eee ENGINE _FOREWORD This repair manual has been prepared to provide information covering general service repairs for the 2H and 12H-T engines mounted on the TOYOTA LAND CRUISER Peavy-Duty), Applicable models HJ60, 61, 75 ‘All information contained in this. manual is the most up-to-date at the time of publication. However, specifications and pro- cedures are subject to change without notice. TOYOTA MOTOR CORPORATIONTOYOTA 2H, 12H-T ENGINE REPAIR MANUAL INTRODUCTION JI ENGINE MECHANICAL [GQ FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM STARTING SYSTEM CHARGING SYSTEM SERVICE SPECIFICATIONS JEW STANDARD BOLT TORQUE SPECIFICATIONS [EM SST AND SSM 1985 TOYOTA MOTOR CORPORATION re ookINTRODUCTION Page HOW TO USE THIS MANUAL ..... - IN GENERAL REPAIR INSTRUCTIONS .... in ABBREVIATIONS USED IN THIS MANUAL ....... IN-7IN2 INTRODUCTION — How to Use This Manual HOW TO USE THIS MANUAL To assist in finding your way through this manual. the Section Title and major heading are given at the top of every page. ‘An INDEX is provided on the 1st page of each section to guide you to the item to be repaired. ‘At the beginning of each section. PRECAUTIONS ore given that pertain to il repair operations contained in that section ‘Read these precautions before starting any repair task. TROUBLESHOOTING tablos are included for each system to help you diagnose the system problem and find the cause. The repair for each possible cause is referenced in the remedy col- tumin 0 quickly lead you to the solution REPAIR PROCEDURES Most repair operations begin with an overview illustration. t identifies the components and shows how the parts fit to- gether Example (eg-ern (t-b, Neel Specified torque @ Non-reusable partINTRODUCTION — How to Use This Manual in Mustration. what to do and where ‘The procedures are presented in a step-by-step format: ‘© The illustation shows what to do and where to do it. ‘® The task heading tells whet to do. ‘© The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example Task heading: what todo REMOVE INJECTION NOZZLES Using SST, remove the timer. ‘SST 09280-47010 109267-76020) Set part No. ts part NO. Anstall and torque the round rut. ——__ orate gt: Torque: 760 kp-om (84 f1-1B. 74 Rim) how to do tase ‘\ Torque Specification ‘This format enables the experienced technician with » FAST TRACK to the information needed. The upper case heading can be read at 8 glance and onty when necessary, the test below it Provides detailed information, important specifications and ‘warnings always stand out in bold type REFERENCES References have been kept t0 a minimum. Hawever, when they ‘are required you Bre Given the page to Go to. SPECIFICATIONS ‘Specifications are presented in bold type throughout the text in the applicable step. You never have to leave the procedure to look up your specs. All specifications are also found in Appen- dix A. specifications, for quick reference. WARNINGS, CAUTIONS, NOTES: ‘© WARNINGS are presented in bold type, and indicate there is 2 possibility of injury 10 you or other people ‘© CAUTIONS ore also presented in bold type and indicate there is a possibdity of damage to the componants being repsired. © NOTES are separated from the text but do not appear in bold. They provide additional information to help you effi- ciently perform the repair,IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER GENERAL REPAIR INSTRUCTIONS al number is stamped on the left side of the 1. Use fender, seat and floor covers to keep the vehicle clean ‘and prevent damage. 2. During disassembly, keep parts in order to facilitate reas- sembly, 3. Observe the folowing (a) Before performing electrical work, disconnect the negative cable from the battery terminal o) if is necessary to disconnect the battery for inspec- tion or repair, always disconnect the cable from the negative (—) terminal which is grounded to the vehi- cle body. fc) To prevent damage to the battery terminal post, Joosen the terminal nut and raise the cable straight up ‘without twisting it or prying it (d} Clean the battery terminal posts and cable terminal with a shop rag. Do not scrape them with a file or other abrasive abject (eb Install the cable terminal to the battery post with the rut loose and tighten the nut after installation. Do not ‘use 8 hammer to tap the terminal onto the post (1) Be sure the cover for the positive (+) terminal is pro- petly in place 4. Check hase end wiring connectors to make sure they are Securely and correctly connected. 5, Non-reusable parts (a) Always replace cotter pins, gaskets, O-rings, oil seats atc, with new ones. (b) Non-reusable parts ar illustrations. by the ~INTRODUCTION — Genes Seal Lock Adhesive = W 12. Repsir Instructions IN-6 Precoated Pi Precoated parts are the bolts. nuts, ete. Which are coated with a seal lock adhesive at the factory, la) If @ precoated part is tightened, loosened or caused to move in any way. it must be precoated with specified adhesive {b) RRecoating of Precoating Parts (1) Clean off the old adhesive from the bolts, nut or installation part threads. (2) Dry with compressed air (3) Apply the specified seal lock adhesive to the bolt or nut threads. (c) Precoated parts are indicated in the component illustrations by the ""#” symbol. When necessary, use 2 sealer on gaskets to prevent leaks Carefully observe all specifications for bolt tightening tor- ques, Always use a torque wrench Use of special service tools (SST) and special service materials (SSM) may be required depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure A list of SST and SSM cen be found at the back of this manual When replacing fuses, be sure the new fuse is the correct ‘amperage rating. DO NOT exceed the fuse amp rating or se one of a