Manual-Book-Kijang-Inova-Diesel (Google Tranlated Indonesian To English)

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

Repair Manual Quality Report
Dear. :
PT. ASTRA TOYOTA MOTOR,
National Service Division, Training Department Jl. South
Motor Style No. 5 North Jakarta 14330 Fax No. 021-6521363
Phone. No. 021-6515551 extension 2902
Date. be made
N ame
Dealer Reporting
Subject
N ame
Description
Problem
No. Publication
U Sulan Repair

PREPARATION
MACHINE CONTROL SYSTEM ,,,,,,,,,,,,,,, 02-1

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-1
FUEL ,,,,,,,,,,,,,,,,,,,,,,,,,, 02-2

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-2
CONTROL EMISSI ,,,,,,,,,,,,,,,,,,,,,,, 02-5

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-5
INTAKE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-6

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-6
MECHANICAL MACHINES ,,,,,,,,,,,,,,,,,,,,,, 02-7

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-7
EXHAUST ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-12

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-12
COOLING ,,,,,,,,,,,,,,,,,,,,,,,,,, 02-13

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-13
lubrication ,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-14

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-14
IGNITION ,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-17

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-17
START & FILLING ,,,,,,,,,,,,,,,,,,,, 02-18

PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-18

02-1
PREPARATION -- MACHINE CONTROL SYSTEM
PREPARATION MACHINE CONTROL

0246K - 01
SYSTEM
Recommended Tools
09082-00040 TOYOTA Electrical Tester SFI SYSTEM (ENGINE 1TR - FE) SYSTEM
TOYOTA electrical tester ECD (MACHINE 2KD - FTV)
(09083-00150) Test Lead Set SFI SYSTEM (ENGINE 1TR - FE) SYSTEM
ECD (MACHINE 2KD - FTV)
Equipment
Radiator cap tester - Tester radiator cap
Service wire harness - harness Wire service Torque wrench
- Key Moments

02-2
PREPARATION -- FUEL
FUEL PREPARATION
0246E - 01
SST
09023-12701 Union Nut Wrench 17 mm INJECTOR ASSY (MACHINE 2KD - FTV)

Union nut key 17 mm SUPPLY PUMP ASSY (MACHINE 2KD - FTV)
COMMON RAIL ASSY (MACHINE 2KD - FTV)
09213-58013 Pully Crankshaft Holding Tool SUPPLY PUMP ASSY (MACHINE 2KD - FTV)
Retaining tool Puli Crankshaft
09268-41047 Injection Measuring Tool Set Tool Set FUEL SYSTEM (ENGINE 1TR - FE)
Pengkur Injection
(09268-41091) NO.7 Union FUEL SYSTEM (ENGINE 1TR - FE)

Union # 7
(09268-41110) Adapter FUEL SYSTEM (ENGINE 1TR - FE)
(09268-41120) 3 Way FUEL SYSTEM (ENGINE 1TR - FE)

3 Directions
(09268-41300) Clamp FUEL SYSTEM (ENGINE 1TR - FE)

Clamp
(95336-08070) Hose FUEL SYSTEM (ENGINE 1TR - FE)

Slang
09280-00010 Bolt Bolt Inspection Inspection INJECTOR ASSY (MACHINE 2KD - FTV)
Union Union
09330-00021 Companion Flange Holding Tool SUPPLY PUMP ASSY (MACHINE 2KD - FTV)
Retaining Tool Companion Flange
09842-30080 Wire "H" EFI Inspection FUEL SYSTEM (ENGINE 1TR - FE)
Cable "H" Examination EFI
(95333-06030) Hose FUEL SYSTEM (ENGINE 1TR - FE)

Slang

02-3
PREPARATION -- FUEL
09950-50013 Puller C Set SUPPLY PUMP ASSY (MACHINE 2KD - FTV)
(09951-05010) Hanger 150 SUPPLY PUMP ASSY (MACHINE 2KD - FTV)

hanger 150
(09952-05010) slide Arm SUPPLY PUMP ASSY (MACHINE 2KD - FTV)

Slide arm
(09953-05020) Center Bolt 150 SUPPLY PUMP ASSY (MACHINE 2KD - FTV)
Central bolt 150
(09954-05021) Claw No. 2 SUPPLY PUMP ASSY (MACHINE 2KD - FTV)

Nails No. 2
09992-00242 Turbocharger Pressure Gauge INJECTOR ASSY (MACHINE 2KD - FTV)
Turbocharger pressure gauge
Recommended Tools
09082-00040 TOYOTA Electrical Tester FUEL SYSTEM (ENGINE 1TR - FE) FUEL
TOYOTA electrical tester SYSTEM (ENGINE 2KD - FTV)
(09083-00150) Test Lead Set FUEL SYSTEM (ENGINE 1TR - FE) FUEL
Cable Test Set SYSTEM (ENGINE 2KD - FTV)
SSM
08826-00080 Seal Packing Black or equivalent INJECTOR ASSY (MACHINE 2KD - FTV)
(FIPG)
Seal Packing Black or equivalent (FIPG)
Equipment
Belt tension gauge - Tension Gauge Belt Clip - Clip
Container Dial
indicator
Hexagon wrench (10 mm) - Hexagon keys (10 mm)
Hose - Slang Intelligent
tester II
Measuring flask Press -
Pressing Tool
Radiator cap tester - Tester Close Radiator Service wire
harness - Wire Harness Service
Square Steel - Steel Quadrangle
Service wire harness - Wire Harness Service

02-4
PREPARATION -- FUEL
Stopwatch
thermometer
Torque wrench - Key Moments
Vernier caliper - Term Sorong

02-5
PREPARATION -- CONTROL EMISSI
EMISSI CONTROL
0247D - 01
PREPARATION
SST
09992-00242 Turbocharger Pressure Gauge EGR SYSTEM (ENGINE 2KD - FTV)
Recommended Tools
09082-00040 TOYOTA Electrical Tester EGR SYSTEM (ENGINE 2KD - FTV)
TOYOTA electrical tester
(09083-00150) Test Lead Set EGR SYSTEM (ENGINE 2KD - FTV)
Cable Test Set
Equipment
Hand - held vacuum pump - Hand Torque wrench pumps Vakuum -
Key Moments

02-6
PREPARATION -- INTAKE
INTAKE
0247E - 01
PREPARATION
SST
09992-00242 Turbocharger Pressure Gauge SYSTEM TURBOCHARGER (ENGINE 2KD -

Turbocharger pressure gauge FTV)
Equipment

02-7
PREPARATION -- MECHANICAL MACHINES
MECHANICAL PREPARATION
0246D - 01
MACHINE
SST
09023-12701 Union Nut Wrench 17 mm GAP VALVE (MACHINE 2KD - FTV) PARTIAL
Union nut key 17 mm ENGINE ASSY (MACHINE 2KD - FTV) CAMSHAFT
(MECHANICAL 2KD - FTV) GASKET CYLINDER
HEAD (MACHINE 2KD - FTV)
09032-00100 Oil Pan Seal Cutter CHAIN SUB - ASSY (MACHINE
Seal cutter Bak Oli 1TR - FE) GASKET CYLINDER HEAD (MACHINE
1TR - FE)
09213-54015 Crankshaft Pulley Holding Tool CHAIN SUB - ASSY (MACHINE
Retaining tool Puli Crankshaft 1TR - FE) GASKET CYLINDER HEAD

(MACHINE 1TR - FE) Retainer SEAL REAR
ENGINE OIL (MACHINE 1TR - FE) OIL PUMP
SEAL (ENGINE 1TR - FE) PARTIAL ENGINE
ASSY (MACHINE 1TR - FE)
(91651-60855) Bolt CHAIN SUB - ASSY (MACHINE
Bolt 1TR - FE) GASKET CYLINDER HEAD

ASSY (MACHINE 1TR - FE)
09213-58013 Pully Crankshaft Holding Tool PARTIAL ENGINE ASSY (MACHINE 2KD - FTV)
Retaining tool Puli Crankshaft SEAL POMPAOLI (MESIN2KD - FTV) OIL SEAL
REAR ENGINE (ENGINE 2KD - FTV)
09214-76011 Crankshaft Pulley Replacer SEAL POMPAOLI (MESIN2KD - FTV)

Changing tool Puli Craknshaft
09223-15030 Oil Seal & Bearing Replacer Retainer SEAL REAR ENGINE OIL (MACHINE
Tool Changing Oil Seal & Bearing 1TR - FE) OIL SEAL REAR ENGINE (ENGINE
2KD - FTV)
09223-50010 Crankshaft Front Oil Seal OIL PUMP SEAL (ENGINE 1TR - FE)
Replacer
Changing the tool front crankshaft oil seals
09228-07501 Oil Filter Wrench PARTIAL ENGINE ASSY (MACHINE 2KD - FTV)
Lock Oil Filter
09243-00020 Idle Adjusting Screw Lock Screw MACHINE (1TR - FE)
Wrench Adjuster Idle

02-8
09268-45014 EFI Fuel Pressure Gauge GAP VALVE (MACHINE 2KD - FTV)
EFI Fuel Pressure gauges
(90405-06167) I Union GAP VALVE (MACHINE 2KD - FTV)
09276-75010 Valve Lifter Tool CAMSHAFT (MECHANICAL 1TR - FE)
Valve Lifter Tool
09301-00110 Clutch Guide Tool CHAIN SUB - ASSY (MACHINE
Introduction Tool Clutch 1TR - FE) GASKET CYLINDER HEAD

ENGINE OIL (MACHINE 1TR - FE) PARTIAL
ENGINE ASSY (MACHINE 1TR - FE)
09308-10010 Oil Seal Puller SEAL POMPAOLI (MESIN2KD - FTV)

Oil Seal Puller Release
09330-00021 Companion Flange Holding Tool CHAIN SUB - ASSY (MACHINE
Retaining Tool Companion Flange 1TR - FE) GASKET CYLINDER HEAD

