> TOYOTA REPAIR MANUAL Aug., 2000FOREWORD This repair manual has been prepared to provide information covering general service repairs for the 1KD~ FTV engine equipped on the LAND CRUISER/LAND CRUISER PRADO. Applicable models: KDJS0, 95 series Al 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 nolice. TOYOTA MOTOR CORPORATION (©2000 TOYOTA MOTOR CORPORATION Ail rights reserved. This book may not be repro- ‘duced oF copied, in whole or in part, without the ‘weitten permission of Toyota Motor Corporation. First Printing: Jul. 10, 2000 01-0007 10-00CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. in the cases that non-specialized or uncertified technicians perform repair or service only using this manu- al or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer's vehicle. In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow the instruction shown below. + Mustread this manual thoroughly. itis especially important to have good understanding all the contents written in the PRECAUTION of "IN" section + The service method written in this manualis very eftective to pertorm repair and service. When performing the operations following the procedures using this manual, be sure to use tools spe- cified and recommended. If using non-specified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer's vehicle before starting the operation. + Ifpartreplacementis necessary, must replace the part with the same part number or equivalent part. Do not replace it with inferior quality. + Itis important to note that this manual contains various "Cautions" and "Notices" that must be carefully abserved 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. Itis 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 PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS ENGINE MECHANICAL TURBOCHARGING EMISSION CONTROL ELECTRONIC CONTROL DIESEL ENGINE FUEL COOLING LUBRICATION STARTING CHARGING ALPHABETICAL INDEX | Ll |INTRODUCTION HOW TO USE THIS MANUAL . 7 GENERAL INFORMATION IN IDENTIFICATION INFORMATION |... IN-3 ENGINE SERIAL NUMBER INS REPAIR INSTRUCTIONS - IN GENERAL INFORMATION Ina FOR ALL OF VEHICLES ... cece IN-8 PRECAUTION Ing HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS... IN-9 GENERAL INFORMATION . IN-o HOW TO PROCEED WITH TROUBLESHOOTING .. cee INO HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ...... IN-20 TERMS |... cee INAS ABBREVIATIONS USED IN THIS MANUAL IN-25:Nt INTRODUCTION — HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL GENERAL INFORMATION 1. INDEX ‘An INDEX is provided on the first page of each section to guide you to the item to be repaired, To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnase the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN~9. Be sure to read this before pertorming troubleshooting. 4, PREPARATION Preparation lists the SST (Special Service Tools), recommended taols, equipment, lubricant and SSM (Spe- cial Service Materials) which should be prepared before beginning the operatian and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview iliustcation. It identifies the components and shows how the parts fit together. Example: Driven Rotor Crankshatt Front Oil Seal SY aie Vane a ¢ Gasket 5, Plug 49 (500, 36) Kim (kafom, #ibi)_] : Specified torque ovine @Non-reusablepart exem2 INTRODUCTION HOW TO USE TAS MANUAL ‘The procedures are presented in a step-by-step format + The illustration shows what to do and where to do it. + The task heading tells what to do. + The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example in | Taskeading what do 21, CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdtive brake pis- ton as shown in the illustration, ‘SST 09350-30020 (09350-06120) Ilustration: what go Eee inene? Set part No. Component part No. Detailed text; how todo task {b) Measure the stroke applying and releasing the compressed air (392 —785 kPa, 4— Bkgt/cm?or57— 114psi) as shown in the illustration. Piston stroke: 1.40 — 1.70 mm (0.0551 — 0.0669 in.) ea This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed informa- tion. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to, 7. SPECIFICATIONS ‘Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick ref- erence. 8. CAUTIONS, NOTICES, HINTS: + CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. + NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired, + HINTS are separated from the text but do not appear in bold. They provide aditional information to help you perform the repair efficiently. 9, SIUNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N-m (310 kgf-cm, 22 ft-lbt}INTRODUCTION —_ IDENTIFICATION INFORMATION us IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration.Ns INTRODUCTION — REPAIR INSTRUCTIONS. (a) (b) raarv7] (©) (3) (e) (9) REPAIR INSTRUCTIONS GENERAL INFORMATION BASIC REPAIR HINT Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following operations (1) Before performing electrical work, disconnect the negative (-) terminal cable from the battery. (2) Ifit is necessary to disconnect the battery for in- spection or repair, always disconnect the negative (-) terminal cable which is grounded to the vehicle body. (3) To prevent damage to the battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or oth- er abrasive objects. (5) _ install the cable ends to the battery terminals with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are secure and correct. Non-reusable parts (1) Always replace cotter pins, gaskets, O-rings and oil seals etc. with new ones. (2) Non-reusable parts are indicated in the component illustrations by the "@" symbol. Precoated paris Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads, (3) Precoated parts are indicated in the component i lustrations by the "*” symbol When necessary, use a sealer on gaskets to prevent leaks.INS INTRODUCTION — REPAIR INSTRUCTIONS (h) Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. (i) Use of