ENGINE MECHANICAL DIESEL ENGINE DIAGNOSIS. DIESEL ELECTRICAL SYSTEM DIAGNOSIS [2H] DIESEL ELECTRICAL SYSTEM DIAGNOSIS [12H-T] TURBOCHARGER DIAGNOSIS [12H-T] TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS [12H-T] ENGINE TUNE-UP ....... COMPRESSION CHECK [2H] COMPRESSION CHECK [12H-T] .. TURBOCHARGER [12H-T] CYLINDER HEAD TIMING GEARS AND CAMSHAFT CYLINDER BLOCKEM-2 ENGINE MECHANICAL — Diese! Engine Diagnosis DIESEL ENGINE DIAGNOSIS 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, 1. Before beginning fuel system tests, first check that the engine compression, valve timing and other major systems are within specifications. PRELIMINARY CHECKS (a) (b) i) (a) (e) (f (g) 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. Check the air filter and clean or replace as necessary. Check for sufficient fuel in the tank. Check if the fuel is contaminated with gasoline or other foreign elements. Only high-quality diesel fuel should be used. Bleed air from the system by pumping the priming pump. Check for water in the sedimenter and fuel tank, and drain as necessary. If the engine will not crank or if it cranks slowly, troubleshoot the electrical system,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 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 r ~~ necessary repairs. | Repair as necessar INOPERATIVE STARTER |— = fi Check for battery voltage at starter terminals 30 I and 50. If Okay, see STARTING SYSTEM page (ST-11) for repair procedure. ENGINE CRANKS SLOWLY-WILL NOT START NOTE: Minimum cranking speed: 100rpm Cold 150rpm Hot (Possible Cause) (Check Procedure and Correction Method) LOOSE OR CORRODED i BATTERY CABLES {Refer to items 1 and 2 of ENGINE WILL NOT CRANK DISCHARGED BATTERY { Check engine oil ] If improper viscosity, drain and refill with oil of viscosity recommended by manufacturer. { (See page LU-4)EM-4 ENGINE MECHANICAL — Diesel Engine Diagnosis ENGINE CRANKS NORMALLY BUT WILL NOT START (Check Procedure and Correction Method) ee NOZZLE | nozzle. - - Crank the engine for about 5 seconds while con- firming that fuel is being discharged from the pipe. If fuel is coming out, begin diagnosis from item 4. | If not, begin from item 2 J [ 2. NO FUEL INTO INJECTION Disconnect inlet hoses to the feed pump and feed | PUMP J clean fuel from separate container directly into | feed pump, | If engine starts, either the sedimenter or fuel line between the fuel tank and feed pump is clogged and should be repaired. If the engine still does not start, check the fuel filter or line between feed pump and injection pump. If normal, the feed pump or injection pump is faulty | and should be repaired. | | NOTE: When feeding fuel directly into pump, keep container at same level as vehicle fuel Uank. FUEL LEAKAGE FROM 1 (‘Check for loose unions or cracks. INJECTION PIPE J If leaking, tighten to specified torque or, if neces- sary, replace pipes). 4, [2H] ith the starter switch turned ON and the glow INOPERATIVE PRE-HEATING plug indicator light illuminated, check that there is OPERATION voltage applied to the glow plug. | If not, refer to ELECTRICAL DIAGNOSIS and repair (Las necessary. (See page EM-11) (12H-T1 {With the ignition switch turned ON and the INOPERATIVE PRE-HEATING —/—————| intake heater indicator light illuminated, check that | OPERATION | there is voltage applied to the intake heater. | If not, refer to ELECTRICAL DIAGNOSIS and repair Las necessary. (See page EM-13) ( Check the glow plug for continuity. (See page ST-5) SPER OMT Ga If no continuity, a broken wire is indicated and the glow plug should be replaced J 7 ‘(12-1 Check the intake heater continuity. (See page ST-9)) FAULTY INTAKE HEATER — | OPERATION If no continuity, a broken wire is indicated and intake heater should be replaced.ENGINE MECHANICAL — Diesel Engine Diagnosis EM-5 ____( Gheck the injection timing. ee page EM-23) eS | Injection timing: 2H 18° BTDC | 12H-T 11° BTDC If not as specified, injection timing must be read- fisted IMPROPER INJECTION TIMING {Check the injection pressure with nozzle tester | [e FautTy insecrio | (See page FU-4 or 10) Opening pressure: 2H 105 — 125 kg/em? | (1,493 ~ 1,778 psid (10,296 ~ 12,258 kPa) } 12H-T 180 — 210 kg/em* (2,560 — 2,987 psi) | (17,652 — 20,594 kPa) If not within specification, nozzle adjustment is improper and pressure should be readjusted. If pressure cannot be adjusted to specification, replace nozzle. (Possible Cau: IMPROPER ADJUSTMENT OF “ith the accelerotor pedal released, check thet the ) ACCELERATOR CABLE adjusting lever is in contact with the idle adjusting | screw. Also, check if the accelerator cable is catch- | ing on something. | If necessary, adjust so lever is in contact with the { screw, or make other requied repairs [ 2. IDLE SPEED Too LOW |— Check the idle speed as specified below. } (See page EM-26 or 28) | Idle speed: M/T 650 rpm AIT (2H) 750 rpm A/T (12H-7) 770 rpm | | If not, adjust with the idle speed adjusting screw. NOTE: If less than specified, idling would (normally be rough. Check for leaks in the injection pump connections, | feed pump, nozzle holder and delivery vaive. | |. FUEL LEAKAGE Tighten any loose connections to specified torqueEM-6 ENGINE MECHANICAL — Diesel Engine Diagnosis IMPROPER INJECTION Refer to item 6 of ENGINE CRANKS NORMALLY | TIMING | BUT WILL NOT START, above =) IMPROPER OPERATION OF “With the engine idling, loosen the injection pipe to 7 INJECTION NOZZLE OR ———] each cylinder in order, and check if the idle speed | DELIVERY VALVE changes. | If no change, a faulty cylinder is indicated. Check according to the following procedure. | © Faulty Nozzle Check the nozzle with nozzle tester. | (See page FU-4 or 10) | Opening pressure: | 2H 105 ~ 125 kg/cm? (1,493 ~ 1,778 psi) | (10,296 — 12,258 kPa) | 12H-T 180 ~ 210 kg/cm’ (2,560 — 2,987 psi) (17.652 — 20,594 kPa) If not within specification, the nozzle is faulty and | injection pressure should be readjusted | © Faulty Delivery Valve If injection pressure is within specification, the delivery valve is defective and should be replaced. _| ENGINE SUDDENLY STOPS {Possible Cause) (Check Procedure and Correction Method) [4._ENGINE WILL NOT RE-START |-————{ Check to see if engine re-starts according to } a prescribed procedure. | If not, refer to ENGINE CRANKS NORMALLY BUT | WILL NOT START, above, and repair as necessary. } ~;~~ idle is not stable, refer to ROUGH IDLE WITH = | WARM ENGINE and repair accordingly. NO FUELINTO INJECTION |___[ Refer to item 2 of ENGINE CRANKS NORMALLY _ PUMP {BUT WILL NOT START, aboveENGINE MECHANICAL — Diesel Engine Diagnosis LACK OF POWER NOTE: 1. First check that the air cleaner is not clogged or the engine overheatin: 2. Not applicable if the customer desires an output power higher than specified for that vehicle. For accuracy, adjust with a chassis dynamo. {Check Procedure and Correction Method) With accelerator fully depressed, check that the adjusting lever is in contact with the maximum speed adjusting screw. (See page EM-26 or 28) | | If not, adjust accordingly J IMPROPER ACCELERATOR — CABLE ADJUSTMENT ‘INSUFFICIENT 7 MAXIMUM SPEED | floor and check that maximum speed is as specified 7 o nan | below. (See page EM-26 or 28) | | Maximum speed: | w/ Fluid cou If not, adjust with the maximum speed adjusting { sorew. _}|--——~{ Reefer to item 3 of ROUGH IDLE WITH WARM —— ENGINE 3. FUEL LEAKAGE CLOGGED FUEL FILTER |__{ disconnect the injection pump inlet hose and outlet : pipe of the feed pump, and connect directly with a suitable pipe. Then pour clean fuel into the inlet side of the feed pump. If the engine condition improves, the fuel filter is clogged and should be replaced. (See page FU-2) NOTE: When feeding fuel directly into the pump, 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 repai \o ry repairs. SJ ‘Refer to item 8 of ENGINE GRANKS NORMALLY) BUT WILL NOT START. J [6 FAULTY INJECTION NOZZLE Refer to item 9 of ENGINE —— a BUT WILL NOT START.EM-8 ENGINE MECHANICAL — Diese! Engine Diagnosis EXCESSIVE EXHAUST ‘SMOKE NOTE: 1. Check that the air cleaner is not clogged. 2. Check with the customer whether or not consumption has been excessive. (Possible Cause) (Check Procedure and Correction Method) —-{ Refer to item 8 of ENGINE CRANKS NORMALLY BUT WILL NOT START. NOTE: Black smoke indicates advanced timing while white smoke indicates retarded ti Adjustments should be made 1. IMPROPER INJECTION TIMING | FILTER |——{ Refer to item 5 of | NOTE: At high speed (2,000 ~ 3,000 rpm). a | | clogged filter tends to make the exhaust | { smoke w white. FAULTY INJECTION NOZZLE _|————~{ Refer to item 9 of ENGINE CRANKS NORMALLY nae 7 } BUT WILL NOT START. | NOTE: Excessive exhaust smoke is often | caused by nozzle pressure being too low. EXCESSIVE FUEL CONSUMPTION NOTE: Check whether the clutch slips, brakes grab, whether the tires are the wrong size or the air filter is clogged. (Check Procedure and Correction Method) Refer to item 3 of ROUGH IDLE WITH WARM — ENGINE, (Possible Caus FUEL LEAKAGE IDLE SPEED TOO HIGH | —_{ aiter sufficiently warming up engine, check that idle speed is as specified below. | (See page EM-26 or 28) | Idle speed: M/T 650 rpm | A/T (2H) 750 rpm AST (12H-1) 770 rpm the idle speed adjusting screw. (Uf not, adjust l ee | floor and check that 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 (screw. - | | [ 3. MAXIMUM SPEED TOO HIGH |—_ Start engine, depress the accelerator pedal to the—M-9 —( Refer to item 8 of ENGINE CRANKS NORMALLY) BUT WILL NOT START. — Refer 10 tem 9 of ENGINE L BUT WILL NOT START. ENGINE NOISE WHEN WARM (Cranking Noise with Excessive Vibration) (Possible Cause) (Check Procedure and Correction Method) 1. COOLANT TEMPERATURE TOO Check coolant temperature with coolant Low temperature gauge. OO If not sufficiently warm, thermostat is faulty and should be replaced, F | l [ 2. IMPROPER INJECTION TimiNG |———{ Refer to iter 8 of ENGINE CRANKS NORMALLY aaa Sana BUT WILL NOT START. [3 FAULTY INJECTION NOZZLE —_|———{ Refer to item 9 of ENGINE CRANKS NORMALLY = — [BUT WILL NOT START. (Possible Cause) (Check Procedure and Correction Method) BINDING ACCELERATOR CABLE | Operate adjusting lever on side of injection pump) Sorassaria is RTE and check if engine returns to idle | If 0, the accelerator cable is binding or improperly | adjusted and should be repaired accordingly. | | If engine does not return to idle, the injection pump {Lis faulty and should be repairedENGINE MECHANICAL — Diesel Engine Diagnosis ENGINE WILL NOT SHUT OFF WITH STOP BUTTON OR KEY (Possible Cause) (Check Procedure and Correcti n Method) [2H M/T (w/o EDIC SYSTEM)] | Operate stop lever (adjusting lever) on side of BINDING STOP CABLE injection pump and check if engine stops. a If 0, stop cable is binding or maladjusted and shoul be repaired accordingly. | If engine does not stop, injection pump is faulty and {_should be replaced. (See page FU-29) | 2. [2H M/T (w/ EDIC SYSTEM)] Operate stop lever (adjusting lever) on side |___ IMPROPER EDIC SYSTEM | of injection pump and check if engine stops. | If so, EDIC system is faulty and should | be repaired. (See page ST-21) | If engine does not stop, injection pump is faulty and should be repaired. (See page FU-29) [ 3. [2H A/T AND 12H-T] _ } Close the intake shutter and check if engine stops. | IMPROPER INTAKE SHUTTER | OPERATION eee) Land should be repaired. (S If it does, the intake shutter system is faulty page EM-33 or 34)ENGINE MECHANICAL — Diesel Electrical System Diagnosis [2H] EM-11 DIESEL ELECTRICAL SYSTEM DIAGNOSIS [2H] ENGINE DOES NOT START COLD NOTE: 1 2. Engine cranks normally. 