings.
LU0484
(c) Install the oil cooler with the nut.

( d) Using SST, torque the nut.
SST 09229-55010
(e) Connect the No.3 and No.2 oil cooler hoses.
LU0476
3. INSTALL OIL FILTER

(See step 2 on page LU-4)
ST-1
STARTING SYSTEM
Page
PRE- HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . ST-2
TROUBLESHOOTING . . ... . . . ................. ST-6
STARTING SYSTEM CIRCUIT ................. ST-6
STARTER . . . . ....... . ...... . .... . ............. ST-7
ST-2 STARTING SYSTEM - Pre-heating System
PRE- HEATING SYSTEM

Super Glow Type
SYSTEM CIRCUIT
Glow Indicator Light

IG1 Fuse
AM1 GAUGE 7.5A
Starter Switch To Alternator Terminal L - ~
IG2 ENGINE 25A

Fuse
AM2
ST2
AM1 AM2
60A 30A
No.1 Glow No.2 Glow

Plug Relay Plug Relay
G 0
(J)
C
Q)
Cf)
Fusible Glow
100A ~
Link 80A
Pre-heating
-
::,
(0
ai
C.
Timer
E
Q)
Glow Plug t--
12 10
T
: Battery
_j_
Current
Sensor 6
2
-
ai
(0
Speed
Sensor
Glow
Plug
ST0460
INSPECTION OF COMPONENTS
Pre-heating Timer
LO CATION: Behind the front console box.
Refer to Diesel Electrical System Diagnosis for inspection
procedures. (See pages EM -10 and 11)
STARTING SYSTEM - Pre-heating System ST-3
(Secs)
I
C
7 ...................
0 6
6 5 4 3 2 1 ~
:::,
0
5 ' ~
'\.
4
0)
C
·.:;
.c. 3 ..___' - - '\
'
0)
-
:.J
..r:
0)
:.J
2
1 -
0
12 11 10 9 7 - 25 - 5 0 20 70
Water Temperature (°C)
ST0049 ST0462
No.1 Glow Plug Relay
r=--~
I
I
B G
g
LOCATION: Near the battery.
L______ _J E
ST0463
1. INSPECT RELAY CONTINUITY

Continuity (a) Using an ohmmeter, check that there is continuity
No G ~ -~
DD between terminals g and E.
Continuity
0
Cl[] (b) Using an ohmmeter, check that there is no continu-
0 0 0
ity between terminals 8 and G.
If continuity is not as specified, replace the relay.
e
ST0470
2. INSPECT RELAY OPERATION

(a) Apply battery voltage between terminals g and E.
Continuity
(b) Using an ohmmeter, check that there is continuity
between terminals B and G.
If there is no continuity, replace the relay.
e ®
Battery
ST0471
ST-4 STARTING SYSTEM - Pre-heating System
No. 2 Glow Plug Relay

LOCATION: Near the engine right mounting.
BE0908
Continuity 1. INSPECT RELAY CONTINUITY

IT] (a) Using an ohmmeter, check that there is continuity
between terminals g and E.
,--,.-....._ No Continuity
(b) Using an ohmmeter, check that there is no continu-
OD ity between terminals B and G.
If continuity is not as specified, replace the relay.
ST0472
2. INSPECT RELAY OPERATION

Continuity (a) Apply battery voltage between terminals g and E.
(b) Using an ohmmeter, check that there is continuity
OD
0 between terminals B and G.
0 If there is no continuity, replace the relay.
Battery ST0473
Ohmmeter ~-~
Glow Plug
[JC]
0 INSPECT GLOW PLUG
(a) Remove the four grommets from the glow plugs.
0
(b) Remove the five nuts and glow plug connector.
(c) Using an ohmmeter, check that there is continu ity
between the glow plug terminal and ground.
If there is no continuity, replace the glow plug.
ST0464
NOTE:
• Be careful not to damage the glow plug pipes as it
could cause an open circuit or shorten life of the plugs.
• Avoid getting oil and gasoline on the glow plugs when
cleaning.
• During inspection, be sure to wipe any oil off the glow
plug terminals and bakelite washer with a dry cloth.
• Be careful not to apply more than 7 volts to the glow
plug as it could cause an open circuit.
ST0216
STARTING SYSTEM - Pre-heating System ST-5
Continuity [TI Glow Plug Current Sensor

0
INSPECTION GLOW PLUG CURRENT SENSOR
Using an o hmmeter, check t hat there is continuity be-
tween t he current sensor terminals.
If t here is no cont inu ity, replace the current sensor.
Continuity Glow Plug Resistor

[JO INSPECT GLOW PLUG RESISTOR
0
Using an ohmmeter, check that there is continuity be-
tween the resistor terminals.
If there is no continuity, replace the resistor.
I
ST0465
I
Ohmmeter
Water Temperature Sensor
I
INSPECT WATER TEMPERATURE SENSOR
I .n. I Remove the connector and measure the resistance be-
I
0
tween t he water temperature sensor terminals.
0
If each resistance value is not as shown in the graph
below, replace the water temperature sensor.
ST0466
Water temperature Sensor Performance Curbe

30
20
10
''~
a-
..:,,:.
Q)
(.)
C
ro
en
'vi
Q)
5
3
2
"' "'-..
"' "
a:
0
CJ)
1
C
Q)
Cf)
0.5
0.3
~
............
0.2 .....
0.1
~
-20 0 20 40 60 80 100 120
Temperature (°C)
$T0066
t ti-'
l
_,
ST-6 STARTING SYSTEM - Troubleshooting, Starting System Circuit
TROUBLESHOOTING
Problem Possible cause Remedy Page
Engine-will not crank Battery charge low Check battery specific gravity CH -3
Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
Fusible link blown Replace fusible link
Starter faulty Repair starter ST-8
Starter switch faulty Replace starter switch
Engine cranks slowly Battery charge low Check battery specific gravity CH -3
Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
Starter faulty Repair starter ST-8
Starter keeps running Starter faulty Repair starter ST-8
Starter switch faulty Replace starter switch

Short in wiring Repair wiring
Starter spins - engine Pinion gear teeth broken or faulty starter Repair starter ST-8
will not crank Flywheel teeth broken Replace flywheel
STARTING SYSTEM CIRCUIT
Starter Switch
AM2 ST2
AM2 30A
Terminal 30 Terminal 50
T
I Battery
_L
Starter
ST0467
STARTING SYSTEM - Starter ST-7
STARTER
COMPONENTS
[1.4 kW] Clutch Assembly
t
M agnetic Switch Assembly S eel Ball
Retum Spring j
J.,_., - - Idle
Qf'' ~ Gear ;
jPini! Gear
-- ---- Bearing
--- --- Starter Housing
----
• 0-Ring ---
Brush Holder
~r • End Cover
Field Frame
Bearing
Armature
Bearing
[2.0 kW] Steel Ball

Return Spring
Magnetic Switch Assembly
Field Frame
• 0-Ring
Armature
Bearing
• Non-reusable part S10476

ST0477
ST-8 STARTING SYSTEM - Starter
DISASSEMBLY OF STARTER
(See page ST-7)
1. REMOVE FIELD FRAME WITH ARMATURE
FROM MAGNETIC SWITCH ASSEMBLY
(a) Remove the terminal nut.
(b) Disconnect t he lead wire from the magnetic switch

terminal.
STOOOS
(1.4 kw type)
(c) Remove t he two through bolts. Pull out the field
frame with t he armature from the magnetic switch
assembly.
(d) Remove t he O-ring from t he field frame.
ST0269
(2.0 kw type)
(c) Remove the two bolts. Pull out the field frame with
the armature from the magnetic switch assembly.
(d) Remove the O-ring from the field frame.
~"'
ST0468
2. REMOVE STARTER HOUSING FROM MAGNETIC

SWITCH ASSEMBLY
(a) Remove t he two screws.
f
ST0270
(b) Remove the starter housing with the pinion gear,

idler gear, beari ng and clutch assembly.
3. REMOVE CLUTCH ASSEMBLY AND GEARS

FROM STARTER HOUSING
4. REMOVE STEEL BALL AND SPRING

Using a magnetic finger, remove the spring and steel ball
Magnetic Finger from the clutch shaft hole.
ST0009
5. REMOVE BRUSHES AND BRUSH HOLDER

