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Engine Manual for HJ60 - 61
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169 views338 pagesEngine Manual 2H 12HT
Engine Manual for HJ60 - 61
Uploaded by
MerlinCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 338
FOREWORD
This repair manual has been prepared to provide information
covering general service repairs for the 2H and 12H-T engines
mounted on the TOYOTA LAND CRUISER (Heavy-Dutyl.
Applicable models
HJ6O, 61, 75 series
All information contained in this manual is the most up-to-date
at the time of publication. However. specifications and pro-
cedures are subject to change without notice.
TOYOTA MOTOR CORPORATION TOYOTA 2H, 12H-T ENGINE
REPAIR MANUAL
INTRODUCTION MIN
ENGINE MECHANICAL [El
FUEL SYSTEM
COOLING SYSTEM
LUBRICATION SYSTEM [QU
STARTING SYSTEM
CHARGING SYSTEM
SERVICE SPECIFICATIONS [EWE
STANDARD BOLT TORQUE SPECIFICATIONS aoe
SST AND SSM
9 1985 TOYOTA MOTOR CORPORATION
AM rights reserved. This book INTRODUCTION
Page
HOW TO USE THIS MANUAL waveiomuvniion: iN
GENERAL REPAIR INSTRUCTIONS .............. IN
ABBREVIATIONS USED IN THIS MANUAL ......._IN-7 IN-2 INTRODUCTION — How to Use This Manual
HOW TO USE THIS MANUAL
To assist in finding your way through this manual, the Section
Title and major heading are given at the top of every page.
‘An INDEX is provided on the 1st page of each section ta guide
vou to the item ta be repaired,
At the beginning of each section, PRECAUTIONS ore given
that pertain to ail repair operations contained in that section
Read these precautions before starting any repair task
TROUBLESHOOTING tables are included for each system to
help you diagnose the system problem and find the cause. The
repair fer each possible cause is referenced in the remedy col-
umn to quickly lead you to the solution
REPAIR PROCEDURES
Most repair operations begin with an overview illustration, It
identifies the components and shows how the paris fit to-
7 Nozzle Leakage Pi
Gosket—____ g° Pipe
Injection Nozzle
‘Nozzle Seat
(kg-em (fi-ib, Niemi: Specified torque
@ Non-reusable part Iastration
what 10 do and where |
oe
INTRODUCTION — How to Use This Mani
The procedures ore presented in a step-by-step format:
© The illustration shows what to do and where to do it
© The tack 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
REMOVE INJECTION NOZZLES
Using SST. remove the timer
SST 09260-47010 (09267-76020)
Set port No. Components part NO.
Install and torque the round nut
install. ond torque the FOUN Mut ——_ seated peut
Torque: 750 kg-em (54 ft-lb, 74 Nm) how fo do task
Torque Specification
This format enables the experienced technician with a FAST
TRACK to the information needed. The upper case heading can
be read at a glance and only when necessary, the test below it
provides detailed information. Important specifications and
warnings always stand out in bold type
REFERENCES
References have been kept to a minimum. Hawever, 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 ta
look up your specs. All specifications are also found in Appen-
dix 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 alsa presented in bold type and indicate there
is-@ possibility of damage to the components being repaired.
@ NOTES are separated from the text but do not sppear in
bold, They provide additional information to help you effi-
ciently perform the repait. IN-&
General Repair instructions
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left side of the
cylinder block
GENERAL REPAIR INSTRUCTIONS
1, Use fender, seat and floor covers to keep the vehicle clean
and prevent damage.
2, During disassembly, keep parts in order to facilitate reas-
sembly,
3. Observe the following:
[s) Before performing electrical work, disconnect the
negative cable from the bettery terminal
ib) If it is necessary to disconnect the battery for inspec-
tion oF repair, always disconnect the cable from the
negative (—) terminal which is grounded to the vehi-
cle body.
ic) 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
ather abrasive abject.
(e} Install the cable terminal to the battery post with the
‘nut loose and tighten the nut after installation. Do not
use a hammer to tap the terminal onto the post
(f) Be sure the cover for the positive I+) terminal is pro-
perly in place
4, Check hose and wiring connectors to make sure they are
securely and correctly connected.
5. Non-reusable parts
lal Always replace cotter pins, gaskets, O-rings, oil seals
‘tte. with new ones.
(>) Non-reusable parts are indicated in the component
illustrations by the ‘'" symbol. INTRODUCTION — General Repair Instructions IN5
6. Precoated Parts
Precoated parts are the bolts, nuts, etc. Which are coated
with @ seal lock adhesive at the factory.
la) Ha precoated part is tightened, laosened or caused
to move in any way, it must be precoated with the
specified adhesive
fb) Recoating of Precoating Parts
(1) Clean off the old adhesive from the bolts, nut or
installation part threads
(2) Dry with compressed air
(3) Apply the specified si
bolt or nut threads.
(c} Precoated parts are indicated in the component
illustrations by the “#"" symbol
When necessary. use a sealer on gaskets to prevent leaks,
Carefully observe ail specifications for bolt tight
‘ques. Always use a torque wrench.
3. Use of special service tools (SST) and special service
materials (SSM) may be required depending on the nature
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
10. When replacing fuses, be sure the new fuse is the comact
amperage rating. DO NOT exceed the fuse amp rating or
use one of a lower rating,
11. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the
proper locations.
(a) If the vehicle is to be jacked up anly at the front or
rear end, be sure ta block the wheels in order to
ensure safety
(b} After the vehicte 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.
| lock adhesive to the
en
ing tor-
12. Observe the following precautions to avoid damage the
parts
(a) To disconnect vacuum hoses, pull on the end, not the
middle of the hose
(o) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(c) Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on 3 hard floor,
they should be replaced and not reused. IN-6
INTRODUCTION
‘General Repair Instructions
13
(a)
(e)
i)
@
When steam cleaning an engine, protect the air filter
nd injection pump from water.
Never use an impact wrench to remove or install ther-
‘mo switenes oF therma sensors
When checking continuity at the wire connector,
insart the tester probe carefully to prevent terminals
‘trom bending
‘When using 2 vacuum gauge, never force the hose
‘anto a connector that is too large. Use a step-down
adapter instead, Once the hose has been stretched, it
may leak
After removing and reinstalling the injection pump and fuel
hoses, clean off the fuel on engine components. In par-
ticular, be sure to check the radiator hose and by-pass
hose, because they deteriorate easily if they come into
contact with fuel INTRODUCTION — Abbreviotions Used in This Manual Wz
ia ABBREVIATIONS USED IN THIS MANUAL
at
AT
ATDC
eoc
BTDC
- EDIC
Ex
HAC
IN
- LH
wT
MP.
- os
Poy
PS
RH
‘SSM
$sT
STD
TDC
us
vsv
- wi
Air Conditioner
Automatic Transmission
After Top Dead Center
Bottam Dead Center
Before Top Dead Center
Electrical Diesel Injection Control
Exhoust
High Altitude Compensator
Intakes
Left-hand
Manual Transmission
Multipurpose
Oversize
Positive Crankcase Ventilation
Power Steering
Right-hand
Special Service Materiats
Special Service Tools.
Standard
Top Dead Center
Undersize
Vacuum Switching Valve
with
Without ENGINE MECHANICAL
Page
DIESEL ENGINE DIAGNOSIS .. seeeeeeses EMD
DIESEL ELECTRICAL SYSTEM
DIAGNOSIS [2H] ..
ne? A) —
DIESEL ELECTRICAL SYSTEM
DIAGNOSIS [12H-T] 2.0.2... . EM-13
TURBOCHARGER DIAGNOSIS (12H-T] co) EMA
TURBOCHARGER ELECTRICAL SYSTEM
DIAGNOSIS [12H-T] ......00..00.0c20e0200, EM19
ENGINE TUNE-UP ..... sees EM-20
COMPRESSION CHECK [2H] ... sereeees MEWS
COMPRESSION CHECK [12H-T] ..... . EM-36
TURBOCHARGER [12H-T] . -. EM-37
CYLINDER HEAD ........ -. EM-87
TIMING GEARS AND CAMSHAFT cece EMIT
CYLINDER BLOCK a seta etn cose EM8d EM-2 ENGINE MECHANICAL — Diesel Engine Diagnosis
DIESEL ENGINE DIAGNOSIS
1.
GENERAL
Diesel engine problems are usually caused by the engine or fuel system. The injection pump is very rarely
‘the cause of fuel system problems
Before beginning fuel system tests, first check that the engine compression, valve timing and other
major systems are within specifications.
PRELIMINARY CHECKS
(a) Before performing fuel system checks. insure that the engine is in good running condition. if
necessary, first check the compression, timing and major components or systems.
(b) Check the air filter and clean or replace as necessary.
le) Check for sufficiant fusl in the tank.
[d) Check if the fuel is contaminated with gasoli
uel should be used
(e) Bleed air from the system by pumping the priming pump
{Check for water in the sedimenter and fuel tank, and drain es necessary
{g]__H the engine will not crank or if it cranks slowly, troubleshoot the electrical system.
1 oF other foreign elements, Only high-quality diesel ENGINE MECHANICAL — Diesel Engine Diagnosis EM-3
PRECAUTION
1. The basic troubleshooting procedures for the diesel engine (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 8 special test bench.
ENGINE WILL NOT CRANK
(Possible Cause! (Cheek Procedure and Correction Method!
(4. LOOSEORCORRODED | Check cables from battery to starter and make ]
BATTERY CABLES necessary repairs
2. DISCHARGED BATTERY | {Check the alternator output and the drive belt:
a Repair as necessary. (Seo page CH-6)
[ 3. INOPERATIVE STARTER |——————! Check for battery voltage at starter terminals. 30
- = =a and 60.
If Okay, see STARTING SYSTEM page (ST-11) for
Eaer |
ENGINE CRANKS SLOWLY-WILL NOT START
NOTE: Minimum cranking speed: 100rpm Cold
150rpm Hot
(Check Procedure and Correction Method)
[* LOOSE OR CORRODED :
C_savrenr cases [sero fems and 2 of GRE Will NOT)
- [— crank.
‘Check engine oil
IF improper viscosity, drain and refill with oif of
viscosity recomended by manufacturer,
(See page LU-4)
|_|
z
3
5S
|
3
z
2
2
Hy
2
: ENGINE MECHANICAL — Diesel Engine Diagno:
ENGINE CRANKS NORMALLY BUT WILL NOT START
ible Cause) (Check Procedure and Correction Method)
(Pos
1, NO FUEL TO INJECTION |____fLeasen any one injection pipe union nut fromits
NOZZLE nozale
Crank the engine for sbout § seconds while con-
firming that fuel is being discharged from the pipe,
fuel is coming out, begin diagnosis fram item 4.
if not, begin from item 2.
2 NO FUEL INTO INJECTION ___ GheonpeisEhewe toie Wed powpiend Teed”
Pump clean fuel from separate container directly inta
feed pump,
If engine starts, either the sedimenter or fuel ine
| between the fuel tank and feed pump ic clogged
and should be repaired
IF the engine still doas not start, check the fuel
filter ar line between teed ump Bnd injection
pump.
If norms, the teed pump ar injection pump is faulty
and should be repaired
NOTE: When feading fuel directly inte pump.
keep container at same level as vehicle fuel |
tank,
{Check for joose unions or cracks.