3. Fusible link okay. 4. . Check the voltage marked with an asterisk (*) just as the Battery voltage at least 12 volts (or 24 volts) — ignition switch OFF. ion switch is placed at ON because the voltage will change with elapse of time. Pre-heating System (Super Glow Type) Check if indicator light lights up with ignition switch ON, Coolant temp. Approx. 20°C (68°F) : Approx. 2 seconds Yes Chock ENGNE Taso Check for short eae Fuse circuit and repair or GLOW Fuse (Others). Blown if necessary [row ox Check incicator wight bulb tag —7[_ Reece bub + No Good | bub ox Ignition switch OFF. Check for battery voltage to terminal 3 of pre-heating timer connector (on wire harness sidel. If okay, pre-heating timer is faulty and should be replaced, 4 * Check for battery voltage to terminal 1 of pre-heating timer with ignition switch ON, No Voltage Check that is 1V between terminals 9 and 12 If faulty, repair glow plug current sensor. If okay, timer is faulty and should be replaced, Voltage i Check if voltage to terminal 1 of pre-heating timer is terminated after engine is started Start the engine and check/if there is a voltage at terminal 9 of pre-heating timer. If faulty, repair charging system as necessary. If okay, timer is faulty and should be replaced, Yes Ignition switch OFF. CONTINUED ON PAGE EM-12 Pre-heating Timer T 1211109 7 oy—M-12 ENGINE MECHANICAL — Diesel Electrical System Diagnosis [2H] |CONTINUED FROM PAGE EM-11 ' Place ignition switch at ON and ‘check if current flow to terminal 5 of timer is in accordance with coolant temperature (See Timer characteristics Diagram on page ST-3). 0K | } | No Voltage _ | 1 ‘After completion of pre-heating, check for voltage at terminal 5 again when starter switch Is placed at ST | No Voltage Voltage | —_+_____ Ignition switch OFF. 1 Place ignition switch at ON and check for voltage to glow plug a few seconds later. Thereafter, voltage should drop about 1/2. | No Voltage at All OK No 172 Voltage Thereafter — Measure glow plug resistance. infinity Approx. 0 0 Glow plug okay Pre-heating Duration is Quite Different Than That Specification i Timer is faulty and should be replaced, T Check for battery voltage at plus 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 replaced, Check for battery voltage to plus side of resistor Intake manifold side). If okay, replace resistor. If no voltage, No. 2 glow plug relay is faulty and should be replaced Glow plug is faulty and should be replaced.ENGINE MECHANICAL — Diesel Electrical 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 temperature sensor okay. (See page ST-9) Pre-heating System 1. INSPECT POWER SUPPLY SECTION Is there continuity in the intake heater? No (See page ST-9) |} “0 +} Replace the intake heater. |Yes | Disconnect the water temperature sensor connector. Replace the fusible link. T T | | 1 When the ignition switch is turned ON, does pre-heat side of the intake heater have battery voltage for 20 seconds (12V type) or 14 seconds (24V typel? | |Fusible Link Blown No Check the fusible link for intake heater. |Fusibte Link OK | oo ates Inspect control section. | (See next pagel |EM-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 connector. 8 it 31 When the ignition switch is turned Ts the ENGINE fuse na No_J (Europe) or GLOW Replace the fuse. ON, does the indicator light light? | Y°-| (Measure the time lighted) fuse (Australia) Okay? le Yes Is the indicator No light bulb Okay? Replace the bulb. |Yes ' |s terminal 10 of the Open circuit or No pre-heating timer [No ground faulty in grounded? wire harness | ————____—__ between terminal wo 10 of the timer and body ground. | Is there battery voltage to terminal 3 of the timer (on wire harness side)? | [No t | Open circuit in wire hamess i between terminal 3 of the Replace the timer. timer and indicator light. Is the lighting time correct? No 12V type: 20 seconds [=| _ Replace the timer. 24V type: 14 seconds Yes | CONTINUED ON PAGE EM-15ENGINE MECHANICAL — Diesel Electrical System Diagnosis [12H-T] EM-15 Yes CONTINUED FROM PAGE EM-14 When the ignition switch is turned ON, is voltage between terminals B and No | Did No. 1 intake heater | ,,, | Replace the No. 1 G of the No. 1 intake heater relay | NO-} relay check out okay? | “°-/ intake heater OV for 20 seconds (12V type) or 14 (See page ST-9) relay. seconds (24V type)? Yes Yes | | 1 When the ignition switch is turned ON, does terminal 1 of the intake | 4, heater timer have battery voltage | N°) Replace the timer. for 20 seconds (12V type) or 14 seconds (24V typel? Yes | © Open circuit in wire harness between terminal 1 of the timer | and terminal g of the No. 1 intake heater relay © Open circuit or ground faulty in wire harness between terminal E of the No. 1 intake heater relay and body ground, | 1 With the engine started, is there 0 voltage 5 between terminals B and G of the No. 2. |_No_| Did No. 2 intake heater | | Replace the No.2 intake heater relay? f——*} Telay check out okay? |“) intake heater { o (See page ST-9) (Measure the time too) eevee ce relay. ] | Yes | Yes No. 1 and No. 2 Intake Heater Relays CONTINUED ON PAGE EM-16EM-16 ENGINE MECHANICAL — Diesel Electrical System Diagnosis [12H-T] Yes CONTINUED FROM PAGE EM-15 | Yes With the engine started, does terminal 5 of the Pre-heating have battery voltage for 70 seconds? Yes No When the ignition | | | Is terminal 9 of the | timer grounded? No__| switch is turned ON, does the charge warning light light? | Yes | Replace the timer. © Open circuit in wire harness between terminal 5 of the timer and terminal g of the No. 2 intake heater relay. © Open circuit or ground faulty in wire harness between terminal E of the No. 2 intake heater and body ground. 2 Is time normal After heat time: [——*° —-| Replace the timer. Approx. 70 seconds [Yes | ——_t Inspect power supply section. (See page EM-13) Tes No Open circuit in wire harness between terminal 9 of the timer and charge warning light. } } { ¥ © Inspect CHARGE fuse. © Inspect alternater regulator.ENGINE MECHANICAL — Turbocharger Diagnosis {12H-T] EM-17 TURBOCHARGER ee (12H-T] INSUFFICIENT ACCELERATION, LACK OF POWER OR EXCESSIVE FUEL CONSUMPTION NOTE: Before troubleshooting the turbocharger, first check the valve clearance, injection (Check Procedure and Correction Method) 1, INSUFFICIENT TURBOCHARGING Check turbocharging pressure. (See page EM-38) PRESSURE Turbocharging pressure: 0.39 — 0.53 kg/cm* (5.5 — 7.3 psi, 38 — 52 kPa) If not within specification, begin diagnosis from Item 2 3 RESTRICTED INTAKE AIR SYSTEM Check intake air system, and repair or ——— ~~~" | replace parts as necessary. (See page EM-40) 3.__ LEAK IN INTAKE AIR SYSTEM I{ Check intake air system, and repair or replace Parts as necessary. (See page EM-40) ee | 4. RESTRICTED EXHAUST SYSTEM {Check exhaust system, and repair or replace parts as necessary. (see page EM-40) ek | ESE eI EX AUC TSYSTEM }{ Check exhaust system, and repair or replace parts as necessary. (See page EM-40) 6. ERRATIC TURBOCHARGER OPERATION|_{ Check rotation of impeller wheel. If it does not tum {—_____________1'| or turns with heavy drag, replace the turbocharger assembly. Check axial play of impeller wheel. (See page EM-43) Axial play: 0.13 mm (0.0051 in.) or less If not within specification, replace the turbocharger assembly.EM-18 ENGINE MECHANICAL — Turbocharger Diagnosis [12H-T) 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 tor deformed exhaust pipe, loose mount bolts VIBRATING 1] or damaged gasket, and repair or replace as necessary. Refer to Item 7 of INSUFFICIENT ACCELER- ATION, LACK OF POWER OR EXCESSIVE FUEL CONSUMPTION. ERRATIC TURBOCHARGER OPERATION EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST (Possible Cause) (Check Procedure and Correction Method) FAULTY TURBOCHARGER SEAL H{ Check for oil leakage in exhaust system and check for excessive carbon deposits on the. | turbine wheel. Excessive carbon deposits would | | inciate'sYouty tabocharger | | | Veta Check for oil leakage in intake air system. © Check for axial play in impeller wheel, and replace the turbocharger if 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 not to diagnosis this as an oll leakage from theENGINE MECHANICAL — Turbocharger Electrical System Diagnosis (12H-T]___EM-19 TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS [12H-T] Troubleshooting of Turbocharger Indicator Light and Warning Light Operation Check for short Do both green indicator ight and amber] yo Blown woming ight ight when ignition switch | N° I heck GAUGE fuse |S" and repair a6 is turned to ON? , necessary tok Check for shor Thea CHARGE and | Blown _[ Check for sh ENGINE fuses J ——d:neray oK 15 charge warning NO Feutty charging light out? [—*Leystem YES ves Faulty combination “hia indicator and warring ants out during meter engine idle? T | Both lights stay on | Is charge warming NO Faulty charging | | light out? system | | [Loreen tight stays on | Check for open circuit in wire harness between Ok _[ Faulty low pressure | low pressure switch and tachometer. TL switch | Amber ight comes on | [Gheck tor open circuit in wire hamess between High pressure switch OK _[Fouy high pressure | [ana tachometer and check for ground connection of switch I “Lewiteh bees Does green indicator light come on when 0.14 kg/cm! (2.0 psi, 13.7 kPa) pressure is. applied to both pressure switches? l | ae pressure switch and tachometer. Check for short circuit in wire hamess between low Faulty low pressure switch, Amber light comes on Does green indicator light come on when 1.09 kgiem™ (16.5 pa NO, [ Faulty high pressure YES. (18.5 psi, 106.9 kPa) pressure applied to both switches? [no 106.9 kPa) pressure applied to bath switches? SST 09992-00241 switch Yes. Faulty combination Does amber indicator light come on when 1.09 kg/om™ | meter pressure switch and tachometer. Check for short circuit in wire hamess between high Faulty high pressure switch Yes Turbocharger indicator light and waming light operation okay.