ASSY (MACHINE 1TR - FE) PARTIAL ENGINE
ASSY (MACHINE 2KD - FTV) SEAL POMPAOLI
(MESIN2KD - FTV) OIL SEAL REAR ENGINE
(ENGINE 2KD - FTV)
09608-06041 Inner Front Hub Bearing Cone CAMSHAFT (MECHANICAL 2KD - FTV)
Replacer
Tool Changing Inner Front Hub Bearing Cone
09843-18030 Tacho - pulse Pickup Wire No. 2 1TR MACHINE - MACHINE
2KD FE - FTV
09843-18040 Diagnosis Check Wire No. 2 MACHINE 1TR - FE
09950-50013 Puller C Set CHAIN SUB - ASSY (MACHINE
1TR - FE) GASKET CYLINDER HEAD

(MACHINE 1TR - FE) OIL PUMP SEAL (ENGINE
1TR - FE) PARTIAL ENGINE ASSY (MACHINE
1TR - FE) SEAL POMPAOLI (MESIN2KD - FTV)

02-9
(09951-05010) Hanger 150 CHAIN SUB - ASSY (MACHINE
hanger 150 1TR - FE) GASKET CYLINDER HEAD

2KD - FTV) SEAL POMPAOLI (MESIN2KD -
FTV)
(09952-05010) slide Arm CHAIN SUB - ASSY (MACHINE
Slide arm 1TR - FE) GASKET CYLINDER HEAD

2KD - FTV) SEAL POMPAOLI (MESIN2KD -
FTV)
(09953-05010) Center Bolt 100 CHAIN SUB - ASSY (MACHINE
Central bolt 100 1TR - FE) GASKET CYLINDER HEAD (MACHINE

1TR - FE) OIL PUMP SEAL (ENGINE 1TR - FE))
(09953-05020) Center Bolt 150 PARTIAL ENGINE ASSY (MACHINE 2KD - FTV)
Central bolt 150 SEAL POMPAOLI (MESIN2KD - FTV)
(09954-05021) Claw No. 2 CHAIN SUB - ASSY (MACHINE
Nails No. 2 1TR - FE) GASKET CYLINDER HEAD

2KD - FTV) SEALPOMPAOLI (MESIN2KD - FTV)
(09957-04010) attachments SEALPOMPAOLI (MESIN2KD - FTV)
09950-60010 Replacer Set CHAIN SUB - ASSY (MACHINE
1TR - FE) GASKET CYLINDER HEAD (MACHINE

1TR - FE) SEALPOMPAOLI (MESIN2KD - FTV)
(09951-00300) Replacer 30 CHAIN SUB - ASSY (MACHINE
1TR - FE) GASKET CYLINDER HEAD (MACHINE
1TR - FE)
(09951-00350) Replacer 35 SEALPOMPAOLI (MESIN2KD - FTV)
09950-70010 handle Set CHAIN SUB - ASSY (MACHINE
Handel Set 1TR - FE) GASKET CYLINDER HEAD

ENGINE OIL (MACHINE 1TR - FE) OIL SEAL
REAR ENGINE (ENGINE 2KD - FTV)

02-10
(09951-07100) handle 100 CHAIN SUB - ASSY (MACHINE
Handel 100 1TR - FE) GASKET CYLINDER HEAD

(MACHINE 1TR - FE) OIL SEAL REAR ENGINE
(ENGINE 2KD - FTV)
(09951-07150) handle 150 Retainer SEAL REAR ENGINE OIL (MACHINE

Handel 150 1TR - FE)
09992-00025 Cylinder Compression Check Gauge MACHINE 2KD - FTV
Set
(09992-00121) No. 4 Attachment MACHINE 2KD - FTV
Attachment No. 4
(09992-00211) gauge Assy MACHINE 2KD - FTV
estimator Assy
09992-00242 Turbocharger Pressure Gauge GAP VALVE (MACHINE 2KD - FTV)

Recommended Tools
09040-00011 Hexagon Wrench Set CHAIN SUB - ASSY (MACHINE
Hexagon Lock Set 1TR - FE) CAMSHAFT (MECHANICAL 1TR -
FE)
(09043-20100) Hexagon Socket Wrench 10 CHAIN SUB - ASSY (MACHINE
Hexagon Socket Lock 10 1TR - FE) CAMSHAFT (MECHANICAL 1TR -
FE)
09090-04020 Engine Sling Device CHAIN SUB - ASSY (MACHINE
Lifting Equipment Engineering 1TR - FE) GASKET CYLINDER HEAD

(MACHINE 1TR - FE) PARTIAL ENGINE ASSY
(MACHINE 1TR - FE) PARTIAL ENGINE ASSY
(MACHINE 2KD - FTV)

02-11
SSM
08826-00080 Seal Packing Black or equivalent CHAIN SUB - ASSY (MACHINE
(FIPG) 1TR - FE) CAMSHAFT (MECHANICAL 1TR - FE)
Seal Packing Black or equivalent GASKET CYLINDER HEAD (MACHINE 1TR - FE)
VALVE GAP (MACHINE 2KD - FTV) CAMSHAFT
(MECHANICAL 2KD - FTV) GASKET CYLINDER
HEAD (MACHINE 2KD - FTV) OIL SEAL REAR
ENGINE (ENGINE 2KD - FTV)
08826-00100 "Packing Seal 1282B" THREE BOND 1282B GASKET CYLINDER HEAD (MACHINE 1TR - FE)
or equivalent (FIPG)
"Packing Seal THREE BOND 1282B 1282B or equivalent
08833-00070 "Adhesive 1324" THREE BOND 1324 or equivalent CHAIN SUB - ASSY (MACHINE
Adhesive 1324 THREE BOND 1324 or equivalent 1TR - FE) CAMSHAFT (MECHANICAL 1TR - FE)
GASKET CYLINDER HEAD (MACHINE 1TR - FE)
PARTIAL ENGINE ASSY (MACHINE 1TR - FE)
PARTIAL ENGINE ASSY (MACHINE 2KD - FTV)
SEAL REAR ENGINE OIL (MACHINE 2KD --FTV)
Equipment
Chain block
CO meter
Compression gauge Compression --Pengukur
Deep socket wrench 19 mm - Socket Lock in 19 mm Dial indicator gauge
Feeler
Hexagon wrench (1:27 mm) - Hexagon Key (1:27 mm) Timing chain tensioner (1TR - FE)
Hexagon wrench (10 mm) - Hexagon keys (10 mm)
Injection nozzle tester - Tester injection nozzle Micrometer
Plastigage
Precision straight edge
Press
Radiator cap tester Radiator --Tester Close Rope - Ropes
Timing chain (1TR Engineering - FE)
slide calipers
Spark plug cleaner - Cleaning Busi
Steel square
Tachometer
timing light
Universal engine lifter
vernier caliper

02-12
PREPARATION -- EXHAUST
EXHAUST
0247F - 01
PREPARATION
Equipment
slide calipers

02-13
PREPARATION -- COOLING
COOLING
0247G - 01
PREPARATION
SST
09230-01010 Radiator Service Tool Set RADIATOR ASSY (MACHINE 1TR - FE) RADIATOR
Radiator Service Tool Set ASSY (MACHINE 2KD - FTV)
(09231-01010) overhaul Handle RADIATOR ASSY (MACHINE 1TR - FE) RADIATOR
Handel Overhaul ASSY (MACHINE 2KD - FTV)
(09231-01030) Claw RADIATOR ASSY (MACHINE 1TR - FE) RADIATOR
Nail ASSY (MACHINE 2KD - FTV)
09231-14010 punch RADIATOR ASSY (MACHINE 1TR - FE) RADIATOR
ASSY (MACHINE 2KD - FTV)
Equipment
Belt tension gauge - Belt Tension Gauge Radiator cap tester -
Tester Radiator cap Torque wrench - Key Moments
Coolant 1TR - FE
item Capacity Classification
Use only "TOYOTA Super Long Life Coolant" (Coolant Durable

Super TOYOTA) or similar high quality liquid cooling technology
with long - life hybrid organic acid ethylene glycol based non -
silicate, non - amine, non-- nitrite, and non - borate (liquid cooling
Engine Coolant A/ 7.3 liters (7.7 US qts, 6.4 Imp. Qts)
technology with long - life hybrid organic acid comprises a
TM / T 7.0 liters (7.4 US qts, 6.2 Imp. Qts)
combination of a low phosphate and organic acids)
2KD - FTV
Use only "TOYOTA Super Long Life Coolant" (Coolant Durable

Super TOYOTA) or similar high quality liquid cooling technology
with long - life hybrid organic acid ethylene glycol based non -
silicate, non - amine, non-- nitrite, and non - borate (liquid cooling
Engine Coolant A/ 10.3 liters (10.9 US qts, 9.1 Imp. Qts)
technology with long - life hybrid organic acid comprises a
TM / T 9.0 liters (9.5 US qts, 7.9 Imp. Qts)
combination of a low phosphate and organic acids)

02-14
PREPARATION -- lubrication
lubrication
0246F - 01
PREPARATION
SST
09023-12701 Union Nut Wrench 17 mm POMPAOLI ASSY (MESIN2KD - FTV)

Union nut key 17 mm
09032-00100 Oil Pan Seal Cutter OIL PUMP ASSY (MACHINE 1TR - FE)
Seal cutter Bak Oli POMPAOLI ASSY (MESIN2KD - FTV)
09213-54015 Crankshaft Pulley Holding Tool OIL PUMP ASSY (MACHINE 1TR - FE)
(91651-60855) Bolt OIL PUMP ASSY (MACHINE 1TR - FE)

Bolt
09213-58013 Pully Crankshaft Holding Tool POMPAOLI ASSY (MESIN2KD - FTV)

09223-00010 Cover & Seal Replacer POMPAOLI ASSY (MESIN2KD - FTV)