If leaking, tighten to specified torque or, if neces-
| sary. replace pipels)
[a FUEL LEAKAGE From
INJECTION PIPE
4 (2H - | With the starter switch turned ON and the glow
INOPERATIVE PRE-HEATING ‘lug indie@tor light iuminated, check that there is
OPERATION voltage applied to the glow plug
W not, refer to BLECTRIGAL DIAGNOSIS and repair |
é 4
[a8 necessary, (See page EM-11) -
5. [12H-T) ( With the ignition switch tumed ON and the ‘|
INOPERATIVE PRE-HEATING | intake heater indicator hight illuminated, check that
OPERATION there is voltage applied to the intake heater.
If not, refer to ELECTRICAL DIAGNOSIS and repair
as necessary. (See page EM-13)
6.
[2H (Check the glow plug for continuity. (Sea page ST-5I
FAULTY GLOW PLUG
Ino continuity, a braken wire is indicated and the
OPERATION glow plug shauld be replaced. )
7. (12H-T] Check the intake heater continuity. (See page ST-9) |
FAULTY INTAKE HEATER 7] If ne continuity, @ broken wire is indicated and
OPERATION intake heater should be replaced ENGINE MECHANICAL
Diesel Engine Diagnosis
IMPROPER INJECTION
TIMING
_ FAULTY INJECTION NOZZLE
ROUGH IDLE WITH WARM ENGINE
‘Check the injection timing, oe page EM-23) |
Injection timing: 2H 18° BTOC |
12H-T 11° BTDG
it not as specified, injection timing must be read-
justed
- J
(Check the injection presture with nozzle teat
(See page FU-4 or 10)
Opening pressure:
2H 105 — 125 kg/em?
(1,493 = 1,778 psi
(10,286 — 12,268 kPe)
180 ~ 210 kg/em*
(2,560 — 2.987 psid
| (17,662 — 20,594 kPal
H not within specification, nozzle adjustment
| is improper and pressure should be readjusted.
If pressure cannot be adjusted to specifi
| replace nozzle,
12-7
(Possible Cause)
IMPROPER ADJUSTMENT OF |
ACCELERATOR CABLE
IDLE SPEED TOO LOW
3. FUEL LEAKAGE
(Chack Procedure and Correction Method)
{With the accelerator pedal released, check that the |
adjusting lever is. in contact with the idle adjusting
screw, Alza, check if the accelerator cable is catch-
ing on something
If necessary, adjust so lever is in contact with the
screw, or make other required repairs.
Check the idle speed as specified below.
(See page EM-26 or 28)
Idle speed: MT 650 rpm
AT (2H) 780 rpm
AT (12H-T) 770 rpm
not, adjust with the idle speed adjusting screw,
NOTE: If less than specified. idling would J
[normally be rough.
‘Check for leaks in the injection pump connections,
feed pump, nozzle holder and delivery valve
Tighten any loose connections to specified tarqi
‘or replace parts. as necessary. ENGINE MECHANICAL — Diesel Engine Diagnosis
‘ —— ~ ——
4, IMPROPER INJECTION Refer to item 6 of ENGINE CRANKS NORMALLY
TIMING [7 BUT WILL NOT START, above, J
5. IMPROPER OPERATION OF | With the en
INJECTION NOZZLE OR each cylind
DELIVERY VALVE ehanges.
: Hf no change, a faulty cylinder is indicated.
Check according ta the following procedure.
© Faulty Nozzle
Check the nozzle with nozzle tester.
(See page FU-4 or 10)
Opening pressure:
2H 108 — 125 kg/em*
(1,493 = 1,778 psid
(10,296 ~ 12,268 kPal
12H-T 180 ~ 210 ka/em’
(2,560 ~ 2,987 ps
(17,652 = 20,594 kPa}
Hf not within specification, the nozzle is faulty and
injection pressure should be readjusted
© Faulty Delivery Valve
It injection pressure is within specification, the
delivery valve is defective and should be replaced.
ine idling, loosen the injection pipe to. |
in order, and check if the idle spoad
ENGINE SUDDENLY STOPS
(Possible Caus! [Check Procedure and Correction Methed)
1, ENGINE WILL NOT RESTART Check to see if engine re-starts according to
prescribed procedure
If not, refer to ENGINE CRANKS NORMALLY BUT
[WILL NOT START, above, and renair as necessary.
2 AOUGH IDLE |e nat stabe, refer 10 ROUGH IOLE WiTH
| Wain ENGINE anal epaw eecordioly
3 NOFuELinTomuEcTiOn | ___[fele wo nem2 of ENGNE cAANKS NORMALY |
PUMP BUT WILL NOT START, above. J ENGINE MECHANICAL — Diesel Engine Diagnosis
LACK OF POWER
For accuracy, adjust
a chassis dynamo.
(Possible Cause) (Check Procedure and Correction Method)
4, IMPROPER ACCELERATOR { With accelerator fully depressed, check that the |
CABLE ADJUSTMENT adjusting lever is in contact with the maximum
speed adjusting screw. (See page EM-26 or 28)
It not, sdjust secordingly
|
MAXIMUM SPEED floor and check thet maximum speed is as specified
below. (See page EM-26 or 28)
Maximum speed:
w/ Fluid coupling 4,170 rpm |
w/o Fluid coupling 4,100 rpm
If not, adjust with the maximum speed adjusting
| 2. INSUFFICIENT LL Start engine, depress the accelerator pedal to the
|
~ FUEL LEAKAGE | 1 Refer to item 3 of ROUGH IDLE WITH WARM.
— ENGINE.
CLOGGED FUEL FILTER Disconnect the injection pump inlet hose and outlet |
————— ~ pipe of the feed pump, and connect directly with a
side of the feed pump.
If the engine condition improves, the fuel filter is
clogged and should be replaced. (See page FU-2)
When feeding fuel directly into the
keep container at same level as vehicle
fuel tank. |
If no increase in engine condition after replacing
the fuel filter, check the feed pump or perform
other necessary repairs.
| suitable pipe. Then pour clean fuel into the inlet
IMPROPER INJECTION TIMING |‘ Refer to iter B of ENGINE CRANKS NORMALLY |
— [BUT WILLNOT START. J
6 FAULTY INJECTION NOZZLE |————/' Refer to item 9 of ENGINE CRANKS NORMALLY
a UT WILL NOT START. EM-8 ENGINE MECHANICAL — Diesel Engine Diagnosis
EXCESSIVE EXHAUST SMOKE
NOTE:
‘Check that the air cleaner is not clogged.
2. Chack with the customer whether or not oil consumption has been excessive.
(Possible Cause) (Check Procedure and Correction Method)
IMPROPER INJECTION TIMING | {Refer to item 8 of ENGINE CRANKS NORMALLY — |
BUT WILL NOT START.
NOTE; Black smoke indicates advanced timing
while white smoke indicates retarded timing.
| Adjustments should be made accordingly.
CLOGGED FUEL FILTER |- 1 Reefer to item 5 of LACK OF POWER.
- | NOTE: At high speed (2,000 — 3,000 rpmi,
clogged filter tends to make the exhaust,
__smoke white.
ga it hi
FAULTY WAEETION WOZRLE} {ee eo ENGNE CRANKS NORMALLY
es om BUT WL WOT START.
NOTE: Excessive exhaust smoke is often
caused by nozzle pressure being too low.
Rice
EXCESSIVE FUEL CONSUMPTION
NOTE: Check whether the cluteh slips, brakes grab, whether the tires are the wrong size or the
air filter is clogged.
(Possible Cause) (Check Procedure and Correction Method)
[1. FUELLEAKAGE |}-—_{ fete to item 3 of ROUGH IDLE WITH WARM
es ENGINE
[2 DLE SPEED Too HIGH} {after uticieaty warming up enlne shock tat
——— idlo speed is a8 specified below.
(See page EM-26 or 28)
Idle speed: MYT 650 rpm
AIT (2H) 780 rpm
AIT (124-7) 70 rpm
I not. adjust with the idle speed adjusting screw.
MAXIMUM SPEED TOO HIGH | Start ongine, depress the accolerator pedal to the |
floor and check that maximum speed is as
specified below. See page EM-26 or 28)
Maximum speed: |
wi Fluid coupling 4.170 rpm
wi Fluid coupling 4,100 rpm
If not, adjust with the maximum speed adjusting
| sorew. ENGINE MECHANICAL — Diesel Engine Diagnosis EM
Refer to item 8 of ENGINE CRANKS NORMALLY )
[BUT WILL NOT START.
{ Refer to item 9 of ENGINE CRANKS NORMALLY
BUT WILL NOT START. }
ENGINE NOISE WHEN WARM
(Cranking Noise with Exe
@ Vibration)
(Possible Cause) (Check Procedure and Correction Method)
1 —
[ 1. COOLANT TEMPERATURE TOO {Crack coolant temperature with coolant
Low ‘temperature gauge.
- - | M not sufficiently warm, thermostat is faulty and
| should be replaced
LH
[ 2. IMPROPER INJECTION TIMING jefer to item 8 of ENGINE CRANKS NORMALI
es BUT WILL NOT START
| Raster to item 9 of ENGINE CRANKS NORMALLY
{ Britt Sram
[ 3. FAULTY INJECTION NOZZLE
ENGINE WILL NOT RETURN TO IDLE
(Check Procedure and Correction Method)
(Possible Cat
| BINDING ACCELERATOR CABLE Operate adjusting lever on side of injection pump
and check if engine returns to idl
I 60, the accelerator cable is binding or improperly
adjusted and should be repaired accordingly.
If engine does not return to idle, the injection pump
faulty and should be repaired. EM-10
ENGINE MECHANICAL — Diesel Engine Diagnosis
ENGINE WILL NOT SHUT OFF WITH STOP BUTTON OR KEY
(Possible Cause)
[2H MIT (w/o EDIC SYSTEM]
BINDING STOP CABLE
[Check Procedure and Correction Metho
Operate stop lever {adjusting lever! on side of
injection pump and check if engine stops.
If 80, stop cable is binding or maladjusted and shoul
be
paired accordingly
If engine does not stop, injection pump is faulty and
should be replaced. [See page FU-29)
2. [2H MT (w/ EDIC SYSTEM]
IMPROPER EDIC SYSTEM
3. [2H A/T AND 12H. ]
IMPROPER INTAKE SHUTTER
OPERATION
ma
stop lever (adjusting leverl on side
sion pump and check if engine stops
If 80, EDIC system is faulty and should
be repaired. (See page ST-21)
f engine does nat stop, injection pump is
faulty and should be repaired. ISee page FU-29)
If it does, the intake shutter system is faulty
and should be repaired. (See page EM-33 or 34)
—— -
Close the intoke shutter and check if engine stops, ENGINE MECHANICAL — Diesel Electrical System Diagnosis (2H)
DIESEL ELECTRICAL SYSTEM DIAGNOSIS [2H]
ENGINE DOES NOT START
NOTE: 1, Battery voltage at
Fusible link okay.
COLD
i
Engine cranks normally.
12 volts (or 24 volts) — ignition switch OFF.
Check the voltage marked with an asterisk {*) just as the ignition switch is placed at
ON because the voltage will change with elapse of time.
