S5 Yw04e06ahinodutro PDF
S5 Yw04e06ahinodutro PDF
S5 Yw04e06ahinodutro PDF
1 MENU
FOREWORD
This workshop manual has been prepared to provide information covering general service repairs for the
W04DïJ engine equipped on the HINO DUTRO.
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Applicable models: WU300, 340, 410 series
Please note that the publications below have also been prepared as relevant service manuals for the compo-
nents and systems in this vehicles.
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
Hino Motors,Ltd.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.
S Must read this manual thoroughly. It is especially important to have a good understanding of
all the contents written in the PRECAUTION of ”IN” section.
S The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using nonïspecified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
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damage to the customer’s vehicle before starting the operation.
S If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
INTRODUCTION 1
PREPARATION 2
SERVICE SPECIFICATIONS 3
FUEL 11
INTAKE 13
ENGINE MECHANICAL 14
EXHAUST 15
COOLING 16
LUBRICATION 17
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STARTING & CHARGING 19
ALPHABETICAL INDEX
INTRODUCTION
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01ï1
INTRODUCTION ï HOW TO USE THIS ENGINE REPAIR MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains ”Removing and Installing, Replacing, Disassembling, Installing and Checking,
Adjusting”, but ”Final Inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
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3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ”disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Nonïreusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:
OVERHAUL Camshaft,
No. 3 Camshaft Subïassy
(d) Tightening torque, oil applying position, and nonïreusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a stepïbyïstep format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
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Illustration: Task heading: what to do
what to do and where
Detailed text:
Set part No. Component part No. how to do task
A59974
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.
01ï3
INTRODUCTION ï HOW TO USE THIS ENGINE REPAIR MANUAL
7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 Nm (310 kgfcm, 22 ftlbf)
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01ï4 INTRODUCTION ï REPAIR INSTRUCTION FOR ENGINE REPAIR
MANUAL
PRECAUTION
1. TO PREVENT FROM ENTERING FOREIGN SUBSTANCES
(a) When foreign substances such as dust, grain of sand or metallic dust enter inside of engine, it often
causes functional failure of the engine.
(1) Precaution before disassembly.
S Remove adequately all sand and mud adhere to the outside of engine .
(2) Precaution at reassembly.
S Protect disassembled parts from dust by using vinyl sheet to cover.
2. TO PREVENT SCRATCHES ON THE PARTS
(a) The existence of scratches on the contact and revolving surfaces often causes oil leak and seisure.
(1) Precautions at disassembly and reassembly.
S When disassemble the contact surface of the parts, use plastic hummer striking lightly. (Do
not pry out by screwdriver).
S When fix the parts to the vise, do not directly catch it in the vise. Fix the parts through alumi-
num bar.
3. TO CLEAN AND WASH THE PARTS
(a) Each parts needs to be well cleaned, washed, and dried by air, and apply specified oil before reas-
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sembly.
(1) Cleaning and washing by alkaline solvent is prohibited:
S Parts made of aluminum and rubber. (ex. cylinder head cover gasket etc.)
(2) Cleaning and washing by flushing oil (ex. kerosene, white gasoline etc.) is prohibited:
S Parts made of rubber. (ex. cylinder head cover gasket etc.)
4. POSITION AND DIRECTION OF EACH PARTS
(a) Each parts needs to be reassembled as the same position and direction as it disassembled.
(1) Precautions at disassembly and reassembly.
S Follow the directions when the manual designates to mark the matchmark and/or direction
mark.
S Disassembled parts needs to be put in order as disassembled, not to change position and/
or direction.
S Follow the directions when the manual instructs the position and direction.
5. INSTALL ENGINE ASSEMBLY TO OVERHAUL STAND WHEN OVERHAUL THE ENGINE
6. PUT THE DISASSEMBLED PARTS IN ORDER AS THEY DISASSEMBLED
7. APPLY ENGINE OIL TO THE SLIDING AND ROTATING SURFACES
8. NONïREUSABLE PARTS SUCH AS GASKET AND SEAL NEEDS TO BE CHANGED TO THE NEW
PARTS
9. BASIC REPAIR HINT
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets:
When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
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D02612
D01201
L1 L2
D01202
(3) Never use any electric equipment like an electric motor or a working light as they may cause
spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.
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(c) In case of reusing the hose, install the clamp on the hose
where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force
Clamp Track to the arrow mark direction after the installation.
D25081
01ï7
INTRODUCTION ï TERMS FOR ENGINE REPAIR MANUAL
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A/T Automatic Transmission (Transaxle)
ATF Automatic Transmission Fluid
AUTO Automatic
AUX Auxiliary
AVG Average
AVS Adaptive Variable Suspension
B+ Battery Voltage
BACS Boost Altitude Compensation System
BAT Battery
BDC Bottom Dead Center
B/L BiïLevel
B/S BoreïStroke Ratio
BTDC Before Top Dead Center
BVSV Bimetallic Vacuum Switching Valve
CB Circuit Breaker
CCo Catalytic Converter For Oxidation
CD Compact Disc
CF Cornering Force
CG Center Of Gravity
CH Channel
CKD Complete Knock Down
COMB. Combination
CPE Coupe
CPS Combustion Pressure Sensor
CPU Central Processing Unit
CRS Child Restraint System
CTR Center
C/V Check Valve
CV Control Valve
CW Curb Weight
DC Direct Current
DEF Defogger
DFL Deflector
01ï8
INTRODUCTION ï TERMS FOR ENGINE REPAIR MANUAL
Abbreviations Meaning
DIFF. Differential
DIFF. LOCK Differential Lock
D/INJ Direct Injection
DLC Data Link Connector
DLI Distributorless Ignition
DOHC Double Overhead Cam
DP Dash Pot
DS Dead Soak
DSP Digital Signal Processor
DTC Diagnostic Trouble Code
ECAM Engine Control And Measurement System
ECD Electronic Controlled Diesel
ECDY Eddy Current Dynamometer
ECT Electronic Control Transmission
ECU Electronic Control Unit
ED ElectroïDeposited Coating
EDU Electronic Driving Unit
EDIC Electric Diesel Injection Control
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EFI Electronic Fuel Injection
E/G Engine
EGR Exhaust Gas Recirculation
EGRïVM EGRïVacuum Modulator
ELR Emergency Locking Retractor
ENG Engine
ESA Electronic Spark Advance
ETCS Electronic Throttle Control System
EVAP Evaporative Emission Control
EVP Evaporator
EïVRV Electric Vacuum Regulating Valve
EX Exhaust
FE Fuel Economy
FF FrontïEngine FrontïWheelïDrive
F/G Fuel Gauge
FIPG Formed In Place Gasket
FL Fusible Link
F/P Fuel Pump
FPU Fuel Pressure Up
FR Front
F/W Flywheel
FW/D Flywheel Damper
FWD FrontïWheelïDrive
GAS Gasoline
GND Ground
HAC High Altitude Compensator
H/B Hatchback
HïFUSE High Current Fuse
HI High
HID High Intensity Discharge (Head Lamp)
HSG Housing
HT Hard Top
HWS Heated Windshield System
01ï9
INTRODUCTION ï TERMS FOR ENGINE REPAIR MANUAL
Abbreviations Meaning
IC Integrated Circuit
IDI Indirect Diesel Injection
IFS Independent Front Suspension
IG Ignition
IIA Integrated Ignition Assembly
IN Intake (Manifold, Valve)
INT Intermittent
I/P Instrument Panel
IRS Independent Rear Suspension
ISC Idle Speed Control
J/B Junction Block
J/C Junction Connector
KD KickïDown
LAN Local Area Network
LB Liftback
LCD Liquid Crystal Display
LED Light Emitting Diode
LH LeftïHand
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LHD LeftïHand Drive
L/H/W Length, Height, Width
LLC LongïLife Coolant
LNG Liquified Natural Gas
LO Low
LPG Liquified Petroleum Gas
LSD Limited Slip Differential
LSP & PV Load Sensing Proportioning And Bypass Valve
LSPV Load Sensing Proportioning Valve
MAP Manifold Absolute Pressure
MAX. Maximum
MIC Microphone
MIL Malfunction Indicator Lamp
MIN. Minimum
MP Multipurpose
MPI Multipoint Electronic Injection
MPX Multiplex Communication System
M/T Manual Transmission
MT Mount
MTG Mounting
N Neutral
NA Natural Aspiration
NO. Number
O2S Oxygen Sensor
O/D Overdrive
OEM Original Equipment Manufacturing
OHC Overhead Camshaft