Changing Tool Cover & Seal
09228-07501 Oil Filter Wrench OIL FILTER SUB - ASSY (MACHINE 1TR - FE)
Lock Oil Filter OIL FILTER SUB - ASSY (MACHINE 2KD - FTV)
09301-00110 Clutch Guide Tool OIL PUMP ASSY (MACHINE 1TR - FE)
Introduction Tool Clutch
09330-00021 Companion Flange Holding Tool OIL PUMP ASSY (MACHINE 1TR - FE)
Retaining Tool Companion Flange POMPAOLI ASSY (MESIN2KD - FTV)
09950-50013 Puller C Set OIL PUMP ASSY (MACHINE 1TR - FE)

POMPAOLI ASSY (MESIN2KD - FTV)
(09951-05010) Hanger 150 OIL PUMP ASSY (MACHINE 1TR - FE)

hanger 150 POMPAOLI ASSY (MESIN2KD - FTV)
(09952-05010) slide Arm OIL PUMP ASSY (MACHINE 1TR - FE)

Slide arm POMPAOLI ASSY (MESIN2KD - FTV)

02-15
(09953-05010) Center Bolt 100 OIL PUMP ASSY (MACHINE 1TR - FE)
Central bolt 100
(09953-05020) Center Bolt 150 POMPAOLI ASSY (MESIN2KD - FTV)

Central bolt 150
(09954-05010) Claw No. 1 POMPAOLI ASSY (MESIN2KD - FTV)

Nails No. 1
(09954-05021) Claw No. 2 OIL PUMP ASSY (MACHINE 1TR - FE)

Nails No. 2 POMPAOLI ASSY (MESIN2KD - FTV)
09950-60010 Replacer Set OIL PUMP ASSY (MACHINE 1TR - FE)
(09951-00300) Replacer 30 OIL PUMP ASSY (MACHINE 1TR - FE)
09950-70010 handle Set OIL PUMP ASSY (MACHINE 1TR - FE)

Handel set
(09951-07100) handle 100 OIL PUMP ASSY (MACHINE 1TR - FE)

Handel 100
Recommended Tools
09090-04020 Engine Sling Device OIL PUMP ASSY (MACHINE 1TR - FE)
Hoisting machine tool
Equipment
Oil pressure gauge - oil pressure gauge Radiator cap
tester - Tester radiator cap
Torque wrench - Key moments
Vernier caliper - Term Sorong
Wooden blocks - Wood Beams

02-16
SSM
08826-00080 Seal Packing Black or equivalent OIL PUMP ASSY (MACHINE 1TR - FE)
(FIPG) POMPAOLI ASSY (MESIN2KD - FTV)
Seal Packing Black or whose quality is commensurate
08833-00070 "Adhesive 1324" OIL PUMP ASSY (MACHINE 1TR - FE)

THREE BOND 1324 or equivalent quality POMPAOLI ASSY (MESIN2KD - FTV)
Lubricants
1TR - FE:
grade Oil 20W - 50 and 15W - 40: API grade SJ or multigrade engine oil SL
10W - 30 and 5W - 30: API grade SJ "Energy - conserving" SL
-- "Energy-conserving" or ILSAC multigrade engine oil
Drain and refill with oil filter change 5.6 liters (5.9 US qts, 4.9 Imp. Qts)
--
without oil filter change 5.3 liters (5.6 US qts, 4.6 Imp. Qts)
charging dry 7.1 liters (7.5 US qts, 6.2 Imp. Qts) --
2KD - FTV:
grade Oil
-- G - DLD1 or grade API CF - 4, CF
Drain and refill with oil filter change 6.9 liters (7.3 US qts, 6.1 Imp. Qts)
--
without oil filter change 6.6 liters (7.0 US qts, 5.8 Imp. Qts)
charging dry 7.4 liters (7.8 US qts, 6.5 Imp. Qts) --

02-17
PREPARATION -- IGNITION
IGNITION
0244A - 01
PREPARATION
Recommended Tools
09082-00040 TOYOTA Electrical Tester IGNITION SYSTEM (MACHINE
TOYOTA electrical Terter 1TR - FE)
09200-00010 Adjust Engine Kit IGNITION SYSTEM (MACHINE
Tuners kit Machine 1TR - FE)
(09857-00031) Spark Plug Gap Gauge IGNITION SYSTEM (MACHINE
Gap gauges Busi 1TR - FE)
Equipment
Spark plug cleaner - Cleaning Spark Plug Torque
wrench - Key Moments

02-18
PREPARATION -- START & FILLING
START & COMPLETION

0247H - 01
PREPARATIONS
Recommended Tools
09082-00040 TOYOTA Electrical Tester SYSTEM START (MACHINE 1TR - FE) SYSTEM
Electrical Terter TOYOTA START (MACHINE 2KD - FTV) HEATING SYSTEM
BEGINNING (PRE-HEATING) (MACHINE 2KD -
FTV)
(09083-00150) Test Lead Set HEATING SYSTEM BEGINNING (PRE-HEATING)
(MACHINE 2KD - FTV)
Equipment
Belt tension gauge - Belt Tension Gauge
Service wire harness - Wire Harness Service Torque wrench
- Key Moments

SPECIFICATIONS SERVICE
BOLT STANDARD ,,,,,,,,,,,,,,,,,,,,,,, 03-1

HOW TO DETERMINE THE POWER OF BOLTS
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-1
Tightening MOMENT THAT PROVIDE FOR BOLTS STANDARD
,,,,,,,,,,,,,,,, 03-2
HOW TO DETERMINE THE POWER MUR
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-3
MACHINE CONTROL SYSTEM ,,,,,,,,,,,,,,, 03-4

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-4
SPECIFICATIONS Tightening MOMENT ,,,, 03-5
FUEL ,,,,,,,,,,,,,,,,,,,,,,,,,, 03-6

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-6
CONTROL EMISSI ,,,,,,,,,,,,,,,,,,,,,,, 03-8

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-8
INTAKE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-10

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-10
MECHANICAL MACHINES ,,,,,,,,,,,,,,,,,,,,,, 03-12

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-12
EXHAUST ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-16

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-16
COOLING ,,,,,,,,,,,,,,,,,,,,,,,,,, 03-18

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-18
lubrication ,,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-20

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-20
IGNITION ,,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-23

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-23
START & FILLING ,,,,,,,,,,,,,,,,,,,, 03-25

DATA SERVICE ,,,,,,,,,,,,,,,,,,,,,,,,,,, 03-25

03-1
SPECIFICATIONS SERVICE -- BOLT STANDARD
BOLT STANDARD
031ZI - 01
HOW TO DETERMINE THE POWER OF BOLTS
type Bolts
Bolt Head Hexagon (Hexagon) Class

bolt Plant bolts Las
Recessed bolt Normal In the recesses Bolts
4 4T
without Signs without Signs without Signs
5 5T
6 6T
with Washer with Washer
7 7T
8 8T
9 9T
10 10T
11 11T
B06431

03-2
032HJ - 01
MO MEN PENG ENCANG AN BOLTS - BOLT STANDARD

Tightening moment Specified
Diameter distance Screw
Class Hexagon head bolts Hexagon flange bolts
(mm)
(Mm) (Mm)
(Mm)
(N · m) (Kgf · cm) (Ft · lbf) (N · m) (Kgf · cm) (Ft · lbf)
68 1 5 55 48 in. · Lbf 6 60 52 in. · Lbf
10 1:25 12.5 130 9 14 145 10
12 1:25 26 47 260 19 29 290 21

4T
14 1:25 74 480 35 53 540 39
16 1.5 115 760 55 84 850 61
1.5 1,150 83 -- -- --
68 1 6.5 65 56 in. · Lbf 7.5 75,175,360,670 65 in. · Lbf
10 1:25 15.5 160 12 17.5 13
12 1:25 32 59 330 24 36 65 26
5T
14 1:25 91 600 43 100 48
16 1.5 140 930 67 1,050 76
1.5 1,400 101 -- -- --
68 1 8 19 80,195,400,730 69 in. · Lbf 9 90,210,440,810 78 in. · Lbf
10 1:25 39 71 14 21 15
12 1:25 110 29 44 32
6T
14 1:25 170 53 80 59
16 1.5 1,100 80 125 1,250 90
1.5 1,750 127 -- -- --
68 1 10.5 110 8 12 120 9
10 1:25 25 52 260 19 38 28 58 290 21
12 1:25 95 530 70 105 590 43

7T
14 1:25 145 970 108 165 1,050 76
16 1.5 230 1,500 166 1,700 123
1.5 2,300 -- -- --
8 1:25 29 300 22 33 330 24
8T 10 1:25 61 620 45 68 690 50
12 1:25 110 1,100 80 120 1,250 90
8 1:25 34 340 25 37 380 27
9T 10 1:25 70 710 51 78 790 57
12 1:25 125 1,300 94 140 1,450 105
8 1:25 38 390 28 42 430 31
10T 10 1:25 78 800 58 88 890 64
12 1:25 140 1,450 105 155 1,600 116
8 1:25 42 430 31 47 480 35
11T 10 1:25 87 890 64 97 990 72
12 1:25 155 1,600 116 175 1,800 130

03-3
031ZK - 01
HOW TO DETERMINE THE POWER MUR
type Mur
Hexagon nut Hexagon nut Old Standards Class

Standard Current Cold Forging Mur Mur Cutting Process
4N
without Signs
5N (4T)
Without Sign (with Washer) Without Sign (with Washer) without Signs
6N
6N
7N (5T)
8N
8N
10N (7T)
10N
without Signs
11N
11N
12N
12N
* : Mur with one or more pins on one side surface of the nut.
B06432
INSTRUCTIONS:
Use the nut of the same number with the classification of the nut or greater strength than the strength classification numbers tighten bolts
during part - part with a bolt and nut. Example: Bolt = 4T
Mur = 4N or more