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 1.25 ~ 1.27 24V 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 air. First blow from the inside thoroughly. Then blow off the outside of the element. [Oil Bath Type] Air Filter ~ CLEAN AIR FILTER Ad ~ (a) Wash the oil case and air filter in kerosine by agitat- ing and rubbing (b) Wipe the oil case and air filter with a clean rag, (c) 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 EM-21 (e) Place the air filter on the tray. (6) 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 lb Drive belt deflection (Others): Used belt 10 — 13 mm (0.39 ~ 0.61 in) New belt 8 — 9 mm (0.31 — 0.36 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 — 125 kg/cm? (1,493 ~ 1,778 psi) (10,296 — 12,258 kPa) New nozzle 115 — 125 kg/cm’ (1,636 ~ 1,778 psid (11,278 — 12,258 kPa) Opening pressure (12H-T): Reused nozzle 180 — 210 kg/cm* (2,560 — 2,987 psi) (17,662 — 20,594 kPa) New nozzle 200 — 210 kg/cm? (2,845 — 2,987 psi) (19,613 — 29,594 kPa)EM-22 ENGINE MECHANICAL — Engine Tune-up INEX_EXIN EX IN Second Ah a EX IN EX eS 8) 1 7. ADJUSTMENT OF VALVE CLEARANCES WARM UP ENGINE Allow the engine to reach normal operating temperature. (124-11 REMOVE INTAKE AIR CONNECTOR AND INTAKE PIPE (See step 2 to 6 on page EM-40) REMOVE CYLINDER HEAD COVER SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Align the groove on the pulley with the timing pointer by turing 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. If not, turn the crankshaft one revolution (360°) and align the mark as above. ADJUST VALVE CLEARANCES (a) Measure only those valves indicated by arrows. Valve clearance (Hot): Intake 0.20 mm (0.008 in.) Exhaust 0.36 mm (0.014 in) © Using a feeler gauge, measure the valve clearance between the valve stem and rocker arm. Loosen the lock nut and turn 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 feeler gauge should slide with a very slight drag. (b) Turn the crankshaft one revolution (360°) and align the mark as above. Adjust only the valves indicated by arrows. INSTALL CYLINDER HEAD COVER (12H-T) INSTALL INTAKE PIPE AND INTAKE AIR CONNECTOR (See steps 9 to 12 on page EM-45 and 46)ENGINE MECHANICAL — Engine Tune-up EM-23 ADJUSTMENT OF INJECTION TIMING | 1, PREPARE INSPECTION PIPE Make an inspection pipe with a injection pipe as shown. About 50 mm (370) 2. (12H-T] REMOVE INTAKE AIR CONNECTOR AND INTAKE PIPE (See steps 2 to 5 on page EM-40) [aa] 3. REMOVE CYLINDER HEAD COVER 4, SET NO. 1 CYLINDER TO 18° (2H) or 11° (12H-T) Pama etree oraich BTDC/COMPRESSION (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. If not, turn the crankshaft one revolution (360°) and align the mark as above. Tining 2] PS AT Fn Spano and 12H nseraond 12H-T Eek WS Nh 8 see JNK 5. ADJUST INJECTION TIMING (2) Remove the No. 1 injection pipe and install the inspection pipe on the No. 1 delivery valve holder. (b) Tum the crankshaft slightly to left and right until fuel surfaces from the inspection pipe (c) Turn the crankshaft counterclockwise, set the No. 1 cylinder just before the 18° (2H) or 11° (12H-T) BTDC/compressionEM-24 ENGINE MECHANICAL — Engine Tune-up ‘2H (w/o PS or AIC) 18° BTDC Mark 2H (w/ PS or A/C) 18° BYDC Mark 11° BTDC Mark (@) (2H A/T and 12H-T1 Align the marks of the stop lever and injection pump governor housing. (e) Slowly turn the crankshaft clockwise, (f) Check the crankshaft pulley position (injection timing position) when the fuel level in the inspection pipe rises. Injection timing: 2H 18° BTDC 12H-T 11° BTDC NOTE: This operation should be repeated at least two or three times. {g) Loosen the other injection pipe union nuts, fuel pipe and oil pipe union bolt at the injection pump side. (h) 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 tilting the Pump @ way from the engine. If the injection timing is advanced, retard it by tilting the pump toward the engine.ENGINE MECHANICAL — Engine Tune-up EM-25 (k) Tighten the four nuts holding the injection pump to the retainer. Torque: 375 kg-cm (27 ft-lb, 37 Nem) (0) Tighten the bolt holding the injection pump stay to stay. Torque: 2H 185 kg-om (13 ft-lb, 18 Nem) 12H-T 360 kg-cm (26 ft-lb, 35 N-m) (m) Recheck the injection timing. (a) Remove the inspection pipe and install the No. 1 injection pipe. (0) Tighten the injection pipe union nuts, oil pipe union bolt and fuel pipe union bolt. 300 kg-em (22 ft-Ib, 29 N-m) 185 kg-cm (13 ft-lb, 18 N-m) Fuel pipe 280 kg-cm (20 ft-lb, 27 N-m) 6. INSTALL CYLINDER HEAD COVER 7 (2H-T) INSTALL INTAKE PIPE AND INTAKE AIR CONNECTOR (See steps 9 to 12 on pages EM-45 and 46) 8. START ENGINE AND CHECK FOR LEAKSEM-26 ENGINE MECHANICAL — Engine Tune-up ADJUSTMENT OF IDLE SPEED AND MAXIMUM SPEED [2H M/T] 1. INITIAL CONDITIONS (a) Air cleaner installed (0) Normal operating coolant temperature (c) Ali accessories switched off {d} All vacuum lines connected fe) 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 If not, adjust the accelerator linkage. (b) Start the engine. {c)_ Check the idle speed. Idle speed: 650 rpm (d) 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 turning the IDLE SPEED 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 throttl valve adjusting screw when the accelerator pedal depressed all the way. If not, adjust the accelerator linkage.ENGINE MECHANICAL — Engine Tune-up EM-27 (b) Start the engine. (c) Depress the accelerator pedal all the way. (a) Check the maximum speed. Maximum speed w/ Fluid coupling 4,170 rpm w/o Fluid coupling 4,100 rpm. (e) Adjust the maximum speed. © Disconnect the accelerator linkage. © Cut out the maximum speed adjusting (speed con- trol) screw 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, raise engine speed and recheck the maximum speed. © Securely tighten the lock nut and recheck the max- imum speed, © Seal the maximum speed adjusting screw with a new seal wire,EM-28 ENGINE MECHANICAL ~ Engine Tune-up ADJUSTMENT OF IDLE SPEED AND MAXIMUM SPEED [2H A/T and 12H-T] 1, INITIAL CONDITIONS {a) Air cleaner installed (b) Normal operating coolant temperature (c) All accessories switched off (d) All vacuum lines connected (e) Valve clearances set correctly (f) Injection timing set correctly (9) Transmission in N range 2. CONNECT TACHOMETER 3. ADJUST IDLE SPEED (a) Check that the adjusting lever touches the idle speed adjusting screw when the accelerator pedal is released. Hf not, adjust the accelerator linkage. (b) Start the engine. (c) Check the idle speed Idle speed: MT 650 rpm. AIT (2H) 750 rpm A/T (12H-T) 770 rpm (a) Adjust the idle speed © Disconnect the accelerator linkage. © Loosen the lock nut of the idle speed adjusting screw. © Adjust the idle speed by turning the IDLE SPEED 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 (2) Check that the adjusting lever touches the maximum speed adjusting bolt when the accelerator pedal is depressed all the way If not, adjust the accelerator linkage.ENGINE MECHANICAL — Engine Tune-up EM-29 Maximum Speed Adjusting Bolt (b) Start the engine. (c) Depress the accelerator pedal all the way. (a) Check the maximum speed. Maximum speed: 4,170 rpm (ec) 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, raise engine speed 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.EM-30 ENGINE MECHANICAL — Engine Tune-up ADJUSTMENT OF POWER STEERING IDLE-UP SETTING SPEED [12H-T A/T] 1. INITIAL CONDITIONS (a) Air cleaner installed (b) Normal operating coolant temperature (c) All accessories switched off (d) All vacuum lines connected (e) Valve clearances set correctly (f1_Injection timing set correctly (g) Idle speed set correctly (h) Transmission in N range 2. CONNECT TACHOMETER Ake Disconnect epomneTs 3. ADJUST POWER STEERING (PS) IDLE-UP SETTING SPEED (2) Start the engine. (b) Disconnect the vacuum hose from the idle-up actua- tor and plug the hose end. (c)_ Apply vacuum to the idle-up actuator. (d) Race the engine to 2,500 rpm for a few seconds, release the throttle and check the PS idle-up setting speed. PS idle-up setting speed: 820 rpm () Adjust the PS idle-up setting speed by turning the PS IDLE-UP ADJUSTING SCREW. {f) Race the engine to 2,500 rpm for a few seconds, release the throttle and recheck the PS idle-up set- ting speed. (g) 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 (c) All accessories switched off (d) All vacuum lines connected {e) Valve clearances set correctly (f) Injection timing set correctly {g)_ 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. (c) Apply vacuum to the idle-up actuator. (a) Race the engine to 2,500 rpm for a few seconds, release throttle and check the A/C idle-up setting speed AJC idle-up setting speed: 950 rpm (e) Adjust the A/C idle-up setting speed by turning the A/C IDLE-UP ADJUSTING SCREW. (f) Race the engine to 2,500 rpm for a few seconds, release the throttle and recheck the A/C idle-up set- ting speed, (g) Reconnect the vacuum hose to the idle-up actuator.EM-32 Disconnect YO AIC Idio-up Adjusting Screw ( yok Type A NI / ENGINE MECHANICAL — Engine Tune-up ADJUSTMENT OF AIR CONDITIONER IDLE-UP SETTING SPEED [2H A/T and 12H-T] 1. INITIAL CONDITIONS (a) Air cleaner installed (b) Normal operating coolant temperature (c) All accessories switched off (e) Valve clearances set correctly (f) Injection timing set correctly (@) Idle speed set correctly (h) wi PSI PS idle-up setting speed set correctly (i) Transmission in N range CONNECT TACHOMETER ADJUST AIR CONDITIONER (A/C) IDLE-UP SETTING SPEED @) Start the engine. (b) Disconnect the vacuum hose(s) from the idle-up actuator and plug the hose end|s). (c)_ Apply vacuum to the idle-up actuator. (d) Race the engine to 2,500 rpm for a few seconds, release the throttle and check the A/C idle-up setting speed AIC idle-up setting speed: M/T 950 rpm (Transmission in neutral) A/T 800 rpm (Transmission in D range) (e) Adjust the A/C idle-up setting speed by tuming the AIC IDLE-UP ADJUSTING SCREW. (f Race the engine to 2,500 rpm for a few seconds, release the throttle and recheck the A/C idle-up set- ting speed. (g) Reconnect the vacuum hose(s) to the idle-up actua- tor.ENGINE MECHANICAL — Engine Tune-up 3 INSPECTION OF INTAKE SHUTTER [2H A/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. (c)_ Check that the vacuum does not drop immediately. 2. INSPECT VACUUM SWITCHING VALVE (VSV) (a) Remove the VSV. (b) 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 Prt ool INSPECTION OF INTAKE SHUTTER [12H-T] 1, INSPECT INTAKE SHUTTER AND ACTUATOR fa) Fully close the throttle valve, and check that it return smoothly. {b) Apply vacuum to the actuator. (c) Check that the vacuum does not drop immediately. 2. INSPECT VACUUM SWITCH VALVE (VSV) (a) Remove the VSV. (b) Check that air flow from pipe E to pipe F. {c)_ Connect the VSV terminals to the battery terminals. (a) Check that air flows from pipe E to pipe G. If operation is not as specified, replace the VSV.ENGINE MECHANICAL — Compression Check [2H] COMPRESSION CHECK [2H] NOTE: If there is lack of power, excessive oil consump- tion or poor fuel economy, measure the cylinder compres- sion pressure EM-35 1. WARM UP AND STOP ENGINE 2, REMOVE GLOW PLUGS (See page EM-49) CAUTION: Make sure the load w not grounded. CHECK CYLINDER COMPRESSION PRESSURE (a) Install SST (gauge adapter) to the glow plug hole. SST 09992-00023 (b) Connect SST (compression gauge) to SST (gauge adapter). SST 09992-00023 (c) Fully open the throttle valve, (d) While cranking the engine with the starter, measure the compression pressure. NOTE: Always use a fully charged battery to obtain engine revolutions of more than 250 rpm. (e) Repeat steps (a) through (d) for each cylinder. Compression pressure: 28.0 kg/cm? (398 psi, 2,746 kPa) or more um pressure: 20.0 kg/cm? (284 psi, 1,961 kPa) Difference betws 2.0 kg/cm? (2.8 psi, 196 kPa) or less (f) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the oylinder through the glow plug hole and repeat steps (a) through (d) for the cylinder with low compression. Mi © If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. © If pressure stays low, a valve may be sticking or seating improperly, or there may be leakage past the gasket. 