lower rating Care must be teken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations {a} if the vehicle is t0 be jacked up only at the front or rear end, be sure to block the wheels in order to ensure safety. (6) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on the vehicle raised on one jack alone, even for a small job that can be finished quickly. ‘Observe the following precautions to avoid damage the parts: lal Tedisconnect vacuum hoses, pull on the-énd. not the middle of the hose (c) To pull apart electrical connectors. pull on the con- nector itself, not the wires, (e) Be careful not to drop electrical components, such as sengors oF relays. If they are dropped on a hard flocr. they should be replaced and not reused,INTRODUCTION — General Repair Instructions a) When steam cleaning an engine, protect the air fiter and injection pump from water. (el Never use an impact wrench to remove or install ther- mo switches or thermo sensors {f) When checking continuity at the wire connector. insert the tester probe carefully to prevent terminals, from bending, Ig) When using vacuum gauge. never force the hose onto a connector that is too large. Use @ step-down adapter instead. Once the hose has been stretched. it may leak 13. After removing and reinstalling the injection pump and fuel hoses. clean off the fuel on engine components. In par- ticular, be suré to check the radiator hose and by-pass hose, because they deteriorate easily if they come into contact with fuelINTRODUCTION — Abbrev: ions Used in This Manual IN-? ABBREVIATIONS USED IN THIS MANUAL ac Air Conditioner aT Automatic Transmission ATDC After Top Dead Center BoC Bottom Dead Center eToc Before Top Dead Center eDIC Electrical Diesel Injection Control x Exhaust HAC High Altitude Compensator N Intake uy Left-hand wT Manual Transmission Me Multipurpose o's Oversi Pov Positive Crankcase Ventilation PS Power Steering RH Right-hand ssM Special Service Mater Sst Special Service Tools STD Standard Toc Top Dead Center vs Undersize vsv Vacuum Switching Valve wi With wio WithoutENGINE MECHANICAL Page DIESEL ENGINE DIAGNOSIS ... . EM2 maar mi DIESEL ELECTRICAL SYSTEM | EM | DIAGNOSIS [12H-T) ..... ceeneeenecees EM3 TURBOCHARGER DIAGNOSIS [12H-T] ..... —M-17 TURBOCHARGER ELECTRICAL eraree DIAGNOSIS [12H-T}) ..... seers, EMS ENGINE TUNE-UP ......... - . » EM-20 ‘COMPRESSION CHECK [2H] ..... —M-35 ‘COMPRESSION CHECK [12H-T] . EM-36 TURBOCHARGER [12H-T) ......... seeeeeess EM-3T CYLINDER HEAD ...... stone —M-47 TIMING GEARS AND CAMSHAFT . --. EM-77 CYLINDER BLOCK ........ teeneseeccoeas EMREEM-2 ENGINE MECHANICAL — Diesel Engine Diagnosis DIESEL ENGINE DIAGNOSIS GENERAL Diesel engine problems are usually caused by the engine or fuel system. The injection pumps very rarely the cause of fuel system problems, Before beginning fuel system tests, first check that the engine compression, valve timing and other major systems are within specifications. 1. PRELIMINARY CHECKS (al (by teh (a) fo) © ) Before performing tus! 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-au fuel should be used. Bloed 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. ity dieselINE MECHANICAL — Diesel Engine Diagnosis —M.3 PRECAUTION 1. The basic troubleshooting procedures for the diesel engine (valve clearance. compression. besrings, ions, etc.) are the some 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 Causs [Check Procedure and Correction Method) (1. Loose on CoRRODED | “Check cables from battery to starter and make | __) BATTERY CABLES: = necessary repairs _seeeane ce} (Rewer eeamae | Repair as necessary. (See page CH-6) 3. INOPERATIVE STARTER | Check for battery voltage at starter terminals. 30 oo Oe a 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 1SOrpm Hot (Possible Cause) (Check Procedure and Correction Method) (1. Loose on GoRRODED — |— BATTERY. CABLES J Refer to items 1 and 2 of ENGINE WILL NOT —_— — aa _J a | CRANK. 2, DISCHARGED BATTERY ara re} aa.) H improper viscosity. drain and refill with of of viscosity recommended by manutacturer. (See page LU-4)M- 4 ENGINE MECHANICAL — Diesel Engine Diagnosis ENGINE CRANKS NORMALLY BUT WILL NOT START (Possible Cause) (Cheek Procedure and Correction Method) NO FUEL TO INJECTION Loosen any one injection pipe union nut from its NozzLE J | nozzle = Crank the engine far about $ seconds. while con- firming that fuel is being discharged from the pipe If fuel is coming out, begin diagnosis from item 4. (Wnt. begin from item 2 = NO FUEL INTO INJECTION { Disconnect inlet hoses to the feed pump and feed PUMP clean fuel from separate container directly into I feed pump. Hf engine starts, either the sedimenter or fue! fine betwaen the fuel tenk and feed pump is cloaged and should be repaired. if the engine still does not start, check the fuel filter or line between feed pump and injection | pump. It normal, the feed pump or injection pump i faulty and should be repaired. NOTE: When feeding fuel directly into pump. at same level as vehicle fuel ee FUEL LEAKAGE FROM ("Check for loose unions or eracks. Y BUECUGH PIES J IW leaking, tighten to specified torque or, if neces- | sary, replace pipes) (2H) With the starter switch turned ON and the giow INOPERATIVE PRE-HEATING plug indicator light illuminated, check that there is OPERATION voltage spplied to the glow piug. | If not, refer to ELECTRICAL DIAGNOSIS and repair | a8 necessary. (See page EM-11) (128-7) th the ignition switch turned ON and the INOPERATIVE PRE-HEATING ;——_ intake heater indicator ight illuminated, check that OPERATION there is voltage applied to the intake heater. = = If not, refer to ELECTRICAL DIAGNOSIS and repair necessary. (See page EM-13) (2H) [Check the glow plug for continuity. (See page ST-5i) eae GLOW PLUG If no continuity, a broken wire is indicated and the |___ OPERATION | slow plug should be replaced. 