OHV Overhead Valve
OPT Option
O/S Oversize
P & BV Proportioning And Bypass Valve
PCS Power Control System
PCV Positive Crankcase Ventilation
01ï10
INTRODUCTION ï TERMS FOR ENGINE REPAIR MANUAL
Abbreviations Meaning
PKB Parking Brake
PPS Progressive Power Steering
PS Power Steering
PTO Power TakeïOff
P/W Power Window
R&P Rack And Pinion
R/B Relay Block
RBS Recirculating Ball Type Steering
R/F Reinforcement
RFS Rigid Front Suspension
RRS Rigid Rear Suspension
RH RightïHand
RHD RightïHand Drive
RLY Relay
ROM Read Only Memory
RR Rear
RRS RearïWheel Drive
RWD RearïWheel Drive
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SDN Sedan
SEN Sensor
SICS Starting Injection Control System
SOC State Of Charge
SOHC Single Overhead Camshaft
SPEC Specification
SPI Single Point Injection
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Standard
STJ ColdïStart Fuel Injection
SW Switch
SYS System
T/A Transaxle
TACH Tachometer
TBI Throttle Body Electronic Fuel Injection
TC Turbocharger
TCCS ComputerïControlled System
TCV Timing Control Valve
TDC Top Dead Center
TEMP. Temperature
TFT FreeïTronic
TIS Total Information System For Vehicle Development
T/M Transmission
TRC Traction Control System
TURBO Turbocharge
TWC ThreeïWay Catalyst
U/D Underdrive
U/S Undersize
VCV Vacuum Control Valve
VENT Ventilator
VIN Vehicle Identification Number
01ï11
INTRODUCTION ï TERMS FOR ENGINE REPAIR MANUAL
Abbreviations Meaning
VPS Variable Power Steering
VSC Vehicle Skid Control
VSV Vacuum Switching Valve
VTV Vacuum Transmitting Valve
VVTïi Variable Valve Timingïintelligent
W/ With
WGN Wagon
W/H Wire Harness
W/O Without
1ST First
2ND Second
2WD Two Wheel Drive Vehicle (4 x 2)
3RD Third
4TH Fourth
4WD Four Wheel Drive Vehicle (4 x 4)
4WS Four Wheel Steering System
5TH Fifth
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01ï12
INTRODUCTION ï TERMS FOR ENGINE REPAIR MANUAL
0108Iï02
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CPP Clutch Pedal Position ï
CTOX Continuous Trap Oxidizer ï
CTP Closed Throttle Position LL ON, Idle ON
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition ï
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Comunication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode ï
ECL Engine Control Level ï
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only Memory
EEPROM Electrically Erasable Programmable Read Only Memory (EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Distributorless Ignition (TDI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control ï
Flash Electrically Erasable Programmable
FEEPROM ï
Read Only Memory
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ï
MVZ Manifold Vacuum Zone ï
NVRAM NonïVolatile Random Access Memory ï
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
OBD OnïBoard Diagnostic OnïBoard Diagnostic System (OBD)
OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module ï
PNP Park/Neutral Position ï
PROM Programmable Read Only Memory ï
PSP Power Steering Pressure ï
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
RM Relay Module ï
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass EïABV
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter ï
SRI Service Reminder Indicator ï
SRT System Readiness Test ï
ST Scan Tool ï
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
01ï14
INTRODUCTION ï TERMS FOR ENGINE REPAIR MANUAL
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PREPARATION
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï1
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï1
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï2
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï2
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . 02ï3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï3
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï6
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï6
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï7
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï7
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï8
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï8
STARTING & CHARGING . . . . . . . . . . . . . . . . . 02ï9
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PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï9
02ï1
PREPARATION ï FUEL
FUEL
02269ï01
PREPARATION
Equipment
Brass brush
Injection nozzle tester
Torque wrench
Retaining nut wrench (Part No. 95092ï10500 for DENSO made)
Wooden stick
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02ï2
PREPARATION ï INTAKE
INTAKE
0226Aï01
PREPARATION
Recomended Tools
09200ï00010 Engine Adjust Kit INTAKE MANIFOLD
Equipment
Dye penetrant
Precision straight edge
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02ï3
PREPARATION ï ENGINE MECHANICAL
ENGINE MECHANICAL
0226Bï01
PREPARATION
SST
09201ï41020 Valve Stem Oil Seal Replacer CYLINDER HEAD ASSY
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(09215ï00461) Camshaft Bearing Remover & TIMING GEAR AND CAMSHAFT
Replacer
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9191ï08252 Bolt PISTON, CRANKSHAFT AND
CYLINDER BLOCK
Recomended Tools
09090ï04020 Engine Sling Device PISTON, CRANKSHAFT AND
CYLINDER BLOCK
SSM
08826ï00080 Seal Packing Black or equivalent CRANKSHAFT PULLEY, OIL PAN
(FIPG) AND FLYWHEEL HOUSING
02ï5
PREPARATION ï ENGINE MECHANICAL
Equipment
Abrasive compound
Connecting rod aligner
Cylinder gauge
Dial gauge
Dye penetrant
Heater
Micrometer
Piston ring compressor
Piston ring expander
Precision straight edge
Press
Sliding hammer
Soft brush
Solvent
Spring tester
Steam cleaner
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Steel square
Straight edge
Torch
Torque wrench
Valve guide bushing brush
Valve seat cutter
Vïblock
Vernier calipers
Wire brush
02ï6
PREPARATION ï EXHAUST
EXHAUST
0226Cï01
PREPARATION
Recomended Tools
09200ï00010 Engine Adjust Kit EXHAUST MANIFOLD
Equipment
Dye penetrant
Precision straight edge
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02ï7
PREPARATION ï COOLING
COOLING
0226Dï01
PREPARATION
SSM
08826ï00100 ”Seal Packing 1282B,” WATER PUMP ASSY
THREE BOND 1282B or equivalent
(FIPG)
Equipment
Bolt
Thread diameter: 10.0 mm (0.394 in.)
Thread pitch: 1.5 mm (0.059 in.)
Heater
Press
Steel pipe
Length: More than 57 mm (2.24 in.)
Inside diameter: 18 ï 21 mm (0.71 ï 0.83 in.)
Outside diameter: Less than 29.5 mm (1.161 in.)
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Thermometer
02ï8
PREPARATION ï LUBRICATION
LUBRICATION
0226Eï01
PREPARATION
Equipment
Dial gauge
Micrometer
Torque wrench
Vise
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02ï9
PREPARATION ï STARTING & CHARGING
PREPARATION
SST
09820ï00031 Alternator Rotor Rear Bearing STARTER ASSY
Replacer
Recommend Tools
09082ï00040 Electrical Tester STARTER ASSY
GENERATOR ASSY
Equipment
Dial indicator
Micrometer
Plastic hammer
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Press
Pull scale Brush spring
Sandpaper Commutator
Soldering iron
Torque wrench
Vernier calipers
SERVICE SPECIFICATIONS
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SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï10
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï11
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï11
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï12
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï12
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . 03ï13
STARTING & CHARGING . . . . . . . . . . . . . . . . . 03ï14
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï14
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . 03ï15
03ï1
SERVICE SPECIFICATIONS ï STANDARD BOLT
STANDARD BOLT
030Y3ï03
Bolt Type
Hexagon Head Bolt Class
Stud Bolt Weld Bolt
Normal Recess Bolt Deep Recess Bolt
4 4T
5 5T
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6 6T
w/Washer w/Washer
7 7T
8 8T
9 9T
10 10T
11 11T
B06431
03ï2
SERVICE SPECIFICATIONS ï STANDARD BOLT
030Y4ï03
6 1 8 80 69 in.·lbf 9 90 78 in.·lbf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
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14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 ï ï ï
4N
No Mark
5N (4T)
6N
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6N
7N (5T)
8N
8N
10N (7T)
10N
No Mark
11N
11N
12N
12N
FUEL
030YCï06
TORQUE SPECIFICATION
Part tightened N·m kgf·cm ft·lbf
Nozzle holder body x Nozzle holder retaining nut 68.5 700 51
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03ï5
SERVICE SPECIFICATIONS ï INTAKE
INTAKE
030Y7ï04
SERVICE DATA
Intake manifold Warpage Maximum 0.20 mm (0.0079 in.)