special service tools (SST) and special service ma- terials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where speci- fied and follow the proper work procedure. A list of SST and SSM can be found in section PP (Preparation) in this ce manual i) When replacing fuses, be sure the new fuse has the cor- rect amperage rating. DO NOT exceed the rating or use one with a lower rating Medium Current Fuse and High Current Fuse Equal Amperage Rating lustration Symbol Part Name ‘Abbreviation ae SSP a FUSE FUSE rd A ese sass a MEDIUM CURRENT FUSE M-FUSE ss swoaee Po HIGH CURRENT FUSE H-FUSE ~-9o FUSIBLE LINK FL -PS4- | oncurrsrecaxen ca (k) Care must be taken when jacking up and supporting the vehicle. Be sure to lit and support the vehicle at the prop- er locations. + Cancel the parking brake on the level place and shift the transmission in Neutral (or N position). + When jacking up the front wheels of the vehicle at first piace stoppers behind the rear wheels. + When jacking up the rear wheels of the vehicle at first place stoppers behind the rear wheels.IN-6 INTRODUCTION —_ REPAIR INSTRUCTIONS. + When either the front or rear wheels only should be set rigid racks and place stoppers in front the other wheels on the ground. + After the vehicle is jacked up, be sure to support it on rigid racks. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a smail job that can be finished quickly. (i) Observe the following precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electric- ity) (2) To disconnect vacuum hoses, pull off the end, not the middle of the hose. (3) To pull apart electrical connectors, pull on the con- nector itself, not the wires. (4) Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. (5) When steam cleaning an engine, protect the eleo- | tronic components, air filter and emission-related ‘components from water. eats (6) Never use an impact wrench to remove or install temperature switches or temperature sensors. (7) When checking continuity at the wire connector, in- sert the tester probe carefully to prevent terminals from bending. (8) When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak.INT INTRODUCTION —_REPAIR INSTRUCTIONS. (m) Tag hoses before disconnecting them: (1) When disconnecting vacuum hoses, use tags to identity how they should be reconnected. (2) After completing a job, double check that the vacu- um hoses are properly connected. A label under the hood shows the proper layout. (n) Unless otherwise stated, all resistance is measured at an ambient temperature af 20°C (68°F). Because the resis- tance may be outside specifications if measured at high temperatures immediately after the vehicle has been run- ning, measurement should be made when the enging has cooled down.IN-8 WWMROQUGTION FOR ALL OF VEHIGLE FOR ALL OF VEHICLES PRECAUTION 1, FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: if large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz- ard. To prevent this, observe the following precautions and explain them to your customer. (a) _ Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. (c)_ Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (a) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. (@) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off and prolonged braking (9) Do not dispose of used catalyst along with parts contaminated with gasoline or oil. 2. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away fram the ECU and sensors of the vehicle's electronic system. (2) _ Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve- hicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Avoid winding the antenna feeder together with the other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. 3. FOR USING HAND-HELD TESTER CAUTION: Observe the following items for safety reasons: + Before using the hand-held tester, the hand-held tester’s operator manual should be read throughly. + Be sure to route all cables securely when driving with the hand-held tester connected to the vehicte. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.) + Two persons are required when test driving with the hand-held tester, one person to drive the vehicle and one person to operate the hand-held tester.INTRODUCTION — HOW 1. TROUBLESHOOT ECU CONTROLLED Ine SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION A large numbers of ECU cantrolled systems are used in the LAND CRUISER/LAND CRUISER PRADO. In general, the ECU controlled system is considered to be a very intricate system Cequiring a high level of techni- cal knowiedge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to Jocate and fix the problem. This manual is designed through emphasis of the above standpoint to help ser- vice technicians perform accurate and etfective troubleshaating, and is compiled for the following major ECU controlled systems: System Page Engine Dia The troubleshooting procedure and how to make use of it are described on the above pages. FOR USING HAND-HELD TESTER + Before using the hand-held tester, the hand held-tester’s operator manual should be read throughly. + Ifthe hand-held tester cannot communicate with ECU controlled systems when you have connected the cable of the hand-held tester to DLCS, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or too! side. (1) If communication is normal when the taal is connected to another vehicle, inspect the diagnosis data link line (Bus@line) or ECU power circuit of the vehicle, (2) communication is still not possible when the tool is connected to another vehicle, the problem is probably in the fool itself, so pertorm the Seif Test procedures outlined in the Tester Operator's Manual.IND INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS, HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro- cedure is shown. Details are provided in each section, showing the most effective methods far eactt circuit Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit (Vehicle Brought to Workshop) D : Vv " [Rape seat tna I 2 orn Confirmation Le 3 _ Sete Crook Trouble — Symptom Simulation 7 f 2,3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. i | (When the prablem symptoms do not appear during confirmation, use the symptom simulation method described later on.) 4 _/ Diagnostic Trouble a 7] / Code Chant | f] Vv | > reste Seton Ta | fl 45,6 Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part Vv which should be checked using tte diagnostic 6 £ Girt inspection or Pais trouble code chart or the problem symptoms table: ree _ / 7 ‘Check and repair the affected system or part in accordance with the instructions in Step 6. 