(1.4 kw type)
(a) Remove the two screws and end cover from the
field frame.
(b) Remove the O -ring.
ST0272
(c) Using a screwdriver, hold the spring back and dis-

connect the brush from the brush holder. Discon -
nect the four brushes and remove the brush holder.
(d) Pull the brush holder off the field frame.
\ ST0039
(2.0 kw type)
(a) Using a screwdriver, hold the spring back and dis -
connect the brush from the brush holder. Discon -
nect the four brushes and remove the brush holder.
(b) Pull the brush holder off the field frame.
6. REMOVE ARMATURE FROM FIELD FRAME
ST0089
INSPECTION OF STARTER
Armature Coil
1. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no continuity
between the commutator and armature coil core.
If there is continuity, replace the armature.
2. INSPECT COMMUTATOR FOR OPEN CIRCUIT

Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
If there is no continuity between any segment, replace
the armature.
S10012
Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND
BURNT SURFACES
If the surface is dirty or burnt, correct it with sandpaper
(No.400) or on a lathe.
2. INSPECT COMMUTATOR CIRCLE RUNOUT

(a) Place the commutator on V-blocks.
(b) Using a dial indicator, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on
a lathe.
S10013
3. MEASURE DIAMETER OF COMMUTATOR

Using calipers, measure the commutator diameter.
Standard diameter: 1.4 kw 30 mm (1.18 in .)
2.0 kw 35 mm (1.38 in .)
Minimum diameter: 1.4 kw 29 mm (1.14 in .)
2.0 kw 34 mm (1.34 in.)
If the diameter is less than minimum, replace the arma-
ture.
STARTING SYSTEM - Starter ST -11
4. INSPECT UNDERCUT DEPTH OF SEGMENT

Check that the u ndercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth:
1.4 kw 0 .6 mm (0.024 in .}
2 .0 kw 0 .7 mm (0.028 in .}
M inimum underc ut depth : 0 .2 mm (0 .008 in.}
If the u ndercut dept h is less than mi n imum, correct it
with a hacksaw blade.
ST0040
1.4 kW Field Frame ( Field Coi I)

1. INSPECT FIELD COIL FOR OPEN CIRCUIT
Usi ng an ohmmeter, Gheck that there is continuity be-
tween t he lead wire and field coil brush lead .
If there is no conti nu ity, replace the field frame.
I
ST0015
I
2 .0kW
ST0130
1.4kW 2. 'INSPECT THAT FIELD COIL IS NOT GROUNDED

Usi ng an ohmmeter, check that there is no continu ity
between the field coil end and field frame.
If t here is continuity, repair or replace t he field frame.
No Continuity
ST0016
2.0 kW
ST-12 STARTIN G SYSTEM - Starter
Brushes
INSPECT BRUSH LENGTH
Using calipers, measure the brush length.
Standard length: 1 .4 kw 15.5 mm (0.610 in.)
2 .0 kw 15.0 mm (0 .591 in.)
Minimum lengt h: 1 .4 kw 10.0 mm (0.394 in.)
2 .0 kw 9 .0 mm (0.354 in. )
If t he length is less than minimum, replace the brush
ST0017 STOOl 8 holder and field frame.
Brush Springs
LJ_
INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring
t separates from the brush.
Spring installed load :
1 .4 kw 1 .70 - 2 .40 kg (3.7 - 5.3 lb, 17 - 24 N)
2.0 kw 2.55 - 3 .30 kg (5.6 - 7 .3 lb, 25 - 32 N)
M inimum Spring installed load:
1.4 kw 1 .44 kg (3.2 lb, 14 N )
ST0019
2.0 kw 2.0 kg (4.4 lb, 20 N )
If the installed load is less than minimum, replace the
brush springs.
Brush Holder
INSPECT INSULAT ION OF BRUSH HOLDER
between the positive ( + ) and negative (- ) brush hold-
ers.
If there is continuity, repair or replace the brush holder.
ST0062
Clutch and Gears

1. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and
clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel ring gear for wear or
damage.
2. INSPECT CLUTCH
Rotate the clutch pinion gear clockwise and check that it
turns freely. Try to rotate the clutch pinion gear counter-
clockwise and check that it locks.
If necessary, replace the clutch assembly.
ST0020
Bearings
1. INSPECT BEARINGS
Turn each bearing by hand while applying inward force.
If resistance is felt or if the bearing sticks, replace the
bearing.
ST0041
2. IF NECESSARY, REPLACE BEARINGS

(1.4 kw)
(a) Using SST, remove the front (large) bearing from
the armature shaft.
SST 09286-46011
(b) Using SST, remove the rear (small) bearing from
the opposite side.
SST 09286-46011
(c) Using SST and a press, press in a new front (large)

bearing.
SST 09201 -41 020
(d) Using a press. press in a new rear (small) bearing.
SST
ST0221 ST0043
(2.0 kw)
(a) Using SST, remove the front (large) bearing from
the armature shaft.
SST 09820-00021
(b) Using SST, remove the rear (small) bearing from the
opposite side.
SST 09286-46011
ST0042
(c) Using a press and socket wrench, install a new front

Socket Wrench (large) and rear (small) bearings.
ST0478
_I
(d) Usi ng a punch, stake the shaft.
::},~'fl/
,g:.Jl,'•
'
.(f ,T \.
l~/~
C'1
t' --4"
~
ST0469
Magnetic Switch
1. PERFORM PULL-IN COIL OPEN CIRCUIT TEST
Usi ng an ohmmeter, check that t here is continuity be-
tween terminal 50 and C.
If there is no continuity, replace the magnetic switch
assembly.
Switch Body 2. PERFORM HOLD-IN COIL OPEN CIRCUIT TEST

Using an ohmmeter, check that there is conti nuity be-
tween terminal 50 and the switch body.
If there is no contin uity, replace the magnetic switch
assembly.
ST0205
ASSEMBLY OF STARTER
(See page ST-7)
NOTE: Use high-temperature grease to lubricate the
bearings and gears when assembling the starter.
1. PLACE ARMATURE INTO FIELD FRAME

Apply grease to the armature bearings and insert the
armature into the field frame.
2. INSTALL BRUSH HOLDER AND BRUSHES

(1.4 kw)
(a) Place the brush holder over the field frame.
(b) Using a screwdriver, hold the brush spring back,
and install the brush into the brush holder. Install
the four brushes.
NOTE: Check that the positive ( + ) lead wires are not
grounded.
(b). Place the O- ring on the field frame.

( c) Install the end cover to the field frame with two
screws.
ST0272
(2.0 kw)
(a) Place the brush holder on the armature shaft and
align the tab of the holder with the notch of the field
frame.
ST0096
(b) Using a screwdriver, hold the brush spring back,

and install the brush into the brush holder. Install
the four brushes.
NOTE: Check that the positive ( + ) lead wires are not
grounded.
ST0089
3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE

(a) Apply grease to the steel ball.
(b) Insert the steel ball into the clutch shaft hole.
ST0044
4. INSTALL GEARS AND CLUTCH ASSEMBLY TO

STARTER HOUSING
(a) Apply grease to the gear, clutch assembly and return
spring.
(b) Install the return spring to the magnetic switch as-
sembly.
ST0099
(c) Place the clutch assembly, idler gear, bearing and

1.4 kw
pinion gear in the starter housing.
Clutch Assembly
•
~ ' \&t}
~
Bearing
~
~
Idler
Gear
Pinion G: ar
ST0475
2.0kW
5. INSTALL STARTER HOUSING

(a) Place the starter housing on the magnetic switch.
STARTIN G SYSTEM - Starter ST-17
(b) Install the two screws.
ST0270
6. INSTALL FIELD FRAME WITH ARMATU RE TO

MAGNET IC SWITCH ASSEMB LY
(a) Place the 0 - ring on the field frame.
(1 .4 kw)
(b) Align the protrusion of the field frame with the
cutout of the magnetic switch assembly.
ST0275
(c) Install the two through bolts.
ST0269
(2.0 kw)
(b) Align the bolt anchor of the field frame with the
mark on the magnetic switch assembly and insert
the field frame with the armature.
ST0479
(c) Instal l the two bolts.
/
.
(d) Connect the lead wire to the magnetic switch termi-

q" •• nal Con the magnetic switch assembly with the nut
C
- '
,r· .••'
)
" )
ST0268
PERFORMANCE TEST OF STARTER

CAUTION : These tests must be performed
within 3 to 5 seconds to avoid burning out the
coil.
1. PERFORM PULL- IN TEST

(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as
shown . Check that the clutch pinion gear moves
ST0276
outward.
If the clutch pinion gear does not move, replace the mag -
netic switch assembly.
2. PERFORM HOLD-IN TEST