Pre-heating System (Super Glow Type)
sok ENGINE Tue
Check if ingicator ight lights up =6lll sien eer ere ‘Check for short
“with ignition switch ON. ‘No. aw elow Fa (Others), | Fuse circuit and repsir
‘Coolant temp. Approx. 20°C (68°F) : Blown
ox. 2 seconds
oe Fuse OK
Yes pasa aes
Check indicator
tbo teas —-L_Feotece bu
No Good
Bub OK
lanition swatch OFF Check for battery voltage to terminal 3 of
fre-heating timar connector (on wire hatness side
HW okay. pre-heating timer is faulty and should be
replaced
t
* Check tor battery voltage to terminal Check that is 1V between terminals 9 and 12.
ting time with ignition H faulty, repair glow plug current sensor.
Ne.
} Stage okay. mer is fouty and should be replace
] Votage
Start the engine and cheok/f there is a voltage
Check if voltage to terminal 1 piptscday prpearenrsap hice
of pre-heating mer le tera | Ne) If faulty, repair charging system as necessary.
engine is started IY okay, timer is faulty and should be replaced
Yes
| CONTINUED ON PAGE EM-12
'
Pre-heating Timer
wile 7 EM-12
ENGINE MECHANICAL — Diesel Electrical System Diagnosis [2H]
|CONTINUED FROM PAGE EM.11
Place ignition switch at ON anct
‘check if current flow to terminal
6 of timer is in accordance
with coolant temperature
(See Timer characteristics Diagram
on page ST-3t.
‘Aftor completion of pre-heating. check:
for voltage at terminal 5 again
‘when starter switch is placed at ST.
Ignition switch OFF
Place ignition switeh at ON
and check for vaitage to glow
plug a few secondls later.
Thereafter, voltage should
drop about 1/2
Wo Woltage at All
No 1/2 Veltaga Thereafter
‘Measure glow plug resistance
infinity
‘Approx. O it
=
Pre-heating Duration is Quite
Different Than That Specification
Timer is faulty and should be replaced
Check for battery voltage at plus side of glow plug
current sensor (Resister side!
HY okay, replace sensor
lf no voltage. No. 1 glow plug relay is faulty and
should be replaced
Check for battery voltage to plus side of resistor
Ontake manifold sidel.
if okay, replace resistor.
If no wattage. No. 2 glow plug rulay is faulty
and should be replaced. ENGINE MECHANICAL — Diesel Electrie
‘System Diagnosis [12H-T] EM-13
DIESEL ELECTRICAL SYSTEM DIAGNOSIS [12H-T]
ENGINE DOES NOT START WHEN COLD
NOTE: 1. Battery voltage at least 12 volts (or 24 volts] — ignition switch OFF.
2. Engine cranks normally.
3, Water ture sénsar okay. (S66 page ST-2)
Pre-heating System
1, INSPECT POWER SUPPLY SECTION
; 7
ss cere each No__F Repco theta nesta
Yes
1
Disconnect the water temperature
‘sensor connector.
Replace the fusible link
Fusiblle Link Blown
When the ignition switch is turned
ON, dogs pre-heat side of the intake
heater hove battery voltage for 20
seconds. (12V type) or 14 seconds
(28V type)?
Check the fusible link for intoke
haater.
Fusibble Link OK
Yes
Lox]
Inspect contro! section
(See next page) 14 ENGINE MECHANICAL — Diesel Electrical System Diagnosis [12H-T]
2. INSPECT CONTROL SECTION
NOTE: Perform this inspection with the intake heater connector fully connected.
Pre-heating Timer
Disconnect the water temperature
sensor connect ert Fy
1109 7
‘When the ignition switch is turned |. _[ Ts the ENGINE Tuse ‘
‘ON, does the indicator light light? 2. (Europe) or GLOW 0__| Replace the fuse.
(Measure the time lighted) fuse (Australis) Okay?
Yes
Yes
Is the indicator No
Night bull> Okay? Replace the bull
Yes:
5 terminal 10 of the wo_| Open circuit or
pre-heating timer — ground faulty in
‘rounded? wire harness
botween terminal
_ 10 of the timer
and body ground.
Is there battery voltage to
‘terminal 3 of the timer
fan wire harness side)?
No
Qpen circuit in wire hamess
between terminal 3 of the
timer and indicator light
Is the lighting
12V type:
24V type:
N
2 =[ Replace the timer.
CONTINUED ON PAGE EM-15 ENGINE MECHANICAL — Diesel Electrical System Diagnosis [1 2H-T]
When the ignition switch is tuned ON,
is voltage between terminals B and
G of the No. 1 intake heater relay
OV for 20 seconds (12V type) or 14
seconds (24V typel?
Yes
With the engine started, is there © voltage
between terminals B and G of the No. 2
intake heater relay?
(Measure the time too}
Yes CONTINUED FROM PAGE EM-14
Did No. 1 intake heater
relay check out okay?
(See page ST-31
Replace the No. 1
intake heater
relay.
When the ignition switch is turned
ON, does terminal 1 of the intake
heater timer have battery voltage
for 20 seconds (12V type) or 14
seconds (24¥ typel?
yes
© Open circuit in
between terminal 1 of the tim
and terminal g of the No. 1 intake
heater relay
© Open circuit or ground faulty
in wire hamess between terminal
E of the No, 1 intake heater
relay and body ground.
Did No. 2 intake heater
relay check out okay?
(See page ST-9}
Yes
CONTINUED ON PAGE EM-16
Yes
No. 1 and No. 2
Replace the timer.
Replace the No.2
jake heater
relay.
Intake Heater Relays
=o EMA ENGINE MECHANICAL — Diesel Electrical System Diagnosis [12H-T!
Yes CONTINUED FROM PAGE EM-15 | Yes
With the engine started, dees
terminal § of the Pre-heating
have battery voltage for 70 seconds?
‘When the ignition
No_| switch is turned
‘ON, does the charge
waming light light?
Is terminal 9 of the
timer grounded?
Yes
Yes No
‘Open circuit in wire
harness batween
Roplace the timer.
eee terminal 9 of the timer
and charge warning light
© Inspect CHARGE fuse.
© Inspect alternater
regulator,
© Open circuit in wire hamess between
terminal 5 of the timer and terminal
g of the No. 2 intake heater relay.
@ Open circuit or ground faulty in wire
hamess between terminal E of the No. 2
intake heater and body ground.
Is tima normal? wa
Approx. 70 seconds
Vos
Inapect power supaty
section
(See nage EM-13} ENGINE MECHANICAL — Turbocharger Diagnasis [12H-T] EM.17
TURBOCHARGER DIAGNOSIS [12H-T]
INSUFFICIENT ACCELERATION, LACK OF POWER OR
EXCESSIVE FUEL CONSUMPTION
(Possible Cause) (Cheek Procedure and Correction Method!
4. INSUFFICIENT TURBOCHARGING ] (Check turbocharging pressure. (See page EM-38)
PRESSURE |) Turbecharging pressu
0.39 — 0.53 kg/em*
(5.8 — 7.3 psi, 38 — 62 kPal
H not within specification, begin diagnasis from
horn 2.
[> RESTRICTED INTAKE AR YEN es
2, RESTRICTED INTAKE AIR SYSTEM | Check intake air system, and repair or
- replace parts as necessary. (See page EM-
—
3. LEAK IN INTAKE AIR SYSTEM Check intake air system, and repair or
replace parts as necessary. (See page EM-40)
4. RESTRICTED EXHAUST SYSTET Check exheust system, and repsir or replace
— «Cs parts: as necessary. (see page EM-40)
[5 LEAKIN EXHAUST SYSTEM Check exhaust system, and repair or replace
parts as necessary. (See page EM-40)
Check rotation of impeller wheel. i it does not turn
or turns with heavy drag, replace the turbocharger
assembly
Check axial play of impeller wheel.
(See page EM-43)
Axial play: 0.13 mm (0.0081 in) or le
If not within specification, replace the turbocharger
assembly.
‘a
RATIC TURBOCHARGER OPERA —M (12H-T]
E MECHANICAL — Turbocharger Diagnos
ABNORMAL NOISE
{Possible Cause} (Check Procedure and Correction Method)
1. TURBOCHARGER HEAT INSULATOR —_| Check for loose, improperly installed or deformed
RESONNANCE insulator mount bolts, and repair or replace as
—— necessary.
2. EXHAUST PIPE LEAKING OR ‘Check for deformed exheust pipe, loose mount bolts
VIBRATING or damaged gasket, and repair or replace as
<== necessary, J
3. ERRATIC TURBOCHARGER OPERATION | { Refer to Item 7 of INSUFFICIENT ACCELER-
——_—— —— | ATION, LACK OF POWER OR EXCESSIVE FUEL
‘CONSUMPTION.
EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST
(Check Procedure and Correction Method)
Check for oil leakage in exhaust system.
'@ Remove the turbine elbow from the turbocharger
and check for excessive carbon deposits on the |
turbine wheel. Excessive carbon deposits would
indicate a foulty turbocharger.
‘Check for oil leakage in intake air system.
© Check for axial play in impeller wheel, and replace
| the turbocharger i! necessary, (See page EM-43}
Axial play: 0.13 mm {0.0051 in} or less
CAUTION: There is some oil mist from the
PCV in the blowby gas so care must be taken
nat to diagnosis this as an oll leakage from the
turbocharger,
Lee r ENGINE MECHANICAL
TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS [12H-T]
Troubleshooting of Turbocharger Indicator Light and Warning Light Operation
Turbocharger Electrical System Diagnosis (12H-T] ___EM-19
r ‘Bo both green indicator ight and amber Blown —_[ Check for short
sri ott when eon wren (heck GAUGE Tse su er
‘Stures to ont pase
si OK
Teck GRANGE] _ town [Seek Hr so
ENGINE tows
- meousy
oo ee
pea
ves.
‘Are indicator and warning lights out during
‘engine idle?
Both lights stay on
Ts charge waming
light aut?
Green light stays on
Cheek for open circuit m wire hamess between Ox | Faulty tow pressure
Faulty charging
system
low pressure switch and tachorneter switch
| tare cana
Chak for epan circuit in wire areas between high prevsure Switeh OK [Faulty high pressure
and tachometer end check for ground connection of switch emich
YES
‘Does green indicator light come on when
O.14 kg/om® (2.0 psi, 13.7 kPal pressure is
applied to both pressure switches?
Check for short creat in wire hamess betwean Tow
pressure switch and tachometer.
Faulty tow pressure
‘switch
j Amber light comes on.
Does green indicator light Come on when 1.09 Kgiem™ NO. [Faulty high pressure
(15.5 psi. 106.8 Pal pressure eppied to both switches? switch
Faulty combination
meter
NO
Check for short evcul m wire hamess between high Faulty high pressure]
pressure switch and tachometer, switch
Gost ambar Fear Tht came on when 1.00 kglent
(15.5 psi, 106.9 kPal pressure applied to both switches?
yes
Turbocharger indicator ight and waming ight
= operation oka EM-20 ENGINE MECHANICAL — Engine Tune-up
ENGINE TUNE-UP
INSPECTION OF ENGINE COOLANT
(See steps 1 and 2 on page CO-3)
INSPECTION OF ENGINE OIL
(See steps 1 and 2 on page LU-3)
INSPECTION OF BATTERY
(See steps 1 and 2 page CH-6)
‘Standard specific gravity:
When fully charged at 20°C (68°F)
12V type 1.28 ~ 1.27
2AV type 1.27 ~ 1.29 (NX series)
1.25 - 1.27 (Others)
CLEANING OF AIR FILTER
(Paper Filter Type]
CLEAN AIR FILTER
Clean the element with compressed ait.