4, INSTALL GLOW PLUGS (See steps 1 to 4 on page FU-8)EM-36 ENGINE MECHANICAL — Compression Check [12H-T) COMPRESSION CHECK [12H-T] NOTE: If there is lack of power, excessive oil consump- tion of poor fuel economy, measure the cylinder compres- sion pressure. 1, WARM UP AND STOP ENGINE 2, REMOVE INJECTION NOZZLES (See page FU-9) CHECK CYLINDER COMPRESSION PRESSURE (a) Install SST (gauge adapter) to the injection nozzle hole. ‘SST 09992-00023 (b) Connect SST (compression gauge) to SST (gauge adapter) SST 09992-00023 {c)_ Fully open the throttle valve. {d) While cranking the engine with the starter, measure the compression pressure. NOTE: Always use a fully charged battery to obtain engine revolutions of more than 250 rpm. (e) Repeat steps (a) through (d) for each cylinder. Compression pressure 30.0 kg/em? (427 psi, 2,942 kPa) or more Minimum pressure: 20.0 kg/cm? (284 psi, 1,961 kPa) Difference between each cylinder: 2.0 kg/em? (28 psi, 196 kPa) or less (f) If the cylinder compression in one or more cylinders is low, pour @ small amount of engine oil into the cylinder through the injection nozzle hole and repeat steps (a) through (d) for the cylinder with low com- pression, © If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. © If pressure stays low, a 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)ENGINE MECHANICAL — Turbocharger [12H-T] EM-37 TURBOCHARGER [12H-T] CAUTION: © Do not stop the engine immediately after pulling a trailer of high speed or uphill driving. Idle the engine 20 — 120 seconds, depending on the severity of the driving condition. Avoid sudden racing or acceleration immediately after starting a cold engine. If the turbocharger is defective and must be rep- laced, first check for the cause of the defect in reference to the following items and replace parts if and quality Conditions under which turbocharger was used Oil lines leading to turbocharger Use caution when removing and reinstalling the tur- bocharger assembly. Do not drop it or bang it against, anything or grasp it by easily-deformed parts, such as the actuator or rod, when moving. © Before removing the turbocharger, plug the intake and exhaust pots and oil inlet to prevent entry of dirt or other foreign material. © If replacing the turbocharger, check for accumula- the oil pipes and, if necessary, es. © Completely remove the gaskets adhered to the lubrication oil pipe flanged and turbocharger oil flange. © If replacing bolts or nuts, do so only with the specified new ones to guard against breakage or deformation. © Ifreplacing the turbocharger, put 20 cc (1.2 cu in.) of | into the turbocharger oi! inlet and turn the impeller wheel by hand to spread oil to the bearing. © If overhauling or replacing the engine, cut the fuel supply and ignition function after reassembly and crank the engine for 30 seconds to distribute oil throughout the engine. Then allow the engine to idle for 60 seconds.EM-38 ENGINE MECHANICAL — Turbocharger [12H-T] 0.68 kglem? ON-VEHICLE INSPECTION OF TURBOCHARGER 1 INSPECT INTAKE AIR SYSTEM Check for leakage or clogging between the air cleaner and turbocharger inlet and between the turbocharger outlet and cylinder head. © Clogged air cleaner ... Clean or replace the element © Hoses collapsed or deformed .... Repair of replace © Leakage from connections ... Check each connection and repair © Cracks in components .... Check and replace INSPECT EXHAUST SYSTEM Check for leakage or clogging between the cylinder head and turbocharger inlet and between the turbocharger out- let and exhaust pipe. © Deformed components .... Repair or replace © Foreign material in passages .... Remove © Leakage from components .... Repair or replace © Cracks in components .... Check and replace INSPECT OPERATION OF ACTUATOR AND WASTE GATE VALVE fa) Disconnect the actuator hose. (b) Using SST {turbocharger pressure gauge), apply about 0.68 kg/cm? (9.7 psi, 67 kPa) of pressure to the actuator and check that the rod moves. SST 09992-00241 CAUTION: Never apply more than 0.8 kg/cm? (11.4 psi, 78 kPa) of pressure to the actuator. If the rod does not move, replace the turbocharger assem- bly. INSPECT TURBOCHARGING PRESSURE (a) Warm up the engine {o) Connect a 3-way union to the intake pipe pressure hose and install SST (turbocharger pressure gaugel to it. SST 09992-00241 (c)_ Press in the clutch pedal, then press the accelerator Pedal down as far as it will go. Measure the tur- bocharging pressure at maximum speed (4,050 — 4,200 rpm) Turbocharging pressure: 0.39 ~ 0.53 kg/em* (5.5 — 7.3 psi, 38 ~ 52 kPa) If the pressure is less than specification, check the intake air and exhaust systems for leakage. If there is no leakage, replace the turbocharger assembly. If the pressure is above specification, check if the actuator hose is disconnected or cracked. If not replace the tubocharger assembly.ENGINE MECHANICAL — Turbocharger [12H-T] EM-39 COMPONENTS © Gasket: Intake Pipe (with Air Hose) Gasket Intake Air Connector (with Air Hose) = _| -— iS - Se [——Heat Insulator PCV Pipe (with Hose) # Gasket © Gosket No.2 Water By-Pass Pipe ° # Gasket | 4 Gasket © Gasket | Turbine Outlet Elbow Turbocherger 9188 03 (Rab, Nim]: Specified torque eae 4 reusable part needENGINE MECHANICAL 1 ‘urbocharger [121 REMOVAL OF TURBOCHARGER (See page EM-39) 1 2. DRAIN ENGINE COOLANT (See page CO-3) REMOVE VACUUM HOSES, VSV AND GAS FILTER REMOVE PCV PIPE (a) Remove the three bolts. (b) Disconnect the PCV hose, and remove the PCV pipe and gasket together with the PCV hose. REMOVE INTAKE AIR CONNECTOR (a) Remove the three bolts. {b) Disconnect the air hose, and remove the intake air connector together with the air hose. REMOVE INTAKE PIPE (a) Remove the two bolts and intake pipe stay. (b) Remove the four bolts and nut. (c) Disconnect the air hose, and remove the intake pipe and gasket together with the air hose.ENGINE MECHANICAL — Turbocharger (12H-T] EM-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. 9. REMOVE NO.1 WATER BY-PASS PIPE (2) Loosen the union nut. (b) Remove the two nuts, two bolts, by-pass pipes and ‘two gaskets. 10, REMOVE TURBOCHARGER (2) Remove the union bolt and 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-T1 {d)_ Remove the four nuts holding the turbocharger to the exhaust manifold. (d) Remove the turbocharger and gasket together with the oil pipe. {e) Remove the gasket of the oil pipe from the cylinder block. 11, REMOVE OIL PIPE Remove the two 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. eae wor)ENGINE MECHANICAL — Turbocharger [12H-T] EM-43 INSPECTION OF TURBOCHARGER v7 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 tum or if it tums with a drag, replace the turbocharger assembly. 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: After 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. INSTALL TURBINE OUTLET ELBOW Install a new gasket and the turbine outlet elbow with the four nuts. Torque: 530 kg-cm (38 ft- ). 52 Nem) INSTALL NO.2 WATER BY-PASS PIPE Install a new gasket and the by-pass pipe with the two nuts, Torque: 75 kg-cm (65 in.-Ib, 7.1 N-m)EM-44 ENGINE MECHANICAL ~ Turbocharger {12H-T] 3. INSTALL OIL PIPE Install a new gasket and the oil pipe with new two nuts. Do not torque the nuts yet. INSTALL TURBOCHARGER (a) 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 the turbocharger to the exhaust manifold. Torque: 530 kg-cm (38 ft-Ib, 52 N-m) (d) Install new two nuts holding the oil pipe to the cylinder block, Torque the four oil pipe nuts. Torque: 185 kg-em (13 ft-lb, 18 N-m) (e)__ Install new two gaskets and the union bolt of the oil pipe. Torque the union bolt. Torque: 250 kg-om (18 ft-lb, 25 N-m) INSTALL NO.1 WATER BY-PASS PIPE (al Install a new gasket and the by-pass pipe with the two nuts and two bolts. Torque: Nut 75 kg-cm (65 in.-tb, 7.1 Nem) Bolt 175 kg-cm (13 ft-lb, 17 Nem) (b) Install the union nut.ENGINE MECHANICAL — Turbocharger [12H-T] EM-45, 6. INSTALL TURBOCHARGER STAY Install the stay with the three bolts. Torque: 700 kg-cm (51 ft-lb, 69 N-m) 7. CONNECT HOSE TO NO.2 WATER BY-PASS PIPE 8. INSTALL HEAT INSULATORS Install the two heat insulators with the five bolts, Torque: 185 kg-cm (13 ft-lb, 18 N-m) 9. INSTALL INTAKE PIPE (a) Connect the air hose, and install a new gasket and the intake pipe with the four bolts and nut. Torque: 185 kg-cm (13 ft-lb, 18 N-m) (b) Install the intake pipe stay with the two bolts. Torque: 185 kg-cm (13 ft-lb, 18 N-m)EM-46 ENGINE MECHANICAL — Turbocharger (12H-T) 10. INSTALL INTAKE AIR CONNECTOR Connect the air hose, and install the intake air connector with the three bolts. Torque: 185 kg-cm (13 ft-lb, 18 N-m) 11, INSTALL PCV PIPE Connect the PCV hose, and install a new gasket and PCV pipe with three bolts. Torque: 185 kg-em (13 ft-lb, 18 N-m) 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)ENGINE MECHANICAL — Cylinder Head EM-47 CYLINDER HEAD COMPONENTS 2H a ——Grommet 8 g — Es Gasket Valve Rocker Shaft Assembly Push Rod | spring Retainer | @—————outer Valve Spring t 1g nee ears or Fuel Fito aan Assembly fF ————— @ Valve Guide Bushing Cylinder Head Water Outlot Assembly C— © Gasket c %— > fen) 9 6) (Rear) | #o%ing Manifold Ring © Gasket ‘© Cylinder Head Gasket [kecem fb, Nn] : Speciied torque @ Non-reusable partEM-48 ENGINE MECHANICAL — Cylinder Head COMPONENTS (Cont'd) 12H-T g ‘Seal Washer Cylinder Head Cover —_—cesket Bruel iter : ‘Svemnty “469859 valve nocker Saft } Aesombiy Push Rod Spring Retainer ~Outer Valve Spring §—__———Inreer Valve Spring ¢——__—— 60 Seal Intake Manifold © Gasket ~ Cylinder Head: Water outet ——5.—\y Assembly Ca <2 Ben. Turbocharger Water: ~ - 080 | By-pass Pipe (with Hose) 4 Exhaust Manifold (Rear) @ Cylinder Head Gasket o-ring Manifold Ring [kg-cm (ft-lb. Ni} : Specified torque Non-reusable part snENGINE MECHANICAL Cylinder Head REMOVAL OF CYLINDER HEAD [2H] (See page EM-47) 1, DRAIN ENGINE COOLANT (See page CO-3) 2. REMOVE PCV HOSE 3, REMOVE INJECTION NOZZLES (See page FU-3) 4. REMOVE GLOW PLUGS (a) Remove the six screw grommets. {b) [Pre-heating System (Super Glow Type)] Remove the current sensor plate. (c)_ Remove the six nuts and glow plug connector. (d) Remove the six glow plugs 5. REMOVE FUEL FILTER ASSEMBLY (a) Remove the two union bolts and four gaskets, and disconnect the fuel pipes from the injection pump. (b) Remove the two bolts and the fuel filter together with the fuel pipes. 6. [M/T (w/ EDIC SYSTEM)] REMOVE EDIC MOTOR (a) Remove the connecting rodEM-50 ENGINE MECHANICAL — Cylinder Head 7. (b) Remove the three bolts, collar and EDIC motor. IM/T (w/o EDIC SYSTEM)] REMOVE OVERINJECTION MAGNET REMOVE INTAKE MANIFOLD (a) (wT) Remove the two vacuum hoses. (b) Remove the twelve nuts, intake manifold and six gaskets REMOVE EXHAUST MANIFOLDS (a) Remove the seven bolts and two heat insulators, (b) Remove the twelve nuts, plate washers, exhaust manifolds and six gaskets.ENGINE MECHANICAL — Cylinder Head EM-81 10, SEPARATE EXHAUST MANIFOLDS 1. 12. 