peed TOYOTA sou: ee | Repoir Manual 1DZ ENGINEFOREWORD This repair manual explains the repair points of the 1DZ model engine equipped ‘on the Toyota Forklift Trucks. Please make good use of this manual for your technical service. This repair manual contains the latest information available as of September 1989. For any chenges thereafter, Toyota reserves the right to make such changes in specifications and descriptions without incurring any obligation and. ithout previous notice. SEP. 1989 TOYOTA MOTOR CORPORATIONSECTION INDEX a 55" | GENERAL ENGINE TUNE-UP ENGINE OVERHAUL _—s—s—sSPa _FUEL SYSTEM _COOLING SYSTEM | LUBRICATION SYSTEM | STARTING SYSTEM | CHARGING SYSTEM SST LIST _ | SERVICE STANDARDS Me | ssoGENERAL SPECIFICATIONS ENGINE EXTERIOR VIEWS ENGINE SECTIONAL VIEWS HOW TO USE THIS MANUAL Explanation Range of Rep: Works Viewpoint of Explanation Contents ‘Signal Word Def Abbrviations REPAIR INSTRUCTIONS .... ‘STANDARD BOLT AND NUT TIGHTENING TORQUES Page 08 o-8 06 06 o8 o8 09‘ombu Exhaust a aaDe 62" ‘Compression anion 0 salons STOO CenENGINE EXTERIOR VIEWS:ona ENGINE SECTIONAL VIEWSoe HOW TO USE THIS MANUAL Explanation Range of Repair Works | | EXAMPLEo-8 Signal Word Definition a1REPAIR INSTRUCTIONS sess, glove, safety ‘engine to prove s Do not bing lates, os and ahers ose 1 otatng pa Eract the tony proven une stern rina ofthe batry, 19 prevent shor 2, PREPARATION BEFORE the function o faite ressembi 2p LURING DISASSEMLY Each tina pat isremoved, check ha pat fr aesebled pats sale arang64 on a Pare tobe 18 toro nd state deformation, damage, roughering eosurront and judgment shal be corse out rqured fr prs tobe reuse, to th erect procera chang hed (2) Always use 9 pas 1 ts depending onthe pace, coat lon the & 6. ADUon STANDARD BOLT AND NUT TIGHTENING TORQUES List OF BOLT TYPES AND STRENGTH aE] Shape med ces [Can | [Hevaaon ne te] Teaaon | ay Balt hesd Na | EET =| mt Oo eat No matk at TT L Length (mm Loienete (am) Hexagon [flange bol cL Sua head bolt Parts No, a 92132-49618 ms PT Eee cn L piameter sw st DiameterENGINE TUNE-UP Page ENGINE OIL INSPECTION ...... 12 \V BELT FLEXURE INSPECTION ‘AND ADJUSTMENT sve V2, VALVE CLEARANCE INSPECTION ‘AND ADJUSTMENT sonnei VB IDLE SPEED INSPECTION ‘AND ADJUSTMENT on MAXIMUM SPEED INSPECTION ‘AND ADJUSTMENT oes 1 INJECTION TIMING INSPECTION ‘AND ADJUSTMENT 15 ; COMPRESSION PRESSURE INSPECTION ... . Ww INJECTION NOZZLE INSPECTION ‘AND ADJUSTMENT 18Coo V BELT FLEXURE INSPECTION AND ADJUSTMENT bas ‘Ser 09216.00020VALVE CLEARANCE INSPECTION AND ADJUSTMENT1-4 IDLE SPEED INSPECTION AND ADJUSTMENT 78-85°C - MAXIMUM SPEED INSPECTION AND ADJUSTMENT 75-85°Cos) 5 cme Vo © ms INJECTION TIMING INSPECTION AND ADJUSTMENTCOMPRESSION PRESSURE INSPECTIONa INJECTION NOZZLE INSPECTION AND ADJUSTMENT fal 11B= 125 kglom? (1695-1777 psi) Note 20 types of washers providedin 0.25 (0.00984 in.) stops in the range of 1.00~ 1,98 mm (0.039~0.0788 in. ™ pressure changes by about Bkglem (719 faeh 0.05 mm (0.00797 In washerENGINE OVERHAUL REMOVAL AND INSTALLATION FROM ENGINE ASSY TO PARTIAL ENGINE CYLINDER HEAD AND VALVE SYSTEM Components Head Disassembly