8 After completing repairs, confirm that the problem has been eliminated (if the problem is not reproduced, pertarm the confirmation test under the same conditions and in the same environment as when it occurred for the first time.)WTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED ment 1. CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the troubleshooting section for each system for your use. Important Points in the Customer Problem Analysis ———- © What Vehicle model, system name © When Date, time, occurrence frequency © Where Road conditions ‘¢ Under what concitione? How did it happen? Running conditions, driving conditions, weather conditions Problem symptoms (Sample) Engine control system check sheet. CUSTOMER PROBLEM ANALYSIS GHECK ENGINE CONTROL SYSTEM Check Sheet _|zspectors ‘Customer's Name Model and Mode! Driver's Name Frame No. Data Venice Brovstt is Engine Model im License No. ‘Odometer Reading les DEngine does ine does not eran Initial combustion (0 complete combustios Engine does | [Engine does not crank No initial combusti No complete combustion piticuitto | Gengine cranks slowly Start other, incorrect frst idle Clidling rpmis abnormal C1 High( rpm) ClLow( GPooriaiieg | CRoughicling _Cother GHesitation Back fre ‘CiMuttler explosion (atter-tre) surging knocking other. Door Bre ability Problem Symptoms Soon after starting I depressed engine Stall | C1 After accelerator pedal released During A/C operation Cshining trom NtoD Other sasiant CiSometimes( times per _—_dayimontIN-12 INTRODUCTION - OW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS, 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the LAND CRUISE/LAND CRUISER PRADO fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during trouble- shooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the LAND CRUIS- ER/LAND CRUISER PRADO. Diagnostic Troube | Input Signal Check ] Cher Diagnosis System Code Check | (Sensor Check) Funetion Engine | o ° (with Test Mode) In diagnostic trouble code check, itis very important to determine whether the problem indicated by the diag- nastic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting fot normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check (Make a Note of and then clear) Confirmation | Diagnostic Trouble| Pr of Symptoms | Code Check roblem Condition Diagnostic Trouble [Problem symptoms] Same diagnostic | problemis stil occurring in the diagnostic (Cade Display exist trouble code is |tycuit displayed Normralcodeis | The problem is stl occurring in a place > displayed ‘other than in the diagnostic circuit (The diagnostic trouble code displayed first is either for a past problem or itis a secondary problem) (No problem The problem occurred in the diagnostic TEymptoms exist circuit in the past Normal Gode Display,_-LProblem symptoms|Normal codeis | The problems stil occurring in a place Brit displayed other than in the diagnostic circuit No probiem Normal codeis [The problem occurred in a place other Symptoms exist | displayed than in the diagnostic circuit in the pastINTRODUCTION ~ HOW TOTROUBLESHOOT ECU CONTROLLED IN-13 SYSTEMS Taking into account the above points, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utlize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnos trouble code troubleshooting or to troubleshooting of problem symptoms. ' Diagnostic trouble code check’ _ | Making a nate of and clearing ofthe diagnostic trouble codes displayed Symptom confirmation | [7] Problem symptoms “ No problem symptoms TSmSIOn eS Ueing IRE I) Simulation test using the symptom | simulation methods __g Vv ‘© Diagnostic trouble code displayed '® Normal code displayed ‘* Normal code displayed » Problem symptoms exist © Problem symptoms exist © No problem symptoms exist VY __ YY Troubleshooting of problem indicated Troubleshooting of each ‘System Normal by diagnostic trouble code problem symptom end _ if a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire hamess and con: nectors (See page IN-20}.IN-14 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS, 3. SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter haw much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong quess somewhere, which will only lead to a standstil. For example, for a problem which only occurs when the en- gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the prob- lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex- ternal causes are applied to the vehicle in a stopped condition important Points in the Symptom Simulation Test Inthe symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To de this, narrow down the possible problem circuits according to the symp- toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symp- (oms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 | VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally WIRE HARNESS Slightly shake the wire harness vertically and horizontally The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thorough: y ‘Swing Slightly PARTS AND SENSOR Vibrate Siightly Apply slight vibration with a finger to the part of the sensor SN considered to be the problem cause and check that the Ry ‘malfunction occurs, TM HINT: Applying strong vibration to relays may resultin open SNF relays, SS Sc Sd. SN |INTRODUCTION - HOW. SYST TQTROUBLESHOOT ECU CONTROLLED INAS 2 | HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction ‘with a hair dryer or similar object. Check to see ifthe malfunction occurs. NOTICE: (1) Do not heat to more than 60°C (140°F). (Temperature is limited not to damage the components.) (2) Do not apply heat directly to parts in the ECU. ‘When the malfunction seems to occur on a rainy day or ina 3._| WATER SPRINKLING METHOD: (hae ee ondtion, Sprinkle water onto the vehicle and check to see if the malfunc- tion ocours, NOTICE: (1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. (2) Never apply water directly onto the electronic ‘components. HINT: Ifa vehicle is subject to water leakage, the leaked water may contasninate the ECU, When testing a vehicle with a water leak- ‘age problem, special caution must be taken. 