03-4
SPECIFICATIONS SERVICE -- MACHINE CONTROL SYSTEM
MACHINE CONTROL SYSTEM DATA

032GO - 01
SERVICE
1TR - FE:
throttle body
Standard throttle valve opening percentage of 60% or more
Accelerator pedal position sensor

Standard voltage 0.6 to 1.0 V
Mass air flow meter assy

Prisoners (+ B) - 2 (E2G) on
--20_C (--4_F) at 20_C 13.6 to 18.4 k
(68_F) at 60_C (140_F) 2:21 to 2.69 k
0493 to 0667 k
Camshaft timing oil control valve assy Prisoners

at 20_C (68_F) 6.9 to 7.9 k
Throttle body assy

Prisoners at 20_C (68_F)
2 (M +) - 1 (M--) 5 0.3 to 100
(VC) - 3 (E2) 1.2 to 3.2 k
Engine coolant temperature sensor Prisoners

About - about 20_C (68_F) about 2:32 to 2:59 k
- about 80_C (176_F) 0.310 to 0.326 k
Knock sensor
Prisoners at 20_C (68_F) 120 to 280 k
The combined relay (relay C / OPN)

specified conditions IJ - 8 - The body, the ignition switch ON 10 to 14V
The combined relay (relay MAIN)

2KD - FTV:
Engine coolant temperature sensor Prisoners
at 20_C (68_F) at 80_C 2:32 to 2:59 k
(176_F) 0.310 to 0.326 k
Intake air temperature sensor

Prisoners at 20_C (68_F) 2:21 until 2.69 k
Prisoners crankshaft position

sensor when cold 1,630 to 2,740
when hot 2,065 to 3,225
Camshaft position sensor

Prisoners when cold 835 to 1,400
when hot 1,060 to 1,645
The combined relay (relay EDU)

The combined relay (relay MAIN)


03-5
SPECIFICATIONS SERVICE -- MACHINE CONTROL SYSTEM
032GP - 01
SPECIFICATIONS Tightening MOMENT

1TR - FE:
Part fastened Nm kgf cm ft lbf
Throttle body assy x Intake manifold 10.8 110 8
Intake manifold assy x Cylinder head 30 306 22
Knock sensor x Block cylinders 20 199 14
Stalk accelerator pedal assy x Body 7.5 76 66 in. lbf
ECM x Reinforcement instrument panel 12.5 127 9
ECM x Blower assy 12.5 127 9
ECM x Bracket ECM 3.0 31 27 in. lbf
2KD - FTV:
Diesel throttle body assy x intake air connector 20 204 15
Water pipe cleaner sub - assy No. 2 x Close the cylinder head 20 204 15
Bracket injector driver x injector driver 2.0 20 18 in. lbf
Injector driver X Body 12.5 128 9
ECM Bracket No. 2 x ECM 3.0 31 27 in. lbf
ECM Bracket No. 1 x ECM 3.0 31 27 in. lbf
ECM Bracket No. 1 x Reinforcement 5.5 56 49 in. lbf
ECM Bracket No. 2 x Body 5.5 56 49 in. lbf
A / T:
TCM x Body 12.5 128 9
A / T:
TCM x Reinforcement 12.5 128 9
Stalk accelerator pedal assy x Body 5.0 51 44 in. lbf

03-6
SPECIFICATIONS SERVICE -- FUEL
FUEL DATA
032GQ - 01
SERVICE
1TR - FE:
281 to 287 kPa (2.87 to 2.93 kgf / cm 2 40.8 to 41.7 psi)
The fuel pressure
Fuel injector Prisoners

at 20_C (68_F) 11.6 to 12.4 66 Sampa 77 cm 2 ( 3.9 to 4.7 cu in.) Per 15 seconds to
The injection volume 13 cm 3 ( 0.9 cu in.) Or less 1 drop or less per 12 minutes
The difference between each cylinder fuel
leak
The fuel pump Prisoners

at 20_C (68_F) 0.2 to 3.0
2KD - FTV:
Supply pump (suction control valve) Prisoners
at 20_C (68_F) 1.9 to 2.3
Prisoners
injector at 20_C (68_F) 0.85 until 1:05
Common rail
Prisoners 1-2 2-3 3 k or less
16.4 k or less
Switch warning surfaces specified

conditions 1-2 (ON) 1-2 Below 1 10 k or higher
(OFF)
The fuel filter assy (switch blockage) Prisoners

at 20_C (68_F) Below 1
Fuel temperature sensor Prisoners

at 20_C (68_F) at 80_C 2:21 to 2.69 k
(176_F) 0287 to 0349 k
Supply pump drive shaft pulley thrust Gap

(Thrust clearance) 0:15 to 0:55 mm (0.0059 to 0.0217 in.)

03-7
SPECIFICATIONS SERVICE -- FUEL
032GR - 01

1TR - FE:
Fuel delivery pipe x Cylinder head 8.5 87 75 in. lbf
Fuel delivery pipe x fuel pressure regulator assy 8.0 80 69 in. lbf
The fuel filter assy x Body 8.5 87 75 in. lbf
The fuel tank x Body 61 622 45
Ventilation pipe fixing plate x fuel tank fuel 4.0 41 35 in. lbf
The fuel tank fuel tank x Protector 4.5 46 40 in. lbf
Pipe filling the fuel tank sub - assy x The fuel tank hose to the filling pipe
for hose clamps 4.0 41 35 in. lbf
Evaporation of the fuel tank / vent pipe sub - assy x The fuel tank
1.5 15 13 in. lbf
2KD - FTV:
Bracket hood x Close the cylinder head 18 184 13
Close the cylinder head sub - x Cylinder head assy 9.0 92 80 in. lbf
Clamp holder x Cylinder head nozzles 22 220 16
Plumbing leaks x injector nozzle assy assy hollow screw 16 163 12

bolts union 12.5 127 9.0
The fuel pipe x Injector and Common Rail 35 357 26

for use with SST 32 326 24
Fuel inlet connection x Common Rail and pump supply 35 357 26

for use with SST 32 326 24
Fuel pipe clamps No. 2 x Pipe fuel 5.0 51 44 in. lbf
Pipe leakage nozzle assy No. 2 x Cylinder head SST (check valve) 21 214 16
Air cleaner assy x Body 14 143 10
Reservoir radiator x Radiator assy 5.0 51 44 in. lbf
Oil reservoir x Body 5.0 51 44 in. lbf
Fan shroud x Body 5.0 51 44 in. lbf
X cooling fan Water pump assy 18 184 13
Pumps supply x Nut mounting gear pump supply 64 653 47
Pumps supply x Timing gear case 21 214 16
Flanged camshaft timing pulleys No. 2 x Puli pump drive shaft 31 316 23
Timing belt tensioner x Timing gear case 13 133 10
Close the timing belt No. 1 x Close timing belt No. 2 6.0 61 53 in. lbf
Oil level gage guide x Intake manifold 8.0 82 71 in. lbf
Clamps x fuel inlet pipe 5.0 51 44 in. lbf
Common rail assy x Block cylinders 38 387 28
Pipe leakage nozzle assy No. 2 x Cylinder head check valve 21 214 16
Bolt 13 133 10
Pipe filling the fuel tank sub - assy x Body 19 194 14
The fuel tank / vent pipe sub - assy x fuel tank assy 1.5 15 13 in. lbf
Belt fuel tank sub - assy No. 1 x Body 61 622 45
Belt fuel tank sub - assy No. 1 Left x Body 61 622 45

03-8
SPECIFICATIONS SERVICE -- CONTROL EMISSI
EMISSI CONTROL DATA

032GY - 01
SERVICE
2KD - FTV:
EGR valve Shaft rise
upwards Standard In Vakuum 26.7 kPa (200 mmHg, 7.87 in.Hg)
EGR valve position sensor 1 (VC) to 2 (2E)

custody at 20_C (68_F) 4.0 to 6.0 k
Sensors picked EGR valve 3 (EGLS) to 2 (E2)

custody at 20_C (68_F) fully open 3.9 k
fully closed 1.0 k
VSV to cut EGR Prisoners

at 20_C (68_F) 37 to 44
E - VRV for EGR

Prisoners at 20_C (68_F) 11 to 13

03-9
SPECIFICATIONS SERVICE -- CONTROL EMISSI
032GZ - 01

2KD - FTV:
EGR pipe x Cylinder block, EGR valve 13 133 10
Intake air connector x Intake manifold 20 204 15
Bracket throttle body x Cylinder head, intake air connector 20 204 15

03-10
SPECIFICATIONS SERVICE -- INTAKE
INTAKE
032H0--01
DATA SERVICE
2KD - FTV:
Standard pressure
turbocharger The maximum speed (about - about 4,600 rpm) of 58.5 to 78.9 kPa (0.60 to 0.80 kgf / cm 2 8.5 to
11.4 psi)
Manifold absolute pressure sensor Voltage

T6--2 (PIM) - T6--1 (E2) 4.5 to 5.5 V
The level of pressure E7--28 (PIM) - E8--28 (E2)
Standard -- 13.3 kPa (100 mmHg, 3.94 in.Hg) 0.1 to 0.4 V
-- 26.6 kPa (199 mmHg, 7.85 in.Hg) 0.2 to 0.6 V
-- 40.0 kPa (300 mmHg, 11.81 in.Hg) 0.4 to 0.8 V
Standard 19.6 kPa (0.20 kgf cm 2 2.84 psi) 0.1 to 0.4 V
39.2 kPa (0.40 kgf cm 2 5.69 psi) 0.4 to 0.7 V
58.8 kPa (0.60 kgf cm 2 8:53 psi) 0.7 to 1.0 V
78.5 kPa (0.80 kgf cm 2 11.4 psi) 1.0 to 1.3 V
98.0 kPa (1.00 kgf cm 2 14.2 psi) 1.3 to 1.6 V
Axial motion of the turbine shaft 0:08 mm (0.0031 in.)
Radial motion on the turbine shaft 0:08 mm (0.0031 in.)
Actuators and the operation of the sewer valve without A / C 114 kPa (1:16 kgf cm 2 16.5 psi)