First blow from the inside thoroughly. Then blow off the
outside of the element.
(Oil Bath Typel
CLEAN AIR FILTER
a) Wash the oil case and air filter in kerosine by agitat-
ing and rubbing.
[b) Wipe the oil case end air filter with @ clean rag
fc) Place the oil case on a level work stand.
(d) Pour in clean engine oil until it reaches the “OIL
LEVEL" mark, ENGINE MECHANICAL — Engine Tune-up
(e} Place the air filter on the tray.
(f) Saturate the air filter with clean engine oil
\
INSPECTION OF ALTERNATER DRIVE BELT
[See page CH-6)
Drive belt tension (Canada):
Used belt 80 + 20 Ib
New belt 125 + 5 ib
Drive belt deflection (Other:
Used belt 10 — 13 mm (0.39 — 0.51 in)
New belt = 9 mm (0.31 — 0,35 in)
INSPECTION OF GLOW PLUG [2H]
{See page ST-5)
INSPECTION OF INTAKE HEATER [12H-T]
(See page ST-9)
INSPECTION OF INJECTION NOZZLES
(See steps 4 to 6 on pages FU-4 and 5) 2H
(See steps 6 to 8 on pages FU-10 and 11) 12H-T
Opening pressure (2H)
Reused nozzle 105 — 126 kg/em'
(1.493 ~ 1.778 psil
(10,286 — 12,268 kPa)
New nozzle 115 — 125 kg/em*
(1,636 — 1,778 psi
(11,278 ~ 12,288 kPa)
Opening pressure (12H-T)
Reused nozzle 180 — 210 kg/cm?
560 — 2.987 pt
(17,652 — 20,594
New nozzle 200 = 210 kg/cm’
(2.845 — 2.987 psil
(19,613 — 20,594 kPa) my
M22
ENGINE MECHANICAL — Engine Tuno-uir
EX IN EX
eae
ADJUSTMENT OF VALVE CLEARANCES
1. WARM UP ENGINE
Allow the engine to reach normal operating twmperature,
2 (124-1)
REMOVE INTAKE AIR CONNECTOR AND INTAKE PIPE
(See step 2 to 6 on page EM-40)
3. REMOVE CYLINDER HEAD GOVER
4. SET NO, 1 CYLINDER TO TDC/COMPRESSION
(a) Align the groove bn the pulley with the timing pointer
bby turing the crankshaft clockwise with a wrench,
lb) Check that the rocker arms on the No. 1 cylindar are
loose and rocker arms on the No. 6 cylinder are tight.
Hf not, turn the crankshaft one revolution (360° and align
the mark as above
5. ADJUST VALVE CLEARANCES
la) Measure only those valves
Vaive clearance (Hot):
Intake 0.20 mm (0.008
Exhaust 0.36 mm (0.014 in)
© Using a feoler gauge, measure the valve clearance
between the valve stem and rocker arm. Loosen
the lock nut and tun the adjusting screw to set the
proper clearance. Hold the adjusting screw in posi-
tion and tighten the lock nut.
© Recheck the valve clearance. The fesler gauge
should slide with e very slight drag,
(b) Tum the crankshaft one revolution (360°) and align
the mark as above,
Adjust only the valves indicated by arrows,
6. INSTALL CYLINDER HEAD COVER,
7. W2H-T) ‘ i
INSTALL INTAKE PIPE AND INTAKE AIR CONNECTOR,
{See steps 9 to 12 on page EM-45 and 46) ee - —T
ENGINE MECHANICAL — Engine Tune-up —M-23
|] About 50 mm
(1.97 in)
> 2H (wie PS or acl]
Timing Pointer
jming 2H tw/ PS or A/C)
and 12H-T
ter
Se
aS
Ly
evatad]
ADJUSTMENT OF INJECTION TIMING
1, PREPARE INSPECTION PIPE
Make an inspection pipe with 8 injection pipe as shown,
2 Wan
REMOVE INTAKE AIR CONNECTOR AND INTAKE
PIPE (See steps 2 to 5 on page EM-40)
REMOVE CYLINDER HEAD COVER:
4. SET NO. 1 CYLINDER TO 18° (2H) of 11° (12H-T)
(BTDC/COMPRESSION Py
(a) Align the groove on the pulley with the timing pointer
by turning the crankshaft clockwise with a wrench.
(b) Check that the rocker arms on the No. 1 cylinder are
loose and rocker arms on the No, 6 cylinder are tight,
rs
not. turn the crankshaft one revolution (360°) and alight
the mark as above Ps
. a
5, ADJUST INJECTION TIMING
la} Remove the No. 1 injection pipe and install the
inspection pipe on the No, 1 delivery valve holder,
* > e
(bl Turn the crankshaft slightly to left afd right until fuel 4
surfaces from the inspection pipe. |
(cl) Turn the crankshaft counterclockwise, set the No. 1
cylinder just before the 18° (2H) or 11%, (12H-T)
BTDC/compression, EM.24 ENGINE MECHANIGAL — Engine Tune-up
18° BTDC Mark
2M (w/ PS oF A/C
11° BTDE Mark
4d) [2H AUT and 12H-T]
‘Align the marks of the stop lever and injection pump
governor housing,
(2) Slowly tum the crankshaft clockwise
(f) Check the crankshaft pulley position linjection timing
pasition) when the fuel level in the inspection pipe
rises.
Injection timing:
2H 18° BTOG
12H-T 11° BTDC
NOTE: This operation shauld be repeated at least two or
three times.
(a Loosen the other injection pipe union nuts, fuel pipe
4nd oil pipe union bait st the injection pump side
{hi Loosen the bolt holding the injection pump stay to
the stay.
i) Loosen the four nuts holding the injection pump to
the retainer.
(Adjust the injection timing by slightly tilting the injec-
tion pump body.
If the injection timing is retarded, advance it by titing the
pump a way from the engine.
If the injection timing is advanced, retard it by tilting the
pump towerd the engine, ENGINE MECHANICAL — Engine Tune-up EM-25
‘k) Tighten the four nuts holding the injection pump to
the retainer
Torque: 378 kg-cm (27 ft-lb, 37 N-mi
W) Tighten the bott holding the injection pump stay to
stay,
Torque:
2H 185 kg-cm (13 ft-lb, 18 Nem!
‘12H-T 360 kg-cm (26 ft-lb, 35 Nem)
{im} Recheck the injection timing,
(nl Remove the inspection pipe and install the No. 1
injection pipe,
lo} Tighten the injection pipe union nuts, oil pipe union
bolt and fuel pipe union bolt
Torque:
Injection pipe 300 kg-cm (22 ft-lb, 29 Nem)
Oil pipe 185 kg-em (13 ft-lb, 18 N-m)
Fuel pipe 280 kg-cm (20 ft-lb, 27 Nem)
INSTALL CYLINDER HEAD COVER
(124-71
INSTALL INTAKE PIPE AND INTAKE AIR CONNECTOR:
(See steps 9 to 12 on pages EM-45 and 46)
START ENGINE AND CHECK FOR LEAKS: —M-26 ENGINE MECHANICAL — Engine Tune-up
Idle Speed Adjusting Screw
ew
AS /
ADJUSTMENT OF IDLE SPEED AND
MAXIMUM SPEED [2H M/T]
1. INITIAL CONDITIONS
fa) Air cleaner installed
b) Normal operating coolant temperature
{cl All accessories switched off
(d) All vacuum lines connected
(e} Valve clearances set correctly
(f) Injection timing set correctly
2. CONNECT TACHOMETER
3. ADJUST IDLE SPEED
(a) Check that the adjusting lever touches the idle speed
(throttle valve) adjusting screw when the accelerator
pedal is released.
H not, adjust the accelerator linkage.
(b) Start the engine.
(c) Check the idle speed.
Idle speed: 650 rpm
Id) Adjust the idle speed.
© Disconnect the accelerator linkage,
* Loosen the lock nut of the idle speed (throttle
valve} adjusting screw.
© Adjust the idle speed by tuming the IDLE SPEEI
ADJUSTING SCREW.
© Securely tighten the lock nut and recheck the idle
‘speed.
Connect the accelerator linkage.
© After adjustment, adjust the accelerator linkage.
4, ADJUST MAXIMUM SPEED
{a} Check that the adjusting lever touches the throttle
valve adjusting screw when the accelerator pedal is
depressed all the way.
If not, adjust the accelerator linkage. q ENGINE MECHANICAL — Engine Tune-up —M-27
(b) Start the engine
(cl) Depress the accelerator pedal all the way.
(d) Check the maximum speed.
7 Maximum speed:
w/ Fluid coupling 4,170 rpm
w/o Fluid coupling 4,100 mpm
Wiasimar Saeed Aahsing Sore fe] Adjust the maximum speed.
= © Disconnect the accelerator linkage.
Ff Ag) aj * © Cut out the maximum speed adjusting (speed con-
tol) serew seal wire
@ Loosen the lock nut of the maximum speed adjust-
ing screw,
@ Adjust the maximum speed by turning the MAX-
IMUM SPEED ADJUSTING SCREW.
NOTE: Adjust at idle speed. Then, reise engine speed
and recheck the maximum speed.
@ Securely tighten the lock nut and recheck the max:
imum speed.
© Seal the meximum speed adjusting screw with a
new seal wire. ENGINE MECHANICAL — Engine Tune-up
ADJUSTMENT OF IDLE SPEED AND
MAXIMUM SPEED [2H A/T and 12H-T]
1. INITIAL CONDITIONS
la} Air cleaner installed
lb) Normal operating coolant temperature
{c) All accessories switched off
id) All vacuum lines connected
le} Valve clearances set correctly
{11 Injection timing set correctly
(9) Transmission in N range
2. CONNECT TACHOMETER
3. ADJUST IDLE SPEED
fa) Check that the adjusting lever touches the idle speed
adjusting bolt when the eccelerator pedal is released.
WW not, adjust the accelerator linkage.
(b) Start the engine.
lc) Check the idle speed
idle speed:
mit 650 rpm
AIT{2H) 750 rpm
AIT(2H-T) 770 rpm
(d) Adjust the idle speed
‘© Disconnect the accelerator linkage
© Loosen the lock nut of the idle speed adjusting
balt.
© Adjust the idle speed by turning the IDLE SPEED
ADJUSTING BOLT
© Securely tighten the lock nut and recheck the idle
speed
© Connect the accaleratar linkage.
© After adjustment, adjust the accelerator linkage
4 ADJUST MAXIMUM SPEED
(a) Check that the adjusting lever touches the maximum,
speed adjusting bolt when the accelerator pedal is,
depressed all the way.
if not, adjust the acceleratar linkage. ENGINE MECHANICAL
Engine Tune-up em.29
(b) Start the engine.
(c} Depress the accelerator pedal all the way.
Wd) Check the maximum speed.
Maximum speed: 4,170 rpm
fe) Adjusting the maximum speed.
© Disconnect the accelerator linkage.
© Cut out the seal wire of the maximum speed
adjusting bolt
® Loosen the lock nut of the maximum speed adjust-
ing bott.
® Adjust the maximum speed by turning the MAX.
IMUM SPEED ADJUSTING BOLT.