4 | OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head! lights, rear window defogger, etc. and check to see if the mal- function occurs.IN-16 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED sysreg 4, DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot- ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example. ¢ DTC No. Indicates the diagnostic trouble code. Page or Instructions Indicates the page where the inspection procedure © Trouble Area | foreach circuit is to be found, or gives instructions Indicates the suspect area of the for checking and repairs. problem ‘* Detection item Indicates the system of the problem or | contents of the problem. piadwosmic TROUBLE CODE CHART HINT; Parahetr stein th chart may rofbe exact the same as yourreadng tothe type instrument or ther factoys. | ita "huntn code is displayed djiring the DTC check in check (test) mdde, check the circuit for that code listed in the table below. For details of each code, tum to the page retertpd to under the “See page” for the respgptve ‘DTC No.” in the DTC ghar. ro OTC No amar? Detection tem “Trova Area sot ete) ont Nomen] Memory sankshatt Postion Sensor ‘© Open or short in crankshaft position sensor circuit 2 CrankshattPositionSensorCircuit —§ Crankshatt postion sensor onna| © (01-12) Maltneson Engine ECU cps pen or shor in engine speed sansor Grout 7 (01-28) | saltuncon cere eoe onina| O | ‘© Open or short in E-VAV for main actuator circuit | | ‘© E-VAV for main actuator ‘5 Diesel Trobe Contr Grcuit _|_—© Dosa trot postion sensor rut (01-32) | Mattuncion ‘ Diese! throttle position sensor onnal © | [ees LT erie 1c Mattnetion Engine eoINTRODUCTION — HOW TO TROUBLESHOOT ECU CONTROLLED: IN-17 SYSTEMS, 5. PROBLEM SYMPTOMS TABLE The suspect circuits or parts for each problem symptom are shown in the table below, Use this table to trou- bleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the prob- lem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, itis considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. | © Page Indicates the page where the flow chart for each circuit is located. ‘Circuit Inspection, inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers. © Circuit or Part Name Indicates the circuit or part which needs to be checked. © Problem Symptom \— —— —— \ | \ PROBLEM SYUPTOMS TABLE \ | ! \ Symptom \ Suspect Area Seo page Ys. starter Engine does not fank (Does nt start “ ° i Z |2. Starter relay VEU power source Srcuit I-93 t 2. Pro-heating systom ste (intial combustion (Does not tar ‘ 3. Compression EM-2 4 Engine ECU noo _| 1. Pre-heating system st2 2, Sater signal iui bis 3. Watertempeature sensor eD-41 4: ljector Cold engine (Dilfeut to stan) c ‘sine 5. Fuel filter Fut 6. Diese! throttle body Dk 26 7. Engine ECU IN-20 | 1. Slater sgnal creat DENG | 2. injector 3. Ful fiter 4 Diese tivotie body 5. Engine FOU 1. Fuel iter 2. Diesolthoitle body 2 wuN18 INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED SYSTEMS 6. CIRCUIT INSPECTION How to read and use each page is shown below. « Diagnostic Trouble Code No. and Detection item ‘Circuit Description The major role and operation, eto. of the circuit and its component parts are explained, DTe) 42 | Grankshail Position Sepor Circuit Malfunc- | L tion pf CIRCUIT DESCRIPTION rrousesinmesgiy2urp, ANE soa snzrgenasies 2g erine2 rns Tenia ECU sets —. res * indicates the diagnostic trouble code, diagnostic |" trouble code set parameter and suspect area of the problem. WIRING DIAGRAM “T © Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL, WIRING DIAGRAM to thoroughly understand the a circuit S T Wire colors are indicated by an alphabetical code. Ole 8 = Black, L = Blue, R = Red, BR LG = Light Green, V = Violet, G = Green, en tes O = Orange, W = White, GR'= Gray, P = Pink, pe —e Y= Yellow Gi. iw le alle The firs letter indicates the basicwire colorand the J — re second letter indicates the color of the stripe. ie Sone SenseINTRODUCTION ~ HOW TO TROUBLESHOOT ECU GONTROLLED IN-19 SYSTEMS, [° Indicates the position of the ignition switch during the check.| | inspection Procedure vock oN Use the inspection procedure to determine (© lanitien Switch LOCK (OFF) (7), !anition Switeh ON | | if the circuit is normal or abnormal, and if Soar ee it is abnormal, use it to determine whether the problem is located in the sensors, Q torion sw lain Switen ACC JD ‘anion Switen START _ actuators, wire hamess or ECU. \ \ INSPECTION PROCEDURE | \ Chock continuity between terminal THW of ECU connector and body ground. Teak "PREPARATION ey aa (@) Remove the glove companment S, {b) Disconnect the E5 connector of ECU inal CHECK: rc gar Measure resistance between termina THW of ECU connector and body ground. Vscwmew | OX: Resistance: 1 Ma or higher I 0K ) | Goto steps. ‘Check water temp. sensor (See page ED-10). X ok | Replace water temp. sensor. —— Indicates the place to check the voltage or resistance. ® Indicates the connector position to be checked, irom the front or back side. J Wire Harness Check trom the connector back