03-11
SPECIFICATIONS SERVICE -- INTAKE
032H1--01

2KD - FTV:
X Exhaust manifold Turbocharger 52 530 38
Turbo oil pipe x Turbocharger Mur 13 133 10
Turbo oil pipe x Block cylinders Bolts 12 122 9
Bolts union 26 265 19
The support is manifold x turbocharger, cylinder block 19 194 14
Water pipe cleaner No. 2 x Intake manifold 20 204 15
Converter exhaust manifold x Turbocharger 26 265 19
Converter exhaust manifold with turbocharger x cantilever cylinder block 24 245 18
Ventilation hose heat insulator x Cylinder head 12 122 9

03-12
SPECIFICATIONS SERVICE -- MECHANICAL MACHINES
MECHANICAL MACHINE
032GS - 01
DATA SERVICE
1TR - FE:
Idle rotation speed 650 to 750 rpm
compression pressure at 250 rpm or more 1,230 kPa (12.5 kgf / cm 2, 178 psi) or more
Minimum 0.88 kPa (9.0 kgf / cm 2, 128 psi) 98 Pa (1.0 kgf / cm 2,
The difference in pressure between each cylinder 14 psi) or less
The concentration of CO 1.5 0.5%
ignition timing TC and CG terminals on DLC3 connected terminals TC and 3 to 7 ˚ BTDC @ idle 0 to 20 ˚ BTDC
CG on DLC3 not connected @ idle
2KD - FTV:
Idle rotation speed 700 to 800 rpm
The maximum rotation speed 4,450 to 4.750 rpm
compression pressure at 250 rpm or more 2,700 kPa (27.5 kgf / cm 2, 391 psi) or more
Minimum 2,200 kPa (22.5 kgf / cm 2, 320 psi) or 500 kPa (5.0 kgf /
The difference in pressure between each cylinder cm 2, 71 psi) or less
slit valve intake 0:20 to 0:30 mm (0.008 to 0.012 in.)

Exhaust 0:35 to 0:45 mm (0.014 to 0.018 in.)
Cylinder head mounting bolt The outer diameter of the outer 11.8 to 12.0 mm (0465 to 0.472 in.)
diameter of minimum standards 11.60 mm (0457 in.)
Gasket cylinder head

New cylinder head gasket thickness ABCDE
0.80 to 0.90 mm (0.0315 to 0.0354 in.)
0.85 to 0.95 mm (0.0335 to 0.0374 in.)
0.90 to 1:00 mm (0.0354 to 0.0394 in.)
0.95 to 1:05 mm (0.0374 to 0.0413 in.)
1:00 to 1:10 mm (0.0394 to 0.0433 in.)
exhaust manifold The maximum crookedness 0:40 mm (0.0157 in.)
intake manifold The maximum crookedness 0:50 mm (0.0197 in.)
Chain tensioner 8.1 bulge to 8.9 mm (0.319 to 0350 in.)

03-13
032GT - 01

1TR - FE:
Part fastened N·m kgf · cm ft · lbf
Hangers machine No. 1 x Cylinder head 42 428 31
Hangers machine No. 2 x Cylinder head 42 428 31
Front engine mounting bracket No. 1 x left cylinder block 51 520 38
Front engine mounting bracket No. Right 1 x Cylinder block 51 520 38
Camshaft timing oil control valve assy x Cylinder head 8.0 82 71 in. lbf
The position sensor crankshaf x Close timing chain 8.5 87 75 in. lbf
Camshaft position sensor x Close timing chain 8.5 87 75 in. lbf
Engine coolant temperature sensor x Cylinder head 20 204 15
Idler pulley sub - assy No. 1 x Cover the timing chain 43 438 32
Pipes by - pass water No. 1 x Cover the timing chain 17.5 179 13
V - ribbed belt tensioner assy x Close timing chain 43 438 32
Compressor mounting bracket No. 1 x Cover the timing chain Bolts B 24.5 250 18
Others 45 459 33
Compressor mounting bracket x Block cylinders 45 459 33
Oil level gage guide x Cylinder head 20 204 15
Exhaust manifold x Cylinder head 41 418 30
Insulating hot exhaust manifold No. 1 x Exhaust manifold 12 122 9
Intake manifold x Cylinder head 25 255 18
Ventilation pipe x Cylinder head 18 184 13
Ignition coil x Close the cylinder head 9.0 92 80 in. lbf
X rear end plate cylinder block 18 184 13
Drive plate & Ring Gear sub - assy x Crankshaft (A / T) 74 755 55
Flywheel sub - assy x Crankshaft (M / T) To - 1 26.5 270 Turn 20 Play

to - 2 Play 90 ˚ 90 ˚ 90 ˚
Engine mounting bracket x Body 38 387 28
Cowl panel sub - assy x Body 8.0 82 71 in. lbf
Kompressor and magnetic clutch x Bracket mounting the compressor 25 255 18
Intakes sub - assy x Bak oil 5.4 55 48
Vane pump assy x Close timing chain 25 255 18
Cables R / B (A / B) x engine room R / B (A / B) 13 133 10
Cables period x Body 13 133 10
Cables period x Block cylinders 31 316 23
Air cleaner x Body 14 143 10
Air inlet connector x Close the cylinder head 8.0 82 71 in. lbf
Chain tensioner slipper x Block cylinders 21 214 15
Chain tensioner assy No. 1 x Block cylinders 10 102 7
Timing chain guide x Cylinder head 10 102 7
Water pump assy x Timing chain 9.0 92 80 in. lbf
Close x Block cylinder timing chain A bolt 36 367 27
Others 21 214 15
Oil sump sub - assy x Block cylinders 26 265 19
Oil sump sub - assy No. 2 x Bak oil sub - assy 9.0 92 80 in. lbf
Drain plug x Bak oil sub - assy No. 2 37.5 382 28

03-14
Oil strainer sub - assy x Bak oil sub - assy 20 204 15
Crankshaft pulley x Crankshaft 260 2,651 192
Close the cylinder head x Cylinder head 9.0 92 80 in. lbf
Camshaft timing gear assy x Camshaft 78 795 58
Close x Cylinder head camshaft bearing A bolt 12 122 9
Others 15.5 158 11
Camshaft timing gear or sprocket x camshaft No. 2 78 795 58
Close the timing chain stoppers x Timing chain 16.6 169 12
Cylinder head x Block cylinders To - 1 39 Play 398 Turn 29 Play
to - 2 to 90 ˚ 90 ˚ 90 ˚
-3 Play 90 ˚ Play 90 ˚ Play 90 ˚
2KD - FTV:
Right engine mounting bracket x Block cylinders 68 694 50
Left engine mounting bracket x Block cylinders 68 694 50
Engine coolant temperature sensor x Cylinder head 20 204 15
Camshaft position sensor x Timing gear case 8.5 87 75 in. lbf
Crankshaft position sensor x Timing gear case 8.5 87 75 in. lbf
Vane pump x Timing gear case 39 398 29
Vacuum pump x Close the timing gear case 21 214 16
Oil level gage guide x Intake manifold 8.0 82 71 in. lbf
Bracket x diesel throttle body air inlet connector 20 204 15
Bracket diesel throttle body x Intake manifold 20 204 15
Diesel throttle body assy x air inlet connector 20 204 15
Bracket vacuum switching valve x air inlet connector 20 204 15
Bracket vacuum switching valve x Intake manifold 20 204 15
X Intake manifold manifold buttresses 19 194 14
The support is manifold x Block cylinders 19 194 14
X water inlet Cylinder head 19 194 14
Compressor mounting bracket No. 1 x Block cylinders 47 479 35
V - ribbed belt tensioner assy x Block cylinders 21 214 16
V - ribbed belt tensioner assy x Water pump assy 21 214 16
Bracket generator x Close the timing gear case 25 255 18
Bracket generator x Generator assy 25 255 18
Exhaust manifold x Cylinder head 40 408 30
Crankshaft pulley x Crankshaft 365 3.722 270
Close the timing belt No. 1 x Close timing belt No. 2 6.0 61 53 in. lbf
Pipe cleaner water sub - assy No. 2 x Cylinder head 20 204 15
Bracket hood x Cylinder head 18 184 13
Right engine mounting bracket x Body 38 388 28
Left engine mounting bracket x Body 38 388 28
X rear end plate cylinder block 8.0 82 71 in. lbf
Compressor cooling compressor assy x Bracket mounting No. 1 50 510 37
Pipe giver x Vane pump pressure 51 520 38
Cable A / B x engine room A / B engine room 13 133 22
Bonnet sub - assy x Hinge bonnet 11.5 117 8.4
Idler pulley timing belt x Block cylinders 35 350 25

03-15
Timing belt tensioner x Block cylinders 13 133 10
Close the timing belt No. 2 x Cylinder head 10 102 7
Close the timing belt No. 2 x Block cylinders 10 102 7
Water hose clamp x Cylinder head 18 184 13
Close bearing x Cylinder head 19 194 14
Camshaft timing pulleys x Camshaft 98 1,000 72
Cylinder head sub - assy x Block cylinders To - 1 85 Rotate 63
to - 2 to Rotate Rotate 867 Rotate Rotate Rotate
-3 90_ 90_ 90_ 90_ 90_ 90_
Rear oil seal retainer x Block cylinder engine Bolts A 13 133 9.6
bolt B 16 163 12

03-16
SPECIFICATIONS SERVICE -- EXHAUST
EXHAUST DATA
032H2--01
SERVICE
1TR - FE, 2KD - FTV:
Spring compressor to exhaust front pipe The minimum length of 40 mm (1:57 in.)