7. (2H-7) ‘Check the intake heater continuity. (See page ST-9)) FAULTY INTAKE HEATER = + it no continuity, a broken wire is indicated and OPERATION intake heater should be replaced.ENGINE MEC CHANICAL — Diesel Engine Diagnosis EM-5 IMPROPER INJECTION TIMING 8 (Check the injection timing. (See page EM-23) 2H 18° BTDC 12H-T 11° BTDG IF not as specified, injection timing must be read juste Injection ti LI 9. FAULTY INJECTION NOzzI t ‘Check the injection pressure with norele tester (See page FU-4 or 10) ‘Opening pressure: 2H 105 — 125 kg/cm? (1,493 — 1,778 psi (10,296 ~ 12,268 KPa) 180 ~ 210 kglem’ (2,560 ~ 2,987 (17.682 ~ 20,594 kPa If pot within specification, nozzle adjustment is improper and pressure shauld be readjusted. 1M pressure cannot be adjusted to specification, [replace nozzle. | 12H-T ROUGH IDLE WITH WARM ENGINE (Possible Cause) IMPROPER ADJUSTMENT OF ACCELERATOR CABLE [» [ 2. IDLE SPEED TOO Low FUEL LEAKAG (Check Procedure and Correction Method) { With the accelerator pedal released, check that the Adjusting lavar is in contact with the idle adjusting screw, Also, check if the accelerator cable is catch- ing on somethi Hf necessary, adjust so lever is in contact with the “screw, oF moke other required repairs | Check the idle speed es specifies below (See page EM-26 or 28) Idle speed: MT 650 rom AT (2H) 750 rm AT (12H-T) 770 rom 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 feed pump, nozzle holder and d Tighten any loose connections to specified torque or replace parts as necessary:EM-6 ENGINE MECHANICAL — Diesel Engine Diagnosis IMPROPER INJECTION ___[ Refer to ito 6 of ENGINE CRANKS NORMALLY TIMING BUT WILL NOT START, above 5. IMPROPER OPERATION OF | [With the engine idling. loosen the injection wipe to) INJECTION NOZZLE OR | ath eviinder in order, and check if the idle speed DELIVERY VALVE changes If no change, @ faulty cylinder is indicated | Check according to the following procedure. ‘© Faulty Nozzle | ‘Cheek the nozzle with nozzle tester. (Soe page FU-# or 10) ‘Opening pressure: 2H 108 = 128 kg/em? | (1,493 ~ 1,778 psd (10,296 — 12,258 kPa) AZH-T 180 = 210 kg/em? (2,560 — 2,987 psid (17.652 = 20,594 kPa) Hf 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! 1. ENGINE WILL NOT RE-START Check to see if engine re-starts according to prescribed procedure | Hf not, refer 10 ENGINE CRANKS NORMALLY BUT WiLL'NOT START, above, and repair as necessary. ROUGH IDLE If idle is not stable, | WARM ENGINE and repair accordingly. 3. NOFUELINTO INJECTION | Refer to item 2 of ENGINE CRANKS NORMALLY PuMP 4 BUT WILL NOT START, above. JENGINE MECHANICAL — Diesel Engine Diagnosis —M-7 LACK OF POWER NOTE: 1. First check that the air cleaner is not clogged or the engine overheating. 2. Not applicable if the customer desires an output power higher than specified for that vehicle, For accuracy, adjust with a chassis dynamo. (Possible Cause) (Check Procedure and Correction Method) 1. IMPROPER ACCELERATOR = | __[ With accelerator fully depressed, check thet the CABLE ADJUSTMENT | adjusting ie contact with the maximum = - | speed adjusting screw. (See page EM-26 or 28) (Lit not, adjust accordingly. [2 INSUFFICIENT | Start engine, depress the accelerator pedal to the MAXIMUM SPEED floor aad check that maximum speed i 03 spectfied ———— SS below. (See page EM-26 or 28) Maximum speed: wi Fluid coupling 4,170 rpm wie Fluid coupling 4.100 rpm Hf mot, adjust with the maximum speed adjusting | soe. [a FUEL LeaKage | feter totem 3 of ROUGH OLE WHT WaRMA — 7 ENGINE. (ee — = (ox ee ile hose ana out CLOGGED FUEL FILTER -— Disconnect the injection pump inlet hose 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, IH no inerease in engine condition after rep the fuel filter, check the feed pump or perform {other necessory repairs 5. IMPROPER INJECTION TIMING | {Refer to item 8 of ENGINE CRANKS NORMALLY — (BUT WILL NOT START, (BUT WILL NOT START. _}-_—{ eter 1o item 9 of ENGINE CRANKS NORMALLY }ENGINE MECHANICAL — Diesel Engine Diagnosis EXCESSIVE EXHAUST SMOKE NOTE: 1, Check that the air cleaner is not clogged, 2 Cheek with the customer whether or not cil consumption has been excessive. (Possibie Cause) [1 IMPROPER INJECTION TIMING | — [2 cLoacen Fuet Fitter (Check Procedure and Correction Method! fer to item 8 of ENGINE CRANKS NORMALLY | BUT WiLL NOT START (NOTE: Black smoke indicates sdvanced timing While white smoke indicates retarded timing. _Adjustments should be made accordingly. { Reter to item 5 of LACK OF POWER. | NOTE: At high speed (2,000 — 3,000 rpmi. a clogged filter tends to make the exhaust smoke white. J [ 3. FAULTY INJECTION NOZZLE |———/ Refer to tom 9 of ENGINE CRANKS NORMALLY EXCESS! BUT WILL NOT START. NOTE: Excess ixhaust smoke is often caused by nozzle pressure being too low. IVE FUEL CONSUMPTION NOTE: Check whether the clutch slips, brakes grab, whether the tires are the wrong size or the air filter is clogged. (Possible Causel (Check Procedure and Correction Method! FUEL LEAI Refer to item 3 of ROUGH IDLE WITH WARM ENGINE, | Satter sutficiently warming up engine, check that idle speed is as specified below: (See page EM-26 or 28) Idle speed: M/T 650 mpm A/T (2H) 750 rpm A/T (12H-T) 770 rpm { 11 not, adjust with the idle speed adjusting screw. | [ 3. MAXIMUM SPEED TOO HIGH |————T Start engine, depress the accelerator pedal to the floor and check that maximum speed is a specified below. (See page EM-26 or 28) Maximum speed: w/ Fluid coupling 4.170 rpm. wie Fluid coupling 4.100 mm Hf not, adjust with the maximum speed adjusting >) JENGINE MECHANICAL — Diese! Engine Diagnosis IMPROPER INJECTION TIMING Refer to