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03ï6
SERVICE SPECIFICATIONS ï ENGINE MECHANICAL
ENGINE MECHANICAL
030YDï04
SERVICE DATA
Cyliner head Warpage STD Longitudinal direction 0.05 mm (0.0020 in.) or less
Lateral direction 0.05 mm (0.0020 in.) or less
Maximum 0.10 mm (0.0039 in.)
Valve and valve Valve seat angle Intake 29˚ 00’ ï 30˚ 00’
seat Exhaust 44˚ 00’ ï 45˚ 15’
Valve face angle Intake 29˚ 45’ ï 30˚ 15’
Exhaust 44˚ 45’ ï 45˚ 15’
Valve sink dimension STD Intake 0.15 ï 0.45 mm (0.0059 ï 0.0177 in.)
Exhaust 0.47 ï 0.77 mm (0.0185 ï 0.0303 in.)
Maximum Intake 0.55 mm (0.0217 in.)
Exhaust 0.87 mm (0.0342 in.)
Valve stem diameter STD Intake 8.95 ï 8.97 mm (0.3524 ï 0.3531 in.)
Exhaust 8.93 ï 8.95 mm (0.3516 ï 0.3524 in.)
Minimum Intake 8.90 mm (0.3504 in.)
Exhaust 8.80 mm (0.3465 in.)
Valve stem oil clearance STD Intake 0.035 ï 0.068 mm (0.0014 ï 0.0027 in.)
Exhaust 0.050 ï 0.083 mm (0.0020 ï 0.0033 in.)
Maximum Intake Position A & B 0.10 mm (0.0039 in.)
C 0.18 mm (0.0071 in.)
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Exhaust Position A & B 0.12 mm (0.0047 in.)
C 0.20 mm (0.0079 in.)
Valve spring Deviation Maximum 2.0 mm (0.079 in.)
Free length Inner 60.2 mm (2.370 in.)
Outer 60.1 mm (2.366 in.)
Installed tension Inner at 43.0 mm (1.693 in.) 86.0 N (8.8 kgf, 19.3 lb)
Outer at 45.5 mm (1.791 in.) 269.0 N (27.4 kgf, 60.5 lb)
Nozzle holder and Nozzle protrusion STD 2.25 ï 3.05 mm (0.1004 ï 0.1201 in.)
nozzle set Maximum 3.05 mm (0.1201 in.)
Valve rocker arm Valve rocker arm bush inside diameter STD 19.020 ï 19.045 mm (0.7488 ï 0.7498 in.)
and shaft Maximum 19.06 mm (0.7504 in.)
Valve rocker arm shaft diameter STD 18.966 ï 18.984 mm (0.7467 ï 0.7474 in.)
Minimum 18.95 mm (0.7461 in.)
Oil clearance STD 0.036 ï 0.079 mm (0.0014 ï 0.0031 in.)
Maximum 0.10 mm (0.0039 in.)
Valve lifter Valve lfter diameter STD 26.95 ï 26.97 mm (1.0610 ï 1.0618 in.)
Valve lifter bore inside diameter STD 27.00 ï 27.02 mm (1.0630 ï 1.0638 in.)
Oil clearance STD 0.025 ï 0.071 mm (0.0010 ï 0.0028 in.)
Maximum 0.10 mm (0.0039 in.)
Cylinder head bolt Length Maximum Bolt No. position 1 ï 13 118 mm (4.65 in.)
14 ï 18 165 mm (6.50 in.)
Valve clearance at cold Intake 0.35 mm (0.014 in.)
Exhaust 0.55 mm (0.022 in.)
Backlash
Crankshaft timing gear x Idle gear STD 0.068 ï 0.194 mm (0.0027 ï 0.0076 in.)
Maximum 0.30 mm (0.0118 in.)
Idle gear x Injection pump drive gear STD 0.065 ï 0.232 mm (0.0026 ï 0.0091 in.)
Maximum 0.30 mm (0.0118 in.)
Idle gear x Oil pump drive gear STD 0.065 ï 0.182 mm (0.0026 ï 0.0072 in.)
Maximum 0.30 mm (0.0118 in.)
Camshaft timing gear x Oil pump drive gear STD 0.065 ï 0.182 mm (0.0026 ï 0.0072 in.)
Maximum 0.30 mm (0.0118 in.)
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No. 3 56.55 ï 56.57 mm (2.2264 ï 2.2272 in.)
Minimum No. 1 56.85 mm (2.2382 in.)
No. 2 56.65 mm (2.2303 in.)
No. 3 56.45 mm (2.2224 in.)
Camshaft bearing inside diameter STD No. 1 57.00 ï 57.07 mm (2.2441 ï 2.2468 in.)
No. 2 56.80 ï 56.87 mm (2.2362 ï 2.2390 in.)
No. 3 56.60 ï 56.67 mm (2.2283 ï 2.2311 in.)
Oil clearance STD 0.030 ï 0.120 mm (0.0012 ï 0.0047 in.)
Maximum 0.15 mm (0.0059 in.)
Bent Maximum 0.05 mm (0.0020 in.)
Thrust clearance STD 0.10 ï 0.18 mm (0.0039 ï 0.0071 in.)
Maximum 0.30 mm (0.0118 in.)
Connecting rod Rod bent Maximum per 200 mm (7.87 in.) 0.10 mm (0.0039 in.)
Rod twist Maximum per 200 mm (7.87 in.) 0.10 mm (0.0039 in.)
Bush inside diameter STD 37.035 ï 37.045 mm (1.4581 ï 1.4585 in.)
Maximum 37.10 mm (1.4606 in.)
Bush oil clearance STD 0.035 ï 0.056 mm (0.0014 ï 0.0022 in.)
Maximum 0.08 mm (0.0031 in.)
Rod big end inside diameter (w/o Bearing) STD 65.985 ï 66.000 mm (2.5978 ï 2.5984 in.)
Maximum 66.06 mm (2.6008 in.)
Rod big end inside diameter (w/ Bearing) STD 61.985 ï 62.000 mm (2.4403 ï 2.4409 in.)
Maximum 62.06 mm (2.4433 in.)
Rod big end oil clearance STD 0.031 ï 0.082 mm (0.0012 ï 0.0032 in.)
Maximum 0.12 mm (0.0047 in.)
Thrust clearance STD 0.20 ï 0.52 mm (0.0079 ï 0.0205 in.)
Maximum 0.60 mm (0.0236 in.)
Piston and piston Piston pin diameter STD 36.989 ï 37.000 mm (1.4563 ï 1.4567 in.)
ring Minimum 36.96 mm (1.4551 in.)
Piston diameter STD 103.908 mm (4.0909 in.)
Minimum 103.902 mm (4.0906 in.)
Piston oil clearance STD 0.0140 ï 0.0172 mm (0.0056 ï 0.0068 in.)
Piston pin boss inside diameter STD 36.987 ï 37.003 mm (1.4562 ï 1.4568 in.)
Minimum 37.05 mm (1.4587 in.)