03-17
SPECIFICATIONS SERVICE -- EXHAUST
032H3--01

1TR - FE, 2KD - FTV:
X Turbine Exhaust front pipe outlet elbow 43 438 32
Exhaust pipe Exhaust pipe middle x front 48 489 35
X rear exhaust pipe exhaust pipe middle 48 489 35

03-18
SPECIFICATIONS SERVICE -- COOLING
COOLING DATA
032H4--01
SERVICE
1TR - FE:
Reservoir pressure radiator
cap opening Minimum 74 to 103 kPa (0.75 to 1:05 kgf / cm 2 10.7 to 14.9 psi) 59 kPa (0.6 kgf / cm 2 8.6 psi)
standards
thermostat Forces valve opening temperature of 80 to 84 ˚ C (176 to 183 ˚ F)

the valve at 95_C (203_F) 8.5 (0.33) or more
2KD - FTV:
Reservoir pressure radiator
cap opening Standard 93 to 123 kPa (0.95 to 1.25 kgf / cm 2 13.4 to 17.6 psi) 78 kPa (0.8 kgf / cm 2 11.4 psi)
Minimum
thermostat Forces valve opening temperature of 80 to 84 ˚ C (176 to 183 ˚ F) 10 mm (0.39 in.) Or

the valve at 95_C (203_F) more

03-19
SPECIFICATIONS SERVICE -- COOLING
032H5--01

1TR - FE:
Drain valve stopper cylinder block cylinder block x 25 255 18
X water pump cylinder block Bolt length 87 mm (3:45 in.) 21 214 155
another bolt 9.0 92 79-in. lbf
V - ribbed belt tensioner x Block cylinders 43 439 32
Idler Pulley x Crain case 43 439 32
Oil level your gaug x Cylinder head 20 204 15
Puli fan fan clutch x x Pump water 25 255 18
X Radiator fan shroud 5.0 51 44 in. lbf
Radiator reserve tank x Fan Shroud 5.0 51 44 in. lbf
X water inlet cylinder block 20 204 15
Radiator x Body 12 122 9
Oil cooler x Mur 14.7 150 11
X Pipe cooling the oil cooler 8:34 85 74 in. lbf
Bracket radiator x tank top / bottom radiator 13 133 10
2KD - FTV:
Drain valve stopper cylinder block cylinder block x 8.0 82 71 in. lbf
Vent plug x Radiator 2.0 20 18 in. lbf
X water pump cylinder block 13 133 10
V - ribbed belt tensioner x water pumps, cylinder block 21 214 15
Kompressor A / C x Block cylinders 25 250 18
Puli fan fan clutch x x Pump water 18 184 13
X Radiator fan shroud 5.0 51 44 in. lbf
X Radiator reserve tank radiator, fan shroud 5.0 51 44 in. lbf
Oil reservoir x Radiator, Fan shroud 5.0 51 44 in. lbf
X water inlet cylinder block 13 133 10
Bracket pipe inside / outside the oil cooler inlet water x A/T 13 133 10
Radiator x Body 12 122 9

03-20
SPECIFICATIONS SERVICE -- lubrication
Lubrication DATA
032GU - 01
SERVICE
1TR - FE:
29 kPa (0.3 kgf / cm 2 4.2 psi) or 160 to 490 kPa (1.6 to 5.0 kgf / cm 2, 23 to 71 psi) or more
oil pressure At idle rotation at 3,000
rpm
2KD - FTV:
oil pressure At idle rotation at 3,000 29 kPa (0.3 kgf / cm 2 4.3 psi) or 245 kPa (2.5 kgf /
rpm cm 2, 36 psi) or more
Supply pump drive shaft pulley thrust Gap

(Thrust clearance) 0:15 to 0:55 mm (0.0059 to 0.0217 in.)

03-21
032GV - 01

1TR - FE:
X oil pressure switch cylinder block 15 153 11
Sub oil filter - oil filter assy x Bracket sub - assy 17.2 175 13
x Bak oil drain plug sub - assy No. 2 37.5 382 28
Water pump assy x Close timing chain 9.0 92 80 in. lbf
Close x Block cylinder timing chain A bolt 36 367 27
bolts more 21 214 15
Camshaft position sensor x Close timing chain 8.5 87 75 in. lbf
Strainer oil sub - assy x Block cylinders 20 204 15
Oil sump sub - assy No. 2 x Bak oil sub - assy 9.0 92 80 in. lbf
Crankshaft pulley x Crankshaft 260 2,651 192
Crankshaft position sensor x Close timing chain 8.5 87 75 in. lbf
Pipes by - pass water No. 1 x Block cylinders 17.5 179 13
Idler pulley sub - assy 1 x Cover the timing chain 43 438 32
V - ribbed belt tensioner assy x Close timing chain 43 438 32
Compressor mounting bracket No. 1 x Block cylinders Bolts 24.5 250 18
Bolts B more 45 459 33
Oil level gage x Close timing chain guide 20 204 15
2KD - FTV:
Timing gear case assy x Block cylinders Bolts 13 133 9
Bolts union 16 160 12
Pipe sender Vakuum No. 1 x Timing gear case assy 8.0 82 71 in. lbf
Oil Strainer x Bak oil sub - assy 8.0 82 71 in. lbf
Oil level gage sub - assy x Intake manifold 8.0 82 71 in. lbf
Idle gear No. 1 x Block cylinders 50 510 37
crankshaft position sensor x Timing gear case assy 8.5 87 75 in. lbf
X Puli supply pump shaft pumps 64 653 47
Timing pulleys crankshaft flange No. 2 x Puli pump drive shaft 31 316 23
Vane pump x Timing gear case assy 39 398 29
Cakuum pump assy x Close timing gear case 21 214 16
X Intake manifold manifold buttresses 19 194 14
The support is manifold x Block cylinders 19 194 14
X rear end plate cylinder block 8.0 82 71 in. lbf
Bonnet sub - assy x Hinge bonnet 11.5 117 8.5
Oil cooler oil cooler assy x Close sub - assy 16 163 12
Oil cooler sub - assy x Block cylinders 13 133 10
Idle gear No. 1 x Bolts service 8.0 82 71 in. lbf
Supply pump assy x Timing gear case 21 214 16
The fuel pipe x Injector and Common Rail 35 357 26

For use with SST 32 326 24

03-22
X fuel inlet pipe and pump Common rail supply 35 357 26

For use with SST 32 326 24
Reservoir radiator x Radiator assy 5.0 51 44 in. lbf
Oil reservoir x Body 5.0 51 44 in. lbf
Fan shroud x Body 5.0 51 44 in. lbf
The cooling fan x water pump assy 18 184 13
Right engine mounting bracket x Body 38 388 28
Left engine mounting bracket x Body 38 388 28
Pipe giver x Vane pump pressure 51 520 38
Cable A / B x engine room A / B engine room 13 133 22
Bracket hood x Cylinder head 18 184 13

03-23
SPECIFICATIONS SERVICE -- IGNITION
IGNITION DATA
032DF - 01
SERVICE
plug
Busi recommended Made in DENSO K20HRU11
Cracks electrode standard 1.1 mm (0.043 in.)
Maximum 1.3 mm (0.051 in.)
Prisoners camshaft position

sensor when cold 835 to 1,400
when hot 1,060 to 1,645
Prisoners crankshaft position

sensor when cold 1,630 to 2,740
when hot 2,065 to 3,225

03-24
SPECIFICATIONS SERVICE -- IGNITION
032DG - 01

Busi x Cylinder head 18 184 13
Ignition coil x Close the cylinder head 9.0 92 80 in. lbf
Camshaft position sensor x Plat close timing chain 8.5 87 75 in. lbf
Crankshaft position sensor x Plat close timing chain 8.5 87 75 in. lbf
Compressor mounting bracket 1 x Block cylinders Bolts 25 255 18

Bolts B more 45 459 33
Compressor cooling compressor mounting assy x Bracket 1 25 255 18
Slang sucker sub - assy x Block cylinders 5.4 55 48 in. lbf

03-25
SPECIFICATIONS SERVICE -- START & FILLING
START & FILLING DATA

032GM - 02
SERVICE
1TR - FE:
Starter
Rated voltage and energy spent Characteristics without
load Flow 90 A or less at 11.5 V
Generator
Value expenditure (output) 12 V 80 A
Voltage regulator voltage
setting 13.2 to 14.8 V
2KD - FTV:
Starter (Type 2.7 kW)
Starter (Type 2.0 kW)
Generator
Value expenditure (output) 12 V 80 A
Voltage regulator voltage
setting 13.2 to 14.8 V
Glow plug
Prisoners at 20_C (68_F) Kira - about 0.95

03-26
SPECIFICATIONS SERVICE -- START & FILLING
032GN - 02

1TR - FE:
Starter x Transmission 37 337 27
Terminal 30 x Starter 9.8 100 87 in. lbf
Generator x V - ribbed belt tensioner Bolts A 62 630 46

bolt B 25 254 19
Generator cable x Generator 6.0 61 53 in. lbf
2KD - FTV:
Starter x Transmission 68 693 50
Terminal 30 x Starter 2.7 kW 21 214 15
2.0 kW 10 102 7
Generator x V - ribbed belt tensioner Bolts A 62 630 46

bolt B 25 254 19
Generator cable x Generator 6.0 61 53 in. lbf
Glow plug x Cylinder head 13 133 10
Glow plug connector x Glow plug 2.2 22 19 in. lbf
Mur x Wire harness 2.0 20 18 in. lbf

MACHINE CONTROL SYSTEM
SFI SYSTEM
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 10-1
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-1
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 10-2
EXAMINATION ON - VEHICLE ,,,,,,,, 10-3
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-5
THROTTLE BODY ASSY

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 10-7
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-7
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-8
KNOCK SENSOR
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 10-10
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-10
ECM
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 10-12
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-12
ROD ASSY accelerator pedal

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 10-14
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-14
ECD SYSTEM
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 10-15
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-15
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 10-17
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-19
DIESEL THROTTLE BODY ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 10-21
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-21
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-22
DRIVER INJECTOR
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 10-24
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-24
ECM
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 10-26
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-26
ROD ASSY accelerator pedal