and Assembly Cylinder Head Inspection and Cleaning TIMING GEAR Components ‘Timing Gear Disessembly and Assembly ‘Timing Gear Inspection and Replacement Ol Pump Drive Gear Bearing Replacement CYLINDER BLOCK Components Cylinder Block Disassembly and Assembly Cylinder Block Inspection Camshaft Bearing Replacement Piston and Connecting Rod Disassembly Connecting Red Bush Replacement Crankshaft Inspection Piston and Connecting Rod Inspection .. Page 22 24 24 27 210 217 2417 218 223 225 227 227 2.29 2:35 237 2:39 2.43 2-83 24822 REMOVAL AND INSTALLATION FROM ENGINE ASSY TO PARTIAL ENGINE REMOVAL PROCEDURE DRa4 CYLINDER HEAD AND VALVE SYSTEM ‘ComponentsDISASSEMBLY PROCEDUT Seeseo9n588o ASSEMBLY PROCEDUREbsPoint 72-10 Cylinder Head Inspection and5X: 0.08~0.07 mm (0.0016~0.00276in. 36.48.1 (1.77 44.51 (1 150.0567)TIMING GEAR218 Timing Gear Disassembly and Assembl. Ramone ination: Point 8) ASSEMBLY PROCEDURE| << er | ing Gear Inspection and lacement 0° Standart: No.1. 46.00~ 48.025 mn (1.721.773) No.2. §0.00~60.026 mm (1.9866 1.9686 EX: 30.85mm (1.5691) !Standard: 0,08-0.131mm (0,0024~0.0051 in) Limits 0.3mm 0.01284,The i aroove side T230~45 gm 21.7~328 Oil Pump Drive Gear Bearing Replacementwe, 2 | | Sp | amu “OPHCylinder Block Disassembly and Assembly eo DISASSEMBLY PROCEDURE eaes asegeT=6.0~7.0 kgm (43.4~ 50.8Standaet |Reterence) Thrust wae ‘STD 2.990~2.990mm (80.126 mm (0.0088: (0.00134 ~0.00276Cylinder Block Inspectionstandard uo oa] 46. 080—: nos | 48. 780~5. Camshaft bearing replacement = ‘Camahat journal outede dlametar standard ram On “6.980-46075 a 47 1.8404) eo | 67.034=47.060 "46.694~46.860, 46.634~48.050 (19517-16528) (.9n30~ 1.24441 (1.8380 1.83661 yeom | #8.909-40.975 46,700 46.725 neat 1.8478 | areseo-.ss00 |PISTON PIN AND CONNECTING ROD INSPECTION 28.950~ 65.980" (2.3896 ~3.3850%n 4Standard: 0,040~0.060 mm (0.0016~0,0024in,) Note stot sree |, 0 1.00] ganee—a4260) e Oi ring: 0.03~0.07 mn (0.00118-0.00278 in) 65. || Crankshaft Inspection & ndard: 64,98-66.00mm (2.8582-2.8590in) 1001970.) a4 ih [4 | a Stendard: 50.48~50.50mmm (1,9874~ 1.96621) 0.05mm (0.00197in.) (0.02 mm 0.000787; Us 0.26] 64:73~64.75 (2.6484-2.5892) | [VIS 0.26) 60.23—50.25 (.0780- 1.0789) Us 0.80] 64.48 64.60 12.6986-2.5994) | [IS 0.50) 49.98 ~60.00 (1.9677~ 1.9088) [is 0.75] 64.25~64.26 12.5201~2.6295) | [IS 0.75) 49.73~40.75 (1.9878~ 1.9887) [Us 1,00] 63.98~ 64.00 (2.5189~2.8197) UiS 1.00] 49.48 49.50 (1.9480~ 1.9488) EEE eerpoy Bunseuuo pulFUEL SYSTEM FUEL FILTER INJECTION NOZZLE INJECTION PUMP Specification Components Removal & Instat Disassembly Inspection Assembly ness Test Adjustment Page 32 35 341 an a2 314 316 328 327 3-40 3-40FUEL FILTER_— FUEL FILTER REMOVAL AND INSTALLATION [Always afr too the key points becouse they in OPERATION AFTER FUEL FILTER INSTALLATIONa4 DISASSEMBLY ASSEMBLYae INJECTION NOZZLE REMOVAL AND INSTALLATION REMOVAL PROCEDURE aaggae INSTALLATION PROCEDUREI . INJECTION NOZZLE INSPECTION - ‘AND ADJUSTEMENT Standart ee Good No good No-goad No gooda8 NOZZLE ASSY DISASSEMBLY AND INSPECTIONNOZZLE HOLDER & NOZZLE REASSEMBLY NOZZLE ASSY INSTALLATIONate sig sero