NOTE: Adjust at idle speed. Then. rai
and recheck the maximum speed.
® Securely tighten the lock nut and recheck the max-
imum speed.
© Seal the maximum speed adjusting bolt with a new
‘seal wire.
engine speed EM-30
ENGINE MECHANICAL — Engine Tune-up
ADJUSTMENT OF POWER STEERING
IDLE-UP SETTING SPEED [12H-T A/T]
My
PS ldlo-up Adjusting Screw
INITIAL CONDITIONS
(a) Air cleaner installed
(b) Normal operating coolant temperature
(c) All eccessories switched off
(d} All vacuum lines connected
(a) Valve clearances set correctly
{Injection timing set correctly
(g) Idle speed set correctly
(h} Transmission in N range
CONNECT TACHOMETER
ADJUST POWER STEERING (PS) IDLE-UP SETTING
SPEED
(a) Start the engine
(b) Disconnect the vacuum hose from the idle-up actua-
tor and plug the hose end
{ec} Apply vacuum to the idle-up actuator.
{d) Race the engine to 2,500 rpm a few seconds, release
the throttle and check the PS idle-up setting speed.
PS idle-up setting speed: 820 rpm
Adjust the FS idie-up setting speed by turning the PS
IDLE-UP ADJUSTING SCREW,
{f] Race the engine to 2,500 rpm a few seconds, release
the throttle and recheck the PS idle-up setting speed
ig) Reconnect the vacuum hose to the PS idle-up actua-
tor. ENGINE MECHANICAL — Engine Tune-up EM-31
ADJUSTMENT OF AIR CONDITIONER
IDLE-UP SETTING SPEED [2H M/T]
1. INITIAL CONDITIONS
(a) Air cleaner installed
(b) Normal operating coolant temperature
(ec) All accessories switched off
(a) Alt vacuum lines connected
(e) Valve clearances set correctly
(f) Injection timing set correctly
(gl Idle speed set correctly
2. CONNECT TACHOMETER
3, ADJUST AIR CONDITIONER (A/C) IDLE-UP SETTING
SPEED
(a) Start the engine.
(b) Disconnect the vacuum hose from the idle-up actua-
tor and plug the hose end.
(cl Apply vecuum ta the idle-up actuator.
(d) Race the engine to 2,500 rpm a few seconds, release
‘throttle and check the A/C idle-up setting speed.
AIC idle-up setting speed: 950 rpm
(e) Adjust the A/C idle-up setting speed by turning the
A/C IDLE-UP ADJUSTING SCREW.
jine to 2,500 rpm a faw seconds, release
the throttle and recheck the A/C idle-up’ setting
speed
ig) Reconnect the vacuum hose to the idle-up actuator, EM-32 ENGINE MECHANICAL — Engine Tune-up
ADJUSTMENT OF AIR CONDITIONER
IDLE-UP SETTING SPEED [2H A/T and 12H-T]
1. INITIAL CONDITIONS
(al Air cleaner installed
(b) Normal operating coolant temperature
(cl All accessories switched off
le) Valve clearances set correctly
(9 injection timing set correctly
{g] Idle speed set correctly
th) (w/ PSI
PS idle-up setting speed set correctly
4) Transmission in N range
2. CONNECT TACHOMETER
3. ADJUST AIR CONDITIONER (A/C) IDLE-UP SETTING
SPEED
{e)Stort the engine
fb) Disconnect the vacuum hosels) fram the idle-up
actuator and plug the hose endis)
el Apply vacuum to the idle-up sctuator.
{d) Race the engine to 2,500 rpm a few seconds, release
the throttle and chack the A/C idle-up setting speed.
AIC idle-up setting speed:
MIT 950 rpm (Transmission in neutral)
A/T 800 rpm (Transmission in B range)
a7 lo} Adjust the A/C idle-up setting speed by turning the
AVC IDLE-UP ADJUSTING SCREW.
{f) Race the engine to 2,500 rpm a few seconds, release
the throttle and recheck the A/C idle-up setting
speed
(g) Reconnect the vacuum hosels) to the idle-up actus-
tor.
<
Tea
. is
‘kip Adhating Brew
ESS
2 ANC ip Austin Seren
ald ENGINE MECHANICAL
ct
Sh
oes
INSPECTION OF INTAKE SHUTTER [2H A/T]
1, INSPECT INTAKE SHUTTER AND ACTUATOR
(0) Fully close the throttle valve, and check that it return
smoothly.
(b) Apply vacuum to the actuator.
(ch Check that the vacuum does not drop immediately.
2. INSPECT VACUUM SWITCHING VALVE (VSV)
fa) Remove the VSV,
fb) Check that air flow from pipe E to pipe F.
\c)_ Connect the VSV terminals to the battery terminals.
{d) Check that air flows from pipe E to pipe G.
If operation is not as specified, replace the VSV, EM-34
ENGINE MECHANICAL — Engine Tune-up
INSPECTION OF INTAKE SHUTTER [12H-T]
1. INSPECT INTAKE SHUTTER AND ACTUATOR
(a) Fully close the throttle valve, and check that it return
smoothly,
(b) Apply vacuum to the actuator
(cl Check that the vacuum does not drop immediately
2. INSPECT VACUUM SWITCH VALVE (vSV)
fa) Remove the VSV.
{b) Check that sir flow from pipe E to pine F
(cl Cannect the VSV terminals to the battery terminals
(dl Check that air flows from pipe E to pipe G.
HW operation is not as spocifiod, replace the VSV. ENGINE MECHANICAL — Compression Check [2H] EM.35
COMPRESSION CHECK [2H]
NOTE: If there is lack of power, excessive oil consump.
tion oF poor {uel economy, measure the cylinder compres-
sion pressure
1. WARM UP AND STOP ENGINE
2. REMOVE GLOW PLUGS (See page EM-49)
CAUTION: Make sure the load wire is nat grounded.
3. CHECK CYLINDER COMPRESSION PRESSURE
(a) Install SST gauge adapter) to the glow plug hole.
SST 09992-00023
lb) Connect SST (compression gouge) to SST (gauge
adapter),
SST 09992-00023
(cl Fully open the throttle valve,
id) While cranking the engine with the starter, meas
the compression pressure, *
NOTE: Always use a fully charged battery to obtain
engine revolutions of more than 250 rpm.
(e) Repeat steps (al through (dl far each cylinder.
Compression pressure:
28.0 kg/orv? (398 p
(Minimum pressure:
20.0 kg/cm? (284 psi, 1.961 kPa)
Difference between each eylinder:
2.0 kg/cm’ (2.8 psi, 196 kPa) or less
(fl If the cylinder compression in one or more cylinders
is low, pour 8 small amount of engine oil into the
cylinder through the glow plug hole and repeat steps
(a) through (dl for the cylinder with low compression,
© If adding oll helps the compression, chances ere
that the piston rings snd/or cylinder bore are worn
‘or damaged
© It pressure stays low, a valve may be sticking or
seating improperly, or there may be leakage past
‘tha gasket
4, INSTALL GLOW PLUGS
{See steps 1 to 4 on page FU-B)
2,746 kPal or more EM-36 ENGINE MECHANICAL — Compression Check [12H-T]
COMPRESSION CHECK [12H-T]
NOTE: If there is lack of power, excessive oil consump-
tion or poor fuel economy, measure the cylinder compres-
sion pressure,
1. WARM UP AND STOP ENGINE
2, REMOVE INJECTION NOZZLES {See page FU-8)
3. CHECK CYLINDER COMPRESSION PRESSURE,
(a) Install SST (gauge adapter) to the injection nozele
hole,
SST 09992-00023
(bl Connect SST (compression gouge) to SST [gauge
adapter)
SST 09992-00023
(cl Fully open the throttle valve
(a) White cranking the engine with the starter, measure
the compression pressure
NOTE: Always use 2 fully charged battery to obtain
engin revolutions of more than 250 rpm.
{e) Repeat steps lal through (d) for each cylinder.
Compression pressu
30.0 ka/om! (427 ps
Minimut pressure:
20.0 kg/cm [284 psi, 1,961 kPa)
Difference between each cylinder:
2.0 kg/cm? (28 psi, 196 kPal or less
fl If the evlinder comprassion in ona or more cylinders
is low, pour 9 small amount of engine oil into the
cylinder through the injection nozzle hole and repest
steps lal through (d) for the cylinder with low com
pression
"8 If adding oil helps the compression, chances are
that the piston rings and/or eylinder bore are worn
‘or damaged
© I pressure stays low, @ valve may be sticking or
‘seating improperly, or there may be leakage past
the gasket
4, INSTALL INJECTION NOZZLES
(See steps 1 to 6 on pages FU-14 and 15)
, 2,942 kPa) or more ENGINE MECHANICAL — Turbocharger [12H-TI EM-37
TURBOCHARGER [12H-T]
CAUTION
© Do not stop the engine immediately after pulling a
trailer of high speed of uphill driving. Idle the engine
20 — 120 seconds, depending on the severity of the
driving condition.
© Avoid sudden racing or acceleration immediately
after starting @ cald engine,
© If the turbocharger is defective and must be rep-
laced, first check for the cause of the defect in
‘eference to the following items and replace parts if
necessary:
Engine oil level and quality
Conditions under which turbocharger was used
Ol lines leading to turbocharg
bocharg;
‘nything or grasp it by easily-detormed parts. such
135 the actuator or red, when moving
* Before removing the turbocharger, plug the intake
and exhaust pots and oil inlet to prevent entry of dirt
‘or other foreign mata
© If replacing the turbocharger, check tor accumula-
tion of siudge particles in the ail pipes and, if
necessary. replace the oil pipes.
© Completely remove the gaskets adhered to the
lubrication oil pipe flanged and turbocharger oil
flange
© If replacing botis or nuts, do so only with the
specified new ones to guard against breakage or
deformation.
© Ifreptacing the turbocharger, put 20 ec (1.2 cu in) of
oil inte the turbocharger oil inlet and turn the
impeller wheel by hand to spread oil to the bearing.
© If averhauling oF replacing the engine, cut the fuel
supply and ignition function after reassembly and
crank the engine for 30 seconds to distribute
throughout the engine. Then allow the engine to is
for 60 seconds. ENGINE MECHANICAL — Turbocharger (12H-T)
ON-VEHICLE INSPECTION OF
TURBOCHARGER
4
INSPECT INTAKE AIR SYSTEM
Check for leakage or clogging between the air cleaner and
turbocharger inlet and between the turbocharger outlet
and cylinder head.
© Cloggad air clean the element,
'@ Hoses collapsed or deformed ... Repair or replace
‘© Leakage from connections .... Check each connection
and repeir
‘© Cracks in components ... Check and replace
INSPECT EXHAUST SYSTEM
Check for ieskage or clogging between the eylinder head
‘and turbocharger inlet and between the turhocharger out-
let and exhaust pips
© Deformed components ... Repair or replace
© Foreign material in passages... Remove
© Leakage from components .... Repair or replace
© Cracks in components .... Check and replace
Clean ar repla
INSPECT OPERATION OF ACTUATOR AND WASTE
GATE VALVE
(ab Disconnect the actuator hose.
(bl Using SST turbocharger prassure gauge). apply
about 0.68 kg/cm? (9,7 psi, 67 KPab of pressure to
the sctuator and check thet the rod moves.