item 8 of ENGINE CRANKS NORMALLY ————— BUT WELL NOT ‘START, [5 FAULTY INJECTION NOZZLE — |———-{ Rieler to item 9 of ENGINE CRANKS NORMALLY —————— BUT WIL NOT START. ENGINE NOISE WHEN WARM (Cranking Noise with Excessive Vibration) (Possible Cause) (Chock Procedure and Correction Method) 1 COgLANT TEMPERATURE TOO | Check coolant temperature with coolant OW temperature gauge H not sufficiently warm, thermostat is faulty and (should bereploced RAPPER ETON TOR} — Fr eat SUN ALY ee ee (but ‘WILL NOT START. La FauLTy JECTION NOZZLE Reler to item 9 of ENGINE CRANKS NORMALLY se - BUT WILL NOT START. ENGINE WILL NOT RETURN TO IDLE (Possible Cause) (Check Procedure and Correction Method! [BINDING ACCELERATOR CABLE { Operate adjusting lever an side of injection pump — ——————— and check i engine returns to idle, so, the accelerator cable is binding or improperty adjusted ond should be repaired accordingly W engine does not retum to idle, the injection pump {Lis faulty and shouid be repsiredEM-10 ENGINE MECHANICAL — Diesel Engine Diognosis ENGINE WILL NOT SHUT OFF WITH STOP BUTTON OR KEY (Possible Cause) (Check Procedure and Correction Method) [2H M/T (w/o EDIC SYSTEM)] [ Operate stop lever (adjusting lever! on side of INDING STOP CABLE injection pump and check if engine stops. Hf 80, stop cable is binging or maladjusted and shout be repaired accordingly. engine does not stop, injection pump is faulty and should be replaced, (See page FU-23) [2H MJT (w/ EDIC SYSTEM) Operate stop lever (adjusting lever on side ) IMPROPER EDIC SYSTEM Of injection pump and check if engine stops | If $0, EDIC system is faulty and should bbe repaired. (See page $T-21) If engine does not stop, injection pump is faulty and should be repaired. (See page FU-28) (2H A/T AND 12H-T1_ {Close the intake shutter and check if engine stops IMPROPER INTAKE SHUTTER If it does. the intake shutter system is faulty, Le resAree ‘and should be repaired. (See page EM-33 or 24)ENGINE MECHANICAL — Diesel Electrical System Disgnosis [2H] DIESEL ELECTRICAL SYSTEM ENGINE DOES NOT START COLD Battery voltage at least 12 volts Engine cranks normally, Fusible link okay. EM.11 DIAGNOSIS [2H] (or 24 volts! — ignition switch OFF. Check the voltage marked with an asterisk (*} just as the ignition switch is placed at ON because the voltage will change with elapse of time. Pre-heating System (Super Glow Type) (Check if indicator fight lights up with ignition switeh ON. Coolant temp. Approx, 20°C ( ‘Approx. 2 seconds Yes ignition switen OFF ‘Check ENGINE Ture Ne 77} 81480 Europe, 1575) _ or GLOW Fuse (Others) Chack indicator light bulb. er Check for short circuit ond repoir it necessary. Fuse Blown Replace bulb. INo Good Bulb OK Check for battery voltage ta terminal 3 of re-heating timer connactor fon wire hamess side) IW okay, pre-heating timer is faulty and should be replaced. * Cheek for battery voltage fo terminal 1 of pra-neating timo wih ignition, il ssmritch ON No Voltage ‘Voltage Chack if voltege to terminal 1 (Of pre-heating timer is terminated = |-—————-»} after engine is storted | ves Ignition switch OFF CONTINUED ON PAGE EM-12 Check that is 1V between terminals 9 and 12, HW foulty, repair glow plug current sensor, H okay, timer is faulty and should be replaced. ‘Start the engine ond check/if thare is 9 votage at terminal 9 of pre-neating timer. HW faulty. repair charging system as necossary, H okay, timer is faulty and should be replaced. Pre-heating Timer eeEM-12 ENGINE MECHANICAL — Diesel Electrical System Diagnosis (2H) JCONTINUED FROM PAGE EN-11 Place ignition ewiteh at ON and check sf current flow to termina i—— 5 of timer is in accordance with coolant temperature {See Timer charecteristics Diagram Pre-heating Duration is Quite on page 87-3) Different Thon That Specification mK ] | After completion of pre-heating, check for voltage at terminal §: again when starter switch is placed at ST. Voltage lgnition switch OFF. a land shack for voltage to glow current sensor (Resister side) We Voltage at All plug a few saconds Inter it okay, roplace sensor, ‘Thereafter, voltage should crop about 1/2 If no voltage, No. 1 glow plug relay is faulty and should be replaced. (ox Check for battery voltage to plus sie of resistor Antate maniotd sida) If okay, replace resistor. If no voltage, No. 2 glow plug relay is faulty and should be replaced. ‘No 1/2 Voltage Thereafter ‘Measure glow plug resistance ‘Approx 0 fh + Glow plug okay Place ignition switeh at ON Check for battery voltage at plus side of glow plugENGINE MECHANICAL — Diesel Electrical System Diagnosis [12H-T] EM-13 DIESEL ELECTRICAL SYSTEM DIAGNOSIS [12H-T] ENGINE DOES NOT START WHEN COLD vottage at least 12 volts (or 24 volts) — ignition switch OFF. normally. 3. Water temperature sensor okay. (See page §) NOTE: 1. Pre-heating System 1, INSPECT POWER SUPPLY SECTION + Replace the intoke heater Disconnect the water temperature 1@ the fusible link. stor ened [pesiemeeemen "| When the ignition switch is tume ON. does pre-heat side of the intake heater have battery voltage for 20 seconds (12V type) or 14 seconds (24V type)? Fusible Link OK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 jsconnect the water temperature sarwoe coonsctar ose at 11108 7 [othe ENGINE Tose] —ze, | ae] fuse (Australia) Okay? ls the indicator No Hight bulb Okay? Replace the bulb. — Is terminal 10 of the o__| Open circuit or pre-heating timer ‘ground faulty in Grounded? Se horens res between terminal 10 of the timer and body ground 1s there battery voltage to terminal 3 of the timer 7 (on wire hamess side)? = ia Open circuit in wire harness between terminal 3 of the Replace the timer fimer and indicator ight Is the lighting 12 type: 24¥ type: Yes CONTINUED ON PAGE EM.15ENGINE