13, (a) Separate the front and rear exhaust manifolds. (e) Using snap ring pliers, remove the two manifold rings. REMOVE WATER OUTLET ASSEMBLY (a) Remove the three bolts holding the water outlet housing to the cylinder head. (b) Disconnect the water by-pass hose from the water Pump, and remove the water outlet assembly and gasket together with the by-pass hose. REMOVE CYLINDER HEAD COVER Remove the four cap nuts, seal washers, cylinder head cover and gasket. 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 MECHANICAL — Cylinder Head 14. 15. REMOVE PUSH RODS Remove the twelve push rods in order, beginning from the No. 1 push rod, NOTE: Arrange the push rods in correct order. REMOVE CYLINDER HEAD fa) Uniformly loosen and remove the twenty-six head bolts in several passes, in the sequence shown, CAUTION: Head warpage or cracl from removing bolts in incorrect order. could result (b) Lift the cylinder head from 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 a screwdriver between the cylinder head and block saliences, CAUTION: Be careful not to damage the cylinder head and block surface on the cylinder and head gasket sides.ENGINE MECHANICAL — Cylinder Head EM-53 REMOVAL OF CYLINDER HEAD [12H-T] (See page EM-48) 1, 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 filter together with the hose and pipe. 4, REMOVE INTAKE MANIFOLD Remove the five bolts, eleven nuts, intake manifold and gasket. 5. REMOVE WATER BY-PASS PIPE OF TURBOCHARGER Remove the bolt, nut, water by-pass pipe and two hose. 6. REMOVE EXHAUST MANIFOLDS (a) Remove the five bolts and two heat insulators,EM-54 ENGINE MECHANICAL — Cylinder Head (o) Remove the twelve nuts, plate washers, exhaust manifold and two gaskets SEPARATE EXHAUST MANIFOLDS (a) Separate the front and rear exhaust manifolds. (b) Using snap ring pliers, remove the two manifold rings. REMOVE WATER OUTLET ASSEMBLY (a) Remove the three bolts holding the water outlet housing to the cylinder head. (6) Disconnect the water by-pass hose from the water pump, and remove the water outlet and gasket together with the by-pass hose. REMOVE CYLINDER HEAD COVER Remove the four cap nuts, seal washers cylinder head cover and gasket.ENGINE MECHANICAL — Cylinder Head EM-55 10. 1. 12, 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 rods in order, begining from the No. 1 push rod. NOTE: Arrange the push rods in correct order. REMOVE CYLINDER HEAD (2) Uniformly loosen and remove the twenty-six head bolts in several passes, in the sequence shown: CAUTION: Head warpage or cracking could resutt from removing bolts in incorrect order. (b) Lift the cylinder head from 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 a screwdriver between the cylinder head and block saliences. CAUTION: Be careful not to damage the cylinder head and block surface on the cylinder and head gasket sides.EM-56 \ Sst 8S8S6see ENGINE MECHANICAL ~ Cylinder Head DISASSEMBLY OF CYLINDER HEAD (See page EM-47) 2H (See page EM-48) 12H-T 1. REMOVE VALVES. (a) Using SST, compress the valve spring and remove the two keepers. SST 09202-43013 (b)_ Remove the spring retainer, valve springs, valve and oil seal. NOTE: Arrange the valves, valve springs and spring retainers in the correct order. [2H] REMOVE COMBUSTION CHAMBERS Using SST, remove the six combustion chambers. SST 09208-48010 NOTE: order. Arrange the combustion chambers in correctENGINE MECHANICAL — Cylinder Head EM-57, INSPECTION, CLEANING AND REPAIR OF CYLINDER HEAD COMPONENTS 1, CLEAN TOP OF PISTONS AND TOP OF BLOCK (a) Turn the crankshaft and bring each piston to top dead center. Using a gasket scraper, remove all the carbon from the piston top. (b) Remove all the gasket material from the top of the block. (c)_ Blow carbon and oil from the bolt holes. WARNING: Protect your eyes when using high pressure ai 2. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the manifold and head surface. cauTio! Be careful not to scratch the surfaces. 3. CLEAN COMBUSTION CHAMBERS Using @ wire brush, remove all the carbon from the corn- bustion chambers. CAUTION: Be careful not to scratch the head gasket contact surface. 4. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings. 5. CLEAN CYLINDER HEAD Using a soft brush and solvent, thoroughly clean the head,EM-58 ENGINE MECHANICAL — Cylinder Head Exhaust Manifold side 6. INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and manifolds for warpage, Maximum warpage: der block side 0.20 mm (0.0079 in) Id side 0.20 mm (0.0079 in.) If 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 of the head for cracks. If cracked, replace the head.ENGINE MECHANICAL — Cylinder Head EM-59 10. CLEAN VALVES (a) Use a gasket scraper, chip any carbon from the valve head. (b) Using a wire brush, thoroughly clean the valve. INSPECT VALVE STEM AND VALVE GUIDE BUSHING (a) Using a caliper gauge or telescoping gauge, measure the inside diameter of the valve guide bushing Bushing inside diameter: 9.010 — 9.030 mm (0.3547 — 0.3555 in) (o) Using 2 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.) (c) 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 in.) 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 valve guide bushing ‘SST 09201-60011EM-60 ENGINE MECHANICAL — Cylinder Head (o) Using a caliper gauge, measure ‘the bushing bore diameter of the cylinder head. If the bushing bore diameter of the cylinder head is more than 14.018 mm (0.5519 in), replace the cylinder head. (c) Using SST and a 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 (a) Using a sharp 9.0 mm reamer, ream the valve guide bushing to obtain the standard specified clearance (See page EM-59) between the valve guide bushing and new valve stem. 11. INSPECT AND GRIND VALVES (a) Grind the valve only enough to remove pits and car- bon. (b) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° (c) Check the valve head margin thickness. ‘Standard margin thickness Intake 1.4 mm (0.055 in) 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, teplace the valve. Margin ThicknessENGINE MECHANICAL — Cylinder Head EM-61 (d) Check the valve overall length. Standard overall tength: Intake 120.7 mm (4,752 in.) Exhaust 120.6 mm (4.748 in) Minimum overall length: Intake 120.2 mm (4.732 in.) Exhaust 120.1 mm (4.728 in.) {e) If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. CAUTION: Do not grind off more than the minimum amount. z 12. INSPECT 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 rotate the valve. (c) Check the valve face and seat for the following: © If blue appears 360° around the face, the valve is concentric. If not, replace the vaive © 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: ENe| 1.4 — 2.0 mm (0.085 ~ 0.079 in) 30 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. WidthEM-62 ENGINE MECHANICAL — Cylinder Head (2) (12H-T Intake] 12H-T Intake If the seating is too low on the valve face, use Others 60° and 45° cutters to correct the seat. (3) [Others] ~ 60° 75° ‘Squareness + 13, If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. (a) Hand-lap the valve and valve seat with an abrasive compound. (e) 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 (b) Using calipers, measure the free length of the valve spring Free length: Inner spring 44.3 mm (1.744 in.) Outer spring 48.1 mm (1.894 in) If the free length is not as specified, replace the valve spring. (c) Using @ spring tester, measure the tension of the valve spring at the specified installed length. Installed tensi Inner spring 7.6 kg (16.8 Ib, 75 N) 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 as specified, replace the valve spring. Outer springFront EMGHENG GAIAM 14, INSPECT ROCKER ARM AND SHAFT (a) Check the valve contacting surface of the rocker erm for wear, (b) Check the rocker arm-to-shaft clearance by moving each rocker arm as shown in the figure. Hf 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 worn, resur- face it with a valve refacer and oil stone, or replace the rocker arm. (a) Check the oil clearance between the rocker arm and shaft. © Using a caliper gauge, measure the inside diameter of the rocker arm. Rocker arm inside diameter: 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 shaft Rocker shaft diameter: 18.472 — 18.493 mm (0.7272 — 0.7281 in) © Subtract the rocker shaft diameter measurement from the inside diameter measurement of the rocker arm. Standard oil clearance: 0.007 ~ 0.049 mm (0.0003 ~ 0.0019 in. Maximum oil clearance: 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the rocker arm and shaft (c) Assemble the valve rocker shaft assembly as shown. Valve Rocker Arm Oil Hole Valve Rocker ShaftENGINE MECHANICAL — Cylinder Head EM-65 18. INSPECT PUSH RODS (a) Place the push rod on V-blocks. (b) Using a dial indicator, measure the circle runout at the center of the push rod. 0.50 mm (0.0197 in.) If the circle runout is greater than maximum, replace the Push rod. Maximum circle runout: 16, INSPECT INTAKE AND EXHAUST MANIFOLDS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Intake Manifold [2H] Maximum warpage: Intake 0.50 mm (0.0197 in.) Exhaust 2H (Front and rear) 0.30 mm (0.0118 in) 12H-T (Front) 0.30 mm (0.0118 in) 12H-T (Rear) 0.20 mm (0.0079 in.) If warpage is greater than maximum, replace the manifold. Intake Manifold [12H-T] Exhaust Manifold [12H-T]EM-66 ENGINE MECHANICAL — Cylinder Head ASSEMBLY OF CYLINDER HEAD (See page EM-47) 2H (See page EM-48) 12H-T NOTE: ® Thoroughly clean all parts to 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. 1. (2H INSTALL COMBUSTION CHAMBERS (2) Align the combustion chamber knock pin with the cylinder head notch. (b) Using a plastic-faced hammer, tap in the combustion chamber. (c) Using a dial indicator, check the combustion cham- ber protrusion, Combustion chamber protrusion: 0 ~ 0.10 mm (0 ~ 0.0039 in.) 2. INSTALL VALVES {a) Install the following parts: (1) New oil seal (2) Valve (3) Inner spring (4) Outer spring (5) Spring retainer (b) Using SST, compress the vaive spring and place the ‘two keepers around the valve stem. SST 09202-43013ENGINE MECHANICAL ~ Cylinder Head EM-67 (c) Using a plastic-faced hammer, lightly tap the valve | stem to assure proper fit. TMNTEM-68 ENGINE MECHANICAL — Cylinder Head INSTALLATION OF CYLINDER HEAD [2H] (See page EM-47) 1. INSTALL CYLINDER HEAD (a) Place a 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. (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 cylinder head bolts in several passes, in the sequence shown. Torque: 1,150 kg-cm (83 ft-tb, 113 N-m) 2, INSTALL PUSH RODS Install the twelve push rods. 3. INSTALL VALVE ROCKER SHAFT ASSEMBLY (a) Place the rocker shaft assembly on the cylinder head, (b) Install and uniformly tighten the fourteen bolts in several passes, in the sequence shown, Torque: 185 kg-cm (13 ft-lb, 18 N-m) 4. ADJUST VALVE CLEARANCES (See steps 4 and 5 on page EM-22) Valve clearance (Reference): Intake 0.20 mm (0.008 Exhaust 0.36 mm (0.014ENGINE MECHANICAL — Cylinder Head EM-69 Ring End Ring End 5. INSTALL CYLINDER HEAD COVER (2) 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-cm (61 in. jb, 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 N-m) ASSEMBLE EXHAUST MANIFOLDS (a) Remove all the O-ring material from the manifold grooves. (b) Install new two O-rings. (c)_ Using snap ring pliers, install the two manifold rings. (a) Position the manifold rings so that the ring ends are as shown. CAUTION: Do not align the ends.EM-70 ENGINE MECHANICAL — Cylinder Head (e) Assemble the front and rear manifolds. INSTALL EXHAUST MANIFOLDS {a) Install new six gaskets and the exhaust manifolds with the twelve plate washers and new nuts, Torque: 210 kg-om (15 ft-lb, 21 Nem) (b) Install the two heat insulators with the seven bolts. Torque: 185 kg-cm (13 ft-lb, 18 N-m) INSTALL INTAKE MANIFOLD (a) Install new six gaskets and the intake manifold with the twelve nuts, Torque: 185 kg-cm (13 ft-lb, 18 Nem) (b) Iw/T] Install the two vacuum hoses.ENGINE MECHANICAL — Cylinder Head EM-71 10. n. 12. 