While connected as above with the clutch pinion gear
out, disconnect the negative (- ) lead from terminal C.
Check that the pinion gear remains out.
If the clutch pinion gear returns inward, replace the mag -
netic switch assembly.
ST0277
3. INSPECT CLUTCH PINION GEAR RETURN

Disconnect the negative (- ) lead from the switch body.
Check t hat the clutch pinion gear returns inward.
If the clutch pinion gear does not return . replace the
magnetic switch assembly.
ST0278
4. PERFORM NO- LOAD PERFORMANCE TEST

(a) Connect the battery and ammeter to the starter as
shown.
(b) Check that t he starter rotates smoothly and steadily
with the pinion gear moving out.
Check that t he ammeter reads the specified current.
Specified current:
1.4 kw 90A or less at 11 .5 V
2.0 kw 120A or less at 11.5 V
.... ,-
CH -1
CHARGING SYSTEM
Page
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-2
TROUBLESHOOTING ..................... ... CH-2
ON -VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . CH-3
ALTERNATOR ............................... CH -7
I
.,..ij·:~•- I
I
I
CH - 2 CHARGING SYSTEM - Precautions, Troubleshooting
PRECAUTIONS
1. Check that the batte ry cables a re co nnected t o
the correct t erminals.
2. Disconnect the battery cables when the battery is

given a quick charge .
3. Do not perform tests with a high volta ge insula-

tion resistanc e t est e r.
4. Never disconnect t he batt ery w hil e the engine is

running .
TROUBLESHOOTING
Problem Possible casue Remedy Page
Discharge warning Fuse blow Check "CHARGE" and

light does not light "ENGI N E" fuses
with ignition ON and Light burned out Replace light
engine off
Wiring connection loose Tighten loose connections
IC regulator faulty Replace IC regulator CH-7
Discharge warning Drive belt loose or worn Adjust or replace drive belt CH -4
light does not go out Battery cables loose, corroded or worn Repair or replace cables
w ith engine running
Fuse blow Check "CHARGE" or
(battery required fre -
"ENGINE" fuse
quent recharging)
Fusible link blown Replace fusible link
IC requlator or alternator fa ulty Check charging system CH - 5
Wiring faulty Repair wiring
CHARGING SYSTEM - Charging Circuit, On-Vehicle Inspection CH -3
CHARGING CIRCUIT
AM1 IG1
h--- -- - -- - ----<
Starter Switch
AM2 IG2
• 1
AM1
(60A)
-§_
<C
AM2 Fuse ENGINE
7.5A
Fusible CHARGE Fuse

Link 100A 7.5A
T Discharge I
Battery I Warning Light
L__
I
l Alternator
• 1: Ex. Cold Area
CH0499
ON-VEHICLE INSPECTION
1. CHECK BATTERY SPECIFIC GRAVITY AND
ELECTROLYTE LEVEL
(a) Check the specific gravity of each cell.
Standa rd specific gravit y
When fully cha rged at 20°C (68°F): 1.25 - 1 .27
Upper Level If not within specifications, charge the battery.
Lower Level _ _ ,._
(b) Check the electrolyte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
2. CHECK BATTERY TERMINALS AND FUSIBLE

LINK
(a) Check that the battery terminals are not loose or
corroded.
(b) Check the fusible link for continuity.
CH0500
CH-4 CHARGING SYSTEM - On-vehicle Inspection
3. DRIVE BELT
COR RECT W ORNG (a) Check that the belt does not touch the bottom of the
Clearance pul ley groove.
MA0035
( b) Check the drive belt deflection of pressi ng on the

belt at the poi nts indicated in the figure with 10 kg
(22.0 lb, 98 N) pressure.
Drive be lt deflection :
Alternator
New belt 6 - 7 mm (0.24 - 0 .28 in.)
Used belt 8 - 11 mm (0.32 - 0 .43 in .)
If necessary, adjust the drive belt deflection.
Crankshaft Pulley
CH0501
[ Ref e rence]
o+-="==--- SST B
Using SST, check the drive belt tension.
SST A 09216 -00020
SST A SST B 09216-00030
Drive belt tension:
New belt 45 - 55 kg
EC0003 EC0004
NOTE:
• " New belt" refers to a belt which has never been used.
• " Used belt" refers t o a belt which has been used on a
running engine for 5 minutes or more.
• After installing the drive belt, check that it fits properly
in the ribbed grooves.
• Check by hand t o confirm that t he belt has not slipped
out of the groove on the bottom of the crank pulley.
• After installing the belt, run the engine for about 5
mi nutes and then recheck the deflection.
4. CHECK FUSES FOR CONTINUITY

CHARGE fuse (7.5 A)
ENG INE fuse (7.5 A)
CHARGING SYSTEM- On-Vehicle Inspection CH-5
5. VISUALLY CHECK ALTERNATOR WIRING AND

LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the alter-
nator while the engine is running .
6. CHECK DISCHARGE WARNING LIGHT CIRCUIT

(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
CH0502
(c) Turn the ignition switch to ON. Check that the dis-
charge warning light is lit.
(d) Start the engine. Check that the light goes out.
If the light does not function as specified, troubleshoot
the warning light circuit.
7. CHECK CHARGING CIRCUIT WITHOUT LOAD

NOTE: If a battery I alternator tester is available, con-
nect the tester to the charging circuit according to the
manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and
ammeter to the charging c ircuit as follows:
-,--
Battery _i_ • Disconnect the wire from terminal B of the alter-
nator and connect it to the negative terminal of
I CH0008
the ammeter.
• Connect the test lead from the positive terminal of
the ammeter to terminal B of the alternator.
• Connect the positive lead of the voltmeter to ter-
minal B of the alternator.
• Connect the negative lead of the voltmeter to
ground.
(b) Check the charging circuit as follows:

Run the engine from idle to 2,000 rpm, and check
the reading on the ammeter and voltmeter.
Standard amperage: Less than 10 A
Standard voltage: 13.5 - 15.1 V (25°C or 77°F)
13.5 - 14.3 V (115°Cor 239°F)
• If the voltage reading is greater than standard
voltage, replace the IC regulator.
CH0412 CH0010
CH -6 CHARGING SYSTEM - On -Vehicle Inspecti on
• If the voltage is less than standard voltage, check

the IC regulator and alternator as follows:
W ith terminal F grounded, start the engi ne and
check the voltage reading of terminal B.
• If the voltage reading is greater than standard,
replace the IC reg u lator.
• If the voltage reading is less than standard, check
the alternator.
8. CHECK CHARGING CI RCUIT WITH LOAD

(a) With the engine running at 2,000 rpm, turn on the
high beam headlights and place the heater fan con -
-~ 10
t rol switch at H I.
0 20 (b) Check the reading on the ammeter.
Standard amperage: M o re than 30 A
V
If t he ammeter reading is less than 30 A, repair the alter-
nator. (See page CH-7)
CH0012
NOTE: If the battery is fully charged, the indication be
less than 30 A.
CHARGING SYSTEM - Alternator CH -7
ALTERNATOR
COMPONENTS
Rotor
Front Bearing
Drive End Frame
Rear Bearing
Bearing Cover
Retainer
(
IC Regulator
Rubber Insulator Brush Holde~ ~...-:::'(,.,..-/ --~

g;,
l
(?) ~
,_ #
Terminal Insulator ~
Pulley
Rear End Frame
-· I ~ ,:;1/ _/J-;:?
' > /
" -,,,.--
~ Cover
Rear End Cover
Rectifier Holder
CH0504
DISASSEMBLY OF ALTERNATOR
1. REMOVE REAR ENO COVER
(a) Remove the nut and terminal insulator.
(b) Remove the three nuts and end cover.
CH0212
2. REMOVE BRUSH HOLDER AND IC REGULATOR

Remove the five screws, brush holder and IC regulator.
CH0083
----
~
CH-8 CHARGING SYSTEM - Alternator
3. REMOVE RECTIFIER HOLDER

Remove the four screws, rectifier holder and rubber, in -
sulators.
CH0 188
4. REMOVE PULLEY
(a) Hold SST A with a torque wrench and tighten SST
B clockwise to t he specified torque.
SST 09820-63010
{b) Confirm that SST A is secured to the pulley shaft.
(c) As shown in the figure, grip SST Cina vise and then
install the alternator to SST C.
(d) To loosen the pulley nut turn SST A in the direction
shown in the figure.
CAUTION: To prevent damage to the rotor
shaft, do not loosen the pulley nut more than one-
half of a turn.
(e) Remove the alternator from SST C.
(f) Turn SST B and remove all SSTs.
(g) Remove the pu lley nut and the pulley.
5. REMOVE REAR END FRAME