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 10-29
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 10-29

MACHINE CONTROL SYSTEM -- SFI SYSTEM (1TR - FE) 10-1
SFI SYSTEM (ENGINE 1TR - FE) LOCATION

100RX - 01
Combination Meter Assy

F MIL
J / BPanel Instrument Assy (J / B

Side Driver)
DLC3
Fuel pumps
Meter
Pedal Position Sensor) Mass Air Flow (MAF) ECM
Rod Assy Pedal Acceleration (Acceleration

R / B, A / B RuangMesin
F Combined relay
(Unit B: Relay C / OPN, Relay MAIN)
injector
Ignition Coil with Igniter Throttle Body Assy (Throttle Position
Sensor and Motor)
Coolant Temperature Sensor Engine

/ Engine Coolant Temperature
Camshaft Position Sensor (ECT)
knock Sensor
Camshaft Timing Oil

Control Valve Assy
Crankshaft Position Sensor
A94233

10-2
MACHINE CONTROL SYSTEM -- SFI SYSTEM (ENGINE 1TR - FE)
100RY - 01
CHART SYSTEM
The engine control system is controlled by the ECM based on signals - signals from the various sensors.
Acceleration Pedal
Ignition Position Sensor
Battery Power Steering Switch
Switch TekananOli combination meter
MIL
Relay C / OPN
ECM DLC3
Fuel pumps Switch PNP
Camshaft Position Sensor
Camshaft Timing Oil Control Valve
MAF Meter
(Built - in IAT Sensor)
Ignit ion Coil with
Igniter
Air
Motor Control Throttle
Throttle Position Sensor
injector
knock Sensor
Crankshaft Position Sensor ECT sensor
A99419

10-3
100RZ - 01
EXAMINATION OF VEHICLES
1. CHECK THE THROTTLE BODY
(A) Check the sound operation of the motor throttle control.
(1) Turn the ignition switch ON.
(2) When pressing the accelerator pedal position sensor lever, check the sound operation of the motor rotation.
Make sure that there is no friction sound coming from the motor. If there was friction,
replace the throttle body assy. (B) Check the throttle position sensor.
(1) Connect the intelligent tester II to DLC3. (2) Turn the

ignition switch ON.
(3) Under the present data, check that the percentage of opening of the throttle valve (throttle position)
is within the standard value.
Standard throttle valve opening percentage: 60% or more
If the percentage is less than 60%, replace the throttle body assy.
ATTENTION:
When examining the percentage of opening of the throttle valve standard, transmission shift lever must be in position N.
2. CHECK THE PEDAL POSITION SENSOR OR accelerator

(A) Turn the ignition switch ON. under the data now, check that the voltage on the throttle position sensor
is within the standard value.
Standard: 0.6 to 1.0 V
If the result is not as specified, replace the accelerator pedal assy.
3. CHECK THE OIL CONTROL VALVE TIMING CAMSHAFT ASSY
(A) Connect the intelligent tester II to DLC3. (B) Start and
heat the engine. (C) Select Active Test VVT from the menu.
(D) With the engine idling, check the engine rotation when the OCV is operated by intelligent tester II.
Standard:
Condition Specified Condition
VVT system OFF (OCV being OFF) Round normal machine
VVT system ON (OCV being ON) Rough idle or engine off
If the result is not as specified, replace the OCV assy.

10-4
4. CHECK THE COMBINED RELAY (RELAY C / OPN)

(A) Use a screwdriver, remove the 2 nails and remove the relay ga-
of flower of J / B engine room.
INSTRUCTIONS:
Wrap the screwdriver tip with adhesive tape before use.
G34545
(B) Measure the voltage on the relay C / OPN.

Standard:
Combined relay relationship Tester Condition Specified Condition
IJ - 8 - The body Ignition switch ON 10 to 14 V
If the result is not as specified, replace the relay Gabu-ngan.
8 IJ
A99733
5. CHECK THE COMBINED RELAY (RELAY MAIN)

(A) Use a screwdriver, remove the 2 nails and remove the relay ga-
of flower of J / B engine room.
INSTRUCTIONS:
G34545
(B) Measure the voltage on MAIN relay.

IJ Standard:
Combined relay
relationship Tester Condition Specified Condition
IJ - 4 - The body Ignition switch ON 10 to 14 V
4
A99733

10-5
EXAMINATION
100S0--01
Air
1. CHECK THE AIR MASS FLOW (MAF) METER / MASS AIR FLOW
METER
(A) Check the voltage out.
E2 VG +B
E2G (1) Give the battery voltage at terminal 1 (+ B) and
THA
2 (E2G).
(2) Use a voltmeter, connect probe tester positive
(+) To terminal VG, and probe tester negative (-) terminal to E2G.
54321
(3) breathed air into MAF meter, and check

that the voltage fluctuates.
30
If the result is not as specified, replace the MAF meter. (B) Check the IAT
20
sensor.
10
(1) Measure the prisoners between terminal 4 (THA) and 5 (E2).
5 Standard:
3
2
-- 20_C (--4_F) 13.6 to 18.4 k
prisoners k
1 20_C (68_F) 2:21 to 2.69 k
60_C (140_F) 0493 to 0667 k

0.5
0.3 If the result is not as specified replace MAF meter.
0.2
2. CHECK THE OIL CONTROL VALVE TIMING CAMSHAFT ASSY
0.1
(A) Measuring prisoners between terminals.
-- 20 0 20 40 60 80 100 (--4) (32) (68) (104)
(140) (176) (212)
Standard: 6.9 to 7.9 at 20_C (68_F)
Temperatur_C (_F) G35065 If the result is not as specified, replace the OCV assy.
(B) Connect the positive cable (+) battery terminal 1 and ka-
1 2
bel negative (-) terminal 2, and check the movement of the valve.
OK:
Valve
Given the positive battery voltage The valve moves in direction
Positive battery voltage disconnected The valve moves in direction
A99422 ATTENTION:
Make sure that the valves move freely and not be bogged down in any
position.
If necessary, replace the OCV assy.
If the valve is not returned properly for their foreign object, there can be little
leakage of pressure in the direction of the future and will exit the DTC.

10-6
3. CHECK THE THROTTLE BODY ASSY

(A) Measure prisoners on the throttle sensor and the motor control.
Standard:
23456 1 2 (M +) - 1 (M--) 20_C (68_F) 0.3 to 100
5 (VC) - 3 (E2) 20_C (68_F) 1.2 to 3.2 k
If the result is not as specified, replace the throttle body assy.

VC E2 M + M--
A75258
4. CHECK THE TEMPERATURE SENSOR-Ngin early retirement FLUID MACHINE

Standard:
30
About - about 20_C (68_F) 2:32 to 2:59 k
20
About - about 80_C (176_F) 0.310 to 0.326 k
10
If the result is not as specified, replace the sensor.
5
Acceptable ATTENTION:
3
If you check the ECT sensor in the water, keep the terminal dry. Upon
inspection, delete the sensor to dry.
0.5 2
0.3
0.2
0.1 1
-- 20 0 20 40 60 80 100
(--4) (68) (104) (140) (176) (32) (212)
S01196
S01699 Z17274
5. CHECK KNOCK SENSOR

Standard: 120 to 280 k at 20_C (68_F)
G37660

MACHINE CONTROL SYSTEM -- THROTTLE BODY ASSY (MACHINE 1TR - FE)) 10-7
THROTTLE BODY ASSY (MACHINE 1TR - FE)

100S1--01
COMPONENTS
8.0 (82, 82 in. Lbf)
Slang Ventilation No. 2
Air Line Connector Sign
slang Vakuum
10.8 (110, 8)
Slang By - pass Air

No. 2
Motor Control Throttle and Throttle Position

Sensor Connector
Slang By - pass Air
No. 1
z gasket
Throttle Body Assy
N m (kgf cm, ft lbf) : Moment of tightening
z Part that can not be reused

A99428

10-8
MACHINE CONTROL SYSTEM -- THROTTLE BODY ASSY (MACHINE 1TR - FE))
100S2--01
REPLACEMENT
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION:
Wait for 90 seconds after removing the cable from the negative terminal (-) battery to prevent the activation of the airbag.
2. Drain LIQUID COOLING MACHINE

3. OFF THE AIR IN LINE CONNECTORS
(A) Remove the hose Vakuum. (B) Remove the
ventilation hose No. 2.
(C) Loosen the hose clamp and remove the two bolts and air inlet connector.
4. OFF THROTTLE BODY ASSY
(A) Disconnect the throttle control motors and connectors sen-
sor throttle position. (B) Remove the
hose by - pass water.
(C) Remove the 2 screws, 2 nuts and throttle body. (D)
Remove the gasket.
A86829
Bulge 5. PAIRS THROTTLE BODY ASSY

(A) Install a new intake manifold gasket.
INSTRUCTIONS:
Align the ridge on the gasket with the groove on intakemani-fold.
Plot
G36423
(B) Replace the throttle body with two screws and two nuts.
Moment: 10.8 N m (110 kgf cm, 8 ft lbf)
(C) Connect the hose by - pass water into the throttle body. (D) Connect the
throttle control motors and connectors
throttle position sensor.
A86829
6. AIR DUCT CONNECTORS PAIRS SIGN

7. FILLIN LIQUID COOLING ENGINE (See page 16-3)
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

10-9
MACHINE CONTROL SYSTEM -- THROTTLE BODY ASSY (MACHINE 1TR - FE))
9. RESET DO WORK FROM START (See page 01-16) CAUTION:
Some specific system need to in - reset from the beginning after removing and replacing the cable from the negative terminal (-)
battery.
10. COOLING FLUID LEAK CHECK THE ENGINE (See page 16-1)

10-10 MACHINE CONTROL SYSTEM -- KNOCK SENSOR (MACHINE 1TR - FE)
KNOCK SENSOR (MACHINE 1TR - FE)

100S3--01
REPLACEMENT

4. OFF STARTER ASSY (See page 19-7)
5. OFF THROTTLE BODY ASSY (See page 10-8)
6. REMOVABLE INTAKE MANIFOLD
(A) Remove the 5 bolts, 2 nuts, intake manifold and gasket.
A99413
7. OFF KNOCK SENSOR

(A) Remove the sensor connector. (B)
Remove the bolt and sensor.
A99414
8. PAIRS KNOCK SENSOR

On
(A) Install the sensor so that horizontal as ditunjuk-
right in the picture. Then put the bolt.
Moment: 20 N m (199 kgf cm, 14 ft lbf)
10_
Front INSTRUCTIONS:
10_ It is acceptable for the sensor which is 10_ from horizontal.
(B) Connect the sensor connector.