side. Check from the connector front side. (without harness) (with harness) In this case, care must be taken not to bend the terminals. # Indicates the condition gf he comecto of ECL during the check ae E6 Connector Connector being checked is connected. Connector being checked is disconnected.IN-20 INTRODUCTION ~ HOW TO TROUBLESHOOT EGU CONTROLLED SYSTEMS. HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDU RE CONNECTOR CONNECTION AND TERMINAL IN- SPECTION + For troubleshooting, diagnostic trouble code charts or problem symptom charts are provided for each circuit with detailed inspection procedures on the following pages. + When all the component parts, wire harnesses and con- nectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is per- formed without the problem symptoms occurring, refer to step 8 to replace the ECU, even if the problem is notin the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method + The instructions "Check wire harness and connector’ and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty con- tact in the connector, and a connector terminal pulled out, etc. HINT: + tis rarely the case that a wire is broken in the middle of it, Most cases occur at the connector. In particular, care- fully check the connectors of sensors and actuators. + Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a de- formation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no ab- normality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or con- rectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there isa short circuit between the wire harness and body ground, check thoroughly whether the wire hares is caught in the body or is clamped properly.INTRODUCTION ~ HOV To TROUBLESHOOT ECU CONTROLLED IN-2t Sensor Side A ECU Side Sensor Side ECU Side 3 <=> Pull Lightly Looseness of Crimping SYSTEMS, 2. CONTINUITY CHECK (OPEN CIRCUIT CHECK) (a) Disconnect the connectors at both ECU and sensor sides. (b) Measure the resistance between the applicable terminals of the connectors. Resistance: 10 or less . Measure the resistance while lightly shaking the wire hax- ness vertically and horizontally. + When tester probes are inserted into a connector, insert the probes from the back. For waterproof connectors in which the probes cannot be inserted from the back, be careful not to bend the terminals when inserting the tester probes. 3. RESISTANCE CHECK (SHORT CIRCUIT CHECK) (a) Disconnect the connectors on both ends. (b) Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 1 MQ or higher HINT: ‘Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4, VISUAL CHECK AND CONTACT PRESSURE CHECK (a) Disconnect the connectors at both ends. (b) Check for rust or foreign material, etc. in the terminals of the connectors. (c) Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly. (d) Prepare a test male terminal and insert it in the female ter- minal, then pull it out. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section.IN-22 INTRODUCTION ~ HOW TOTROUBLESHOOT ECU CONTROLLED SYSTEMS, A Fig. 1 ECU Loren] @ ® Sensory y t Ai} 2. 2 ECU 5. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 6. CHECK OPEN CIRCUIT For the open circuit in the wire hamess in Fig. 1, perform "(a) Continuity Check” or "(b) Voltage Check’ to locate the section (a) Check the continuity (1) (2) Disconnect connectors A” and °C" and measure the resistance between them. in the case of Fig. 2, Between terminal 1 of connector “A” and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector “A” and terminal 2 of connector "C" > Continuity Therefore, it is found out that there is an open circuit, between terminal 1 of connector "A” and terminal 4 of connector °C” Disconnect connector "B" and measure the resis- tance between the connectors. In the case of Fig. 3, Between terminal 1 of connector "A" and terminal 1 of connector "B1" -» Continuity Between terminal 1 of connector "B2” and terminal 1 of connector "C" > No continuity (open) Therefore, itis found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C’INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED IN-23 SYSTEMS, ou ® Sensor é i al Fig. 6 ecu Sensor (b) Check the voltage. Ina circuit in which voltage is applied (to the ECU connec- tor terminal), an open circuit can be checked for by con- ducting a voltage check. As shown in Fig. 4, witht each connector still connected, measure the voltage between body ground and terminal 1 of connector “A” at the ECU SV output terminal, terminal 1 of connector "B", and terminal 1 of connector "C”, in that order. (Cthe results are: 5V: Between Terminal 1 of connector “A’ and Body Ground 5V: Between Terminal 1 of connector "B" and Body Ground OV: Between Terminal 1 of connector "C* and Body Ground Then it is found out that there is an open circuit in the wire hat- ness between terminal 1 of "B” and terminal 1 of "C” 7. CHECK SHORT CIRCUIT Ifthe wire hamessis ground shorted as in Fig. 5, locate the sec- tion by conducting a “continuity check with ground”. Check the continuity with ground, (1) Disconnect connectors “A” and °C” and measure the resistance between terminal 1 and 2 of connec- tor "A" and body ground. In the case of Fig. 6 Between terminal 1 of connector ground > Continuity (short) Between terminal 2 of connector "A" and body ground -» No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector “A” and terminal 1 of connector "C and bodyINTRODUCTION (2) HOW To TROUBLESHOOT ECU CONTROLLED SYSTEMS Disconnect connector "B" and measure the resis- tance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. Between terminal 1 of connector "A" and body ground > No continuity Between terminal 1 of connector "B2" and body ground > Continuity (short) ‘Therefore, itis found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector °C" 8. CHECK AND REPLACE ECU First check the ECU ground circuit. Ifit is faulty, repair it If itis normal, the ECU could be