(a) Remove the four nuts.
(b) Using SST, remove the rear end frame.
SST 09286 -46011
6. REMOVE ROTOR FROM DRIVE END FRAME

CHARGING SYSTEM - Alternator C H -9
INSPECTION AND REPAIR OF

ALTERNATOR
Rotor
1. INSPECT ROTOR FOR O P EN C IR C U IT
Using an ohmmeter, check for continuity between the
slip rings.
Standard resistance: Less than 30
CH01 90 If t here is no continuity, replace the rotor.
2. INSPECT ROTOR FOR GROUND

between the sli p ring and rotor. If there is continuity,
replace the rotor.
CH0191
3. INSPECT SLIP RINGS

(a) Check that the slip rings are not roJgh or scored. If
rough or scored, replace the rotor.
(b) Using calipers, measure the slip ring diameter. If the
diameter of the slip ring is less than the minimum,
replace the rotor.
Standa rd diameter:
14.2 - 14.4 mm (0.559 - 0. 567 in.)
Minimum diameter:
.___ __ _ _ _ __ __ _ _ _
c H_o ,__,
92 12.8 mm (0.504 in .)
Stator
1. INSPECT STATOR FOR OPEN C IRCUIT
Using and ohmmeter, check all leads for continuity. If
there is no continuity, replace the drive end frame assem -
bly.
CH0 245
2. INSPECT THAT STATOR IS NOT GROUNDED

between the coil leads and drive end frame. If there is
continu ity, replace the drive end frame assembly.
\
CH0246
CH -10 CHARGIN G SYSTEM - Alternator
Brush and Brush Holder

1. MEASUR E EXPOSED BRUSH LENGTH
I
Using a scale, measure the exposed brush length.
Standard exposed length : 10.5 mm (1 .413 in.)
Minimum exposed length: 1 .5 mm (0.059 in.)
If the exposed length is less than minimum, replace the
brush.
CH0247
-s:- ...... _ 2. IF NECESSA RY REPLACE BRUSHES

(a) Unsolder and remove the brush and the spring .
(b) Run the wire of the brush through the hole in the
~
--7 brush holder, and insert the spring and brush into
the brush holder.
\()
CH0248
(c) Solder the brush wire to the brush holder at the

exposed length.
Standard exposed length: 10.5 mm (0.413 in.}
(d) Check that the brush moves smoothly in the brush
holder.
( e) Cut off the excess wire.
(f) Apply insulation pai nt to the soldered point.
CH0414
Ohmmeter Rectifie r
()
1. INSPECT POSITIVE SIDE RECTIFIE R
(a) Using an ohmmeter, connect one tester probe to the
positive stud and the other to each rectifier terminal.
Positive Stud1-----1r
Rectifier Term inal """"::------,~:J l'i
CH0465
(b) Reverse the polarity of the tester probes and repeat

Ohmmeter
step (a).
()
( c) Check that one shows con ti nu ity and the other
0 1o1e
shows no continuity.
If not, replace the rectifier holder.
Position Stud _ ___,,
Rectifier Terminal ~-~~,
CH0466
CHARGING SYSTEM - A lternator CH -11
Ohmmeter 2. INSPECT NEGATIVE SIDE RECTIFIER

J1
Negative Termina l (a) Connect one tester probe to each rectifier terminal
and the other to each rectifier negative terminal.
Rectifier
Terminal CH0467
Ohmmeter ( b) Reverse the polarity of the tester probes.

(c) Check that one shows continuity and the other
shows no continuity.
If not, replace the rectifier holder.
Rectifier
Terminal
CH0468
Bearings
1. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
/
I
CH0227
2. IF NECESSARY, REPLAC E FRONT BEARIN G

(a) Remove the four screws and bearing retainer.
CH0228
(b) Using a press and socket wrench, press out the front
bearing.
Socket Wrench
CH0390
CH -12 CHARGING SYSTEM - Alternator
(c) Using SST and a press, press the front bearing into
the drive end frame.
SST 09608-2001 2 (09608-00030)
(d) Install the bearing retainer with the four screws.
3. INSPECT REAR BEARING

Check that the bearing is not rough or w orn.
CH0199
4. IF NECESSARY, REPLACE REAR BEARING

(a) Using SST, remove the rear bearing and covers.
SST 09820-00021
CAUTION : Be ca reful not t o d amage the fan .
CH0200
(b) Using SST and a press, install a new rear bearing.

SST 09820-00030
(c) Install the bearing cover.
CH0296
CHARGING SYSTEM - Alternator CH-13
ASSEMBLY OF ALTERNATOR
(See page CH -7)
1. INSTALL ROTOR TO DRIVE END FRAME
2. INSTALL REAR END FRAME

(a) Using a plastic hammer, lightly tap the rear end
frame on the drive end frame.
(b) Install the four nuts.
CH0218
3. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the
pulley nut by hand.
(b) Hold SST A with a torque wrench and tighten SST
B clockwise to the specified torque.
SST 09820-6301 0
Torque: 400 kg-cm (29 ft - lb, 39 N -m)
C,
.I
(c) Check that SST A is secured to the pulley shaft.

(d) As shown in the figure, mount SST C in a vise and
then install the alternator to SST C.
(e) To torque the pulley, nut turn SST A in the direction
shown in the figure.
Torque: 1,125 kg-cm (81 ft-lb, 110 N -m)
(f) Remove the alternator from SST C.
(g) Turn SST B and remove SSTs A and B.
4. INSTALL RECTIFIER HOLDER

(a) Install the four rubber insulators on the lead wires.
CH -14 CHARGING SYSTEM - Alternator
(b) Install the rectifier wit h four screws.
CH0188
5. INSTALL BRUSH HOLDER AND IC REGULATOR

I ./ (a) Place the brush holder cover to the brush holder.
(b) Install the IC regulator and brush holder to the rear
end frame horizontally as shown in the figure.
NOTE: Make sure the brush holder's cover doesn't slip
to one side during installation.
CH0334
(c) Install and tighten the five screws.

NOT E: Make sure the gap between the brush holder
connector is at lease 1 mm (0.04 in.).
6. INSTALL REAR END COVER

(a) Install the end cover with the three nuts.
(b) Install the terminal insulator with the nut.
CH0212
7. MAKE SURE ROTOR ROTATES SMOOTHLY
CH0341
A-1
SERVICE SPECIFICATIONS
Pa g e
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . A -2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A -7
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . A -10
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . A-11
STARTING SYSTEM . . .. . . .. .. . .. . .. . .. .. . .. . A -11
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . A -11
r
A-2 SERVICE SPECIFICATIONS - Engine Mechanical
ENGINE MECHANICAL
Specifications
Engine _tune-up Engine coolant capacity 5.7 liters 6.0 US qts. 5.0 Imp. qts
Engine oil capacity
Dry fill 4.2 liters 4.4 US qts. 3.7 Imp. qts
Drain and refill
w / o Oil filter change 3. 1 liters 3.3 US qts. 2.7 Imp. qts
w/ Oil filter change 3.8 liters 4.0 US qts. 3.3 Imp. qts
Battery specific gravity 1.25 - 1.27 when fully charged at 20°C (68°F)
Drive belt deflection with
10kg(22.1 lb, 98N)
New belt 6 - 7 mm 0.24 - 0.28 in.
Used belt 8 - 11 mm 0.32 - 0.43 in.
Drive belt tension New belt 45 - 55 kg
Injection timing 0° BTDC
At 0.77 - 0.83 mm
(0.0303 - 0.0327 in.)
Injection order 1 - 3-4-2
Valve clearance Intake 0.22 - 0.28 mm 0.009 - 0.011 in.
Exhaust 0.27 - 0.33 mm 0.011 - 0.01 3 in.
Idle speed 700 rpm
Maximum speed 5,800 rpm
Injection nozzle opening pressure 1 35 - 1 55 kg/ cm 2

(1 ,920 - 2,205 psi, 13,239 - 15,200 kPa)
Compression STD 30.0 kg- cm 2 427 psi 2,942 kPa

pressure
Limit 25.0 kg-cm 2 356 psi 2,452 kPa
Differential of pressure between 2
Less than 5.0 kg -cm (71 psi, 490 kPa)
each cylinder
SERVICE SPECIFICATIONS - Engine Mechanical A-3
Specifications (Cont'd)
Cylinder head Head surface warpage Limit 0.1 mm 0.004 in.
Manifold surface warpage Limit 0.2 mm 0.008 in.
Valve seat Refacing angle 30°, 45°, 75°
Contacting angle 45•
Contacting width Intake 1.2 - 1.6 mm 0.047 - 0.063 in.
Exhaust 1.6 - 2.0 mm 0.063 - 0.079 in.
Valve guide Inner diameter 6.01 - 6.03 mm 0.2366 - 0.2374 in.

bushing Outer diameter STD 11 .033 - 11 .044 mm 0.4344 - 0.4348 in.
0 IS type 0.05 11.083 - 11.094 mm 0.4363 - 0.4368 in.
Replacing temperature (cylinder head side) 9o•c 194°F
Valve Valve overall length STD 91.28 mm 3.5937 in .