Clearance between piston pin boss and piston pin STD 0.013 (T) ï 0.014 (L) mm (0.0051 (T) ï 0.0055 (L) in.)
Maximum 0.05 mm (0.0020 in.)
Piston ring groove width STD 1st 2.58 ï 2.60 mm (0.1016 ï 0.1024 in.)
2nd 2.06 ï 2.08 mm (0.0811 ï 0.0819 in.)
Oil 4.01 ï 4.03 mm (0.1579 ï 0.1587 in.)
Maximum 1st 3.10 mm (0.1220 in.)
2nd 2.20 mm (0.0866 in.)
Oil 4.08 mm (0.1606 in.)
Piston ring thickness STD 1st 2.47 ï 2.49 mm (0.0972 ï 0.0980 in.)
2nd 1.97 ï 1.99 mm (0.0776 ï 0.0783 in.)
Oil 4.97 ï 4.99 mm (0.1957 ï 0.1965 in.)
Maximum 1st 2.32 mm (0.0913 in.)
2nd 1.82 mm (0.0717 in.)
Oil 4.95 mm (0.1949 in.)
Piston ring groove clearance STD 1st 0.09 ï 0.13 mm (0.0035 ï 0.0051 in.)
2nd 0.07 ï 0.11 mm (0.0028 ï 0.0043 in.)
Oil 0.02 ï 0.06 mm (0.0008 ï 0.0024 in.)
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Maximum 0.30 mm (0.0118 in.)
Piston ring end gap STD 0.30 ï 0.42 mm (0.0118 ï 0.0165 in.)
Maximum 1.20 mm (0.0472 in.)
Crankshaft Crankshaft pin diameter STD 61.940 ï 61.960 mm (2.4386 ï 2.4394 in.)
Minimum 60.76 mm (2.3921 in.)
Bent Maximum 0.04 mm (0.0016 in.)
Main journal diameter STD 72.94 ï 72.96 mm (2.8716 ï 2.8724 in.)
Minimum for repair 72.74 mm (2.8638 in.)
for use 71.76 mm (2.8252 in.)
Main journal oil clearance STD 0.039 ï 0.090 mm (0.0015 ï 0.0035 in.)
Maximum 0.13 mm (0.0051 in.)
Thrust clearance STD 0.05 ï 0.22 mm (0.0020 ï 0.0087 in.)
Maximum 0.40 mm (0.0157 in.)
Cylinder block Warpage STD 0.05 mm (0.0020 in.) or less
Maximum 0.10 mm (0.0039 in.)
Main bearing bore diameter (w/o bearing) STD 77.985 ï 78.000 mm (3.0703 ï 3.0709 in.)
Maximum 78.20 mm (3.0787 in.)
Main bearing bore diameter (w/ bearing) STD 73.000 mm (2.8740 in.)
Maximum 73.30 mm (2.8858 in.)
Main bearing cap Length STD 94.00 mm (3.7008 in.)
bolt Maximum 95.20 mm (3.7480 in.)
TORQUE SPECIFICATION
Part tightened N·m kgf·cm ft·lbf
Cylinder head x Cylinder block Cylinder head bolt 132 1,350 97
Cylinder head Additional bolt 52 530 38
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Main bearing cap x Cylinder block 147.1 1,500 109
Connecting rod cap x Connecting rod 122.6 1,250 90
03ï10
SERVICE SPECIFICATIONS ï EXHAUST
EXHAUST
030Y8ï04
SERVICE DATA
Exhaust manifold Warpage Maximum 0.20 mm (0.0079 in.)
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03ï11
SERVICE SPECIFICATIONS ï COOLING
COOLING
030Y9ï04
SERVICE DATA
Thermostat Valve opening temperature 80 ï 84˚C (176 ï 183˚F)
Valve lift at 95˚C (203˚F) 10 mm (0.39 in.) or more
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03ï12
SERVICE SPECIFICATIONS ï LUBRICATION
LUBRICATION
030YAï04
SERVICE DATA
Oil pump Backlach STD 0.091 ï 0.217 mm (0.0036 ï 0.0085 in.)
Maximum 0.30 mm (0.0118 in.)
Drive gear shaft diameter STD 18.088 ï 18.106 mm (0.7121 ï 0.7128 in.)
Minimum 18.062 mm (0.7111 in.)
Drive gear bush inside diameter STD 18.146 ï 18.173 mm (0.7144 ï 0.7155 in.)
Maximum 18.20 mm (0.7165 in.)
Oil clearance between drive gear shaft and bush STD 0.040 ï 0.085 mm (0.0016 ï 0.0033 in.)
Maximum 0.10 mm (0.0039 in.)
Driven gear shaft diameter STD 17.979 ï 17.997 mm (0.7078 ï 0.7085 in.)
Minimum 17.97 mm (0.7074 in.)
Driven gear bush inside diameter STD 18.037 ï 18.054 mm (0.7101 ï 0.7108 in.)
Maximum 18.07 mm (0.7114 in.)
Oil clearance between driven gear shaft and bush STD 0.040 ï 0.075 mm (0.0016 ï 0.0030 in.)
Maximum 0.10 mm (0.0039 in.)
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03ï13
SERVICE SPECIFICATIONS ï LUBRICATION
030YBï03
TORQUE SPECIFICATION
Part tightened N·m kgf·cm ft·lbf
Oil pump case subïassy x Cylinder block 22.5 230 17
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03ï14
SERVICE SPECIFICATIONS ï STARTING & CHARGING
SERVICE DATA
Starter assy
Starter armature Commutator diameter STD 32.8 mm (1.291 in.)
assy Minimum 30.0 mm (1.181 in.)
Commutator undercut depth STD 0.5 ï 0.8 mm (0.020 ï 0.032 in.)
Minimum 0.2 mm (0.008 in.)
Starter brush Brush length STD 18.0 mm (0.709 in.)
Minimum 12.0 mm (0.472 in.)
Starter brush hold- Brush spring installed load STD 42.2 ï 51.0 N (4.3 ï 5.2 kgf, 9.3 ï 11.2 lbf)
er assy Minimum 22.5 N (2.3 kgf, 4.9 lbf)
Magnet starter Pullïin coil resistance (between terminal 30 and 50) STD 0.12 ï 0.15 :
switch assy Holdïin coil resistance
(between terminal 50 and switch body) STD 0.83 ï 1.01 :
Starter clutch Inner sleeve diameter (A) STD 26.0 mm (1.024 in.)
subïassy Minimum 25.9 mm (1.020 in.)
Starter clutch diameter (B) STD 12.1 mm (0.476 in.)
Minimum 12.0 mm (0.472 in.)
Drive housing Diameter of starter drive housing bush inside STD 26.0 mm (1.024 in.)
Maximum 26.2 mm (1.031 in.)
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Motor housing Diameter of motor housing bush inside STD 12.1 mm (0.476 in.)
Maximum 12.3 mm (0.484 in.)
Starter commuta- Diameter of end frame bush inside STD 12.0 mm (0.472 in.)
tor end frame assy Maximum 12.2 mm (0.480 in.)
Generator assy
Rotor Resistance between slip rings STD 12.5 : at 20_C (68_F)
Resistance between slip rings and rotor body
at 20_C (68_F) STD More than 1 M:
Minimum Less than 0.5 M:
Slip ring diameter STD 34.5 mm (1.358 in.)
Minimum 33.5 mm (1.319 in.)
Brush holder as- Brush exposed length STD 21.0 mm (0.827 in.)
sembly Minimum 7.0 mm (0.276 in.)