MECHANICAL — Diese! Electrical System Diagnosis {12H-T] Yes CONTINUED FRO! When the ignition switch is turned ON. is voltage between terminals 8 and G of the No. 1 intake heater rolay OV for 20 seconds (12V type) or 14 seconds (24¥ type)? IM PAGE EM-14 Did No. 1 intake heater telay check out okay? (See page ST-9) ‘When the ignition switch is tuned ON, does terminal 1 of the intake heater timer have battery voltage for 20 seconds (12 typel or 14 seconds (24M typel? ves © Open circuit in wire harness between terminat 1 of the timer ‘and terminal g of the No. 1 intake heater relay © Open circuit or ground faulty in wire hamess between terminal E of the No. 1 intake heater relay and body ground. intake heater relay? (Measure the time: too} With the engine started, is thare 0 voltage between terminals 8 and G of the No, 2 CONTINUED ON PAGE EM-16 Did No. 2 intake heater relay check out okay? (See page ST-9) Yes No EM-15. Replace the No. 1 intake heater relay. Replace the No.2 intake heater relay. No. 1 and No. 2 Intake Hoater RelaysEM-16, ENGINE MECHANICAL — Diesel Electrical System Diagnosis [12H-T] Yes CONTINUED FROM PAGE EM-15 | Yes With the engine started, does terminal § of the Pre-heating have battery voltage for 70 seconds? When the ignition switch is tumed ON, does the charge warning light light? Is terminat 9 of the timer grounded? Yes Open circuit in wire hamess between terminal 8 of the timer and charge warning light, '@ Inspect CHARGE fuse. ‘© inspect alternater regulator. © Open circuit in wire harness between terminal 5 of the timer and terminal @ of the No. 2 intake heater relay. © Open circuit oF ground faulty in wire hamess between terminal E of the No. 2 intake heater and body ground, \s time normal? After hoat time: Approx, 70 seconds Yes Inspect power supply section. (See page EM-13)ENGINE MECHANICAL — Turbocharger Disgnosis (124-7) EM-17 TURBOCHARGER DIAGNOSIS [12H-T] INSUFFICIENT ACCELERATION, LACK OF POWER OR EXCESSIVE FUEL CONSUMPTION re troubleshooting the turbocharger, first check the valve clearance. ion timing, ete. (Possible Cause) (Check Procedure and Correction Method) Check turbocharging pressure. (See page EM-38) Turbocharging pressure: 0.30 = 0.83 kg/iem* (6.5 ~ 7.3 psi, 38 — 52 kPa) Hf not within specification, begin diagnosis from tem 2. 1, INSUFFICIENT TURBOCHARGING SURE |. RESTRICTED INTAKE AIR SYSTEM Check intake air system, and repair oF reploce parts 86 necessary. (See page EM-40) TEM —_|{ Check intake air system, and repair or replace parts as necessary. (See page EM-40} Check exhaust system. and repair or replace ports as necessary. (see page EM-40) [B_MEAK IN EXWAUST SYSTEM ———_|-(Chack wuhaust nystom, and repair or replace parts as necessary. (See page EM-40) 6. ERRATIC TURBOCHARGER OPERATION|_{ Check rotation of impeller wheel. If it does not turn + | or tums 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 (Passible Cause) (Check Procedure and Correction Method! 1. TURBOCHARGER HEAT INSULATOR Check for loose, improperly installed or deformed RESONNANCE insulator mount belts, and repair or reploce 2s necessary. J 2. EXHAUST PIPE LEAKING OR Check for deformed exhaust pipe, loose mount bolts ‘VIBRATING or damaged gasket. and repair or replace as necessary. [- ERRATIC TURBOCHARGER OPERATION |_| Refer to item 7 of INSUFFICIENT ACCELER- } ee | | ATION, LACK QF POWER OR EXCESSIVE FUEL CONSUMPTION. EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST (Possible Cause) (Check Procedure and Correction Method) FAULTY TURBOCHARGER SEAL Check for oil leekege in exhpust oyster: - | ‘© Remove the turbine elbaw from the turbocharger | and check for excessive carbon deposits on the | turbine wheel. Excessive carbon deposits would indicate a faulty turbocharger. 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 oil leakags ‘theENGINE MECHANICAL — Turbocharger El TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS [12H-T] Troubleshooting of Turbocharger Indicator Light and Warning Light Operation ‘Do both green indicator light and amber warming light hight whee ignition switen \s turned to ON? ‘Cheek for short ‘and repair as necessary (Cheek GAUGE fuse JOE" [Check CHARGE and ENGINE fuses charge waning light out? ES Faulty combination Tie indicator and warning Wnts out during] meter engine iste? | Jun tts tay on Ts charge warning No_[ Fauty cherong light out? [—~*L system | Green light stays an Ghack for open crcuit im wire harness between 10K | Fauity tow pressure low pressure switch and tachometer. “| switch } Amber light comes on Cheek for open eircult in wire Hamers between high pressure switch OK [Faulty high pressure ‘and tachometer and check for ground connection of switch switch ves ‘Does green incicator ight come on when 0,14 kg/cm? (20 ps, 13.7 KPa prossur applied to both prossure switches? NO Check for short circuit mn wire hamess between low LOK [Faulty low pressure pressure switch and tachometer switch ‘Amber light comes an Doss arson incientor ight come on when 108 kom No _[Fauny high previure {15.5 psi, 106.9 kPa) prossure applied to both switches? sich | ves les Faany combination Tes amber HACaIOT TAT ome On whoa TOR Kear meter 115.5 pai, 106.9 KPa) pressure applied to both switches? No. Check for short eircut in wire hamous batween high Faulty high pressure pressure switch and tachomater sovten Turbocharger indicator ight and warn light ‘operation oka—M-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 Ci Standard specific gravit ‘Whan fully charged 12V type 1.25 24V type 1.27 1.25 — 1.27 (Others) ‘CLEANING OF AIR FILTER CLEAN AIR FILTER Clean the element with compressed air. First blow from the inside thoroughly. Then blow off tne Outside of the element, [Oil Bath Type] ‘ir For (CLEAN