faulty, so replace the ECU with a nor- mal functioning one and check that the symptoms appear. Example a) Ground = Pa fA a ECU Side (2) l Ground ! = i Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 0 or less Disconnect the ECU connector, check the ground terminals on the ECU side and the wire haress side for bend and check the contact pressure.TERMS IN-25 iTRODUCTION —_TEAMS ABBREVIATIONS USED IN THIS MANUAL ‘Abbreviations Meaning AG. ‘A Conattioning Ae ‘Aerating Current ‘Ace Accessory ACIS ‘Acoustic Control Induction System ‘ACSD ‘Automatic Cala Stan Devon ALT Alternator AMP, Ampiier [aPpRox Approxmatoly AT, ‘Automatic Transmigeion Transaxle BACS Boost Alituda Compensation System BAT eatery BIDE. Before Top Dead Center Bvsv Binetalic Vacuum Switcring Vaive ca Gircuit Breaker 00) Calvi Converar for Oxiation bc Direct Curent DLC Data Link Connector ore, Diagnostic Trouble Code E00) Blectronie Gontrol Diesel ECT Electron Gana Transmission ECU Electronic Control Unit EDU Electronic Driving Unit EFL Fjectonic Fuel injection EG Engine EGA Exhaust Gas Recirculation EVAP Evaporative Emission Contra EWAV Electronic Vacuurn Regulating Vawve x Exhaust FPG Formed in Place Gasket FL Fusible Link Fr Front GND. Ground HAG High Alttuge Compensator 1G Ignition In ‘inegrtea ignition Assembly N Intake isc lela Speed Corto) 8 “Junction Block ue Junction Connector uco igus Crystal Display LED. Light Emiting Dioge jus Let HanaIN-26 INTRODUCTION — TERMS HO LeftHand Drive to low MAP) Maniois Absolute Pressure MAX. Maximum wil Maltoncion Indicator Lamp MIN. Minimum Me Muttiurpose Mt ‘Manual Transmission N Noutal 028 Oxygen Sensor On, Overctve os Oversize Ka Parking Brake PS, Power Steering RAM Fandom Access Memory AS Relay Block BH Fight Hang PHO. Fight-Hana Drive ROM ead Only Memory Re Rear 10S ‘Starting Injesion Control System SPEC Speciication| SSM Speci Service Materials SST ‘Special Service Tools S70) ‘Standara Sw Switch TAGH Tachometer 00) “Top Dead Center TEMP, Temperature Te “Transmission TMC TOYOTA Motor Corporation| TWO. Three-Way Catalyst uo Underdtve. voy, ‘Vacuum Contol Vave vin Vehicle identification Number vsv, Vacuum Switching Valve wi wit wi Wire Harness wi wanout wu=Twe Warm Up Tivoe-Way Catalytic Converter aw. “Two Wheel Dive Vehicle (4x2) aw. For Whee! Brivo Venice (4x4)PREPARATION ENGINE MECHANICAL TURBOCHARGING EMISSION CONTROL ELECTRONIC GONTROL DIESEL ENGINE FUEL COOLING LUBRICATION ... STARTING CHARGING PP PP-8, PP PP-i3 PP15 Pte PP-22 PP-27 PP-30PREPARATION —_ ENGINE MECHANICAL ENGINE MECHANICAL SST (Special Service Tools) ID-TONR valve Spring Compressor - (09222-06010) Femover & Replacer (CYLINDER BLOCK OO 8 (09222-06020) Guide — GYLINDER BLOCK Es (09222-05030) Base ~ PBYLINDER BLOCK = (09223-00010 Gover & Seal Replacer TRING GEAR (09223-15030 Oi Seal & Beating Repacar OVLINDER BLOCK | 19223-50010 Crarkshalt row a Sea (CYLINDER HEAD placerPp-2 PREPARATION ENGINE WECHANICAL g oRI-TBIO Cranks Oy Seal Replacer TIMING GEAR = ‘05248-55050 Vane Clearance Adust Toul Set, VALVE CLEARANCE - (09248-05510) Valve Liter Pross VALVE CLEARANCE — (05248-05520) Valve Liter Stopper VALVE CLEARANCE 7 (09252-10010) No.1 Roplacer Hardie ~~" evunper stock 05308-10010 0% Seal Puler TIMING GEAR (09330-00021 Companion Fnge Hoigng Too! TING GEAR (09955-20017 Unvereal Pur TIMING GEAR (09950-40011 Puller 8 Set TaNG GEAR TIMING BELT (09951-94010) Hanger 150, TIMING GEAR, TIMING BELT (09952-04010) Side Arm “TIMING GEAR TIMING BELT "(09953-D4620) Center Bolt 150 - TIMING GEAR TiMnG att (09954-04010) Arm 25 ‘Timi Gear ce TIMING BELTPREPARATION — ENGINE MECHANICAL (09955-04041) Claw No.4 AED = (opss 0106) Gawnoe Friis et D9a50- S001? Pater et Tuna GzAR (WHRsI-05010) Wangeriso "iG GEAR - (09952-05010) Slide Arm — TIMING GEAR o — (69953-05010) CeonerBoi 00 Ting GEAR css (09954-05020) caw No TING GEAR asian Pepe a CvaNDER ERD ob (08951-00280) Repacer 28 CyUNDER HEAD © S (09951-00500) Feplacer 50 ~ | evLINDes HEAD ; 2 (09952-06010) Adapter — ‘CYLINDER HEAD * 09950-70010 Handle Set CYLINDER HEAD L- (09951-07100) Handle 00 [evince HEADPpa PREPARATION -_ ENGINE MECHANICAL 2 09960-10010 Variable Pin Wrench Set Trimine Gear 7 EE ye Pa Wh Ticea fF (09963-00600) Pin 6 - “| Tiwine GEAR _ (oomR-DI21}) Gauge ay [coupnessionPREPARATION. —_ ENGINE MECHANICAL PP-5 RECOMMENDED TOOLS ‘ DOONO-DODIT Hesagan Waren Br _| ps0 tn010 Bana a 09905-00013 Snap Ring Pliers: aPP-6 EQUIPMENT PREPARATION ENGINE MECHANICAL Carbide cuter Caliper gauge Connecting rod aligner Gyinder gauge Dialingicator| Dye penatrant| Engine une-up tester Gasket scraper Micrometer Magnetic tingor Piston rag compressor ton rng expander Prastgage Precision sraght edge Sot brosh Spring ester Vave spring Stool square ‘vawve spring “achomoter Thermometer Torque wrench Valve seat cutor Voblock Verniar calipersPP-7 PREPARATION ENGINE MECHANICAL SSM (Special Service Materials) ‘08876-0008 Sea) Packing Black or equivalent (Firs) ‘08826-00100 Seal Packing 12528, ‘Wate’ temperature wonder gauge THREE BOND 12628 of egunalent (Pe) (08833-00070 Adhesive 1324 Fiywheo) THREE BOND 1924 or equiva Drive patePP-8 PREPARATION —_TURBOCHARGING TURBOCHARGING SST (Special Service Tools) F TST aanadTatachane Pasar Gane ee Qo TURBOCHARGERPREPARATION —_TURBOCHARGING RECOMMENDED TOOLS, BS ‘09082-00040 TOYOTA Ewcvical TesterPP-10 PREPARATION —_TURBOCHARGING. EQUIPMENT - Dia indicator Protractor ‘Steet square “Torque wrenchPPL PREPARATION ~ EMISSION CONTROL EMISSION CONTROL RECOMMENDED TOOLS ‘09082-00040 TOYOTA Electieal Testo:Ppa2 PREPARATION —__EWISSION CONTROL EQUIPMENT IMITYVAG (Hand-held vacuum tester Torque wrench Vacuum gaugePP-13 PREPARATION — ELECTRONIC CONTROL DIESEL ELECTRONIC CONTROL DIESEL RECOMMENDED TOOLS (9082-00) TOYOTA Estes TesierPP-14 EQUIPMENT PREPARATION — ECTRONIG CONTROL DIESEL. 