03ï15
SERVICE SPECIFICATIONS ï STARTING & CHARGING
030YWï03
TORQUE SPECIFICATION
Starter assy
Part tightened Nm kgfcm ftlbf
Starter commutator end frame assy x Starter drive housing 14.7 150 11
Motor housing x Starter drive housing 15 155 11
Magnet starter switch assy x Starter drive housing 14.7 150 11
Starter commutator end frame assy x Starter brush holder assy 4.3 44 38 in.lbf
Generator assy
Part tightened Nm kgfcm ftlbf
Bearing retainer x Front bracket 3.2 ï 4.4 33 ï 45 29 ï 39 in.lbf
Generator pulley x Rotor 96 ï 127 980 ï 1,300 71 ï 94
Front bracket x Rear bracket 5.9 ï 8.8 60 ï 90 52 ï 78 in.lbf
Brush holder assembly x Rectifier holder 1.9 ï 2.5 19 ï 25 17 ï 22 in.lbf
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FUEL
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11ï1
FUEL ï NOZZLE HOLDER AND NOZZLE SET (W04DïJ)
COMPONENTS
z Gasket
Joint Bolt
Adjusting Shim
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Pressure Spring
Nozzle Holder Body
Pressure Pin
Distance Piece
Nozzle Assy
OVERHAUL
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Do not touch the nozzle mating surfaces with your fin-
gers.
(b) Using a wooden stick, remove the carbon adhering to the
nozzle needle tip.
A72454
(c) Using a brass brush, remove the carbon from the exterior
of the nozzle body (except lapped surface).
(d) Check the nozzle body for burns or corrosion.
(e) Check the nozzle needle tip for damage or corrosion.
If any of these damages are found, replace the nozzle assy.
A72453
A71746 A71949
11ï3
FUEL ï NOZZLE HOLDER AND NOZZLE SET (W04DïJ)
(c) Check that the needle falls into the body vent smoothly by
its own weight when released.
(d) Repeat this test, rotating the needle slightly every time.
If the needle does not fall smoothly, replace the nozzle assy.
A71746 A71950
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A79561
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13ï1
INTAKE ï INTAKE MANIFOLD (W04DïJ)
INTAKE MANIFOLD
1305Eï01
INSPECTION
A71759
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If the warpage is greater than the maximum, replace the intake
manifold.
(c) Visually check the seal surface of the intake manifold for
deformation or wear.
A64523 If damage such as deformation and wear is excessive, replace
the manifold.
ENGINE MECHANICAL
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OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï31
14ï1
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
COMPONENTS
25 (250, 18)
x6 Cylinder Head Bolt
132 (1,350, 97)
x5
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z Gasket
Cylinder Head
Additional Bolt
52 (530, 38) x9
Adapter
22.1 (225, 16)
Collar
25 (250, 18)
Nozzle Holder
Keeper Shim
Spring Ring Packing
Valve Rocker Shaft Retainer Gasket
Inner Compression Spring
Outer Compression Spring
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Valve Adjusting
Screw
Push Rod
z Oil Seal
Spring Seat
Valve Lifter
Valve
z Valve Guide Bush
Valve Seat
Valve Seat
OVERHAUL
1. REMOVE INTAKE AIR CONNECTOR
A71065
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A71066
A71067
A71658
14ï4
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
A71660
Exhaust Side (b) Loosen the cylinder head bolts little in 3 stages, in the or-
der as shown in the illustration.
(c) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a bench.
Intake Side
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A71661
Cylinder Block
A71662
7. REMOVE VALVE
SST
(a) Using SST, compress the compression springs and re-
move the 2 keepers.
SST 09202ï70020 (09202ï00030)
(b) Remove the spring retainer, 2 compression springs and
valve.
(c) Remove the oil seal and spring seat.
HINT:
A72786 Arrange the valves, compression springs, spring seats and
spring retainers in the correct order.
8. INSPECT CYLINDER HEAD SUBïASSY
(a) Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(b) Using a wire brush, remove all the carbons from the com-
bustion chambers.
A71664
14ï5
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(c) Using a valve guide bushing brush and solvent, clean all
the guide bushes.
(d) Using a soft brush and solvent, thoroughly clean the cylin-
der head.
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A71665
6
3 2
1 1 4
5
A71666
EM0580 A53867
14ï6
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
cardiagn.com
lapping, does not result in proper seating.
S When handïlapping, always recheck the seating condi-
tion.
CAUTION:
When grinding, a metal tip may fly off on impact. Wear safe-
ty glasses to protect your eyes.
Valve seat angle:
Intake 29˚ 00’ ï 30˚ 00’
Exhaust 44˚ 00’ ï 45˚ 15’
Valve face angle:
Intake 29˚ 45’ ï 30˚ 15’
30_ 45_
Exhaust 44˚ 45’ ï 45˚ 15’
A71668
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B B
30_ 45_ A 46.500 ï 46.516 mm (1.8307 ï 1.8313 in.)
A A Intake
B 8.800 ï 9.000 mm (0.3465 ï 0.3543 in.)
C C
A 41.000 ï 41.016 mm (1.6142 ï 1.6148 in.)
D C D C Exhaust
B 7.200 ï 7.300 mm (0.2835 ï 0.2874 in.)
30_ Intake 45_ Exhaust
A71670 Valve seat dimension:
C 46.585 ï 46.600 mm (1.8341 ï 1.8346 in.)
Intake
D 7.500 ï 7.700 mm (0.2953 ï 0.3031 in.)
C 41.130 ï 41.145 mm (1.6193 ï 1.6199 in.)
Exhaust
D 6.000 ï 6.200 mm (0.2362 ï 0.2441 in.)
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Intake 8.95 ï 8.97 mm (0.3524 ï 0.3531 in.)
Exhaust 8.93 ï 8.95 mm (0.3516 ï 0.3524 in.)
Minimum valve stem diameter:
Intake 8.90 mm (0.3504 in.)
Exhaust 8.80 mm (0.3465 in.)
A63453
If the stem diameter is less than the minimum, replace the valve.
A (b) Using a cylinder gauge, measure the inside diameter of
the valve guide.
90˚
B (c) Subtract the diameter measurement of the valve stem
C from the inside diameter measurement of the valve guide.
Standard oil clearance:
Intake 0.035 ï 0.068 mm (0.0014 ï 0.0027 in.)
A: 5 mm (0.197 in.)
Exhaust 0.050 ï 0.083 mm (0.0020 ï 0.0033 in.)
B: 25 mm (0.984 in.)
C: 45 mm (1.771 in.)
Maximum oil clearance:
A71672
A&B 0.10 mm (0.0039 in.)
Intake
C 0.18 mm (0.0071 in.)
A&B 0.12 mm (0.0047 in.)
Exhaust
C 0.20 mm (0.0079 in.)
If the oil clearance is greater than the maximum, replace the
valve or valve guide.
A63501
14ï9
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
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SST 09201ï41020
CAUTION:
When striking, a metal tip may fly off on impact. Wear safety
glasses to protect your eyes.
A71674
HINT:
Coat Oil S After installing the valve stem seal, make sure that there
are gaps (A) and (B) as shown in the illustration.
S Do not use the SST if its surface contacting the valve
spring lower seat is deformed.
S Check that the seal has not been deformed or cracked af-
ter the installation.
A63489
EM0988 A53807
14ï10
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
EM0801
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EM0281
A63503
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Minimum shaft diameter: 18.95 mm (0.7461 in.)
If the diameter is less than the minimum, replace the rocker arm.
(c) Subtract the diameter measurement of the rocker arm
shaft from the inside diameter measurement of the rocker
A71676 arm bush.
Standard oil clearance:
0.036 ï 0.079 mm (0.0014 ï 0.0031 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than the maximum, replace the
rocker arm bush.
A71677
A71679
cardiagn.com
A71680
NOTICE:
S Be sure to apply engine oil to the contact surface of
the parts before the assembly.
S Be sure to place each valve in its original position.
S When the valve spring is compressed, be careful that
the upper seat will not damage to the stem seal.
S Since this valve spring is evenly pitched, it can be
installed with either end up.
A71682
14ï13
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
Oil Hole
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A71683
(c) Insert the push rods in the correct order after applying en-
gine oil to both ends.
(d) Mount the rocker arm assy on the cylinder head, and
make sure that the push rods interlock with the adjusting
screws.