AIR FILTER: 4 a {al h the oil case and air filter in kerosine by agitat- ing and rubbing. {b) Wipe the oil case and sir filter with a clean rag, (c) Place the cil case on a level work stand. (@) Pour in clean engine oil until it reaches the “OIL LEVEL” markENGINE MECHANICAL — Engine Tune-up EM fe} Place the air filter on the tray {f) Saturate the aie filter with clean engine oil \ INSPECTION OF ALTERNATER DRIVE BELT (See page CH-6) Drive belt tension (Canadal: Used belt 80 = 20 Ib New belt 125 = 5 Ib Drive belt deflection (Others) Used belt 10 — 13 mm (0.39 — 0.51 in} . New belt 8 — 9 mm (0.31 ~ 0.35 in} INSPECTION OF GLOW PLUG [2H] (See page ST-5) INSPECTION OF INTAKE HEATER [12H-T] (See page ST-9) r INSPECTION OF INJECTION NOZZLES (See steps 4 to © 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 psid r (10,296 — 12,258 kPa) New nozzle 115 — 125 kglem* (1.636 ~ 1,778 psi) (11,278 — 12,258 kPa) Opening pressure (12H-T) Reused nozzle 180 — 210 kg/em= (2,560 ~ 2,987 psi) (17,652 — 20.594 kPa) New nezzie 200 ~ 210 kg/cm’ (2.845 ~ 2.987 psi) (19,613 = 20,594 kPa!GINE MECHANICAL — Engine Tune-up First ADJUSTMENT OF VALVE CLEARANCES 1, WARM UP ENGINE Allow the engine te reach normal operating temperature. 2 (2-7) REMOVE INTAKE AIR CONNECTOR AND INTAKE PIPE (See step 2 to & on page EM-40) 3. REMOVE CYLINDER HEAD Gover 4, SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Align the groove'on the pulley with the timing pointer by turning the crankshaft clockwise with a wrench. (ob) Check that the rocker arms on the No. 1 cylinder are loose and rocker arms on the No. 6 cylinder ore tight. Hf not, turn the crankshaft one revolution (260°) and align the mark a¢ above ® 5. ADJUST VALVE CLEARANCES la) 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 « feeier gouge, 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. tb) Tum the crankshaft one revolution (380°) and align the mark as above ‘Adjust only the velves indicated by arrows. 6. INSTALL CYLINDER HEAD COVER, 7, (12-7) : INSTALL INTAKE PIPE AND INTAKE AIR CONNECTOR: (See steps 9 to 12 on page EM-45 and 46) -a _ ENGINE MECHANICAL — Engine Tune-up EM.23 About Timing 2H inter «and ns 60 mm (1.979) (wi PS oF AIC) 12H-T ADJUSTMENT OF INJECTION TIMING 1, PREPARE INSPECTION PIPE Make an inspection pipe with a injection pipe as shown. 2 (12H-1) REMOVE INTAKE AIR CONNECTOR AND INTAKE PIPE (See steps 2 to 5 on page EM-40} REMOVE CYLINDER HEAD COVER 4, SET NO. 1 CYLINDER TO. BTOC/COMPRESSION {a} Align the groove on the pulley with the timing pointer by turning the crankshaft clockwise with @ wrench. ty to) Check that the rocker arms on the No. 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. (2M) or 19° (124-7) 5, ADJUST INJECTION TIMING (a) Remove the No. 1 injection pipe and install the leapection pips onthe Mo, 1 delve fre hokey i » ? (hb) Turn the crankshaft slightly to left afd right until fuel ‘surfaces from the inspection pipe. (c} Turn the crankshaft counterclockwise, sét the No. 1 cylinder just before the 18° (2H) or 11% (12H-1) BTDC/compreasion, SeEM.24 (a) (ob 0 12H mt 11° BTS Mork a Injection timing: 2H ENGINE MECHANICAL — Engine Tune-up (2H A/T and 12H-T) ‘Align the marks of the stop lever and injection pump Governor housing, ‘Slowly turn the crankshaft clockwise ‘Check the crankshaft pulley position (injection timing position) when the fuel level in the inspection pipe rises, BToC BToC 12H-T NOTE: This operation should be repeated at least two or three times. Loosen the other injection pipe union nuts, fuel pipe end oil pipe union bolt at the injection pump side. Loosen the bolt holding the injection pump stay to the stay. Loosen the four nuts holding the injection pump to the retainer. Adjust the injection timing by slightly tilting the injec- tion pump body. 11 the injection timing is retarded, advance it by silting the pump 2 way from the engine th pump toward the engine. injection timing is advanced, retard it by titing theENGINE MECHANICAL — Engine Tune-up EM-25 (k) Tighten the four nuts holding the injection pump to the retainer. Torque: 375 kg-em (27 tt @ Tighten the bolt holding the injection pump stay to stay. Torque: 2H 185 ka-cm (13 ft-lb, 18 Nem Y2H-T 360 kg-om (26 ft-lb, 35 Nm) (m} Recheck the injection timing. ln) Remove the inspection pipe ond install the No. 1 injection pipe. {0} Tighten the injection pipe union nuts, oll pipe union bolt and fuel pipe union bolt Torque: Injection pipe 300 kg-cm (22 ft-lb, 29 N-m} Oil pipe 185 kg-cm (13 ft-lb, 18 N-mb Fuel pipe 280 kg-em (20 ft-lb, 27 Nm) INSTALL CYLINDER HEAD COVER (12H-T) INSTALL INTAKE PIPE AND INTAKE AIR CONNECTOR (See steps 9 to 12 on pages EM-45 and 46) 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 (b) Normal operating coolant temperature (c}_ All accessories switehed off (@) All vacuum tings connected (e} Valve clearances set correctly {f) Injection timing set correctly 2. CONNECT TACHOMETER 3. ADJUST IDLE SPEED (a) Check that the adjusting lever touches the idle speed Ithvottle volve) adjusting screw when the accelerator pedal is released. Hf not, adjust the accelerator linkage lc) Check the idle speed. Idle speed: 650 rpm —— {dl Agjust the idle speed an Speed na ase ®@ 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 © Conneet the accelerator linkage: © After adjustment, adjust the accelerator linkage 4. ADJUST MAXIMUM SPEED (a) Check that the adjusting lever touenes the throttle vaive adjusting screw when the accelerator pedal is depressed all the way. If not, adjust the accelerator linkage.ENGINE MECHANICAL — Engine Tune-up EM-27 Maiimam Speed Adjusting Screw Pale 3a (b) Start the engine, (cl Depress the accelerator pedal all the way. (a) Check the maximum speed Maximum speed: wi Fluid