Limit 90.78 mm 3.5740 in.
Valve face angle 44.5°
Stem diameter Intake 5.970 - 5.985 mm 0.2350 - 0.2356 in .
Exhaust 5.965 - 5.980 mm 0.2348 - 0.2354 in.
Stem oil clearance STD Intake 0.025 - 0.060 mm 0.0010 - 0.0024 in.
Exhaust 0.030 - 0.065 mm 0.0012 - 0.0026 in.
Limit Intake 0.08 mm 0.0031 in.
Exhaust 0.10 mm 0.0039 in.
Valve head edge thickness Limit Intake 0.08 mm 0.0031 in.
Valve spring Free length 41.52 mm 1.6346 in.

Installed length 34.16 mm 1.3449 in.
Installed tension STD 18.41 kg 40.6 lb 181 N
Limit 17.49 kg 38.6 lb 172 N
Squareness Limit 2.0 mm 0.079 in.
Camshaft Thrust clearance STD 0.08 - 0.18 mm 0.0031 - 0.0071 in.

Limit 0.25 mm 0.0098 in.
Journal oil clearance STD 0.037 - 0.073 mm 0.0015 - 0.0029 in.
Limit 0.1 mm 0.004 in.
Journal diameter 26.979 - 26.995 mm 1.0622 - 1.0628 in.
Circle runout Limit 0.02 mm 0.0008 in.
Cam lobe hight STD Intake 43.84 - 43.94 mm 1.7260 - 1.7299 in.
Exhaust 43.88 - 43.95 mm 1.7276 - 1.7303 in.
Limit Intake 43.54 mm 1.7142 in.
Valve lifter Out diameter STD 33.966 - 33.976 mm 1.3372 - 1.3376 in.
Valve lifter oil clearance STD 0.024 - 0.050 mm 0.0009 - 0.0020 in.
Limit 0. 10 mm 0.0039 in.
A -4 SERVICE SPECIFICAT IONS - Engine Mechanical
S pecifications (Cont'd)
Intake and Man ifold surface Limit 0.2 mm 0.008 in.

exhaust
manifold
Combusion Protrusion Minus 0.03 - Plus 0.03 mm

chamber (Minus 0.0012 - Plus 0.0012 in.)
Flange thickness 1 4.95 - 4.98 mm 0.1949 - 0.1961 in.
2 4.99 - 5.01 mm 0.1965 - 0.1972 in .
3 5.02 - 5.04 mm 0.1976 - 0.1984 in.
Idler pulley Free length 45.55 mm 1.7933 in.

tension spring Installed tension at 52.7 mm (2.07 in.)
STD 8.1 kg 17.9 lb 79 N
Limit 5.4 kg 11.9 lb 53 N
Cylinder block Warpage Limit 0.1 mm 0.004 in.

Cylinder bore STD 74.00 - 74.03 mm 2.9134 - 2.9146 in.
Cylinder bore wear
On standard sized piston Limit 74.23 mm 2.9224 in.
On oversized piston (0 / S 0.50) Limit 74.73 mm 2.9421 in.
Taper and out-of-round Limit 0.02 mm 0.0008 in .
Cylinder block main journal bore
STD 1 54.036 - 54.044 mm 2.1274 - 2.1277 in.
2 54.045 - 54.052 mm 2.1278 - 2.1280 in.
3 54.053 - 54.060 mm 2.1281 - 2.1 283 in.
UIS 0.25, 0.50 54.036 - 54.060 mm 2.1274 - 2.1283 in.
Piston and Piston diameter STD 73.955 - 73.985 mm 2.9116 - 2.91 28 in.
piston ring 0/S 0.50 74.455 - 74.458 mm 2.9313 - 2.9314 in.
Piston to clearance STD 0.035 - 0.055 mm 0.0014 - 0.0022 in.
Limit 0.10 mm 0.003 in.
Piston ring end gap STD No. 1 0.23 - 0.36 mm 0.0091 - 0.0142 in.
No. 2 0.40 - 0.55 mm 0.0157 - 0.0217 in.
Oil 0.10 - 0.60 mm 0.0039 - 0.0236 in.
Limit No. 1 0.96 mm 0.0378 in.
No. 2 1.05 mm 0.0413 in.
Oil 1.20 mm 0.0472 in.
Ring to ring groove clearance STD 0.04 - 0.08 mm 0.0016 - 0.0031 in.
(New piston ring)
Piston pin installing temperatu re 80°c 176°F
Connecting Thrust clearance STD 0.08 - 0.30 mm 0.0031 - 0.0118 in.

rod and Limit 0.4 mm 0.016 in.
bearing · Big end inner diameter STD 1 47.015 - 47.022 mm 1.8510 - 1.8513 in.
2 47.023 - 47.030 mm 1.8513 - 1.8516 in.
3 47.031 - 47.038 mm 1.8516 - 1.8519 in.
)
•
SERVICE SPECIFICATIONS - Engine Mechanical A-5
Specifications (Cont'd)
/
Connecting Connecting rod bearing STD 1 1.488 - 1.492 mm 0 .0586 - 0.0~! 7 in.
rod and center wall thickness 2 1.491 - 1.496 mm 0.0587 - 0.0589 in.
bearing 3 1 .496 - 1.500 mm 0.0589 - 0.0591 in.
(Cont'd)
Bearing oi l clearance STD 0.030 - 0.058 mm 0.001 2 - 0.0023 in.
Limit 0.08 mm 0.0023 in.
Pin to bushing oil clearance STD 0.007 - 0.015 mm 0.0003 - 0.0006 in.
Limit 0.05 mm 0.0020 in.
Piston pin diameter 23.500 - 23.512 mm 0.9252 - 0.9257 in .
Bushing inside diameter 23.511 - 23.523 mm 0.9256 - 0.9261 in .
Rod bend per 100 mm (3.94 in.) Limit 0.05 mm 0.0020 in.
Rod twist per 100 mm (3.94 in. ) Limit 0.15 mm 0.0059 in.
Crankshaft Thrust clearance STD 0.02 - 0.22 mm 0.0008 - 0.0087 in.

Lim it 0.3 mm 0.012 in.
Thrust washer thickness STD 2.430 - 2.480 mm 0.0957 - 0 .0976 in.
0/S 0.125 2.493 - 2.543 mm 0.0981 - 0. 1001 in.
0/S 0.250 2.555 - 2.605 mm 0.1006 - 0.1026 in.
Main journal oil clearance STD 0.020 - 0.051 mm 0.0008 - 0.0020 in.
Lim it 0.08 mm 0.0031 in.
Main journal diameter STD 49.985 - 50.000 mm 1.9679 - 1.9685 in.
Main journal finished diameter
U/S 0.25 49.745 - 49.755 mm 1.9585 - 1.9589 in.
Main bearing center wall STD 1 2.005 - 2.008 mm 0.0789 - 0.0791 in .
thickness 2 2.009 - 2.01 2 mm 0.0791 - 0.0792 in.
3 2.01 3 - 2.01 6 mm 0.0793 - 0.0794 in.
UIS 0.25 2.125 - 2.131 mm 0.0837 - 0 .0839 in .
0.50 2.250 - 2.256 mm 0.0886 - 0.0888 in.
Crank pin diameter STD 43.988 - 44.000 mm 1.7318 - 1.7323 in.
Circle runout Limit 0.06 mm 0.0024 in.
Main journal taper and
out-of round Limit 0.02 mm 0.0008 in.
Crank pin journal taper and
out-of round Limit 0.02 mm 0.0008 in.
Flywheel Runout Lim it 0.1 mm 0.004 in.