ea—86—3-26 7S LL | —96—AssemblyThe plunger spring shim shal not be tcenes bythe fo 5.9 (0.023)-4 og equator. sion KF 4 Thkness em tn 2.50010 22165-58010 22184-68010 22186-58010 1200871 22186-68010, 15 (00581 22187-64010 naan 8554010 2.010.078)Always use new head pooAdjustment ADJUSTMENT SEQUENCE148~188 Kalen? (2063 ~2204 pei ! INSPECTION AND PREPARATION BEFORE TEST |RUNNING-IN the ume chamber as ban Coxtion IF he fuel doesnot come out correct itis fouty 1180" opposite. ‘TEMPORARY ADJUSTMENT (LEVER AT FULL POSITION)(OVERFLOW RATE INSPECTION (LEVER AT FULL POSITION) 77 ~968cc/1000st 222.2 evin 100050) TIMER ADJUSTMENT (LEVER AT FULL POSITION) Standecds Pump ee6d 00 005-088 (0.002~0.033) 1100 10-18 (01030-0071) 22626-58010 22621-54010 22622-54010 7.0 10.0384)FULL-LOAD INJECTION VOLUME AD- > | JUSTMENT (LEVER AT FULL, i POSITION) ADJUSTMENT OF INJECTION VOLUME AT STARTING (LEVER AT FULL POSITION) 23787 58078 4210.10) | 22767 64022 22787-58018 450 22767-54023 5.9 (0.208) 22787-58020 a7 22767-54026 550.217 22707-54021 49 10.1997 | 22707-60028 57 0.2281 the deviation doesnotFULL-LOAD INJECTION VOLUME CHECKnae LOAD SENSING TIMER ADJUSTMENT | treetLOW SPEED LEVER SETTING Lover ang azCOOLING SYSTEM Page COOLING SYSTEM COMPONENTS 42 ‘THERMOSTAT 43 WaTER PUMP aa aYT 42 | COOLING SYSTEM COMPONENTS I - |INSPECTIONWATER PUMP WATER PUMP REMOVAL AND INSTALLATION INSTALLATION PROCEDURELUBRICATION SYSTEM LUeRIcATION SYSTEM COMPONENTS BeOIL PRESSURE INSPECTION OIL PRESSURE INSPECTION not be mined, Standard ing spec: [At 1600 pm 3.8 Kglem® (49.6 psi ENGINE OIL AND OIL FILTER REPLACEMENT ENGINE OIL AND OIL FILTER REPLACEMENTlL PUMP OIL PUMP ASSY REMOVAL AND INSTALLATION ‘Aways tee tothe key points as they incuIng ctection INSPECTION Standard: 0100.17 mm (0.0039 ~0.0076 in) (0.2 mm (0.0079 in) Standard 0,08~0.15 mm {0.002~0.006 in. Limits 0.2 mm 10.0078 in) Reference valve: 7.81~7.97 mm (o3n~03idin)8 OIL STRAINER REMOVAL aroun ha Pan Kani 26 INSTALLATION“otal capecty I 2 US ga) FIPG Coating and Parts Assembly ProcedureSTARTING SYSTEM PREHEATING SYSTEM Circuit Diagram Components Glow Plug Removal and Inspection Prehes ing Timer Inspection and Removal Water Temperature Sensor Removal and Inspection STARTING MOTOR Components Disassembly Inspection Reassembly Starting Motor Individu Inspection Page 62 62 62 63 os os 6s 66 69 13 615Glow Plug Removal and Inspection Standard T= 100 = 160kgom (7.23~ 11 Fb) Preheating Timer Inspection and Removali) STARTING MOTOR ASSY COMPONENTS:InspectionStandardReassemblySrarting Motor Assy Individual instCHARGING SYSTEM ON-VEHICLE TEST ALTERNATOR Components Circuit Diagram Removal and Installation Disassembly Inspection Reaesembly Page 72 73 73 7 74 75 78 7-10| ALTERNATOR: ComponentsDisassembly 12) 1G regulator assy7-8 Inspection Standard: 12V voice: sbout 2.90Reassembly 1 cso betng Carry ou thie operation then the bearing removedSST LIST Page SST (SPECIAL SERVICE TOOL) LIST 82t000$1260 S11 (1001 OIAUAS VIDS) LSSSERVICE STANDARDS ENGINE TUNE-UP . ENGINE BODY FUEL SYSTEM COouNG system LUBRICATION system STARTING SYSTEM CHARGING sysTEM TIGHTENING TORQUES Page 92 