19 mm deep socket wrench 22mm doop socket wrench (08D # ean 100! Torque wrench ‘Vacuum gaugePREPARATION —_ ENGINE FUEL ENGINE FUEL SST (Special Service Tools) PPS es ‘09528-64010 Foe! Fiter Wiende (9023-12700 Unien War Wench 7mm (09023-12900 Union Nur Wrench 18mm Ste "99092-00242 Turbocharger Prosure GaugePP16 PREPARATION — ENGINE FUEL RECOMMENDED TOOLS ‘09082-00040 TOYOTA Eleaiica TesterPP-17 PREPARATION — ENGINE FUEL EQUIPMENT “Torave wrench (QD I scan too!PP-18 COOLING SST (Special Service Tools) PREPARATION COOLING. MIE 22 (05230-01010 Aadater Service Tool Sar oo GPO TRADIATOR (09231-14010 Puneh & | RADIATORPP-19 PREPARATION ~ COOLING RECOMMENDED TOOLS | ‘05082-00040 TOYOTA Electrical TesterPP-20 EQUIPMENT Heater PREPARATION - COOLING Radiator cap tester ‘Thermometer “Torque wrench Vernier calipersPREPARATION ~ COOLING. PP-21 tern Capaciy (Ciassiication| Engine coolant “Toyota Long Lite Coolant or equivalent \Ww/ Rear heater MW | 10.5 ers (11.1 US als, 92 imp. ats) AT | 1.0 ers (11-8 US als, 9.7 imp. ats) wie Power heater BS 95 Iters (10.0 US als, 84 Imp. qs) 10.0 ters (10.6 US q's, 88 Imp. as)Pp22 PREPARATION — LUBRICATION LUBRICATION SST (Special Service Tools) 7 {09032-00100 01 Pan Seal Cuter OL PUMP (09228-10002 OW Fier Wrench ‘Ol AND FILTERPP-23 PREPARATION ~_ LUSRICATION RECOMMENDED TOOLS E (HOA0-OOOIT Henagen Wench Set es — Se HY Se T VSPP-24 PREPARATION _LUSRIGATION EQUIPMENT ‘Gilpressu'e gauge Torque wrenchPP25 PREPARATION — LUBRICATION LUBRICANT tom Capacity Ciasstication Engine of API grade OF-4 ry fi 75ers (7.9 US dfs, 66 Imp. ats) (You may also use API CF or E or CO) Drain and refi -wOilfiter change 7.0 ors (7.4 US als, 62 mp. ats) wo Oititer change 6.4 ers (6.8 US ote, 5.6 Imp. ats)PP-26 PREPARATION — LUBRICATION SSM (Special Service Materials) ‘8876-00080 Seal Packing Black er equivalent (FiPo) Oi pump Oilpan (08833-00080 —_Achesve 1944 THREE BOND 1244 LOGTITE 282 oF equivatont (il pressure ewichPP-27 PREPARATION — STARTING STARTING SST (Special Service Tools) Ls (09950-60010 Replacer Ser T Soteeeene sO | © (09951-00380) Replacerse ‘rush heerPP-28 PREPARATION — STARTING. RECOMMENDED TOOLS ‘5082-004 TOYOTA Elccical TesterPP-29 PREPARATION ~_ STARTING EQUIPMENT Dial indicator Commutator 98008 Sandeaper Commute varie calipers Commutator Brush Terque wrench V-block VisoPP-30 PREPARATION — CHARGING CHARGING SST (Special Service Tools) T Rotor rear bearing cover 7 Puter oe one Rep (ee 2 q 3 (09820-00021 ‘Aerator Rea Bearing Puller ; (09820-00030 “venalor Rear Beating ReplaceePP-31 PREPARATION — CHARGING RECOMMENDED TOOLS ‘09082-0004 TOYOTA Electical TesterPP-32 EQUIPMENT ‘AmmeterA) PREPARATION — CHARGING Battery specific gravy gauge. Torque wrench Except maintenance-free bavery Verner calipers Rotor (Sip ring)SERVICE SPECIFICATIONS STANDARD BOLT... cee Sst ENGINE MECHANICAL ....... ss S84 TURBOCHARGING sites SSO EMISSION CONTROL cesses SSH ELECTRONIC CONTROL DIESEL ......... SS-13 ENGINE FUEL . cece SSE COOLING... cee SS-17 LUBRICATION ......... ss-19 STARTING cesses cere sS-21 CHARGING cect, $823SERVICE SPECIFICATIONS —_STANDARO BOLT STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt —____——__ Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt oN OO Ofte one oO wiWasherSs-2 SERVICE SPECIFICATIONS STANDARD BOLT | ‘Specified torque, clas | ane rch Tnapneaa Tape igs bat Regen | tem 3 7 3 ener | 6 oat 3 1s ee Bw te mf mt ar 12 1.25 47 480 35 53 540 39 " 3 mw fm aw ' 3 nro 8s : : ¢ 7 ow | 8 3 us es | sme ts o is em » |e mw B oT 12 1.25 59 600 43, 85 670 48 Pa is oo | mom ts ts wo wo | : " 3 7 2 ene | 8 Tem : us ee ee ee fw i som » | # ww 2 ® 12 1.25 n 730 5a 80, 810 59 “ ‘3 mo utes 6 ts mio | ° : 3 7 so rr 3 1s mf mt ~{ . B mom « | & 9 © 2 i & | ats sam ‘ 1 ne ts is eo tava | " i ¢ vas a a | is rr ts mo soo | mtao 3 7 # aes oa x | 1B nm st er t ie tena] tate 3 128 a wr | 12 mm) te as foo ms | ste | 8 a 80H rr mm} is oe wo & | 3» om» @ 2 iB tao ne |e topss-3 HOW TO DETERMINE NUT STRENGTH Nate Present Standard Old Standard Hexagon Nut Class Hexagon Nut Cold Forging Nut Cutting Processed Nut an G '5N (4T) No Mar Washer oar Wan Nota QQ XM os 6N ~ © [4 , mien J 8N uN RN *: Nut with 1 or more marks on one side surface of the nut. HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas- sification number when tightening parts with a bolt and nut, Example: Bolt = 4T Nut = 4N or moressa SERVICE SPECIFICATIONS — ENGINE MECHANICAL SERVICE DATA ENGINE MECHANICAL Compression pressure Diference of pressure between each cylinder at 250 «pm Minimum 2,700 KPa (27 5kgllem®, 891 pai) or more 2,200 kPa (22.5kgllom?, 320 psi) of more S500 kPa (5.0 kaon?, 71 ps) or less Valve clearance Adjusting shim thickness, at col Intake Exhaust Mare 2525 2550 2575 2600 2625 2650 2675 2700 2725 2750 2775 2800 225 2850 2075 2000 2005 2950 2975 3000 3025 3050 3075 3100 3125 3150 3178. 3200 325 250 3275 3900 (0.20 0:30 mm (0.008 -0.012 in) 0.35 0.45 mm (0014 ~0.018 in) 2.525 mm (0.0984 in) 2.550 mm (0.1004in) 2.575 mm (0.1014in) 2.800 > (0.1024 in) 2.625 mm (0-1088in}) 2.650 mm (0.1043 in) 2675 mm (0.1058in) 2.700 mm (0.1068in} 2.725 mm (0.1078in) 2.760 mm (0.1088 in) 2.775 mm (0.1083in) 2.800 mm (0.1102 in) 2.825 mm (01112in) 2.850 mm (0.1122in) 2.875 mm (0.1182in) 2.900 mm (0.1142in}, 2.925 mm (0.162in) 2.950 mm (0.164 in.) 2.878 mm (0.1171 in) 3.000 mm (0.118 in) 1.025 mm (0.1194 in) 3,050 mm (0.1201 in) 3,075 mm (0.1211 in) 3.100 mm (0.1220 in) 3.128 mm (0.1290in) 3.160 mm (0.1240 in) 3.178 mm (0.125010) 3.200 mm (0:1260in) 3.225mm(0.1270in) 8.250 mm (0.1280 in) 8.275 mm (0.1288 in) 23.300 mm (0.1269n) Idle speed = (850 — 750 rom Maximum speed _|— 4500 ~ 4,700 pe Timing bet tansionar Protrusion from housing end 8.1-8.8mm (0319-0.350in.) Timing gear Idier gear trust clearance Idler goar inside diameter Ioler gear shat diameter Inler gear oil ewarance Gear backdash SID Maxim sro Maximum sto Maximum 0.08 ~ 0.11 mm (0.0024 0.0043 in} 0.30mm (00118in.) {44,000 ~ 44,025 mm (1.7323 ~ 1.7333 in) 43.955 ~ 43.990 mm (1.7905 ~ 1.7319 in 0.010 0.070 mm (0.0004 ~0.0028 in 0.20 mm (0.0079 