A -6 SERVICE SPECI FICATIONS - Engine M echanical
Torque Specifications
Part tightened kg -cm ft - lb N-m
Cylinder head x Camshaft bearing cap 140 10 14

Cylinder head x Water inlet housing 195 14 19
Cylinder head x Water outlet 195 14 19
Cylinder head x No. 1 Engine hanger 195 14 19
Cylinder head x No. 2 Engine hanger 380 27 37
Cylinder head x Cylinder head cover 80 69 in.-lb 7.8
Cylinder head x Intake manifold 195 14 19
Cylinder head x Exhaust manifold 400 29 39
Cylinder head x Water pump 195 14 19
Cylinder head x Glow plug 130 9 13
Cylinder head x Injection holder 650 47 64
Cylinder head x Cylinder block 1st 690 50 68
2nd so·
3rd so·
Cylinder block x Crankshaft bearing cap 600 43 59
Cylinder block x Oil nozzle 80 69 in. - lb 7.8
Cyl inder block x Oil strainer Bolt 120 9 12
Nut 80 69 in. - lb 7.8
Cylinder b lock x Oil pump 195 14 19
Cylinder b lock x Rear oil seal retainer 80 69 in. -lb 7.8
Cylinder b lock x Rear end plate 50 43 in. - lb 4.9
Cylinder b lock -x Injection pump stay 195 14 19
Cylinder block x Water inlet pipe 185 13 18
Cylinder block x Oil pan 80 69 in. -lb 7.8
Cylinder block x Oil cooler Relief valve 1,700 123 167
Cylinder block x Alternator bracket 400 29 39
Cylinder block x RH Engine mounting bracket 440 32 43
Crankshaft x Flywheel 900 65 88
Crankshaft x Crankshaft pulley 1,200 87 118
Camshaft x Camshaft timing pulley 900 65 88
Injection pump x Injection pump drive pulley 650 47 64
Injection pump x Water pump 195 14 19
Injection pump x Injection pump stay 195 14 19
Injection pump x No. 4 Nozzle leakage pipe 225 16 22
Injection nozzle holder x No. 1 Nozzle leakage pipe 300 22 29
Connecting rod x Connecting rod cap 1st 250 18 25
2nd 90°
Alternator belt adjusting bar x RH Engine mounting bracket 195 14 19
Alternator belt adjusting bar x Alternator 195 14 19
Alternator x Alternator bracket 400 29 39
Accelerator wire bracket x Water pump 80 69 in.-l b 7.8
Oil pan drain plug x Oil pan 250 18 25
SERVICE SPECIFICATIONS - Fuel System A-7
FUEL SYSTEM
I
Injection Nozzle type Ex. Austria ND - DNOPD31 \
nozzle (Stamped on nozzle assembly) Austria ND - DN1OPD41
Nozzle opening pressure Reused nozzle 1 35 - 1 55 kg/ cm 2

(1 ,920 - 2,205 psi, 13,239 - 15,200 kPa)
New nozzle 145 - 1 55 kg / cm 2
(2,062 - 2,205 psi, 14,220 - 15,200 kPa)
Adjusting shim thickness 0.900 mm 0.0354 in.
0.925 mm 0.0364 in.
0.950 mm 0.0374 in.
0.975 mm 0.0384 in.
1.000 mm 0.0394 in.
1.025 mm 0.0404 in.
1.050 mm 0.0413 in.
1.075 mm 0.0423 in.
1.100 mm 0.0433 in.
1.125 mm 0.0443 in.
1.150mm 0.0453 in.
1.175 mm 0.0463 in.
1.200 mm 0.0472 in.
1.225 mm 0.0482 in.
1.250 mm 0.0492 in.
1.275 mm 0.0502 in.
1.300 mm 0.0512 in.
1.325 mm 0.0522 in.
1.350 mm 0.0531 in.
1.375 mm 0.0541 in.
1.400 mm 0.0551 in .
1.425 mm 0.0561 in .
1.450 mm 0.0571 in.
1.475 mm 0.0581 in.
1.500 mm 0.0591 in.
1.525 mm 0.0600 in.
1.550 mm 0.0610 in.
1.575 mm 0.0620 in.
1.600 mm 0.0630 in.
1.625 mm 0.0640 in.
1.650 mm 0.0650 in.
1.675 mm 0.0659 in.
1.700 mm 0.0669 in.
1.725 mm 0.0679 in.
1.750 mm 0.0689 in.
1.775 mm 0.0699 in.
1.800 mm 0.0709 in .
1.825 mm 0.0719 in.
1.850 mm 0.0728 in.
1.875 mm 0.0738 in.
1.900 mm 0.0748 in.
1.925 mm 0.0758 in.
1.950 mm 0.0768 in.
A -8 SERVIC E SPECIF ICATION S - Fuel System
FUEL SYSTE M (Cont' d)

Injection Direction of rotation Clockwise as seen from drive side
pump Injection order 1 - 3 - 4 - 2 (A - B - C - D)
Adjusting lever moving angle 42 - 52°
Roller height variation 0.02 mm 0.0008 in.
Plunger spring
STD 30.0 mm 1.181 in.
Free length
Limit 29.5 mm 1.161 in .
Squareness
Delivery valve spring
Free length STD 24.4 mm 0.961 in.
Limit 23.5 mm 0.925 in.
Governor shaft protrusion 2.0 - 2.5 mm 0.079 - 0.098 in.
0.15 - 0.35 mm 0.0059 - 0.0138 in.
Flyweight holder thrust clearance
Plunger spring shim thickness 0.5 mm 0.020 in.
0.8 mm 0.031 in.
1.0 mrr 0.039 in.
1.2 mm 0.047 in.
1.5 mm 0.057 in.
1.8 mm 0.071 in.
2.0 mm 0.079 in.
1.9 mm 0.075 in.
Plunger adjusting shim thickness
2.0 mm 0.079 in.
2.1 mm 0.083 in.
2.2 mm 0.087 in.
2.3 mm 0.091 in.
2.4 mm 0.094 in.
2.5 mm 0.098 in.
2.6 mm 0.102in.
2.7 mm 0.106 in.
2.8 mm 0.110 in.
2.9 mm 0.114 in.
1.05 mm 0.04 13 in.
Governor gear adjusting washer thickness
1.25 mm 0.0492 in.
1.45 mm 0.0571 in.
1.65 mm 0.0650 in .
1.85 mm 0.0728 in.
3.0 mm 0.118 in.
Governor sleeve plug head thickness
3.1 mm 0.122in.
3.2 mm 0.126 in.
3.3 mm 0.130 in.
3.4 mm 0. 134 in.
3.5 mm 0.138 in.
3.6 mm 0.142 in.
(VJ.7 mm
3.8 mm
0.146 in.
0.150 in.
3.9 mm 0.154 in.
4.0 mm 0.157 in.
4.1 mm 0.161 in.
4.2 mm 0.165 in.
SERVIC E SPECIF ICATIO NS - Fuel System
A -9
Inject ion Pump Adjus tment and Test

Preparations Test noz.zle type DN12S D12
of pump Test nozzle opening pressure 145 - 1 55 kg/ cm 2
tester
(2,062 - 2,205 psi, 14,220 - 15,200 kPa)
Injection pipe Outer diameter 6.0 mm 0.236 in.
Inner diameter 2.0 mm 0.079 in.
Length 840 mm 33.07 in.
Minimum bending radius More than 25 mm (0.98 in.)
Fuel temperature 40 - 45•c 104 - 113°F
Fuel feeding pressure 0.2 kg /cm 2 2.8 psi 20 kPa
Fuel cut solenoid voltage 12 V
Pre-setti ng No. of
Pump revolutio n Injection volume
measuring
Full load injection volume (rpm) cc (cu in.)
stroke
1,300 ) 200 6.2 - 6.6 (0.38 - 0.40)
Pump revolutio n No. of

measuring Injection volume
Maximum speed (rpm) cc (cu in.)
stroke
2,900 200 1.6 - 2.8 (0.10 - 0.17)
Pump revolutio n
Inner pressure kg /cm 2 (psi, kPa)
(rpm)
Pump inner pressure
500 2.4 - 3.0 ( 34 - 43, 235 - 294)
2,900 7.6 - 8.2 (108 - 117, 745 - 804)
Pump revolutio n
Overflow volume cc/min. (cu in./min. )
Overflow volume (rpm)
2,900 392 - 845 (23.9 - 51.6)