coupling 4,170 mpm. wie Fluid coupling 4,100 rpm (e) Adjust the maximum speed. Disconnect the accelerator linkage. *® Cut out the maximum speed adjusting (speed.con- trol) screw seat wire, © Loasen the lock nut of the maximum speed agjust- ing screw. ‘® Adjust the maximum speed by turing the MAX- IMUM SPEED ADJUSTING SCREW. NOTE: Adjust ot idle speed. Then, raise engine speed and recheck the maximum speed ‘@ Securely tighten the lock nut and recheck the max- 1um speed. "© Seal the maximum speed adjusting screw with @ new seal wire.EM-28, ENGINE MECHANICAL Engine Tune-up ADJUSTMENT OF IDLE SPEED AND MAXIMUM SPEED [2H A/T and 12H-T] z 3. \cle Speed Aajusting Serew 4. H not, adjust the acct if not, adjust INITIAL CONDITIONS {a} Air cleaner installed (b} Normal operating coolant temperature (c) All accessories switched off (dh All vacuum fines connected le) Valve clearances set correctly (f) Injection timing set comectly (a) Transmission in N range CONNECT TACHOMETER ADJUST IDLE SPEED (a) Check that the adjusting lever touches the idle speed adjusting bolt when the accelerator pedal is released. tor linkage. (b} Start the engine, {cl Check the idle speed I MIT 850 rpm AIT(2H) 750 rpm. AIT (12H-T) 770 rpm. (a) Adjust the idle speed. * Disconnect the accelerator linkage. ® Loosen the lock nut of the idle speed adjusting bot, © Agjust the idle speed by tuming the IDLE SPEED ADJUSTING BOLT. © Securely tighten the lock nut and recheck the idle speed, © Connect the accelerator linkage ‘® Alter adjustment, adjust the accelerator linkage ADJUST MAXIMUM SPEED fo) Check that the adjusting lever touches the maximum speed adjusting bolt when the accelerator pedal is depressed all the way, accelerator linkageENGINE MECHANICAL — Engine Tuno-up EM.28 ©) Start the engine (c) Depress the accelerator pedal alll the way. (d) Check the maximum speed. Maximum speed: 4,170 rpm (e) 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 batt ‘© Adjust the maximum speed by tuming the MAX- IMUM SPEED ADJUSTING BOLT, NOTE: Adjust at idle speed. Then, ‘and recheck the maximum speed. ‘© Securely tighten the lock nuit and recheck the max- imum speed. ‘© Seal the maximum speed adjusting bolt with anew ‘seal wire jee ongine speodENGINE MECHANICAL june-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: (ec) All accessories switched off (dd) All vacuum lines connected (e) Valve clearances set corractly (f) Injection timing set correctly (a) Idle speed set correctly (hh Transmission in N range 2. CONNECT TACHOMETER 3. ADJUST POWER STEERING (PS) IDLE-UP SETTING SPEED {al 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 10 2,500 rpm a few seconds. release the throttle and check the PS idle-up setting speed. PS idle-up setting speed: 820 ram fe) Adjust the PS idle-up setting speed by turning the PS. IDLE-UP ADJUSTING SCREW. (f) Race the engine to 2,600 rpm a few seconds, release the throttle and recheck the PS idle-up setting speed, (g) Reconnect the vacuum hose to the PS idfe-up actua- torENGINE MECHANICAL — Engine Tune-up EM.34 ADJUSTMENT OF AIR CONDITIONER IDLE-UP SETTING SPEED [2H M/T] 1. INITIAL CONDITIONS (a) Air cleaner installed (t) Normal operating coolant temperature Ic) All accessories switched off Id) Ail vacuum fines connected le) Valve clearances. set correctly (6) Injection timing set correctly ig) Kite speed vet correctiy 2. CONNECT TACHOMETER 3. ADJUST AIR CONDITIONER (A/C) IDLE-UP SETTING ‘SPEED (@) Start tne engine. (&) Disconnect the vacuum hose from the idle-up actua- tor and plug the hose end. {e) Apply vacuum to the idle-up actuator: (d) Race the engine to 2,500 rpm a few seconds, release ‘throttle and check the A/C idle-up setting speed. AJC idle-up setting speed: 950 rpm (e) Adjust the A/C idle-up setting speed by turning the AVC IDLE-UP ADJUSTING SCREW. (Race the engine to 2,500 rpm a few seconds, eiease the throttle and recheck the A/C idle-up setting speed Ig) Reconnect the vacuum hase to the idie-up actuator.ENGINE MECHANICAL — Engine Tune-up ADJUSTMENT OF AIR CONDITIONER IDLE-UP SETTING SPEED [2H A/T and 12H-T] 1. INITIAL CONDITIONS a) tb) re) e) " 6) "Actuator m 4 cy a) alc aS z (eh ‘Clap Aduaing Ser ues ie: a ¢ (gh Air cleaner installed Normal operating coolant temperature All accessories switched off Valve clearances set correctly Injection timing set correctly idle speed set correctly iw PSI PS igle-up setting speed set correctly Transmission i N range 2. CONNECT TACHOMETER 3. ADJUST AIR CONDITIONER (A/C) IDLE-UP SETTING ‘SPEED. (a) Stort the engine. sx (b) Disconnect the vacuurn hose(s} from the idle-up actuator and plug the hose end{s). ‘Apply vacuurn to the idle-up actuator. Roce the engine to 2,500 rpm a few seconds, release the throttle and check the A/C idle-up setting speed idle-up setting sp M/T 960 rpm (Transmission in neutral ‘Adjust the A/C idle-up setting speed by turing the ‘AUC IDLE-UP AQJUSTING SCREW. Race the engine to 2.500 rpm 2 few seconds, release the throttle and recheck the A/C idle-up setting speed. Reconnect the vacuum hose(s) to the idle-up actus- tor.ENGINE MECHANICAL — Engine Tune-up EM.33 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. (©) Apply vacuum to the actuator. (cl Check that the vacuum does not drop immediately. 2. INSPECT VACUUM SWITCHING VALVE (VSV) (a) Remove the VSV. fb) Check that air flow from pipe to pipe F. fc) Connect the VSV terminals to the battery terminals. id) Check that air flows from pipe E to pipe G. If operation is not as specified. replace the VSV.ENGINE MECHANICAL — Engine Tune-up INSPECTION OF INTAKE SHUTTER [12H-T] 1. INSPECT INTAKE SHUTTER AND ACTUATOR fa) Fully close the throttle valve, and check that it retum ‘smoothly. (b) Apply vacuum to the actuator: (c}_ Check that the vacuum does not drop immediately. 