NOTICE:
Always loosen the lock nuts, and raise the adjusting
screws fully to the top.
A71685
14ï14
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
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Exhaust Side (b) Tighten the cylinder head bolt.
(1) Tighten M12 bolts No. 1 ï No. 18 in the order shown
in the illustration.
Torque: 132 Nm (1,350 kgfcm, 97 ftlbf)
(2) After tightening bolt No. 18, check the torque again
all through the bolts from No. 1 to No. 18.
HINT:
When adding torque, never untighten the nuts even if they have
Intake Side A71686 been overtightened.
A71660
14ï15
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
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A71688
Flywheel
Housing
Pointer
TDC
A71689
A71690
14ï16
ENGINE MECHANICAL ï CYLINDER HEAD ASSY (W04DïJ)
A71658
cardiagn.com
A71066
A71065
COMPONENTS
Crankshaft Pulley
Crankshaft Pulley*
18.15 (185, 13)
OïRing
Spacer
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Dust Cover
Flywheel
Ring Gear
Seal Plate
z OïRing
Oil Pan
z Soft Washer
41 (420, 30)
Drain Plug
N·m (kgf·cm, ft·lbf) : Specified torque
z Nonïreusable part 22.5 (230, 17)
* If so equipped
A78205
14ï18 ENGINE MECHANICAL ï CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL
HOUSING (W04DïJ)
1414Aï01
OVERHAUL
1. REMOVE CRANKSHAFT PULLEY
2. REMOVE OIL PAN SUBïASSY
A71692
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the flywheel from the crankshaft while rotating the crank-
shaft.
NOTICE:
The flywheel is heavy. When removing, be careful not to
drop it on your feet.
A71693
A71695
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A64132
A71698
A71699
14ï20 ENGINE MECHANICAL ï CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL
HOUSING (W04DïJ)
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A71700
A64137
ENGINE MECHANICAL ï CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL 14ï21
HOUSING (W04DïJ)
Crankshaft Collar (d) Apply clean engine oil to the threads of the flywheel bolt
1 and the flywheel bolt seat. Be sure to tighten 2 or 3
threads provisionally by hand. Then, tighten the 4 fly-
5 3
wheel bolts with a lowïtorque impact wrench.
(e) Pull out the guide bar and tighten the remaining 2 flywheel
bolts provisionally as in step (d).
4 6
(f) Tighten the flywheel bolts in the order shown in the il-
2 lustration.
A71702 Torque: 186 Nm (1,900 kgfcm, 137 ftlbf)
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A74775
A71657
COMPONENTS
Camshaft Timing Gear
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Camshaft
Crankshaft Timing Gear
Thrust Plate
Key
24.5 (250, 18)
Camshaft Timing Gear
z OïRing
z OïRing Retainer Ring
Power Steering Oil Pump* Ball Bearing
Bearing Holder
A79562
Case
Power Steering Oil
Pump Drive Gear
N·m (kgf·cm, ft·lbf) : Specified torque
z Nonïreusable part
* If so equipped A78207
14ï23
ENGINE MECHANICAL ï TIMING GEAR AND CAMSHAFT (W04DïJ)
14144ï01
OVERHAUL
A71704
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Pointer
A71705
Timer Cover
A71706
A71707
14ï24
ENGINE MECHANICAL ï TIMING GEAR AND CAMSHAFT (W04DïJ)
A71708
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A71709
A64449
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13. INSPECT CAMSHAFT
(a) Visually check the camshaft surface for wear and
scratches.
A64098
EM2538
14ï26
ENGINE MECHANICAL ï TIMING GEAR AND CAMSHAFT (W04DïJ)
cardiagn.com
A71711
A69313
A78201
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A78202
No. 3
No. 2
No. 1
A78203
SST
A72452
14ï28
ENGINE MECHANICAL ï TIMING GEAR AND CAMSHAFT (W04DïJ)
A74776
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A71708
A71716
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14ï30 ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER
BLOCK (W04DïJ)
COMPONENTS
Pin
Tight Plug
Tight Plug
Tight Plug
Camshaft Bearing
Cylinder Block
Bush
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Pin
Pin Tight Plug Crankshaft Main
Piston Ring (1st) Bearing
Piston Ring (2nd)
Crankshaft Thrust
Piston Ring (Oil)
Washer
Piston
Retainer Ring
Piston Pin
OVERHAUL
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ends, which may cause deformation or damage.
S Arrange the removed parts in order of the cylinder num-
bers. Be careful not to change the combination of the con-
necting rod and cap.
S 2 pistons can be removed at a time (Nos. 1 and 4, Nos.
2 and 3).
2. REMOVE CRANKSHAFT
(a) Remove the bearing cap mounting bolts.
A69305
A71721
14ï32 ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER
BLOCK (W04DïJ)
A71722
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A71723
A71724
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A69307
A69308
(c) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for bend.
Maximum bend:
0.10 mm (0.0039 in.) per 200 mm (7.87 in.)
If the bend is greater than the maximum, replace the connecting
rod with a new one.
A69309
A69310
14ï34 ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER
BLOCK (W04DïJ)
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A69312
A69302
ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER 14ï35
BLOCK (W04DïJ)
Y Y
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A69301
HINT:
Machined dimension of filet R
Crankshaft pin: 3.50 ï 4.00 mm (0.1378 ï 0.1575 in.)
R
CORRECT WRONG
A71766
14ï36 ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER
BLOCK (W04DïJ)
A69303
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Diameter
15 mm
(0.59 in.)
A71725
HINT:
Apply the value measured at the most worn point to the cylinder
liner inside diameter.
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HINT:
T = tightening allowance, L = clearance
If the clearance is greater than the maximum, replace the piston
or piston pin.
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A69293
A69291
(a) Performing the dye penetrant test, and check the crank-
shaft for cracks.
HINT:
Pay special attention to the finished R section and oil hole of the
crankshaft journal and crankshaft pin.
(b) Visually check the condition of the crankshaft journal and
pin for damage or wear.
If any damages are found, replace the crankshaft with a new
A69291 one.
A69294
ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER 14ï39
BLOCK (W04DïJ)
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A69290
X
Y
A69289
14ï40 ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER
BLOCK (W04DïJ)
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A69290
HINT:
Undersize machining dimension: 4 sizes below
0.25 mm (0.0098 in.)
0.50 mm (0.0197 in.)
0.75 mm (0.0295 in.)
1.00 mm (0.0394 in.)
If the oil clearance is greater than the maximum, replace the
bearing with a correct one.
HINT:
Make sure to replace the top and bottom main bearings as one
set. The top and bottom main bearings must be round.
R HINT:
Machined dimension of filet R
Main crankshaft journal:
CORRECT WRONG 3.00 ï 3.50 mm (0.1181 ï 0.1378 in.)
A71766
ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER 14ï41
BLOCK (W04DïJ)
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A69299
HINT:
Connecting Rod S Bring the lever W punched on the guide above the pin.
S Make sure to align both supporting surfaces of the guide
and press subïassy flatly on a plane.
(b) Using the SST, remove the bush.
(1) Set the connecting rod assembled without crank-
shaft pin bore bearing on the guide and press subï
Guide Press Subïassy assembly.
A72436
Spindle (2) Using SST, install the spindle into the bush.
Groove Bush SST 09402ï1460 (press subïassy)
Connecting HINT:
Rod Align the groove of the spindle with the oil hole of the bush.
Oil Hole
Press
Subïassy
A71728
14ï42 ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER
BLOCK (W04DïJ)
Press
(3) Using a press, remove the bush.
Spindle HINT:
Always operate the press slowly and smoothly.
Connecting Rod
A72437
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A71729
Position of
Mark A, B or C
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A71732
A71733
A72438
A79563
14ï44 ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER
BLOCK (W04DïJ)
(b) Install the thrust washers onto the 4 points of the No. 2
journal of the cylinder block and either side of the bearing
caps.
(c) Install the crankshaft onto the cylinder block.