Automat ic Pump revolutio n (rpm) Piston strokes
timer
700 0.20 - 1.20 mm 0.0079 - 0.0472 in.
1,300 2.37 - 3.37 mm 0.0931 - 0.1327 in.
2,300 6.06 - 7.06 mm 0.2386 - 0.2780 in.
2,900 7.70 - 8.70 mm 0.3031 - 0.3425 in.
Full load No. of
injection Adjustin g Pump revolutio n Injection volume
lever angle measuring Remarks
volume (rpm) cc (cu in.)
strokes
1,300 6.2 - 6.6 (0.38 - 0.40) Adjust
Plus 42 - 52° 500 200 5.1 - 5.8 (0.31 - 0.35)
-
2,600 6.1 - 6.9 (0.37 - 0.42)
Maximum No. of
speed Adjustin g Pump revolution Injection volume
lever angle measuring Remarks
(rpm) cc (cu in.)
strokes
2,900 1.6 - 2.8 (0.10 - 0.17) Adjust
Plus 42 - 52° 2,800 200 4.2 - 5.8 (0.26 - 0.35)
-
3,100 Less than 1.5 (0.09)
A -10 SERVICE SPECIFICATIONS - Fuel System, Cooling System
Injection Pump Adjustment and Test (Cont'd)

Injection Adjusting Pump No. of Varation
Injection volume
volume lever revolution measuring limit Remarks
cc (cu in.)
angle (rpm) strokes cc (cu in.)
Basic fu ll load
1,300 6.2 - 6.6 (0.38 - 0.40) 0.4 (0.02)
injection volume
Plus Volume during

100 6.6 - 11.4 (0.40 - 0.70) 1.2 (0.07)
42 - 52° 200 starting
500 5.1 - 5.8 (0.31 - 0.35) -

0.5 (0.03)
2,600 6.1 - 6.9 (0.37 - 0.42) -
Idle No. of
Pump revolution Injection volume
speed measuring Remarks
Pre-setting id le (rpm) cc (cu in.)
strokes
speed by idle
adjusting screw 500 1,000 q = 0.5 - 1.5 (0.03 - 0.09) Adjust
350 q plus 5 - 9 (0.31 - 0.55) -

No. of
Pre- setting idle Pump revolution Injection volume
measuring
speed by dash pot (rpm) cc (cu in.)
strokes
adjusting screw
500 1,000 q plus 0.7 - 1.2 (0.04 - 0.07)
No. of
Pump revolution Injection volume
Adjust lever angle measuring
(rpm) cc (cu in.)
strokes
Plus 42 - 52° 350 1,000 8.75 - 12.25 (0.53 - 0.75)
COOLING SYSTEM
Rad iator Relief valve open ing pressure STD 0.75 - 1.05 kg -cm
(10.7 - 14.9 psi, 74 - 103 kPa)
59 kPa
Limit ( 0.6 kg -cm 8.5 psi
Thermostat Va lve opening temperatu re

Starts to open at 80 - 84°c 176 - 183°F
Fully opens at 95•c 203°F
Valve opening travel More than 8 mm (0.31 in.)
SERVICE SPECIFICATIONS - Lubrication System, Starting System, Charging System A -11
LUBRICATION SYSTEM
Oi l pressure Oil pressure at idle More than 0.5 kg-cm 2 (7.1 psi, 49 kPa)
at 3,000 rpm 2.5 - 6.0 kg -cm 2
(36 - 85 psi, 245 - 588 kPa)
Oil pump Body clearance STD 0.1 0 - 0.17 mm 0.0039 - 0.0067 in.
Limit 0.20 mm 0.0079 in.
Tip clearance STD 0.05 - 0.15 mm 0.0020 - 0.0059 in.
Limit 0.20 mm 0.0079 in.
Rotor protrusion (reference) STD 5.00 - 5.08 mm 0.1969 - 0.2000 in.
STARTING SYSTEM
Pre- heating Type Super glow
system Light lighting time at 2o·c (68°F) Approx. 2 - 4 seconds
Starter Rated voltage and output power 12 V 1.4 kw 12 V 2.0 kw

No- load characteristic Ampere 90 A or less at 11.5 V 120 A or less at 11 .5 V
rpm _) 00 rpm or more 4,000 rpm or more
Commutator -
Outer diameter STD 30 mm 1.1 8 in. 35 mm 1.38 in.
Limit 29 mm 1.14 in. 34 mm 1.34 in.
Undercut depth STD 0.6 mm 0.024 in. 0.7 mm 0.028 in .
Limit 0.2 mm 0.008 in. +-
Circle runout Limit 0.05 mm 0.0020 in. +-
Brush length STD 15.5 mm 0.610 in. 15.0 mm 0.591 in.
Limit 10.0 mm 0.394 in. 9.0 mm 0.354 in.
Spring installed load STD 1.70 - 2.40 kg 2.55 - 3.30 kg
(3.7 - 5.3 lb, 17 - 24) (5.6 - 7.3 lb, 25 - 32)
Limit 1.44 kg 3.2 lb 14 N 2.0 kg 44 lb 20 N
CHARGING SYSTEM
Battery specific gravity When fully charged at 20°C (68°F) 1.25 - 1.27
Drive belt deflection New belt 6 - 7 mm 0.24 - 0.28 in.

Used belt 8 - 11 mm 0.31 - 0.43 in.
Drive belt tension New belt 45 - 55 kg
Alternator Rated output 12 V 55 A

Rotor coil resistance Less than 3 Q
Slip ring diameter STD 14.2 - 14.4 mm 0.559 - 0.567 in.
Limit 12.8 mm 0.504 in.
Brush exposed length STD 10.0 mm 0.413 in.
Alternator Regulating voltage 13.5 - 15.1 V

regulator
B -1
STANDARD BOLT
TORQUE SPECIFICATIONS
Page
STANDARD BOLT TORQUE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . B -2
J IDI
B-2 STANDARD BOLT TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS

HOW TO DETERMINE BOLT STRENGTH
M ark Class Mark Class
Hexagon 4- 4T Stud bolt

head bolt ~ Bolt No.
head 5- 5T No mark
,,,..... /
6- 6T
7- 7T
I 4T
0 No mark 4T
I
Hexagon
0
flange bolt / Grooved
w/washer No mark 4T 'C
~
hexagon bolt g
~ 6T
Hexagon
head bolt
0
Two
protruding 5T
lines
Hexagon Welded bolt
0
flange bolt Two
w/washer protruding 6T
hexagon bolt lines
~
4T
Hexagon
head bolt Three
0 protruding
lines
7T
STANDARD BOLT TORQUE SPECIFICATIONS B-3
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
Diameter Pitch
Class mm mm Hexagon head bolt Hexagon flange bolt
kg -cm ft-lb N-m kg -cm ft-lb N •m
6 1 55 48 in.- lb 5.4 60 52 in. -lb 5.9
8 1.25 130 9 13 145 10 14
10 1.25 260 19 25 290 21 28

4T
12 1.25 480 35 47 540 39 53
14 1.5 760 55 75 850 61 83

16 1.5 1,150 83 113 -
6 1 65 56 in. -lb 6.4 -
8 1.25 160 12 16 -
10 1.25 330 24 32 -
5T
12 1.25 600 43 59 -
14 1.5 930 67 91 -
16 1.5 1,400 101 137 -
6 1 80 69 in. -lb 7.8 90 78 in.-lb 8.8
8 1.25 195 14 19 215 16 21
6T 10 1.25 400 29 39 440 32 43
12 1.25 730 53 72 810 59 79
14 1.5 - 1,250 90 123
6 1 110 8 11 120 9 12
8 1.25 260 19 25 290 21 28
10 1.25 530 38 52 590 43 58

7T
12 1.25 970 70 95 1,050 76 103
14 1.5 1,500 108 147 1,700 123 167
16 1.5 2,300 166 226 -

C -1
SST AND SSM

Page
SST (SPECIAL SERVICE TOOLS) C-2
SSM (SPECIAL SERVICE MATERIALS) . . . . . . . . C-5
)
C-2 SST AND SSM- SST (Special Service Tools)
SST (SPECIAL SERVICE TOOLS)

NOTE: Classification
A = SST required for vehicle inspections and minor repairs
and multipurpose SST.
B = SST required for major repairs involving disassembly of
components.
C SST required for rather special, less frequent work not of
classifiable as either A or B.
Section
Classification
\
Part Name EM FU co LU ST CH Note
Part No.
Illustration \ \
~ 09032-00100 ( Oil Pan Seal )
Cutter
A
• Starter armature
~ 09201 -41020 ( Valve Stem Oil )

Seal Replacer
B
• bearing for
1.4 kw only
~ ;<L'.rl 09201 -70010

( Valve Guide
Bushing Remover
& Replacer
)
B
•
~ 09202-70010 ( Valve Spring)
Compressor
A
•
~ 09213-31021 ( Crankshaft )
Pulley Puller
A
•
~ ~ - c . ! k";r"'"""
'~<)•C•.:--~- ::::
() _,; ;., .. - , -=- ,_ ,_
~-- , ... I> - - -
o:=-
I)-~
o,=..- 09213-60017 ( Crankshaft Pulley )
& Gear Puller Set
A
•
~ 09213-70010 ( Crankshaft Pulley )
Holding Tool
A
•
~~ 09216-00020 ( Belt Tension )
Gauge
A
• •
~
✓
09216-00030 ( Belt Tension )
Cable
A
• •
~ •
( Connecting Rod )
09222-66010 Bushing Remover B
& Replacer
er 09223-41020 ( Crankshaft Rear )