2. INSPECT VACUUM SWITCH VALVE (¥SV) fa) Remove the VSV. fb) Check that air flow from pipe E to pipe F. [c)_ Connect the VSV terminals to the battery terminsis. {d) Check that air flows from pipe E to pipe G. If operation is not as specified, replace the VSV.ENGINE MECHANICAL — Compression Check (2H) EM-35 COMPRESSION CHECK [2H] NOTE: If there is lack of power, excessive ail consump- tion oF poor fuel economy, measure the cylinder compres sion pressure. 1. WARM UP AND STOP ENGINE 2. REMOVE GLOW PLUGS (See page EM-49) CAUTION: Make sure the load wire is not grounded. 3. CHECK CYLINDER COMPRESSION PRESSURE (o} Install SST (gauge adapter] to the glow plug hole. SST 09992-00023 (b} Connect SST (compression gauge) to SST igeuge adapted SST 09992-00023 fc) Fully open the throttle valve {a1 While cranking the engine with the starter, measure the compression pressure. , NOTE: Always use a fully charged bettery to obtain engine revolutions of more than 250 rpm. fe} Repeat steps (0) through (dl for each cylinder. Compression pressure: 28.0 kg/em' (398 psi, 2,746 kPa) or more Minimum pressur 20.0 kg/em® (284 psi, 1,961 kal Difference between each cylinder: 2.0 kg/cm* (2.8 psi, 196 kPa} or less ff) If the cylinder compression in one or more cylinders is low, pour a small amount of engine off into the eylinder thraugh the glow plug hole and repeat steps. a) through (2) for the cylinder with low compression. © If adding oll helps the compression, chances are ‘that the piston rings and/or cylinder bore are wom 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 Fem. = Compression Chack [12H-TI COMPRESSION CHECK [12H-T] NOTE: If there is tock 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 fo) install SST (gauge adapter) to the injection nozzie hole. SST 09992-00023 tb) Connect SST (compression gauge) to SST (gouge adapter) SST 09992-00023 Ie) 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 mare than 250 rpm. (@) Repeat steps (a) through (a) for each cylinges Compression pressur 30.0 kg/cm’ (427 psi, 2,942 kPal 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 (fl If the cylinder compression in one or more cylinders is low, pour 3 small amount of engine oil into the cylinder through the injection nozzle hole and repeat steps (al through (d) for the cylinder with low com- pression. © If adding oil helps the compression. chances are that the piston nngs and/or cylinder bore are worn or damaged. © I pressure stays low. a valve may be sticking or seating improperly. or there may be leakege past the gasket 4. INSTALL INJECTION NOZZLES (See steps 1 to 6 on pages FU-14 andENGINE MECHANICAL — Turboc! ger (12H-T) EM.37 TURBOCHARGER [12H-T] CAUTION: © Do not stop the engine immediately after pul trailer or high speed or uphill driving. Idle the engin: 20 ~ 120 seconds, depending on the severity of the driving condition. # Avoid sudden racing of acc after starting @ eold 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 necessary: Engine oil level and qui Conditions under which turbocharger was used ines leading to turbocharger ‘ation immediately * Use caution when removing and reinstalling the tur- bocharger assembly, Do not drop it or bang it against sp it by easily-deformed parts, such f oF rod, when moving, * Before removing the turbocharger, plug the intake and exhaust pots and oil inlet to provent entry of dirt or other foreign material. ue {{ replacing the turbocharger, check for sccumula- tion of sludge partictes in the oil pipes and, if necessary, replace the oil pipes. * Completely remove the gaskets adhered to the lubrication cil pipe flanged and turbocharger nge. If replacing bolts or nuts, do so only with the specified new ones to guard against breakage or deformation. ¢ if replacing the turbocharger. put 20 cc (1.2 cu in) of into the turbocharger oil inlet and turn the impeller wheel by hand to spread ail 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 secon:ENGINE MECHANICAL — Turbocharger (12H-T] ON-VEHICLE INSPECTION OF TURBOCHARGER Ay INSPECT INTAKE AIR SYSTEM. Check for leakage or clogging between the air cleener and turbacharger inlet and between the turbocharger outlet and cylinder head. © Clogged air cleaner ... Clean oF replace the olement © Hoses collapsed or deformed .... Repair or 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 cylindar head and turbocharger inlet and between the turbocharger out- let and exhaust pipe. © Deformed components ... Repair o replace © Foreign material in passages .... Remove © Loakage from components ... Repair or replace © Cracks in components ... Check and replace INSPECT OPERATION OF ACTUATOR AND WASTE GATE VALVE fe) Disconnect the actuator hose. 4b) Using SST turbocharger pressure gaugel, apply about ©.68 kg/cm" (9.7 psi, 67 kPa} of pressure to the actuator and check that the rod moves. ‘SST 09992-00240 CAUTION: Never apply more than 0.8 kg/em? (11.4 psi, 78 kPa) of pressure to the actuator. If the rod does not move, repiace the turbocharger assem- bly INSPECT TURBOCHARGING PRESSURE (0) Warm up the engine {b} Connect a 3-way union to the intake pipe pressure hose and install SST (turbocharger pressure gauge) to it SST 09992-00240 (c) Press in the clutch pedal, then press the occolerator pedal down as for as it will go. Measure the tur- bocharging pressure ot maximum speed (4,050 - 4,200 rpm). Turbocharging pressure: 0,38 ~ 0.53 kg/em* 15.5 ~ 7.3 psi, 38 — 52 kPa) If the pressure is less than specification. check the intake air and exhoust systems for leakage: If there is no leakage, replace the turbocharger assembly. IW the prassure is above specification, chack if the actustor hose is disconnected or cracked. If not replace the tubocharger assembly.