13, [M/T (w/ EDIC SYSTEM)] INSTALL EDIC MOTOR {a) Install the EDIC motor with the collar and three bolts. {b) Install the connecting rod, IM/T (w/o EDIC SYSTEM)] INSTALL OVERINJECTION MAGNET INSTALL FUEL FILTER ASSEMBLY {a) Install the fuel filter assembly with the two bolts, Torque: 375 kg-cm (27 ft-lb, 37 N-m) (b) Connect the two fuel pipes to the injection pump with new four gaskets and the two union bolts. Tor- que the union bolts 280 kg-cm (20 ft-lb, 28 N-m) Torque INSTALL GLOW PLUGS (a) Install the six glow plugs. Torque: 125 kg-cm (9 ft-lb, 12 N-m) {b) Install the glow plug connector with the six nuts. (c)_ {Pre-heating System (Supper Glow Type)] Install the current sensor plate. (d) Install the six screw grommets.EM-72 ENGINE MECHANICAL — Cylinder Head 14. 15. 16. 17, 18, 19. INSTALL INJECTION NOZZLES (See steps 1 to 3 on page EM-8) INSTALL PCV HOSE 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, 3 to 6 on page EM-22)ENGINE MECHANICAL — Cylinder Head —M-73 1 INSTALLATION OF CYLINDER HEAD [12H-T] (See page EM-48) INSTALL CYLINDER HEAD (a) Place a 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. (c)_ Apply a light coat of engine oil on the threads and under the cylinder head bolts. (a) Install and uniformly tighten the twenty-six cylinder head bolts in several passes, in the sequence shown, Torque: 1,150 kg-em (83 ft-lb, 113 N-m) INSTALL PUSH RODS Install the twelve push rods. INSTALL VALVE ROCKER SHAFT ASSEMBLY (2) Place the rocker shaft assembly on the cylinder head. (0) Instal and uniformly tighten the fourteen bolts in several passes, in the sequence shown, Torque: 185 kg-cm (13 ft-lb, 18 N-m) 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) _ 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-cm (61 in-tb, 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 N-m) ASSEMBLE EXHAUST MANIFOLDS fa) Remove all the O-ring material from the manifold grooves, (©) Install new two O-rings. {c) Using snap ring pliers, install the two manifold rings (d) Position the manifold rings so that the ring ends are as shown, CAUTION: Do not ign the ends.ENGINE MECHANICAL — Cylinder Head EM-75 le) Assembly the front and rear manifolds. 8. INSTALL EXHAUST MANIFOLDS (a) Install new two gaskets and the exhaust manifolds with the twelve plate washers and new nuts. Torque: 210 kg-em (16 ft-lb, 21 N-m) (b) Install the two heat insulators with the five bolts, Torque: 185 kg-cm (13 ft-lb, 18 N-m) INSTALL WATER BY-PASS HOSE OF TURBOCHARGER 10. INSTALL INTAKE MANIFOLD (a) Install a new gasket to the intake manifold. (b) Install the intake manifold with the five bolts and eleven nuts. Torque: 185 kg-cm (13 ft-lb, 18 N-m)EM-76 ENGINE MECHANICAL — Cylinder Head u. 12, 13, 14, 15. 16. 17. INSTALL FUEL FILTER ASSEMBLY (a) Install the fuel filter assembly with the two bolts. Torque: 375 kg-cm (27 ft-lb, 37 N-m) (b) Connect the fuel pipe and hose to the injection pump with new four gaskets and the two union bolts. Tor- que the union bolts. Torque: 280 kg-cm (20 ft-lb, 28 N-m) 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 — Timing Gears and Camshaft EM-77 TIMING GEARS AND CAMSHAFT COMPONENTS 2H (w/o PS A/C) @ Gasket Timing Gear Cover———— Crankshaft Pulley- > 9 v [4.500 (62s. 441) ——) @ | Timing Gear Cover i ‘@ Oil Seal 2H (w/ PS or A/C) and 12H-T iz Te O- Washer Drive Gear ‘Automatic Timer (12H-T) ae (Rtomate Timer (2H) fl J. No. 2 Idle Gear met Bee |iming Gear Cover- #01 oak ao Idle Gear (rea 77}- +o & (476 (94,477 -}— a res Ns in ho 1 Idle Gear Shaft ‘No. 1 Idle Gear Camshaft Thrust 5 Plate @—$ @ es a REPLACEMENT OF CAMSHAFT (OR CAMSHAFT TIMING GEAR) 1, REMOVE CAMSHAFT fa) Using SST, remove the bolt and plate washer. SST 09278-54012 (b)_ Using a 19 mm socket wrench and press, press out the camshaft. 2, INSTALL NEW CAMSHAFT {a) Install the timing gear set key to the camshaft, (b) Assembly the camshatt, thrust plate and timing gear as shown. (c)_ Using a 29 mm socket wrench and press, align the timing gear set key with the key groove of the timing gear, and press in the camshaft timing gear. (a) Using SST, install the plate washer and bolt. Torque the bolt. SST 09278-54012 Torque: 450 kg-cm (33 ft-lb, 44 N-m) 3. CHECK CAMSHAFT THRUST CLEARANCE (See page EM-84) Standard thrust clearance: 0.060 — 0.130 mm (0.0024 — 0.0081 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.)EM-86 ENGINE MECHANICAL — Timing Gears and Camshaft REPLACEMENT OF AUTOMATIC TIMER DRIVE GEAR [12H-T] 1. REMOVE DRIVE GEAR (a) Mount the timer hub in a soft jaw vise. (b) Remove the four bolts, spring washers and drive gears. 2. INSTALL NEW DRIVE GEAR (a) Install the drive gear onto the timer as shown, {b) Install the four spring washers and bolt. Torque the bolts. Torque: 230 kg-cm (17 ft-lb, 23 N-m)ENGINE MECHANICAL — Timing Gears and Camshaft EM-87 REPLACEMENT OF CRANKSHAFT FRONT OIL SEAL REPLACE CRANKSHAFT FRONT OIL SEAL NOTE: There are two methods (A and B) to replace the oil seal as follows. A. If timing gear cover is removed from cylinder block: (a) Using a screwdriver and hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge SST 09214-76011 (c) Apply MP grease to the oil seal lip. B. If ti (a) Using SST, remove the oil seal ‘SST 09308-10010 jing gear cover is installed to cylinder block: (b) Apply MP grease to a new oil seal lip. (c)_ Using SST and a hammer, tap in the oil seal until its surface is flush with the timing gear cover edge. SST 09214-76011EM-88. ENGINE MECHANICAL — Timing Gears and Camshaft INSTALLATION OF TIMING GEARS AND CAMSHAFT (See page EM-77) 1, INSTALL CRANKSHAFT TIMING GEAR (a) Put the timing gear on the crankshaft with the timing mark facing frontward. (b) Align the timing gear set key with the key groove of the timing gear. (c) Using SST and a hammer, tap in the timing gear. SST 09608-35014 (09608-06040) SY GEOO) | 2. INSTALL NO. 1 IDLE GEAR SPY) Gowara Ad | ‘i a) Set the crankshaft timing gear with the key groove facing upward by turning the crankshaft clockwise cy Key Groove (b) Assemble the idle gear gear and gear shaft. (c) Align the “0” timing marks of the crankshaft timing and idle gears, and mesh the gears. (d) Apply a light coat of the engine oil on the threads and under the bolt heads. (c) Install the thrust plate with the two bolts. Torque the bolts. Torque: 475 kg-cm (34 ft-Ib, 47 N-m) 3. CHECK BACKLASH OF NO. 1 IDLE GEAR (See page EM-81) Stardard backlash: 0.050 — 0.116 mm (0.0019 — 0.0045 in.) Maximum backlash: 0.30 mm (0.0118 in.) 4, CHECK THRUST CLEARANCE OF NO. 1 IDLE GEAR (See page EM-81) Standard thrust clearance: 0.050 ~ 0.150 mm (0.0019 — 0.0089 i Maximum thrust clearance: 0.30 mm (0.0118 in.)ENGINE MECHANICAL — Timing Gears and Camshaft EM-89 5. INSTALL NO. 2 IDLE GEAR (a) Assemble the idle gear and gear shaft. (b) Align the “1” timing marks of the idle gears, and mesh the gears, (c)_ Apply a light coat of engine oil on the threads and under the bolt heads. (d) Install the thrush plate with the two bolts. Torque the bolts. Torque: 475 kg-cm (34 ft-lb, 47 N-m) 6. CHECK BACKLASH OF NO. 2 IDLE GEAR (See page EM-81) Standard backlas! 0,050 - 0.113 mm (0.0019 — 0.0044 Maximum backlash: 0.30 mm (0.0118 ) 7. CHECK THRUST CLEARANCE OF NO. 2 IDLE GEAR (See page EM-81) Standard thrust clearance: 0.050 — 0.150 mm {0.0019 — 0.0059 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) 8. INSTALL CAMSHAFT TIMING GEAR AND CAMSHAFT ASSEMBLY (a) Insert the camshaft into the cylinder block. CAUTION: Be careful not to damage the camshaft bearings. (b) Align the “3” timing marks of the No. 2 idle and ‘camshaft timing gears, and mesh the gears.—M-90 ENGINE MECHANICAL — Timing Gears and Camshaft 10. m. (c) Install and torque the two bolts. Torque: 375 kg-om (27 ft-lb, 37 N-m) CHECK BACKLASH OF CAMSHAFT TIMING GEAR (See page EM-80) Standard backlash: 0.050 ~ 0.113 mm {0.0019 — 0.0044 in.) Maximum backlash: 0.30 mm (0.0118 in.) INSTALL AUTOMATIC TIMER (a) Align the automatic timer set key with the key groove of the automatic timer. (b) Align the “2” timing marks of the No. 1 idle and automatic timer drive gear, and mesh the gears. (c)_ Apply a light coat of engine oil on the threads and under the round nut. (a) Install the washer (12H-T) and round nut. Torque the round nut. Torque: 750 kg-cm (54 ft-lb, 74 N-m) CHECK BACKLASH OF AUTOMATIC TIMER DRIVE GEAR (See page EM-80) Standard backlash: 0.060 ~ 0.111 mm. {0.0019 — 0.0043 in.) Maximum backlash: 0.30 mm (0.0118 in.)ENGINE MECHANICAL — Timing Gears and Camshaft EM-91 ms = 12. INSTALL TIMING GEAR COVER « OF [w/o PS or A/C] NOTE: Use the bolts indicated > OS omDp Install a new gasket and the gear cover with the sixteen bolts, Torque: 250 kg-em (18 ft-lb, 25 N-m) [w/ PS or A/C] NOTE: Use the bolts indicated “A,"* “ and “D.” > Gia Install a new gasket and the gear cover with the sixteen bolts. Torque: 250 kg-cm (18 ft-Ib, 25 N-m) 13. (12H-T] INSTALL OIL PIPE Torque the union bolts. Torque: 185 kg-cm (13 ft-lb, 18 N-m)EM-92 ENGINE MECHANICAL — Timing Gears and Camshaft 14, INSTALL CRANKSHAFT PULLEY {a) Align the pulley set key with the key groove of the pulley. {b) Using SST and a hammer, tap in the pulley. SST 09608-35014 (09608-06040) (c) Apply a light coat of engine oil on the thread and under the pulley mount bolt. (d) Using SST and a 46 mm socket wrench, install and torque the pulley mount bolt. SST 09213-58011 and 09330-00021 Torque: 4,500 kg-em (325 ft-lb, 441 N-m) 15, INSTALL VALVE LIFTER Carefully insert the twelve lifters into the lifter bores 16. INSTALL PUSH ROD COVER Install a new gasket and the push rod cover with the eight bolts. Install the two push rod covers. Torque: 130 kg-cm (9 ft-lb, 13 Nm) 17. INSTALL VALVE ROCKER SHAFT ASSEMBLY (See steps 2 to 5 on pages EM-68 and 69) 2H (See steps 2 to 5 on pages EM-73 an 74) 12H-T 18. 112-11 INSTALL TURBOCHARGER (See steps 3 to 12 on pages EM-44 to 46) 19. INSTALL WATER PUMP PULLEY AND FAN (See page CO-10)ENGINE MECHANICAL — Timing Gears and Camshaft EM-93 20. INSTALL AND ADJUST DRIVE BELT (See page CH-6) 21. START ENGINE AND CHECK FOR LEAKS 22, CHECK ENGINE OIL LEVEL 23, READJUST VALVE CLEARANCES. (See steps 1 to 7 on page EM-22)EM-94 ENGINE MECHANICAL — Cylinder Block CYLINDER BLOCK COMPONENTS __—Piston Ring (No. 1 Compression Ring) ———Piston Ring (No. 2 Compression Ring) —Piston Ring (Oil Ring and Coil) 12H-T | cn are one |@ Snap Ring-a ———Piston 9} Connecting Rod @ Expansion Plug! | Injection Pump. corm) Cylinder Block ———— | © Gasket Flywheel ll Pump: (Timing \Gear Case! ex Ol Seal Rear End Plate [250 118, 28) | Crankshaft ———-——Thrust Washer Main Bearing Main Bearing Cap. —% kg:em fc. Niml) = Specitied torque + Non-reusable part =ENGINE MECHANICAL — Cylinder Block EM-95 DISASSEMBLY OF CYLINDER BLOCK (See page EM-94) 10. ooh 12 (w/t) REMOVE FLYWHEEL [A/T] REMOVE DRIVE PLATE REMOVE REAR END PLATE Remove the three bolts and rear end plate. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY (24-11 REMOVE TURBOCHARGER (See pages EM-40 to 42) REMOVE INJECTION PIPES (See page FU-3) 2H (See page FU-9 and 10) 12H-T REMOVE CYLINDER HEAD (See pages EM-49 to 52) 2H (See pages EM-53 to 55) 12H-T REMOVE TIMING GEARS AND CAMSHAFT (See pages EM-78 to 82) REMOVE INJECTION PUMP {See pages FU-30 and 31) REMOVE OIL PAN AND OIL PUMP (See page LU-6 and 7) REMOVE REAR OIL SEAL RETAINER Remove the six bolts, retainer and gasket. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the rod back and forth. Standard thrust clearanc: 0.200 — 0.340 mm (0.0079 — 0.0134 in) Maximum thrust clearance: 0.40 mm (0.0157 in.) If the clearance is greater than maximum, replace the con- necting rod assembly. If necessary, replace the crankshaft.EM-96 ENGINE MECHANICAL Cylinder Block 13. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE (a) Using a punch or numbering stamp, place match- marks on the connecting rod and cap to ensure cor- rect reassembly. (b) Remove the connecting rod cap nuts ()__ Using a plastic-faced hammer, lightly tap the con- necting rod bolts and lift off the connecting rod cap. NOTE: Keep the lower bearing inserted with the con- necting rod cap. (a) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (e) Clean the crank pin and bearing, (f) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing are damaged, replace the bear- ings. If necessary, grind or replace the crankshaft.ENGINE MECHANICAL — Cylinder Block EM-97 (g)_ Lay a strip of Plastigage across the crank pin, {h) Install the connecting rod cap. (See page EM-116) Torque: 900 kg-cm (65 ft-Ib, 88 N-m) NOTE: Do not turn the crankshaft. (i) Remove the connecting rod cap. () Measure the Plastigage at its widest point. Standard oil clearance: STD 0,030 — 0.070 mm {0.0012 — 0.0028 in.) U/S 0.25, 0.50, 0.75 and 1.00 0.030 — 0.072 mm (0.0012 — 0.0028 i Maximum oil clearance: 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the bearing. If necessary, grind or replace the crankshaft. NOTE: If using a standard bearing, replace with one hav- ing the same number marked on the connecting rod cap. There are two sizes of standard bearings, marked ""1"" and "2" accordingly, ‘Standard bearing thickness (at center wall): Mark "1" 1.480 ~ 1.485 mm. (0.0583 — 0.0585 in) 1.485 — 1.490 mm (0.0585 — 0.0587 in) (kd) Completely remove the Plastigage. Mark 14, REMOVE PISTON AND CONNECTING ROD ASSEMBLIES (a) Remove all the carbon from the piston ring ridge. (b) Cover the connecting rod bolts. (See page EM-96) (c)_ Push the piston, connecting rod assembly and upper bearing out through the tap of the cylinder.—M-98. ENGINE MECHANICAL — Cylinder Block NOTE: © Keep the bearings, connecting rod and cap together. © Arrange the piston and connecting rod assemblies in correct order. 15. CHECK CRANKSHAFT THRUST CLEARANCE 16. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. ‘Standard thrust clearance: 0.040 ~ 0.240 mm {0.0016 ~ 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: STD 2.930 ~ 2.980 mm (0.1154 ~ 0.1173 in.) O/S 0.125 2.993 ~ 3.043 mm (0.1178 ~ 0.1198 in) O/S 0.250 3.055 ~ 3.105 mm (0.1203 — 0.1222 in.) REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE (a) Remove the main bearing cap bolts. {b) Using the removed main bearing cap bolts, pry the cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No. 4 main bearing cap only). NOTE: © Keep the lower bearing and main bearing cap together. © Arrange the main bearing cap and lower thrust washers in correct order. (6) Lift out the crankshaft. NOTE: Keep the upper bearing and upper thrust washers together with the cylinder block. (a) Clean each main journal and bearing. (€) Check each main journal and bearing for pitting and scratches. If the journal or bearing are damaged, replace the bearing. If necessary, grind or replace the crankshaft.ENGINE MECHANICAL — Cylinder Block EM-99 — ewer (9} is 0 a os oe Thickess| i Number Mark Front anos) 17. (f) Place the crankshaft on the cylinder block. (g) Lay a strip of Plastigage across each of the main journal. (h)__ Install the main bearing caps. (See page EM-115) Torque: 1,390 kg-cm (100 ft-lb, 136 N-m) NOTE: Do not turn the crankshaft. {Remove the main bearing caps. () Measure the Plastigage at its widest point. Standard oil clearance: STD 0.032 ~ 0.068 mm (0.0013 ~ 0.0027 in.) U/S 0.25, 0.50, 0.75 and 1.00 0.030 ~ 0.074 mm (0.0012 ~ 0.0029 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the main bearing. If necessary, grind or replace the crankshaft. NOTE: Ifusing a standard bearing, replace with one hav- ing the same number marked on the cylinder block. There are three sizes of standard bearings, marked "1" and "2" accordingly. Standard be Mark “" 9 thickness (at center wall): 1.981 — 1,985 mm (0.0780 ~ 0.0781 in) 1.985 — 1.989 mr (0.0781 ~ 0.0783 in.) 1,989 — 1.993 mm (0.0783 ~ 0.0785 in.) {K)_ Completely remove the Plastigage. Mark Mark " REMOVE CRANKSHAFT fa) (b) Remove the upper bearings and upper thrust washers from the cylinder block. NOTE: Arrange the main bearing caps, bearings and thrust washers in correct order. out the crankshaft.EM-100 ENGINE MECHANICAL ~ Cylinder Block ) Thrust © direction Front @ Axial Direction L 10mm A (0.39 in) — Middle Li 10mm T_ 10.39 in) zee INSPECTION OF CYLINDER BLOCK 1. REMOVE GASKET MATERIAL Using @ gasket scraper, remove all the gasket material from the cylinder block surface CLEAN CYLINDER BLOCK Using a soft brush and solvent, clean the block, INSPECT TOP OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head gasket for war- page. Maximum warpage: 0.20 mm (0.0079 in) If warpage is greater than maximum, replace the cylinder block. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all six cylinders. INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: STD 91.000 ~ 91.030 mm (3.5827 ~ 3.5839 in) Maximum diameter: STD 91.23 mm (3.5917 in) 0/S 0.50 91.73 mm (3.6114 in) If the diameter is greater than maximum, rebore all six cylinders, If necessary, replace the cylinder block.ENGINE MECHANICAL — Cylinder Block EM-101 6. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in), use a ridge reamer to machine the piston ring ridge at the top of the cylinder. DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES (See page EM-94) 1, CHECK FIT BETWEEN PISTON AND PIN Try to move the piston back and forth on the piston pin. It any movement is felt, replace the piston and pin as a set. 2. REMOVE PISTON RINGS (6) Using a piston ring expander, remove the piston rings. {b) Remove the oil ring and coil by hand. NOTE: Arrange the rings in correct order only. 3. DISCONNECT CONNECTING ROD FROM PISTON {a) Using needle-nose pliers, remove the snap rings,EM-102 ENGINE MECHANICAL — Cylinder Block (b) Gradually heat the piston to approx. 60°C (140°F) (c) Using a plastic-faced hammer and driver, lightly tap out the piston pin and remove the connecting rod. NOTE: © The piston and pin are a matched set. 2s 0 we ; oe 4 5 6 © Arrange the pistons, pins, rings, connecting rods and bearings in correct order. INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLIES ~| 1. CLEAN PISTON (a) Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the (b) ring grooves.ENGINE MECHANICAL — Cylinder Block EM-103 (c)_ Using solvent and a brush, thoroughly clean the piston CAUTION: Do not use a brush. INSPECT PISTON DIAMETER AND OIL CLEARANCE (a) Using a micrometer, measure the piston diameter at a right angle to the piston pin hole center line, 25mm (0.94 in) or 9mm (0.35 in.) from the skirt bottom edge. Standard diameter: 2H STD 90.930 — 90.960 mm (3.5799 — 3.5811 in) 0/S 0.50 91.430 — 91.460 mm (3.5996 — 3.6008 in) 12H-T STD 90.940 — 90.970 mm (3.5803 - 3.5815 in.) O/S 0.50 91.440 — 91.470 mm 209 (3.6000 - 3.6012 in.) (b) Measure the cylinder bore diameter in the thrust directions (See page EM-100) and subtract the piston diameter measurement from the cylinder bore diameter. Oil clearance: 2H 0.060 ~ 0.080 mm (0.0024 — 0.0032 in.) 12H-T 0.050 — 0.070 mm (0.0020 — 0.0028 in.) If the clearance is not within specification, replace all six pistons. If necessary, rebore all six cylinders or replace the cylinder block, 3. INSPECT CLEARANCE BETWEEN WALL OF PISTON RING GROOVE AND NEW PISTON RING INo. 1 Ring] Install a new No. 1 piston ring to the piston. Using a feeler gauge, measure the clearance between the piston ring and wall of the piston ring groove Ring groove clearance: 2H 0.097 - 0.137 mm (0.0038 — 0.0054 in.) wae 12H-T 0.139 — 0.204 mm (0.0055 — 0.0080 in.) INo. 2 and Oil Ring] Using a feeler gauge, measure the clearance between new piston ring and the wall of the piston ring groove. Ring groove clearanc No. 2 0.060 —0.100 mm (0.0024 — 0.0039 in.) Oil 0.020 — 0.060 mm (0.0008 — 0.0024 in.) If the clearance is not within specification, replace the piston.EM-104 ENGINE MECHANICAL — Cylinder Block 4 INSPECT PISTON RING END GAP (2) Insert the piston ring into the cylinder bore (b) Using @ piston, push the piston ring a little beyond the bottom of the ring travel, 140 mm (6.51 in) from the top of the cylinder block. (c) Using a teeter gauge, measure the end gap. Standard end gap: No.1 2H 0,200 - 0.440 mm (0.0079 — 0.0173 in.) 12H-T 0.200 — 0.470 mm {0.0079 — 0.0185 in.) No. 2 0.200 — 0.440 mm {0.0079 — 0.0173 in.) on 0,150 ~ 0.490 mm {0.0059 — 0.0193 in.) Maximum end gap: No.1 2H 1.24 mm (0.0488 12H-T 1.27 mm (0.0500 No. 2 1.24 mm (0.0488 in.) on 1.29 mm (0.0508 in.) If the gap is greater than maximum, replace the piston ring. If the gap is greater than maximum, even with a new piston ring, rebore the cylinder and use an oversized piston ring ) CHECK PISTON PIN FIT At 60°C (140°F) you should be able to push the pin into the piston with your thumb, If the pin can be installed at a lower temperature, replace the piston and pin as a set. INSPECT CONNECTING RODS (a) Using a rod aligner, check the connecting rod align- ment. © 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,ENGINE MECHANICAL — Cylinder Block EM-105 © Check for twist Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly. (b) Using a caliper gauge, measure the inside diameter of the connecting rod bushing, Bushing inside diameter: 2H 29.008 — 29.020 mm (1.1420 — 1.1426 in.) 12H-T 32,008 - 32.020 mm (1.2602 —1.2606 in.) (c) Using a micrometer, measure the diameter of the piston pin, Piston pin diameter: 2H =~ 29.000 — 29.012 mm (1.1417 — 1.1422 in) 12H-T 32.000 - 32.012 mm (1.2598 — 1.2603 in.) (a) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.004 ~ 0.012 mm (0.0002 — 0.000! Maximum oil clearance: 0.03 mm (0.0012 in.) ) If the clearance is greater than maximum, replace the con- necting rod bushing. If necessary, replace the piston and piston pin assembly. REPLACEMENT OF CONNECTING ROD BUSHINGS 1. REMOVE CONNECTING ROD BUSHING Using SST and a press, press out the bushing. SST 09222-66010EM-106 ENGINE MECHANICAL — Cylinder Block Oil Hole (2H oniy) 2. INSTALL NEW CONNECTING ROD BUSHING (a) Align the oil holes of the bushing and connecting rod. (b) Using SST and a press, press in the bushing, SST 09222-66010 HONE CONNECTING ROD BUSHING AND CHECK PISTON PIN FIT IN CONNECTING ROD (2) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See page EM-105) between the bushing and piston pin {b) Check the piston pin fit at normal room temperature, Coat the piston pin with engine oil and push it into the rod with your thumb,ENGINE MECHANICAL — Cylinder Block EM-107 BORING OF CYLINDERS NOTE: © Bore all six cylinders for the oversized pistons outside diameter. © Replace the piston rings with ones to match the over- sized pistons. 