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A71721
HINT:
S When reusing a bearing, make sure to reassemble the re-
moved bearing as it was originally installed.
S Install the thrust washers with the groove side (front) to-
ward the crankshaft arm and with the part number stamp
(back) toward the main bearing cap or cylinder block.
S Apply engine oil or grease to the back of the bearing to
prevent looseness during the installation.
S Fit the bearing to the mounting groove of the block and
cap side.
A71735
A72441
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A71737
a complete fit.
24. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial gauge, measure the crankshaft thrust clear-
ance.
Standard thrust clearance:
0.05 ï 0.22 mm (0.0020 ï 0.0087 in.)
Maximum thrust clearance: 0.40 mm (0.0157 in.)
If the thrust clearance is greater than the maximum, replace the
thrust bearing.
A72442
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HINT:
S Never change the combination of the coil and oil ring.
Identification S Connect the joint of the coil expander for the oil ring and
Mark install it inside the piston ring. Assemble the ring with the
1st Ring 2nd Ring Oil Ring joint 180˚opposite to the matching point of the ring.
Joint
Gap
A71740
HINT:
Oil Ring I 5 mm Gap
Position the matching points of the piston ring at an even dis-
tance. Be careful not to position at the piston boss.
1st Ring
2nd Ring
A71741
ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER 14ï47
BLOCK (W04DïJ)
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A72445
HINT:
S Before the installation, apply engine oil to the piston pin,
piston ring, cylinder liner and connecting rod bearing.
S Recheck the matching point of each piston ring.
A71742
I 5 mm Gap
A72447
14ï48 ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER
BLOCK (W04DïJ)
A74757
(c) Tighten the connecting rod nut in the order shown in the
illustration to the specified torque below.
(1) Tighten the connecting rod nuts 1 and 2 temporarily,
dividing into small amount.
Torque: 122.6 N·m (1,250 kgf·cm, 90 ft·lbf)
HINT:
When adding torque, never untighten the nuts even if they have
1 2 been overïtightened.
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A79564
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15ï1
EXHAUST ï EXHAUST MANIFOLD (W04DïJ)
EXHAUST MANIFOLD
1507Vï01
INSPECTION
A71760
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If the warpage is greater than the maximum, correct the exhaust
manifold by grinding it so that the warpage is within 0.1 mm
(0.004 in.) per 2 flanges or 0.1 mm (0.004 in.) per flange.
If damage such as deformation and wear is excessive, replace
A64097 the manifold.
COOLING
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16ï1
COOLING ï WATER PUMP ASSY (W04DïJ)
COMPONENTS
Housing
Pulley Seat
Rotor
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Bearing & Shaft Subïassy Water Pump Seal
Slinger
Rotor
Housing
Pulley Seat
Slinger
OVERHAUL
A71751
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A71752
A71754
16ï3
COOLING ï WATER PUMP ASSY (W04DïJ)
A71755
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A71756
A71757
THERMOSTAT
160IRï01
INSPECTION
1. INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening tempera-
ture.
82_C
A64555
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If the valve opening temperature is not as specified, replace the
thermostat.
P24124
A64556
LUBRICATION
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17ï1
LUBRICATION ï OIL PUMP ASSY (W04DïJ)
COMPONENTS
EXAMPLE
Driven Gear
Driven Gear
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z Gasket
22.5 (230, 17)
z OïRing
Guide
OVERHAUL
1. REMOVE OIL PUMP ASSY
(a) Remove the 7 bolts, the oil pump assy, drive gear and gasket.
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the drive gear and driven gear.
Standard backlash:
0.091 ï 0.217 mm (0.0036 ï 0.0085 in.)
Maximum backlash: 0.30 mm (0.0118 in.)
B58376 If the backlash is greater than the maximum, replace the oil
pump assy with a new one.
(c) Inspect the clearance between the drive gear shaft and
driven gear bush.
(1) Using a micrometer, measure the diameter of the
drive gear shaft.
Standard shaft diameter:
18.088 ï 18.106 mm (0.7121 ï 0.7128 in.)
Minimum shaft diameter: 18.062 mm (0.7111 in.)
A71763
(d) Inspect the clearance between the driven gear shaft and
driven gear bush.
(1) Using a micrometer, measure the diameter of the
driven gear shaft.
Standard shaft diameter:
17.979 ï 17.997 mm (0.7078 ï 0.7085 in.)
Minimum shaft diameter: 17.97 mm (0.7075 in.)
B58377
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B58378
A71762
A71765
17ï4
LUBRICATION ï OIL COOLER ASSY (W04DïJ)
INSPECTION
1. INSPECT OIL COOLER ASSY
NOTICE:
Before the inspection, please refer to the following items.
S Be sure to clean the oil cooler element and oil pas-
sage, using a commercial cleaning agent.
S Clean the metal parts, using treated oil.
(a) Carry out a pneumatic test for the oil cooler element.
Test pressure: 6 kg/cm2 (85.3 lb/sq.in.)
Test time: 1 min.
If defective, replace the oil cooler element with a new one.
(b) Visually check each part for damage or wear.
If the damage or wear is excessive, replace the safety valve
with a new one.
If the spring is flattened, replace the safety valve with a new
one.
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B58455
STARTING & CHARGING
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19ï1
STARTING & CHARGING ï STARTER ASSY (W04DïJ)
STARTER ASSY
190KFï01
COMPONENTS
Cover
Magnet Starter
Switch Assy
Plate
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4.3 (44, 38 in.lbf)
Starter Armature Assy
Pin
z Starter Dust Protecter
Bush
Pinion Gear Armature
Bearing
z Rubber Seal
Starter Clutch
Subïassy z Dust Protecter Cap
z Snap Ring
Drive Housing
OVERHAUL
A71217
(b) Remove the 2 through bolts, and pull out the starter yoke
together with the armature.
HINT:
Hold the starter by hand so that it will not fall.
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A71218
B58383
B58384
B58385
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B58386
B58387
Ohmmeter
12. INSPECT STARTER ARMATURE ASSY
Continuity
If the surface of the commutator is dirty or burned, polish the
part with sandpaper (#400) or replace the armature assy.
(a) Check the commutator open circuit.
(1) Using an ohmmeter, check that there is continuity
between the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature assy.
B58389
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B58390
B58391
B58392
B58393
19ï5
STARTING & CHARGING ï STARTER ASSY (W04DïJ)
B58394
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B58419
B58420
(b) Take the pull scale reading the instant brush spring sepa-
rates from the brush.
Standard installed load:
42.2 ï 51.0 N (4.3 ï 5.2 kgf, 9.3 ï 11.2 lbf)
Minimum installed load: 22.5 N (2.3 kgf, 4.9 lbf)
If the installed load is less than the minimum, replace the brush
springs.
B58421
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B58424
A71220
19ï7
STARTING & CHARGING ï STARTER ASSY (W04DïJ)
A71221
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B58428
Apply Grease
B58430
Apply Grease
B58431
19ï8
STARTING & CHARGING ï STARTER ASSY (W04DïJ)
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B58433
B58434
Apply Grease
B58435
B58385
19ï9
STARTING & CHARGING ï STARTER ASSY (W04DïJ)
Apply Grease
B58436
Cutout
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B58437
B58439
GENERATOR ASSY
190KHï01
COMPONENTS
Generator Rotor Assy
Stator Coil
Bearing Retainer
Retainer Plate
Generator Rotor Bearing
Felt Cover
Felt
Front Bracket
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129 (1320, 95)
Collar
Fun
Pulley
Rear Bracket
Oïring
Condenser
Generator Brush
Holder Assy
Rectifier
Insulator
OVERHAUL
HINT:
The following procedure is published important points for the generator overhaul.
A71212
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A71222
A71223
A71538
19ï12
STARTING & CHARGING ï GENERATOR ASSY (W04DïJ)
A71539
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A71540
Continuity No Continuity (2) Connect the ohmmeter positive (+) lead to the recti-
fier terminal and the (ï) lead to the rectifier holder.