4lee so00s Tana Fase] ENGINE TUNE-UP olan eaecty legine 1s oat ] 1 | Tes capacity 58 (Fd temperature at 20°C 68°F ca aon pees 10.276 0.364) a New part, ring 1s ton reese Kalen? os) 18Fame ENGINE BODY CYLINDER HEAD (0.00201 ex 0°, 45°, 75" ia16 Zora VALVE GUIDE BUSH To10-B.080 @3i5-0310) Tees08 (o45440.0161‘Overall length rom a 5 [— - w | 787=7.890 ~ lan 10.314~0.315) - | vaive spans Hocker sem inside di mm fin.) | ,18,500~ 18.521 so | 24 (0.7284 ~0.7292) ey diameter and shi 10.0003 ~0.001: .hs ‘Standard | Page (Crankshaft timing gear x n. a oo eal ‘si ‘mm fin.) a 2-20 . (0.00197) «o.o118) | 7 I 5 , 103 Ty wm | 208 03 Taao ~ 0012~0.0043) | 10.0118) | 72° [82 | raavve-oo10 | woz | 22°a os corre | 229 oer rom tn) | [oog8 0.008 03 | op 2 [Moa022~0.0037 | ore | 222 ices re ee CAMSHAFT AND BEARING Camahat ann = 008) 2a ee (0.00187) yaeme-woom | sea? | py "| drsro—1s760 | sq | 22 cam nein mmm, i =to ei tipo) | 222 Nes = | 208 ISTO! Journal a sim tn | N02 — | 236 Not | inesea~resea_ | ~ | 298 won | a7ow0~47.028 |_| a9 2 | ras04~ 1.8514) | >| sse00-46825 | baa, mmm ind | peamacs-earee | cosa) | 227 07: — | oa 0.260 ae —178— iCYLINDER BLOCK Diameter PISTON AND PISTON RING 95,95~0598 19:9698~9.58501 : 36.45 -06.46 rmmint | 8080 | gracas—3.40 sto 100 | _#6.95-86.98 018 100 | g4as9—a.4240) 0.08~008 27,000-27 012 19.06289~ 1.66390) = fon .08=0008, Net | raoote7=0.00354) 0.05~0 (0.00197 0.009541 10.00118~0.00276) mini | No2 evese 2 | woreca 0200.40 | o.007070.0t601 Pn ftng temperature seve] 60101 - | a4CONECTING ROD AND BEARING Canacting rod bending Ina 100mm 2.95mi) oom in.) - ¢ rod twittng (per 100 mm (3.8319) mm i) E Lage end thrust stance rn pat (0.0022~0.0012) ring Oi Clearance rom tint | Obad=207 eo (0.00173 0.00289) CRANKSHAFT AND BEARING ‘Crankshaft bending rm int = 23 taper and out roundness 7 orm cea jo.oooren| 2-48 reset rust mmm ta | oon 04, 03 | ow “ 10.00167~0.008461 | sao1a | 22 ao 2.5302, 980 on8=0 08 |rocossatoooges| ~~ a ea0e-6500 | L 5683 2.6 ‘ wso2s | gisasszeen | ~ : woos | 04806450 |_| 243 : 2.5300~ 2.8804) aaa sore | 84246425 $075 | i2isio1-2.6290) uss 1.00 | - mmm tn} iagorse—o.ce27e | coco, | 22Trepecion tam I Page FUEL SYSTEM NOZZLE, NOZZLE HOLDER in pening pressure lem ip a INJECTION PUMP = 325® INJECTION PUMP ADJUSTMENT See 1 Part No, 99400-0540 (2062 ~ 2208 igh presire ine Tes ‘Solna vig when ci 30-32 High eneed ver set pont | 131 aa Pup speed om) Fue nara oe emarks 906 22-2 ~ ee 69.8~68.21 Use (09394—0.0700)(200 st cui 200 (o.134~0.249) e609 ain (600 ot) ae 08) 20.4 20.007 0.14)40.007 ‘lel with thelover a fll poon ‘whe the pomp ie raning st 1100COOLING SYSTEM ‘THERMOSTAT LUBRICATION SYSTEM ou puMP 008-015 10 0020-3.000 010-017 02 vo.0030—0.00871_| 10.0078),| STARTING sysTEM STARTER (OC SERIES REDUCTION TYPE} v 10 - Sood ~ ‘Departure trom 7 roundness NI.) ~ con Ousiedomwmnin) | = | evo odecsion | waa | 2 Brut eng ae 1 Lacan contin "200 -|- 350 59) STARTER RELAY 13—[sera Tm] Foxe) Low PLUG PREHEATING TIMER9-17 CHARGING SYSTEM ALTERNATOR (STO) ALTERNATOR (HIGH POWER TYPE} rush length rom in) 78 rm i) 78TIGHTENING TORQUES Tghteing Poin 0.55~085, 5-22