SST 09992-00240
CAUTION: Never apply more than 0.8 kg/cm! (11.4
psi, 78 kPa) of pressure to the actuator.
the rod does not move, replace the turbocharger assemn-
bly.
INSPECT TURBOCHARGING PRESSURE
(a) Warm up the engine
(©) Connect a 3-way union to the intake pipe pressure
hose and install SST (turbocharger pressure gauge!
toit
SST 09992-00240
{c]_ Press in the clutch pedal, then press the accelerator
Pedal down as far as it will go, Measure the tur-
maximum speed (4,050 ~
0.39 — 0.53 kg/cm?
15.5 — 7.3 psi, 38 — 52 kPal
If the pressure is less than specification, check the intake
air and exhaust systems for leakage. If there is no leakage,
Teplace the turbocharger assembly.
If the pressure is above specification, check if the actuator
hose is disconnected or cracked. If net replace the
tubocharger assembly. r ENGINE MECHANICAL — Turbocharger [12H-T] EM-39
COMPONENTS
Intake Air Connector
(weith Air Hose)
Intake Fipe Stay
- ‘Turbocharger Stay-
© Gasket -
- No.2 Water By-Pass Pipe:
# Gasket fa
- (® Gasket- a
- ==}—___—_——"»
Nami : Specified torque Oil Pipe
part st
Turbine Outlet Elbow
‘Turbocharger EM-40 ENGINE MECHANICAL — Turbocharger [12H-T}
REMOVAL OF TURBOCHARGER
(See page EM-39)
1. DRAIN ENGINE COOLANT (See page CO-3)
2, REMOVE VACUUM HOSES, VSV AND GAS FILTER
3. REMOVE PCV PIPE
(a) Remove the three bolts.
(b} Disconnect the CV hose, and remove the PCV pipe:
and gasket together with the PCV hose.
4, REMOVE INTAKE AIR CONNECTOR
[al Remove the three bolts
(b) Disconnect the air hose, and remove the intake sir
connector together with the air hose
5. REMOVE INTAKE PIPE
fa) Remove the two bolts and intake pipe stay
fb) Remove the four bolts and nut.
fc) Disconnect the air hose, and remove the intake pipe
and gasket together with the air hose. ENGINE MECHANICAL
Turbocharger {12H-T] —M-41
6. REMOVE HEAT INSULATORS
Remove the five bolts and two heat insulators.
7. DISCONNECT HOSE FROM NO.2 WATER BY-PASS
PIPE
8. REMOVE TURBOCHARGER STAY
Remove the three bolts and stay,
8. REMOVE NO.1 WATER BY-PASS PIPE
(a) Loosen the union nut,
tb) Remove the two nuts, two bolts, by-pass pipes and
two gaskets,
10, REMOVE TURBOCHARGER
(a) Remove the unian bolt ond two gaskets of the oil
Pipe
(b} Remove the two nuts holding the oil pipe to the
cylinder block. EM-42 ENGINE MECHANICAL — Turbocharger [12H-T]
(c) Remove the four nuts holding the turbocharger to the
exhaust manifold,
{d) Remove the turbocharger and gasket together wit
the ail pipe.
fe) Remove the gasket of the oil pipe from the cylinder
block.
11, REMOVE OIL PIPE
Remove the twa nuts, oil pipe and gasket.
12, REMOVE NO.2 WATER BY-PASS PIPE
Remove the two nuts, by-pass pipe and gasket.
13. REMOVE TURBINE OUTLET ELBOW
Remove the four nuts, turbine outlet elbow and gasket, ENGINE MECHANICAL — Turbocharger [12H-T] —M-43
INSPECTION OF TURBOCHARGER
1, INSPECT IMPELLER WHEEL ROTATION
Grasp the edge of the turbine wheel and tune it. Check
that the impeller wheel turns smoothly.
If the impeller wheel does not turn or if it turns with a drag,
replace the turbocharger assembly.
2. INSPECT AXIAL PLAY OF IMPELLER WHEEL
Insert a dial indicator into the exhaust side, hold the tur-
bine wheel edge by hand and check the axial play,
‘Axial play: 0.13 mm (0.0051 in.) or less
If the axial play is not within specification, replace the tur-
bocharger assembly
INSTALLATION OF TURBOCHARGER
(See page EM-39)
CAUTION: Aftar replacing a turbocharger assembly,
pour about 20 cc (1.2 cu in) of new oil into the oil inlet
‘and then turn the impeller wheel by hand to splash oil
‘on the bearing.
1, INSTALL TURBINE OUTLET ELBOW
Install a new gasket and the turbine outlet elbow with the
four nuts.
Torque: 530 kg-cm (38 ft-lb, 52 N-m)
2. INSTALL NO.2 WATER BY-PASS PIPE
Install a new gasket and the by-pass pipe with the two
nuts,
Torque: 75 kg-em (65 inIb, 7.1 Nem) Ema ENGINE MECHANICAL — Turbocharger [12H-T]
T 3. INSTALL OIL PIPE
Install a new gasket and the oil pipe with new two nuts. Do
nat torque the nuts yet
4. INSTALL TURBOCHARGER:
{2} install new two gaskets to the cylinder block and
exhaust manifold.
b) Install the turbocharger and oil pipe together.
(c) Install the four nuts holding 1
exhaust manifold
Torque: 630 kg-cm (38 ft-lb, 52 N-m)
turbocharger to the
4a) Install new two nuts holding the oil pipe to the
cylinder block. Torque the four oil pipe nuts.
Torque: 185 kg-cm (13 ft-lb, 18 N-m)
(e) Install new two: gaskets and the union bolt of the ail
pipe. Torque the union bolt.
Torque: 250 kg-om (18 ft-lb, 25 N-m}
5. INSTALL NO.1 WATER BY-PASS PIPE
(a) Install a new gasket and the by-pass pipe with the
two nuts and two bolts,
Torque:
Nut 76 kg-em (69 in.-Ib, 7.1 Nem)
Bolt 175 kg-em (13 ft-lb, 17 Nem)
{b} Install the union nut. ENGINE MECHANICAL — Turbocharger [12H-T] EM-a5
INSTALL TURBOCHARGER STAY
Install the stay with the three bolts.
Torque: 700 kg-cm (61 ft-Ib. 69 Nem)
(CONNECT HOSE TO NO.2 WATER BY-PASS PIPE
INSTALL HEAT INSULATORS
Install the two heat insulators with the five bolts.
Torque: 185 kg-cm (13 ft-lb, 18 Nem)
INSTALL INTAKE PIPE
(a) Connect the air hose, and install a new qusket and
the intake pipe with the four bolts and nut,
Torque: 186 kg-cm (13 ft-lb, 18 N-m)
(o) Install the intake pipe stay with the two bolts.
Torque: 185 kg-om (13 ft-lb, 18 Nem) EM-46 ENGINE MECHANICAL — Turbocharger [1.2H-T]
10, INSTALL INTAKE AIR CONNECTOR
Connect the air hose, and install the intake air connector
with the three bolts.
Torque: 185 kg-em (13 ft-lb, 18 Nem)
11. INSTALL PCV PIPE
Connect the PCV hose, ond install a new gesket and PCY
pipe with three bolts
Torque: 185 kg-cm (13 ft-lb, 18 Nem)
12, INSTALL VACUUM HOSES, VSV AND GAS FILTER
13, FILL WITH ENGINE COOLANT
(See page CO-3)
14, START ENGINE AND CHECK FOR LEAKS
15, CHECK ENGINE OIL LEVEL (See page LU-3) CYLINDER HEAD
COMPONENTS
2H
# Cylinder Head Gasket
(ig-am Wil: Specie torque
# Non-reusal
Grommet
Glow Phig Connector
a -—— Pug
‘Seal Washer
-Cylindor Head Cover
Gasket
Valve Rocker Shaft
Ascembly
Push Rod
=e —_____Spring Retainer
Outer Valve Spring
Inner Valve Spring
il Seal
Valve Guide Bushing
1.186 (03. 1731 t
—Heat
Inguilator
ge
j 2 eg —— East
Exhaust Manitold (Fron) ——p- Mantas
c (Rear)
40-8ing
Manifold Ring EM-48 ENGINE MECHANICAL — Cylinder Head
COMPONENTS (Cont'd)
Seal Washer
Cylinder Head Cover
Fuel Fitter
‘Assembly —Vaive Rocker Shaft
[yes 13. 160 }—¥ Assembly
Push roa
5g Retainer
& Outer Vole Spring
@cosket }__laner Vala Sing
. - -@ Oil Seal
+ Valve Gulde Bustong
Intake aol
Manifold 1.100 a.
@ Gacket
Cynder Head = oh
E — 2 beat
Water Outer: talon
Assembly i.
‘Turbocharger Water
By-poss Pine (with Hose! 4
//€xhaust Manifold
(tear)
# Cylinder Head Gasket 0-Ring
Manifold Ring
[kgeem WE, Nl « Specified torque
# Non-rousable part ENGINE MECHANICAL — Cylinder Head
M49
REMOVAL OF CYLINDER HEAD [2H]
(See page EM-47)
zx
DRAIN ENGINE COOLANT (See page CO-3)
REMOVE PCV HOSE
REMOVE INJECTION NOZZLES (See page FU-3)
REMOVE GLOW PLUGS
fa) Remove the six screw grommets
tb) [Pre-heating System (Super Glow Typell
Remove the current sensor plate.
fc) Remove the six nuts and glow plug connector.
(6) Remove the six glow plugs
REMOVE FUEL FILTER ASSEMBLY
(a) Remove the two union bolts and four gaskets, and
disconnect the fuel pipes from the injection pump.
(o) Remove the two bolts and the fuel filter together
with the fuel pipes.
IM/T (w/ EDIC SYSTEM}
REMOVE EDIC MOTOR
{a} Remove the connecting rod EM-50, ENGINE MECHANICAL — Cylinder Head
(b) Remove the three bolts, collar and EDIC motor.
7. (MIT (w/o EDIC SYSTEM)]
REMOVE OVERINJECTION MAGNET
8, REMOVE INTAKE MANIFOLD
fo) (M/TI
Ramove the two vacuum hoses.
(b) Remove the twelve nuts, intake manifold and six
gaskets.
9, REMOVE EXHAUST MANIFOLDS
{a} Remove the seven bolts and two heat insulators.
(b) Remove the twelve nuts, plate washers, exh
manifolds and six gaskets. ENGINE MECHANICAL — Cylinder Head EM.51
10, SEPARATE EXHAUST MANIFOLDS:
(a) Separate the front and rear exhaust manifolds.
(b) Using snap ring pliers, remove the two manifold
rings
‘11, REMOVE WATER OUTLET ASSEMBLY
(a) Remove the three bolts holding the water outlet
housing to the cylinder head
(b) Disconnect the water by-pess hose from the water
pump, and remove the water outlet assembly and
gasket together with the by-pass hose.
12, REMOVE CYLINDER HEAD COVER
Remove the four cap nuts, seal washers, cylinder head
cover and gasket
13. REMOVE VALVE ROCKER SHAFT ASSEMBLY
(a) Uniformly loosen and remove the fourteen bolts in
several passes, in the sequence shown
(b) Remove the rocker shaft assembly. EM-52
ENGINE MECHANIGAL — Cylinder Head
nT
14, REMOVE PUSH RODS
Remove the twelve push rods in order, beginning from the
No. 1 push rod,
NOTE: Arrange the push rads in correct order.