If there is no continuity, replace the rectifier.
¨ © ¨ ©
Normal Abnormal
A71541
A71542
No Continuity Continuity (2) Connect the ohmmeter positive (+) lead to the recti-
fier terminal and the (ï) lead to the rectifier holder.
If there is continuity, replace the rectifier.
¨ © ¨ ©
6. INSPECT GENERATOR ROTOR ASSY
Normal Abnormal (a) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor assy.
A71543
19ï13
STARTING & CHARGING ï GENERATOR ASSY (W04DïJ)
Continuity
A71544
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A71545
A71546
A71557
Continuity
A71547
19ï14
STARTING & CHARGING ï GENERATOR ASSY (W04DïJ)
No Continuity
A71548
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A71549
A71550
A71551
A71552
19ï15
STARTING & CHARGING ï GENERATOR ASSY (W04DïJ)
A71212
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00ï1
ALPHABETICAL INDEX
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00ï2
ALPHABETICAL INDEX (A ï T)
A L
Page Page
ABBREVIATIONS USED IN THIS MANUAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï8
(TERMS FOR ENGINE REPAIR MANUAL) . . . . . . . 01ï7 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï12
C N
COMPONENTS (CRANKSHAFT PULLEY, OIL NOZZLE HOLDER AND NOZZLE SET (W04DïJ) . . . . 11ï1
PAN AND FLYWHEEL HOUSING (W04DïJ)) . . . . . 14ï17
COMPONENTS (CYLINDER HEAD ASSY
(W04DïJ)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï1
O
COMPONENTS (GENERATOR ASSY (W04DïJ)) . . . . 19ï10
OIL COOLER ASSY (W04DïJ) . . . . . . . . . . . . . . . . . . . . 17ï4
COMPONENTS (NOZZLE HOLDER AND
OIL PUMP ASSY (W04DïJ) . . . . . . . . . . . . . . . . . . . . . . 17ï1
NOZZLE SET (W04DïJ)) . . . . . . . . . . . . . . . . . . . . . . 11ï1
OVERHAUL (CRANKSHAFT PULLEY, OIL PAN
COMPONENTS (OIL PUMP ASSY (W04DïJ)) . . . . . . 17ï1
AND FLYWHEEL HOUSING (W04DïJ)) . . . . . . . . . . 14ï18
COMPONENTS (PISTON, CRANKSHAFT AND
OVERHAUL (CYLINDER HEAD ASSY (W04DïJ)) . . . 14ï3
CYLINDER BLOCK (W04DïJ)) . . . . . . . . . . . . . . . . . 14ï30
OVERHAUL (GENERATOR ASSY (W04DïJ)) . . . . . . . 19ï11
COMPONENTS (STARTER ASSY (W04DïJ)) . . . . . . . 19ï1
OVERHAUL (NOZZLE HOLDER AND NOZZLE
COMPONENTS (TIMING GEAR AND
SET (W04DïJ)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11ï2
CAMSHAFT (W04DïJ)) . . . . . . . . . . . . . . . . . . . . . . . . 14ï22
OVERHAUL (OIL PUMP ASSY (W04DïJ)) . . . . . . . . . . 17ï2
COMPONENTS (WATER PUMP ASSY (W04DïJ)) . . . 16ï1 OVERHAUL (PISTON, CRANKSHAFT AND
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï7 CYLINDER BLOCK (W04DïJ)) . . . . . . . . . . . . . . . . . 14ï31
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï11 OVERHAUL (STARTER ASSY (W04DïJ)) . . . . . . . . . . 19ï2
CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL
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OVERHAUL (TIMING GEAR AND CAMSHAFT
HOUSING (W04DïJ) . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï17 (W04DïJ)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï23
CYLINDER HEAD ASSY (W04DïJ) . . . . . . . . . . . . . . . . 14ï1 OVERHAUL (WATER PUMP ASSY (W04DïJ)) . . . . . . 16ï2
E P
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï3 PISTON, CRANKSHAFT AND CYLINDER
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï6 BLOCK (W04DïJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï30
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï6 PRECAUTION (REPAIR INSTRUCTION FOR
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï10 ENGINE REPAIR MANUAL) . . . . . . . . . . . . . . . . . . . . 01ï4
EXHAUST MANIFOLD (W04DïJ) . . . . . . . . . . . . . . . . . . 15ï1 PREPARATION (COOLING) . . . . . . . . . . . . . . . . . . . . . . 02ï7
PREPARATION (ENGINE MECHANICAL) . . . . . . . . . . 02ï3
F PREPARATION (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . 02ï6
PREPARATION (FUEL) . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï1
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï1 PREPARATION (INTAKE) . . . . . . . . . . . . . . . . . . . . . . . . 02ï2
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï4 PREPARATION (LUBRICATION) . . . . . . . . . . . . . . . . . . 02ï8
PREPARATION (STARTING & CHARGING) . . . . . . . . 02ï9
G
R
GENERAL INFORMATION (HOW TO USE THIS
ENGINE REPAIR MANUAL) . . . . . . . . . . . . . . . . . . . . 01ï1 REPAIR INSTRUCTION FOR ENGINE REPAIR
GENERATOR ASSY (W04DïJ) . . . . . . . . . . . . . . . . . . . 19ï10 MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01ï4
GLOSSARY OF SAE AND TOYOTA TERMS
(TERMS FOR ENGINE REPAIR MANUAL) . . . . . . . 01ï12
S
H SERVICE DATA (COOLING) . . . . . . . . . . . . . . . . . . . . . . 03ï11
SERVICE DATA (ENGINE MECHANICAL) . . . . . . . . . . 03ï6
HOW TO DETERMINE BOLT STRENGTH SERVICE DATA (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . 03ï10
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï1 SERVICE DATA (INTAKE) . . . . . . . . . . . . . . . . . . . . . . . . 03ï5
HOW TO DETERMINE NUT STRENGTH SERVICE DATA (LUBRICATION) . . . . . . . . . . . . . . . . . . 03ï12
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï3 SERVICE DATA (STARTING & CHARGING) . . . . . . . . 03ï14
HOW TO USE THIS ENGINE REPAIR MANUAL . . . . . 01ï1 SPECIFIED TORQUE FOR STANDARD BOLTS
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï2
STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï1
I STARTER ASSY (W04DïJ) . . . . . . . . . . . . . . . . . . . . . . . 19ï1
INSPECTION (EXHAUST MANIFOLD (W04DïJ)) . . . . 15ï1 STARTING & CHARGING . . . . . . . . . . . . . . . . . . . . . . . . 02ï9
INSPECTION (INTAKE MANIFOLD (W04DïJ)) . . . . . . 13ï1 STARTING & CHARGING . . . . . . . . . . . . . . . . . . . . . . . . 03ï14
INSPECTION (OIL COOLER ASSY (W04DïJ)) . . . . . . 17ï4
INSPECTION (THERMOSTAT (W04DïJ)) . . . . . . . . . . 16ï4 T
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï2
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï5 TERMS FOR ENGINE REPAIR MANUAL . . . . . . . . . . . 01ï7
INTAKE MANIFOLD (W04DïJ) . . . . . . . . . . . . . . . . . . . . 13ï1 THERMOSTAT (W04DïJ) . . . . . . . . . . . . . . . . . . . . . . . . 16ï4
TIMING GEAR AND CAMSHAFT (W04DïJ) . . . . . . . . 14ï22
00ï3
ALPHABETICAL INDEX (T ï W)
Page
TORQUE SPECIFICATION (ENGINE
MECHANICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï9
TORQUE SPECIFICATION (FUEL) . . . . . . . . . . . . . . . . 03ï4
TORQUE SPECIFICATION (LUBRICATION) . . . . . . . . 03ï13
TORQUE SPECIFICATION (STARTING &
CHARGING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï15
W
WATER PUMP ASSY (W04DïJ) . . . . . . . . . . . . . . . . . . . 16ï1
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