1. KEEP OVERSIZED PISTON Oversized piston diameter: 0/S 0.50 2H — 91.430 — 91.460 mm (3.5996 —3.6008 in.) 12H-T 91.440 - 91.470 mm (3.6000 — 3.6012 in.) 2. CALCULATE AMOUNT TO BORE CYLINDER (a) Using a micrometer, measure the piston diameter at a right angle to the piston pin hole center line, 25 mm (0.941 in) or 9 mm (0.35 in) from the skirt bottom edge. 2H: 25mm T2H-T: “9mm {b) Calculate the amount each cylinder is to be rebored as follows Size to be rebored P = Piston diameter € = Piston clearance 2H 0.060 — 0.080 mm (0.0024 — 0.0032 i 12H-T 0.050 ~ 0.070 mm (0.0020 — 0.0028 in.) H = Allowance for honing 0.02 mm (0.0008 in.) or less 3. BORE AND HONE CYLINDERS TO CALCULATED DIMENSIONS Maximum honing: 0.02 mm (0.0008 in.) CAUTION: Excess honing will destroy the roundness. P+C-HEM-108 ENGINE MECHANICAL — Cylinder Block , INSPECTION AND REPAIR OF CRANKSHAFT 1 INSPECT CRANKSHAFT FOR RUNOUT fa) Place the crankshaft on V-blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft. INSPECT MAIN JOURNALS AND CRANK PINS (a) Using a micrometer, measure the diameter of each main journal and crank pin. journal diameter: STD 69.980 — 70.000 mm (2.7551 —2.7559 in.) U/S 0.25 69.730 — 69.740 mm (2.7453 — 2.7457 in.) U/S 0.50 69.480 — 69.490 mm (2.7354 — 2.7358 in) U/S 0.75 69.230 ~ 69.240 mm (2.7256 — 2.7260 in.) U/S 1.00 68.980 — 69.990 mm (2.7187 -2.7161 in) Mai Crank pin diameter: STD 54.980 — 55.000 mm (2.1646 — 2.1654 in) U/S 0.25 54,730 - 64.740 mm (2.1547 — 2.1551 in) U/S.0.50 54.480 — 54.490 mm (2.1449 — 2.1453 in.) U/S 0.75 54.230 — 54.240 mm {2.1350 — 2.1354 in.) U/S 1.00 53.980 ~ 53.990 mm (2.1252 — 2.1259 in.) if the diameter is not within specification, check the oil clearance. If necessary, grind or replace the crankshaft. {b) Check each main journal and crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If taper and out-of-round is greater than maximum, rep- lace the crankshaft. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the undersized finished diameter. (See procedure step 2) Install new main journal and/or crank pin undersize bear- ings.ENGINE MECHANICAL — Cylinder Block EM-109 INSPECTION AND REPAIR OF CAMSHAFT eh BEARINGS AND CAMSHAFT 1, INSPECT CAMSHAFT OIL CLEARANCE (a) Using a cylinder gauge, measure the inside diameter of the camshatt bearing Bearing inside diameter (from front sTD No. 1 51,200 - 61.230 mm (2.0157 — 2.0169 in.) No.2 51,000 — 51.030 mm (2.0079 — 2.0091 in.) No. 3. 60,800 ~ 50.830 mm {2.0000 — 2.0012 in.) No. 4 60,600 — 50.630 mm (1.9921 — 1.9933 in) U/S 0.125 No.1 51.074 — 51.139 mm (2.0108 — 2.0133 in.) No. 2 50.874 — 50.939 mm (2.0029 — 2.0055 in.) No. 3 50.674 ~ 50.739 mm (1.9950 — 1.9976 in.) 50.474 — 50.539 mm (1.9872 — 1.9897 in) U/S 0.25 No.1 50.950 — 51.015 mm (2.0059 — 2.0086 in.) No. 2 50.750 ~ 50.815 mm (1.9980 — 2.0006 in.) No. 3 60.550 — 50.615 mm (1.9902 — 1.9927 in.) No. 4 50.350 — 50.415 mm (1,9823 — 1.9848 in) (b) Subtract the journal diameter measurement (See page EM-83) from the bearing inside diameter measurement. No. Standard oil clearance: sTD 0.030 - 0.079 mm (0.0012 — 0.0031 in) U/S 0.125 0.039 — 0.114 mm (0.0015 — 0.0045 in.) U/S 0.250 0.040 ~ 0.115 mm (0.0016 — 0.0045 in) Maximum oil clearance: 0.15 mm (0.0059 in.) If the clearance is greater than maximum, replace the camshaft bearings. If necessary, grind or replace the camshaft. IF NECESSARY, GRIND AND HONE CAMSHAFT JOURNALS Grind and hone the journals to the undersized finished diameter (See page EM-83) Install new camshaft undersized bearings.EM-110 No.1 No. 2and No.3 No.4 24mm 20mm 24 mn (094 in) 10.79n) (O.94'ind DOG Bearing Thickness Oil Groove Ney SNe 3 1 jon Hote IOUS | pa » ENGINE MECHANICAL ~ Cylinder Block IF NECESSARY, REPLACE CAMSHAFT BEARINGS Remove expansion plug Using SST and a hammer, tap out the expansion plug SST 09215-00100 (09215-00130, 09215-00150, 09215-00210) Remove camshaft bearings Using SST, remove the bearings SST 09215-00100 (09215-00120, 09215-00130, 09215-00140, 09215-00150, 09215-00160, 09215-00280} Install new camshaft bearings (a) Install new bearings in their proper location. (b) Align the oil holes of the bearing and cylinder block. {c}_ Using SST, install the bearings. SST 09215-00100 (09215-00120, 09215-00130, 09215-00140, 09215-00150, 09215-00160, 09215-00280)ENGINE MECHANICAL — Cylinder Block EM-111 D. Check camshaft oil clearance (See page EM-109) E. Install expansion plug (2) Apply liquid sealer to the expansion plug surface of the cylinder block. (b) Using a hammer, tap in a new expansion plug until its surface is flush with the cylinder block edge. SST 09215-00100 (09215-00280) INSPECTION OF VALVE LIFTER BORES INSPECT VALVE LIFTER OIL CLEARANCE (a) Using calipers, measure the valve lifter bore diameter. Bore diameter: 22.200 — 22.221 mm (0.8740 — 0.8748 in) (b) Subtract the valve lifter diameter measurement (See page EM-84) from the vale lifter bore diameter ‘measurement. Standard oil clearance: 0.010 — 0.051 mm (0.0004 = 0.0020 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve lifters.EM-112 ENGINE MECHANICAL — Cylinder Block REPLACEMENT OF CRANKSHAFT REAR OIL SEAL NOTE: There are two methods (A and B) to replace the oil seal as follows. REPLACE CRANKSHAFT REAR OIL SEAL A If rear oil seal retainer is removed from cylinder block: (a) Using a screwdriver and hammer, tap out the oil seal (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 (cl_ Apply MP grease to the oil seal lip. If rear oil seal retainer is installed to cylinder block: (2) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal CAUTION: Be careful not to damage the crankshaft. Tape the screwdriver. (c) Apply MP grease to a new oil seal (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010ENGINE MECHANICAL — Cylinder Block EM-113 Piston. Piston. Sized Sized Front. i (Protrusion) (Protrusion) il Ring Ends ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES 1. ASSEMBLE PISTON AND CONNECTING ROD (a) Install a new snap ring on one side of the piston pin hole. (b) Gradually heat the piston to approx. 60°C (140°F) (c)_ Position the piston sized mark of the piston with the front mark of connecting rod, and push in the piston pin with your thrumb, (4) Install a new snap ring on the other side if the piston pin hole. 2. INSTALL PISTON RINGS fa) Install the coil and oil ring by hand NOTE: Face the end gap of the oil ring in the opposite direction of the coil joint.EM-114 ENGINE MECHANICAL — Cylinder Block 2H No. 2 Compression Oil Ring Front - a Ring g ran ol compression Piston Sized Mark COMPYESSICN, 12H-T No. 2 Compression Oil Ring Front - Oil Ring No. 1 col Compression Piston Sized Mark ‘evzee 3. (b) Using a piston ring expander, install the two com- pression rings with the code mark facing upward. (c)__ Position the piston rings so that the ring end gaps are as shown. CAUTION: Do not align the end gaps. INSTALL BEARINGS (a) Align the bearing claw with the claw groove of the connecting rod or connecting rod cap. (b) Install the bearings in the connecting rod and con- necting rod cap.ENGINE MECHANICAL — Cylinder Block EM-115 ASSEMBLY OF CYLINDER BLOCK (See page EM-94) NOTE. ‘© Thoroughly clean all parts to be assembled. © Before installing the parts, apply new engine cil to all sliding and rotating surfaces. © Replace all gaskets and oil seals with new parts. 1. INSTALL MAIN BEARINGS No. 4 Others (a) Align the bearing claw with the claw groove of the main bearing cap or cylinder block, (b) Install the bearing in the cylinder block and main bearing caps in the proper location. 30. mm 23 mm (1.18 in) (i INSTALL UPPER THRUST WASHERS Thrust Washer Install the thrust washers under the No. 4 main bearing cap position of the block with the oil grooves facing out- ward. 3. PLACE CRANKSHAFT ON CYLINDER BLOCK Oil Groove sse70 > _ 4. _ INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS (a) Install the lower thrust washers on the No. 4 main bearing cap with the oil grooves facing outward. Ol Groove a {b) Install the main bearing caps in their proper locations,EM-116 ENGINE MECHANICAL — Cylinder Block (c)_ Apply a light coat of the engine oil on the threads and under the bolt heads of the main bearing caps. (d) Install and uniformly tighten the fourteen bolts of the main bearing caps in several passes, in the sequence shown, Torque: 1,390 kg-cm (100 ft-lb, 136 N-m) (e) Check that the crankshaft turns smoothly. () Check the crankshaft thrust clearance. (See page EM-98) 5. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES (a) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft and cylinder bore from damage. (b) Position the piston sized mark of the piston. 12HT 2H (c) Using a piston ring compressor, push the correctly Piston Piston = numbered piston and connecting rod assembly into Sized 2) Sized KG ‘the cylinder. Mark Front 6. INSTALL CONNECTING ROD CAPS Front Mark (a) Match the numbered cap with the numbered con- necting rod. (b) Install the connecting rod cap with the front mark facing forward (Protrusion)ENGINE MECHANICAL — Cylinder Block EM-117 10. WW. 12, 13, 14. 15, (c)_ Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap. (d) Install and alternately tighten the nuts of the connect- ing rod cap in several passes. Torque: 900 kg-cm (65 ft-lb, 88 N-m) {e) Check that the crankshaft turns smoothly. (f) Check the connecting rod thrust clearance. (See page EM-95) INSTALL REAR OIL SEAL RETAINER Install a new gasket and the retainer with the six bolts. Torque: 185kg-cm (13 ft-lb, 18 N-m) INSTALL OIL PUMP AND OIL PAN (See pages LU-11 to 13) INSTALL INJECTION PUMP. (See pages FU-98 and 99) INSTALL TIMING GEARS AND CAMSHAFT (See pages EM-88 to 92) INSTALL CYLINDER HEAD (See pages EM-68 to 71) 2H (See pages EM-73 to 76) 12H INSTALL INJECTION PIPES (See page FU-8) 2H (See page FU-14 and 15) 12H-T (124-11 INSTALL TURBOCHARGER (See pages EM-44 to 46) REMOVE ENGINE STAND INSTALL REAR END PLATE Install the rear end plate with the three bolts. Torque 12 mm bolt head 185 kg-cm (13 ft-lb, 18 N-m) 17 mm bolt head 650 kg-cm (47 ft-lb, 64 N-m)EM-118 ENGINE MECHANICAL — Cylinder Block 16. (M/T] INSTALL FLYWHEEL (2) Apply a light coat of engine oil on the threads and under the bolt heads. (b) Install the flywheel on the crankshaft. (c) Install and uniformly tighten the six bolts in several passes, in the sequence shown. Torque: 1,200 kg-cm (87 ft-lb, 118 N-m) 17. [aT] INSTALL DRIVE PLATE (See procedure step 16) Torque: 1,000 kg-cm (72 ft-Ib, 98 Nm)