15, REMOVE CYLINDER HEAD.
(al Uniformly loosen and remove the twenty-six head
‘baits in several passes, in the sequence shown
CAUTION: Head warpage or cracking could result
from removing bolt
(b) Lift the cylindor head trom the dowels on the cylinder
block and place the head on wooden blocks on a
bench
NOTE: If the cylinder head is difficult to lift off, pry with
2 screwdriver between the cylinder heed and block
salience:
CAUTION: Be careful not to damage the cylind.
head and block surface an the cylinder and head
et side: ENGINE MECHANICAL — Cylinder Head EM-53
REMOVAL OF CYLINDER HEAD [12H-T]
(See page EM-48)
REMOVE TURBOCHARGER
(See steps 1 to 10 on pages EM-40 to 42)
2, REMOVE INJECTION NOZZLES (See page FU-9}
3, REMOVE FUEL FILTER ASSEMBLY
[a] Remove the two union bolts and four gaskets, and
disconnect the fuel hose and pipe from the injection
pump.
(b} Remove the two bolts and the fuel fiter together
with the hose and pipe.
4, REMOVE INTAKE MANIFOLD
Remove the five bolts, eleven nuts, intake manifold and
gasket
REMOVE WATER BY-PASS PIPE OF TURBOCHARGER
Remove the bolt, nut, water by-pass pipe and two hose.
6. REMOVE EXHAUST MANIFOLDS
fa) Remove the five bolts and two heat insulators, EM.54 ENGINE MECHANICAL — Cylinder Head
(b} Remove the twelve nuts, plate washers, exhaust
manifold and two gaskets
7, ‘SEPARATE EXHAUST MANIFOLDS
{al Separate the front and rear exhaust manifolds.
{b) Using snap ring pliers, remove the two manifold
rings.
8. REMOVE WATER OUTLET ASSEMBLY
la) Remove the three batts holding the water outlet
housing to the cylinder head.
(h) Disconnect the water by-pess hese from the water
pump, and remove the water outlet and gasket
together with the by-aass hose.
9. REMOVE CYLINDER HEAD COVER
Remove the four cap nuts, seal washers cylinder head
cover and gasket, ENGINE MECHANICAL — Cylinder He:
10,
MW
REMOVE VALVE ROCKER SHAFT ASSEMBLY
(a) Uniformly loosen and remove the fourteen bolts in
several pass, in the sequence shown.
(b) Remove the rocker shaft assembly,
REMOVE PUSH RODS
Remove the twelve push rads in order, begining fram the
No. 1 push rod
NOTE: Arrange the push rods in correct order.
REMOVE CYLINDER HEAD
‘a) Uniformly loosen and remove the twenty-six head
bolts in several passes, in the sequence shown.
CAUTION: Head warpage or cracking could result
from removing bolts in incorrect order.
(bl Liftthe cylinder head from the dowels on the cylinder
block and place the head on wooden blocks on a
bench,
NOTE: I the cy ifficult to litt off, pry with
screwdriver between the cylinder head and block
saliences,
gasket sides. EM-56
ENGINE MECHANI
= Cylinder Head
ssT
1 203
a
5
DISASSEMBLY OF CYLINDER HEAD
(See page EM-47) 2H
{See page EM-48) 12H-T
1. REMOVE VALVES
(al Using SST, compress the valve spring and remove
the two keepers.
SST 09202-43013
(6) Remove the spring retainer, valve springs. valve and
oil seal.
NOTE: Arrange the valves, valve springs and spring
retainers in the correct order.
2 (2H)
REMOVE COMBUSTION CHAMBERS
Using SST, remove the six combustion chambers
SST 09208-48010
NOTE: Arrange the combustion chambers in correct
order ENGINE MECHANICAL
Cylinder Head EM-.57
INSPECTION, CLEANING AND REPAIR OF
CYLINDER HEAD COMPONENTS
1, CLEAN TOP OF PISTONS AND TOP OF BLOCK
la) Turn the crankshaft and bring each piston to top
dead center. Using a gasket scraper, remove all the
carbon from the pisten top.
(ob) Remove all the gasket material fram the top of the
block.
(e} Blow carbon and oil from the bolt holes,
WARNING: Protect your eyes when using high
pressure air.
2, REMOVE GASKET MATERIAL
Using a gasket sc remove all the gasket material
from the manifold and head surface.
CAUTION: Be careful not to scratch the surfaces.
3. CLEAN COMBUSTION CHAMBERS
Using a wire brush, remove all the carbon from the com-
bustion chambers,
CAUTION: Be careful not to seratch the head gasket
contact surface.
4. CLEAN VALVE GUIDE BUSHINGS
Using 2 valve guide bushing brush and solvent, clean ell
the guide bushings.
6, CLEAN CYLINDER HEAD
Using a soft brush and solvent, thoroughly clean the head. EM-58 ENGINE MECHANICAL — Cylinder He:
Intake Manifotd side [12H-T]
Exhaust Manifold side
oes
INSPECT CYLINDER HEAD FOR FLATNESS
Using 2 precision straight edge and feeler gauge, measure
the surfaces contacting the cylinder black and manifolds
for warpage.
ide 0.20 mm (0.0079 in}
Manifold side 0.20 mm (0.0079 in}
it warpage is greater than maximum, replace the head
INSPECT CYLINDER HEAD FOR CRACKS:
Using a dye penetrant, check the combustion chamber,
intake and exhaust ports, head surface and the top af the
head for cracks.
It cracked, replace the head. ENGINE MECHANICAL — Cylinder
10,
CLEAN VALVES
(a) Use # gasket scraper, chip any carbon from the valve
head
fb) Using @ wire brush, thoroughly clean the valve
INSPECT VALVE STEM AND VALVE GUIDE BUSHING
fa) Using # celiper gauge or telescoping geuge, measure
the inside diameter of the valve guide bushing
Bushing inside diame
9.010 — 9.030 mm (0.3547 — 0.3585 in.)
(o) Using @ micrometer, measure the diameter of the
valve stem.
‘Valve stem diameter:
Intake 8.973 - 8.989 mm
(0.3533 — 0.3539 in}
Exhaust 8.954 — 8.970 mm
(0.3525 — 0.3531 in)
(cl Subtract the valve stem diameter measurement from
‘the bushing inside diameter measurement.
Standard stem oil clearance
Intake 0.021 ~ 0.057 mm
(0.0008 — 0.0022 in}
Exhaust 0.040 = 0.076 mm
(0.0016 — 0.0030 in)
Maximum stem oil clearance:
Intake 0.10 mm (0.0039 ind
Exhaust 0.12 mm (0.0047 in)
If the clearance is greater than maximum. replace the valve
and valve guide bushing.
IF NECESSARY, REPLACE VALVE GUIDE BUSHING
(a) Using SST and a hammer, tap out the vaive guide
bushing
SST 09201-60011 EM-60 ENGINE MECHANICAL — Cylinder Head
"
=
Margin Thickness
{
(b) Using @ caliper gauge, measure the bushing bore
dismeter of the cylinder head,
If the bushing bore diameter of the cylinder head is mere:
than 14.018 mm (0.5519 in), replace the cylinder head,
{c)_ Using SST and @ hammer, tap in a new valve guide
bushing to where there is 14.8 — 15.2 mm (0.583 —
0.598 in.) protruding from the cylinder head.
SST 09201-60011
{d) Using a sharp 9.0 mm reamer, ream the valve guide
bushing to oblain the standard specified clearance
(See page EM-59) between the valve guide bushing
and new valve stem,
INSPECT AND GRIND VALVES
lal Grind the valve only enough to remove pits and car-
bon,
(o) Check that the valve is ground to the correct valve
face angle
Valve face angle: 44.5°
lc) Check the valve head margin thickness
Standard margin thicknes
intake 1.4 mm (0.055 ind
Exhaust 1.8 mm (0.071 in}
Minimum margin thickness:
Intake 0.9 mm (0.035 in}
Exhaust 1.3 mm (0.051 in}
If the valve head margin thickness is less than minimum,
replace the valve. ENGINE MECHANICAL — Cylinder Head EM-61
|
‘Wcth,
1d) Check the vaive overall length,
‘Standard overall lengtt
Intake 120.7 mm (4.762 im)
Exhaust 120.6 mm (4.748 in)
Minimum overall length:
Intake 120.2 mm (4.732 in)
Exhaust 120.1 mm (4,728 in)
(a) If the valve stem tip is worn, resurface the tip with a
grinder of replace the val
CAUTION: Do not grind off more than the minimum
amount.
12. INSPECT AND CLEAN VALVE SEATS
(a) Using 8 45° carbide cutter, resurface the valve seats,
Remave only enough metal to clean the seats.
tb} Check the valve seating position
Apply 8 thin coat of prussian blue lor white lead) to
‘he valve face. Install the valve. While applying light
pressure to the vaive, rotate the valve against the
seat.
(cl Check the valve face and seat for the fellowing:
© If blue appears 360° around the face, the valve is
concentric. if not, replace the valve
© If blue appears 360° around the valve seat, the
guide and seat are concentric. If not, resurface the
seat
© Check that the seat contact is on the middle of the
valve face with the following width:
1.4 — 2.0 mm (0.055 ~ 0.079 in]
If not, correct the valve seat as follows
(1) If the seating is too high on the valve face, use
30° and 45° cutters to correct the seat. EM-62
E MECHANICAL — Cylinder Head
12H-T Intake
xno
13,
(2) (12H-T Intake!
If the seating is too low on the valve face, use
60° and 45° cutters to correct the seat
(3) loters]
If the seating is too low on the valve face, use
‘75° and 48° cutters to correct the sest
id) Hand-lap the valve and valve seat with an abrasive
compound,
(le) After hand-lapping, clean the valve and valve seat,
INSPECT VALVE SPRINGS
(a) Using @ steel square, check the squareness of the
valve spring
Maximum squareness: 2.0 mm (0.079 in)
If squareness is greater than maximum, replace the valve
spring
fb) Using calipers, measure the fi
spring,
Free length:
Inner spring 44.3 mm (1.744 in}
Outer spring 48.1 mm (1,894 ind
If the free length is not as specified, replace the valve
spring.
length of the valve
(cl Using & spring tester, measure the tension of the
valve spring at the specified installed length.
Installed tension:
7.6 kg (16.8 tb, 75 ND
at 36,0 mm (1.417 in)
22.5 kg (49.6 Ib, 221 N)
at 40.0 mm (1.575 in)
If the installed tension is not es specified, replace the valve
spring. ENGINE MECHANICAL — Cylinder Head EM-63
Front
A§OdGMediouaddd
14,
INSPECT ROCKER ARM AND SHAFT
(a) Check the valve contacting surface of the rocker arm_
for wear.
(b) Check the rocker arm-to-shatt clearance by moving
‘each rocker arm a3 shown in the figure.
If movement is felt, disassemble and inspect.
{c) Disassemble the valve rocker shaft assembly,
NOTE: Arrange the rocker arms and rocker supports in
correct order.
If the contacting surface of the rocker arm is wom, resur-
face it with a valve retacer and oil stone, or replace the
rocker arm.