in) 0.02 0.15 mm (0.0008 -0.0060 in) 10.20 mm (0.0079 in)SERVICE SPECIFICATIONS — ENGINE MECHANICAL, Ss-5 Cyindernead | warpage (0.18 mm (0.0059in) Valve seat Felacing angle Ywiaka |25°, 45°, 70" Exhaust | 25°, 48°,75° Contacting angle 4s Contacting width Intake | 1.21.6 mm (0.047 ~0.0631n3, Exhaust | 1.6—2.0 mm (0.083 -0.078 in) Valve guide bushing bore ameter TO | 10.985 ~ 11.008 mm (0.4325 ~0.43331n 018 00 } 11.038 ~ 11.056 mn (0.4344 - 0.4953 in) Cylinder head bot outer diameter st0 | 11.8~120 mm (0.485~0.472in) Minimum | 11.6 mm (0.457 in.) Now eyindor head gasket thickness ‘A 0:60-0:90 mm (0.0815 ~0.0354 in 8 | 0.85 ~0.95 mm (0.0835 ~0.0374 in) 6 | 0.90 ~ 1.00 myn (0.0354 ~0.0394 in.) | 0:95 —1.05 mm (0.0874 —0.0813 in) E | 1.00~1.10 mm (0.0394 ~0.0843 in) Valve guide Inside diame {6.010 ~ 6.090 mm (0.2368 -0.2374 in) Bushing (Outside diameter for repr part STD | 11.039 - 11.044 mm (0.4344~ 0.4110 in) 018 0005 | 11.083 ~ 11.094 mm (0.4969 - 0.4968 in) vave Valve overal length ‘STD take | 105.18 ~ 105.75 mm (4.1998 — 4.1694in) Exhaust | 105.02 ~ 105.62 mm (4.1346 4.1583 in Minimum intake | 104.65 ram (4.120 in.) Exhaust | 104.52 mm (4.1150in.) ‘Stem diameter Intake | 5.970 ~5.985 mm (0.23504 - 0.23568 in.) Exhaust | 5.980 ~5.975 mm (0.23465 ~ 0.23524 in) ‘stem oll clearance STD Intake | 0.025 ~0.080 mm (0.0010 0.0024 in) Exhaust | 0.035 ~0.070 mm (00014 ~ 0.0028 in) Maximum intake | 0.08 mm (0.003 in.) Exhaust | 0.10 mm (0.0039 in.) Margin thickness ‘STD Intake | 1.1 mm 0.083.) Exhaust | 1.2mm (0.047 in} Minimum intake | 0.6 mm (0.023 in) Exhaust | 0.7 mm (0.027 in) ‘Valve sexing | Deviation Maximum | 20 mm (0.079 in) Freslengin Paint color uo | 46.8 mm (1.843) None | 46.5 mm (1.831 in) Installed tension at 98.1 mm (1.903in.) Paint color ive | 149.9 166.1 N(15.9- 16.9 Kgl, 93.7 -97.4 In) None | 150.2~ 16581 (159-189 kal, 93.8-37.3 bh) Valve iter (ylinder head iter bore diameter ‘31.000 31.021 mm (1.22047 ~ 1.22190in) Liter damoter 30 986 ~ 30.976 mm (1.21913 ~ 1.219531.) Oil clearance TD | 0.024 ~0.055 mm (0.00098 - 0.00217 in Maximum | 0.08 mm 0.003" in) Camshat Thwust dearance 0.038 — 0.185 mm (0.00138 0.00728 in) Journal oil clearance STD | 0.025 ~0.082 mm (0.0010 - 0.0024 in) Maximum | 0.08 mm (0.0031 in) Journal hametor 27.969 ~ 27,985 mm (1.1011 ~ 1.1018 in) Circle cunut| Maxirnum | 0.08 mm (0.0012 In.) (Cam lobe height STD Intake | 47.180 ~ 47.280 mm (1.85748 — 1.86141 in) Exhaust | 48.070 — 48.170 mm (1.89252 ~ 1.89645 in) Minimum intake | 46.78 mm (1.8409 in) Exhaust | 47.65 mm (1.8760 in) Camshaft gear backlash STD | 0.035 -0.185 mm (0.00138-~ 0.00728 in) Maximum ] 0.389 mm (0.00784 in.) Manifold warpage ‘Maximum [0.4 mm (0,018 indsso tao) osmcatioam oamascsosrey via) aromeneros No.1 Bearing inside iameter No.2 Bearing inside diameter No.8 Bearing inside ciameter No.1 journal dameter No.2 journal dameter No. journal dameter 42.000 ~ 42,020 mm (1,8535~ 1.6543 in.) 141.000 ~ 41.020 mm (1.6142~ 1.6159 in.) 32.000 ~31.020 mm (1.2598 1.2608 in.) 41.941 ~ 41,960 mm (1.6512 1.6520in.) 449.931 ~ 40,950 mm (1.6115 ~ 1.6122 in) 31,941 ~31,960 mm (1.2575 1.2583 in.)SERVICE SPECIFICATIONS. ENGINE MECHANICAL ss7 Connecting rad "Trust clearance sto Maximum Connecting rod oll clearance sto Maximum Connecting rd bearing canter wal ‘STD Mark 2 thickness (Reterence) Mark 3 Mark 4 Mack S Mark 6 Rodbend Maximum per 100 rim (3.94 in.) Rod ist Maximum par 100 mm (3.96 in) Bushing inside diamator Piston pin diametor (0.10 — 0.90 mn (0.0039 — 0.01185) 0.40 mm (0.0187 in) 0.06 ~ 0.084 mm (0.0014 -0,002 in.) (0.10 mm (0.00389 in) 1.486 ~ 1.489 mm (0.0585 ~ 0.0586 in.) 1.489 ~ 1,492 mm (0.0886 —0.0587 In.) 1.492 ~ 1.485 mm (0.0587 ~0.0589 In} 4495 ~ 1.498 mm (0.0589 ~ 0.0590 in 1.498 ~ 1.40% rom (0.0590 ~ 0.0591 in) 0.03 mm (0.0012 in) 0.15 mm (0.0089 in.) 34,012 ~34.024 mm (1.83905 ~ 1.93952 in.) £33,996 ~ 34.008 mm (1.99642 — 1.99889 in) Piston pin oll earance TD | 0,012 ~0.020 mm (0.00047 ~0,00079 in.) Maximum {0,03 men (0.0012 in) Connecting od bat tension potion giameter 70 | 8500-8600 (0.3346 - 0.2988 in) Minimum | 8.30 mm (0:3268 in) ‘Crankshaft Thus sarance ‘STD [0.040 ~ 0.240 mm (0.0016 0.0084 in Maximum | 0.20 mm (0.0118 in.) ‘Thiust washer thickness STD (STO) | 2.430 ~2.480 mm (0.0957 - 0.0976 in) (US 0.285 | 2.585 ~ 2.605 mm (0,106 -0.1026 in.) (US 1.125) | 2.498 ~2.543 mm (0.0981 ~0.1001 In} Main journal ollclearance STO (STD) | 0,036-0.054 mm (0.0014 ~ 0.0021 in) (UIS 0.28 ara US 0.50) | 0.037 —0.077 mm (0.0015 - 0.0088 n.) Maximum | 0,10 mm (0.0039 in.) Main journal diameter STD Mark 1 | 69.994 ~ 70.000 mm (27587-27559 in.) Mark 2 | 89.988 ~ 68,994 mm (2.7554 ~ 2.7567 in} Mark 3 | 68.982 ~ 69.988 mm (2.7852 ~ 2.7554 in) Main beating center wall hicknass (Reference) STD Mark2 | 2.482 2.485 mm {0.08772 ~0.08783 in) Mark } 2.485 ~ 2.488 mm (0.09783 ~ 0.08795 in) Mark | 2.488 ~ 2.491 mm (0.09786 ~ 0.08807 in.) ‘Mark 5 | 2.491 ~ 2.494 mm (0.09807 -0.08813in ) Mark 6 | 2.494 - 2.487 mm (0.09819 ~ 0.08831 in.) Crank pin diameter 'S¥O Mark 5 | 58.984 59.000 mm (2.3228 ~ 2.3228 in) Mark2 ) 8.988 ~ 58.994 mm (2.3224 ~ 2.3226 in) Mark 3 } 58.982 ~ 58,988 mm (2.3221 ~ 2.5224 in) Cirle runout Maxims | 0.06 mm (0.0024 in.) Main journal taper and out-ot-round Maximum | 0.002 mm (0.0008 in.) ‘Crank pin taper ans aut-ot-round Maximum | 0.002 mm (0.0008 in.) Main bearing cap bot outer careter TD Maxienum 13.500 ~ 14,000 mm (0.6315 ~ 0.5512 in) 12.60 mm (0.4961 in)SS-8 SERVICE SPECIFICATIONS ENGINE MECHANICAL TORQUE SPECIFICATION ere ii icra = = mSERVICE SPECIFICATIONS — TURBOCHARGING SERVICE DATA TUREOCHARGING, sso [Turbocrarger Turbocharging pressure “Turbine shatt anal play “Turbine shatt racial play 205 kPa (2.1 kglom®, 15.6 ps) 0.18 mm (0.0083 in) 0.13 mm (0.0081 in) ‘Step motor Rod stoke 11 = 0.03 mm (0.43 = 0.0012in) Compensate reeistor Resistance Mark 21a—2280 285-303. 972-2980 472-502 600-638. 763-81. 989- 1,051 0 1.290 1,370.0 1727-160