Oil Seal Replacer
B
•
'
SST AND SSM- SST (Special Service Tools) C-3
SST (SPECIAL SERVICE TOOLS) (Cont'd)

Section
Classification
co
\
Pa rt Nam e EM FU LU ST CH N ot e
Pa rt N o.
Illustration \ \
~ 09223-46011 ( Crankshaft Front )
Oil Seal Replacer
B
•
liID 09228-10000 (Oil Filter Wrench) A
•
~ 09228-64010 (Fuel Filter Wrench) A
•
c:J ,
09229-55010 ( Oil Cooler Rel ief )
Valve Wrench B
•
~
~/
<J
~
">00 ~
Oo
09230-00010 ( Radiator Service)
Tool Set
B
•
ce,
~,c::,,,,,.,.
0 c§:;,c::?
v 09236-00101 ( Water Pump ) B
Overhaul Tool Set
CO' ei "'
-- -- --- --- - - - -- - - --- -- --------- ---- ---- - -------- - -
a:..
~ (09237-00070) ( Shaft "C")
• Governor sleeve
plug
l
"'~
. ~-
1Jt 09241 -76022 ( Injection Pump )
Stand Set
C
•
~ •
09245-54010 ( Injection Pump) C
Stand Arm
~-3 09248-55010 ( Valve Clearance)

Adjusting Tool
A
•
~~ 09260-54012 ( Injection Pump) C
a o o (D) uO Tool Set
--------- - -- - - ------ --------- -- -- - ---- -- -- ------ - -
ID) (09262-54010) ( Distributor Head)

Plug Wrench
•
~ (09262-54020) ( Regulator Valve )
Wrench
•
0) (09269-54020) (Socket 14 mm)
•
...
C- 4 SST AND SSM- SST (Special Service Tools)

Section
Classification
~
Part Name EM FU co LU ST CH Note
Part No.
Illustration \ \
~ (09269-54030) (Tweezers)
•
0 (09269-54040) ( Governor Lever
Support Bolt Wrench
)
•
0 V 09268-64010 ( Injection Nozzle )
Wrench Set
A
••
~ 09275-54010 ( Plunger Stroke )
Measuring Tool
A
•
~ ;;,i 09278-54012 ( Drive Shaft )
Holding Tool
A
• 1
Starter Armature
~
*1 *2 •
09286-46011 ( Inj ection Pump

Spline Shaft Puller
) C
•• 2
bearing
• Starter rear end
frame
~ 09330-00021 ( Companion Flange )

Holding Tool
A
•
~~~@0
( Front Hub & )
@Qe,_g 09608-20012 Drive Pinion Bearing B
Tool Set
- ---- - - ---- - ----- - -- ----------- ----------- ------ --
@ (09608-00030) ( Replacer)
• Drive
bearing
end frame
(
0 09816-30010 ( Oil Pressure )
Switch Socket B
•
*1
••
1
~
• Starter armature
( Alternator Rear )
09820-00021
Bearing Puller
B bearing for
2.0 kw only
oc=J 09820-00030 ( A lternator Rear )

Bearing Puller
B
•
0~ 09820-63010
( Alternator Pulley )
Set Nut Wrench
Set
B
•
~~~Q
~
- -~
~~o
.-,.~
Q ....
09950-20017 (Universal Puller) A
•
SST AND SSM - SST (Special Service Tools), SSM (Special Service Materials) C-5

Section
Classification
~
Part N ame EM FU co LU ST CH Note
Part No .
Illust ration \ \
~ l ' l . , ,<,, ..,c,
~
~:~...---
~
,,,,,,.--
..J----.C. 09992-00024
( Cylinder Compres- )
sion Check Gauge
Set
A
•
SSM (SPECIAL SERVICE MATERIALS)
Part Name Part No. Sec. Use etc.
) EM
Rear oil seal retainer
No. 1 camshaft bearing
08826-00080
Seal packing or equivalent
Oil pan
LU
Oil pump
08826-00100 co Water pump
Stud bolt (for water outlet)

Stud bolt (for vacuum pump)
EM Union
THREE BOND 1324 or equivalent 08833-00070 Drain cock
Flywheel mounting bolt
LU Oil pump mounting bolt
THREE BOND 1344 or equivalent Water temp. sender gauge

08833-00080 EM
Oil pressure switch
r
'
TOYOTA
QUALITY SERVICE
r
I I
, ,
'
, ' ,
II ' , ' I
I
,
, '
OVERSEAS SERVIC !VISION filll Prlnllng

TOYOTA MOTOR CORPORATION flr9t fl...,_o,i P1;n1-.d

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TOYOTA

This repair manual has been prepared 10 provide information

Apphcabte models. N P70 series

Manual Name Pub No

All information in this manual 1s based on the latest product

TOYOTA MOTOR CORPORATION

1995 TOYOTA MOTOR CORPORATION

INT ROD UCT ION

REP AIR PRO CED URE S

195 (14, 19)

The procedures are presented in a step-by-step format:

9. INSTALL GOVERNOR LINK

This format provides the experienced technician within FAST

WARNINGS, CAUTIONS , NOTES:

IDEN TIFIC ATIO N

GENE RAL REPAIR

12. Observe the following precautions to avoid d amage to

(d) When steam cleani ng an engine , protec t the air filter

ABBREVIATIONS USED IN THIS MANUAL

DIES EL ENG INE DIA GNO SIS

ssion, valve timing and other major

PREL IMIN ARY CHEC KS

(b) Check the air fi lter and clean or replace it if necessary.

(c) Confirm that there is sufficie nt fuel in the tank.

elements. Only good-q uality diesel

the electrical system.

ENGINE WILL NOT CRANK

(Possible Cause) (Check Procedure and Correction Method)

1. LOOSE OR CORRODED Check cables from battery to starter and make

12. DISCHARGED BATTERY I

13. INOPERATIVE STARTER I

ENGINE CRANKS SLOWLY-WILL NOT START

(Possible Cause) (Check Procedure and Correction Method)

I 3. IMPROPER ENGINE OIL lt ---- - ----1 Check engine oil.

ENGINE CRANKS NORMALLY BUT WILL NOT START

( Possible Cause) (Check Procedure and Correction M ethod )

Disconnect inlet hoses to fuel fi lter and feed clean

6. FUEL LEAKAGE FROM Check for loose unions or cracks.

7 . IMPROPER INJECTION Turn crankshaft pulley clockwise to where either

ROUGH IDLE WITH WARM ENGINE

(Possible Cause) (Check Procedure and Correction Method)

12. IDLE SPEED TOO LOW I

, 3. FUEL LEAKAGE I Check for leaks at the pump connections, pump

4. IMPROPER INJECTION Refer to item 7 of ENGINE CRANKS NORMALLY

ENGINE SUDDENLY STOPS

(Possible Cause) (Check Procedure and Correction Method)

2. ROUGH IDLE If idle is not stable, refer to ROUGH IDLE WITH

3. MALFUNCTION OF FUEL-CUT Refer to ENGINE CRANKS NORMALLY BUT WILL

Refer to item 3 of ENG INE CRANKS NORMALLY

(Possible Cause) (Check Procedure and Correction Method)

1. IMPROPER ACCELERATOR With accelerator fully depressed, check that

2. INSUFFICIENT Start engine, depress accelerator pedal to floor and

3. INTERCHANGED OVERFLOW NOTE: Overflow screw is marked "OUT" and

, 4. FUEL LEAKAGE I Refer to item 3 of ROUGH IDLE WITH WARM

, 6. IMPROPER INJECTION TIMING l>--------< 1

7. FAULTY NOZZLE OR NOZZLE (

EXCESS IVE EXHAU ST SMOKE

( Possible Cause) (Check Procedure and Correction M eth od)

,, . IMPROPER INJECTION TIMING :-----1 Refer to item 7 of ENGINE CRANKS NORMALLY

12. CLOGGED FUEL FILTER

3 . FAULTY NOZZLE OR NOZZLE Refer to item 9 of ENGINE CRANKS NORMALLY

EXCESS IVE FUEL CONSU MPTION

(Possible Cause) (Check Procedure and Correction Method)