{d) Check the oil clearance between the rocker arm and.
shaft
© Using 4 caliper gauge, messure the inside diameter
of the rocker arm
Rocker arm inside diamet
18.500 — 18.521 mm (0.7283 — 0.7292 in.) EM-64, ENGINE MECHANICAL — Cylinder Head
© Using a micrometer, measure the diameter of the
rocker shat.
shaft diameter:
18.472 = 18.493 mm (0.7272 ~ 0.7281 in)
® Subirect the rocker shett diemeter measurement
‘from the inside diameter measurement of the
rocker arm
Standard oll clearance: 0,007 = 0.049 mm
{0.0003 — 0.00:
nce: 0.10 mm 10.003
Hf the clearance is greater than maximum, replace the
rocker am end shaft.
fo) Assemble the valve rocker shaft assembly 2s shown,
Maximum oil cleat
Valve Rocker Arm
g
ee
Valve Rocker Support
Valve Rocker Shatt ENGINE MECHANICAL — Cylinder Head EM-65
18. INSPECT PUSH RODS
fa) Place the push rod on V-blocks.
Yo] Using a dial indicator, measure the circle runout at
the center of the push rod.
Maximum circle runout: 0.50 mm (0.0187 in.)
Wf the circle runout is greater than maximum, replace the
push rod.
16. INSPECT INTAKE AND EXHAUST MANIFOLDS
Using precision straight edge and feeler gauge, measure
the surface contacting the eylinder head for warpage
Maximum warpage:
Intake Manifold [2H]
Intake 0.50 mm (0.0197 in!
aa Exhaust
te eT 2H (Front and rear) 0,30 mm (0.0114 in)
—_ ” 12H-T (Front! 0.30 mm (0.0118 in}
12H-T (Rearl 0.20 mm (0.0079 in.)
If warapege is greater than maximum, replace the
manifold.
Intake Manifold [124-1]
Exhaust Manifold [2H]
Exhaust Manifold (12H-T] page EM-47) 2H
page EM-48) 12H-T
NOTE
'@ Thoroughly clean all parts ta be assembled,
‘© Before installing the parts, apply new engine oil to all
sliding and rotating surfaces,
© Replace all gaskets. and oil seals. with new ones,
(2H
INSTALL COMBUSTION CHAMBERS
(a) Align the combustion chamber knack pin with the
cylinder head notch.
(a) Using a plastic-faced hammer, tap in the combustion
chamber with the shim.
(cl Using a dial indicator, cheek the combustion cham~
ber protrusion
Combustion chamber protrusio
0 mm (0 = 0.003:
INSTALL VALVES
{a} Install the follwing parts:
(1) New oil sea!
(2) Valve
(3) inner spring
(4) Outer spring
(5) Spring retainer
fb) Using SST, compress the valve spring and place the
two keepers around the valve stam.
SST 09202-43013 ENGINE MECHANICAL — Cylinder Head EM-67
[cl] Using a plastic-faced hammer, lightly tap the valve
stem to assure proper fit EM-68 ENGINE MECHANICAL — Cylindor Hoad
INSTALLATION OF CYLINDER HEAD [2H]
(See page EM-47)
INSTALL CYLINDER HEAD
(s} Plece @ new cylinder heed gasket on the cylinder
block,
CAUTION: Be careful of the installation direction.
(b) Place the cylinder head on the cylinder head gasket
(c)_ Apply a light coat of engine oil on the threads and
under the cylinder head bolts.
{d) Install and uniformly tighten the twenty-six <1
head bolts in several passes, in the sequence shown
Torque: 1,150 kg-cm (83 ft-lb, 113 Nem)
2. INSTALL PUSH RODS
Install the twelve push rods
3. INSTALL VALVE ROCKER SHAFT ASSEMBLY
la) Place the rocker shaft assembly on the cylinder head,
(bo) Install and wnifermly tighten the fourtsen bolts in
several passes, in the sequence shown
Torque: 188 kg-cm (13 ft-lb, 18 Nemb
4. ADJUST VALVE CLEARANCES
(See stens 4 and 5 on page EM-22)
‘Valve clearance (Referencel:
Intake 0.20 mm (0,008 in.
Exhaust 0.36 mm (0.014 in} Fy ENGINE MECHANICAL — Cylinder Head EM-69
Ring End Ring End
INSTALL CYLINDER HEAD COVER
{a} Install a new gasket to the cylinder head cover,
(b} Install the cylinder head cover with the four seal
washers and cap nuts.
Torque: 70 kg-om (61
Ib, 6.9 N-m)
INSTALL WATER OUTLET ASSEMBLY
Connect the water by-pass hose to the water pump, and
install a new gasket and the water outlet assembly with
the three bolts.
Torque: 375 kg-cm (27 ft-lb, 37 Nm)
ASSEMBLE EXHAUST MANIFOLDS
a) Remove all the O-ring material from the manifald
grooves,
(be) Install new two O-rings.
lel Using snap ring pliers, install the two manifold rings,
[d) Position the manifold rings so that the ring ends ore
as shown.
CAUTION: Do not align the ends. EM-70
&
ENGINE MECHANICAL — Cylinder Hid
fe) Assemble the front and rear manifolds.
INSTALL EXHAUST MANIFOLDS
{al Install new six gaskets and the exhaust manifolds
with the twelve plate washers and new nuts.
Torque: 210 kg-em (16 ft-lb, 21 N-mb
(b) Install the two heat insulstors with the seven bolts
Torque: 185 kg-em (13 ft-tb, 18 Nem)
INSTALL INTAKE MANIFOLD
(a) Install new six gaskets and the intake manifold with
the twelve nuts.
Torque: 185 kg-cm (15 ft-lb, 18 N-mi
‘bh [WT]
Install the two vacuum hoses. ENGINE MECHANICAL — Cylinder Head
10. [M/T (w/ EDIC SY¥STEMIT
INSTALL EDIC MOTOR
a} Install the EDIC motor with the collar and three bolts,
(b) Install the connecting od,
11. [M/T (w/o EDIC SYSTEM)}
INSTALL OVERINJECTION MAGNET
12. INSTALL FUEL FILTER ASSEMBLY
(a) Install the fuel filter assembly with the twe bolts,
Torque: 376 kg-cm (27 ft-lb, 37 N-m)
(bl Connect the two fue! pipes to the injection pump.
with new four gaskets. and the two union bolts. Tor~
ue the union bolts
Torque: 280 kg-em (20 ft-lb, 28 N-m)
13. INSTALL GLOW PLUGS
(a) Install the six glow plugs.
Torque: 125 kg-cm [9 ft-lb, 12 Nem)
(0) Install the glow plug connector with the six nuts
(ce) [Pre-hesting System (Supper Glow Typell
Install the current sensor plate.
(d) Install the six screw grommets. IECHANIGAL — Cylinder Head
14. INSTALL INJECTION NOZZLES
(See steps 1 to 3 an page EM-8!
15. INSTALL PCV HOSE
16, FILL WITH ENGINE COOLANT (See page CO-3)
17. START ENGINE AND CHECK FOR LEAKS
18. CHECK ENGINE OIL LEVEL (See page LU-3)
19. READJUST VALVE CLEARANCES
(Seo steps 1, 3 to 6 on page EM-22) vlinder Head EM.
3
INSTALLATION OF CYLINDER HEAD [12H-T]
(See page EM-48)
1, INSTALL CYLINDER HEAD.
(a) Place 2 new cylinder head gasket on the cylinder
block
CAUTION: Be careful of the installation direction.
(b) Place the cylinder head on the cylinder head gasket.
fc) Apply a light cost of engine oll on the threads and
under the cylinder head bolts.
(4) install and uniformly tighten the twenty-six cylinder
head boits in several passes, in the sequence shown.
Torque: 1.150 kg-om (83 ft-tb, 113 Nm)
2. INSTALL PUSH RODS
Install the twelve push rods.
3, INSTALL VALVE ROCKER SHAFT ASSEMBLY
(a) Place the rocker shaft assembly on the eylinder head.
(0) instal and uniformly tighten the fourteen bolts in
several passes, in the sequence shown.
Torque: 188 kg-em (13 ft-tb, 18 N-m)
4, ADJUST VALVE CLEARANCE
(See steps 4 and 5 on page EM-22)
Valve clearance (Reference):
Intake 0.20 mm (0.008 in)
Exhaust 0.36 mm (0.014 in) EM-74
ENGINE MECHANICAL — Cylinder Head
Ring End
Ring End
INSTALL CYLINDER HEAD COVER
(a) Installs new gasket to the cylinder head cover.
(b) Install the cylinder head cover with the four seal
washers ond cap nuts.
Torque: 70 kg-em (61 in-t
INSTALL WATER OUTLET ASSEMBLY
Connect the water by-pass hose to the water pump, and
install a new gasket and the water outlet assembly with
the three bolts.
375 kg-cm (27 ft-tb, 37 N-m)
ASSEMBLE EXHAUST MANIFOLDS:
fa) Remove all the O-ring material from the manifold
grooves,
ib) Install new two O-rings.
le} Using snap ring plies, install the two manifold rings
(a) Position the manifold rings 80 that the ring ends are
as shown,
CAUTION: Do not align the ends. ENGINE MECHANICAL — Cylinder Head EM-75
(6) Assembly the front and rear manifolds.
8. INSTALL EXHAUST MANIFOLDS
fa) Install new twa gaskets and the exhaust manifolds
with the twelve plate washers and new nuts.
210 kg-crm (15 ft-Ib, 21 Nem)
tb} Install the two heat insulators with the five bolts.
Torque: 185 kg-em (13 ft-Ib, 18 N-m)
9. INSTALL WATER BY-PASS HOSE OF
TURBOCHARGER
10, INSTALL INTAKE MANIFOLD
a) install a new gasket to the intake manifold,
fo) Install the intake manifold with the five bolts and
eleven nuts,
Torque: 185 kg-cm (13 ft-lb, 18 N-m} 12,
13,
15,
7.
ENGINE MECHANICAL — Cylinder Head
. INSTALL FUEL FILTER ASSEMBLY
a)
Torque:
tb)
Install the fuel fitter assembly with the two bolts,
375 kg-cm (27 ft-lb, 37 Nem)
Connect the fuel pipe and hose to the injection pump.
with new four gaskets and the two union bolts. Tar-
que the union bolts
Torque: 280 kg-cm (20 ft-lb, 28 Nem)
INSTALL INJECTION NOZZLES
(See steps 1 to 4 on pages FU-14 and 15)
INSTALL TURBOCHARGER
(See steps 3 to 12 on pages EM-44 and 46)
FILL WITH ENGINE COOLANT (See page CO-3)
START ENGINE AND CHECK FOR LEAKS
CHECK ENGINE OIL LEVEL (See page LU-3)
READJUST VALVE CLEARANCES
(See steps 1 to 7 on page EM-22) ENGINE MECHANICAL
ing Gears and Camshaft EM-77
TIMING GEARS AND CAMSHAFT
COMPONENTS
2H (w/o PS A/C) © Gasket
Timing Gear Cover
rankshatt Pulley A
[aise i328, aan) |} XE ‘Tening Goer Cover |
a
2H Iwi PS or A/C) pan
and 12H-T
cans ([za0 107. 231 |
I Pipa
(790 184, 74) |
[anna a} ——o» 929 1 Lance
4 Gasket @ ter,
Crankshaft Pusey || Washer Orie Gear |
[4500 2s, aan |——
Wo. | lle Gear Shaft