A99415

MACHINE CONTROL SYSTEM -- KNOCK SENSOR (MACHINE 1TR - FE) 10-11
9. INSTALL INTAKE MANIFOLD

(A) Install a new gasket and intake manifold with 5 bolts
and 2 nuts.
A99413
PAIRS 10. THROTTLE BODY ASSY (See page 10-8)

11. INSTALL STARTER ASSY (See page 19-7)
12. POST AIR IN LINE CONNECTORS
15. RESET DO WORK STARTS FROM THE BEGINNING (See pages 01-16) CAUTION:
battery.
16. CHECK THE ENGINE COOLING FLUID LEAK (See page 16-1)
17. CHECK THE THROTTLE BODY FUNCTION
18. HEAT ENGINE

10-12 MACHINE CONTROL SYSTEM -- ECM (ENGINE 1TR - FE)
ECM (ENGINE 1TR - FE)

100S4--01
REPLACEMENT
2. REMOVABLE DRAWER DOOR ASSY
3. OFF ECM
(A) Remove all - 4 connector. (B) Remove the
bolts, 2 nuts and the ECM.
G36414
4. ECM OFF BRACKET NO.1

(A) Remove the two screws and bracket.
G36415
5. BRACKET OFF ECM NO.2

G36416
6. ECM BRACKET INSTALL NO.2

(A) Attach the bracket with the 2 screws.
Moment: 3.0 N m (31 kgf cm, 27 in. Lbf)
G36416

10-13
MACHINE CONTROL SYSTEM -- ECM (ENGINE 1TR - FE)
7. POST BRACKET NO.1 ECM

G36415
8. PAIRS ECM
(A) Replace ECM with screws and two nuts.
Moment: 12.5 N m (127 kgf cm long, 9 ft lbf)
(B) Connect to - 4 connector.
G36414
9. INSTALL DOOR DRAWER ASSY

10. CABLE TO CONNECT THE NEGATIVE BATTERY TERMINAL
battery.

10-14 MACHINE CONTROL SYSTEM -- ROD ASSY accelerator pedal (MACHINE 1TR - FE)
ROD ASSY accelerator pedal (MACHINE 1TR - FE) REPLACEMENT

100S5--01
2. TAKE ROD ASSY accelerator pedal

(A) Disconnect the accelerator position sensor. (B) Remove the 2
screws and rod accelerator pedal.
ATTENTION:
S Do not drop or hit the pedal rod-lerator of action.
S Do not disassemble the accelerator pedal rod.
A99092
3. PAIRS ROD ASSY accelerator pedal

(A) Replace the accelerator pedal rod with two screws.
(B) Connect the accelerator position sensor.
5. RESET DO WORK STARTS FROM THE BEGINNING (See halaman01--16) CAUTION:
battery.

MACHINE CONTROL SYSTEM -- ECD SYSTEM (ENGINE 2KD - FTV) 10-15
ECD SYSTEM (ENGINE 2KD - FTV) LOCATION

100S6--01
Rod Assy Pedal Accelerator (Accelerator

Pedal Position Sensor)
DLC3
ECM
activator injector
R / B, A / B Space Engineering
G34731

10-16
MACHINE CONTROL SYSTEM -- ECD SYSTEM (ENGINE 2KD - FTV)
Throttle Body Diesel

Intake Air Temperature Sensor / IntakeAir
Temperature (IAT) Sensor
CairanPendingin Temperature Sensor Engine /

Engine Coolant Temperature (ECT) Sensor
Crankshaft Position
Sensor
(Ne)
Camshaft Position
Sensor
(G1)
G35066

10-17
100S7--01
CHART SYSTEM
The engine control system is controlled by the ECM based on signals - signals from the various sensors.
Fuel Pressure Sensor
Delimiter Pressure Fuel
Common Rail Assy
Supply
Pump
Assy SCV
injector Assy
Fuel Temperature Sensor
Fuel Crankshaft Position

Sensor
(Ne)
Communities
ECM
Filter Assy Fuel Tank
Camshaft Position
Sensor
(G1)
G37568

10-18 MACHINE CONTROL SYSTEM -- ECD SYSTEM (ENGINE 2KD - FTV)
100S8--01
EXAMINATION ON - VEHICLE
1. PERIKSARODASSY accelerator pedal (the accelerator pedal POSITION SENSOR) (See pages 05-313)
2. CHECK THE COMBINED RELAY (RELAY EDU)

(A) Using a screwdriver, remove the 2 nails and loose relay
combination of J / B. machine room.
INSTRUCTIONS:
Balutlah tip screwdriver with adhesive tape sebelumdigunakan.
G34545
(B) Measure the voltage on the relay EDU.

Standard:
IJ - 8 - Massa body Ignition switch ON 10 to 14 V
8 IJ
A99733
3. CHECK THE COMBINED RELAY (RELAY MAIN)

(A) Using a screwdriver, remove the 2 nails and loose relay
combination of J / B. machine room.
INSTRUCTIONS:
Balutlah tip screwdriver with adhesive tape sebelumdigunakan.
G34545
(B) Measure the voltage on MAIN relay.

IJ Standard:
IJ - 4 - Massa body Ignition switch ON 10 to 14 V
If the result is not as specified, replace the relay Gabu-ngan
4
A99733

10-19
100S9--01
EXAMINATION
1. CHECK THE FLUID TEMPERATURE SENSOR-Ngin early retirement MACHINE

ohmmeter
(ECT)
(A) Measure prisoners between terminals - terminals.
Standard:
30
20
10
5
3
If you check the ECT sensor in the water, keep the terminal - the terminal
remains dry, then remove the sensor to dry.
prisoners k
0.5 2
0.3
0.2
0.1 1
-- 20 0 20 40 60 80 100
(--4) (68) (104) (140) (176) (32) (212)
S01196
Temperatur_C (_F)
S01699 Z17274
2. CHECK THE AIR TEMPERATURE SENSOR IN (IAT)
ohmmeter
Standard: 2:21 to 2.69 k at 20_C (68_F)
ATTENTION:
If you check the IAT sensor in the water, keep the terminal - the terminal
remains dry. After inspection remove the sensor to dry.
10
2
prisoners k
0.5
0.3
0.2
0.1 3
-- 20 0 20 40 60 80 100 (--4) (32) (68)

(104)(140) (176) (212)
Temperatur_C (_F) 30 20 A98859

10-20
3. CHECK THE POSITION SENSOR CRANKSHAFT

Standard:
1-2 Cold 1,630 to 2,740
1-2 Hot 2,065 to 3,225
ATTENTION:
In the above table, the term "cold" and "hot" refers to the temperature of
E34870 the coil. "Cold" means about - about --10 to 50_C (14 to 122_F). "Hot"
means about - about 50_ up to 100_C (122 to 212_F).
4. CHECK THE POSITION SENSOR CAMSHAFT

Standard:
1-2 Cold 835 to 1,400
1-2 Hot 1,060 to 1,645
ATTENTION:
In the above table, the term "cold" and "hot" refers to the temperature of
A64984 the coil. "Cold" means about - about --10 to 50_C (14 to 122_F). "Hot"
means about - about 50_ up to 100_C (122 to 212_F).

MACHINE CONTROL SYSTEM -- DIESEL THROTTLE BODY ASSY (MACHINE 2KD - FTV) 10-21
DIESEL THROTTLE BODY ASSY (MACHINE 2KD - FTV) COMPONENTS

100BZ - 02
Close Machinery Sub - assy No. 1
Diesel Throttle Body Assy
z gasket
connectors
20 (204, 15) 20 (204, 15)
The air hose No. 2

20 (204, 15)
The air hose No. 1

connectors
Water Pipe Cleaner Sub - assy No. 2
N · m (kgf · cm, ft · lbf): Moment of tightening
z Parts that can not be reused.

G36610

10-22
MACHINE CONTROL SYSTEM -- DIESEL THROTTLE BODY ASSY (MACHINE 2KD - FTV)
100SA - 01
REPLACEMENT
2. SHUT OFF MACHINE SUB - ASSY NO.1

(A) Remove the hood from the bracket.
A98879
(A) (B) 3. OFF AIR CLEANER PIPE SUB - ASSY NO.2

(C)
(A) Remove the manifold absolute pressure sensor connector. (B) Remove the
(C)
hose Vakuum of an absolute pressure sensor
manifold. (C) Loosen the
two clamps.
(D) Remove the bolt and remove the pipe together with 2
air hose.
(D)
A98889
4. DIESEL OFF THROTTLE BODY ASSY

(A) Remove the 2 connector.
A98877
(B) Remove the 2 screws, 2 nuts, throttle body and gasket.

5. TIDE DIESEL THROTTLE BODY ASSY
(A) Install a new gasket and throttle body with 2 screws and
2 nuts.
A98878

10-23
MACHINE CONTROL SYSTEM -- DIESEL THROTTLE BODY ASSY (MACHINE 2KD - FTV)
(B) Connect the two connectors.
A98877
(D) (C) 6. PIPELINE POST AIR CLEANER SUB - ASSY NO.2

(B)
(A) Connect the pipe (with two air hoses) and pairs
(B)
bolt.
(B) Tighten - 2nd klemnya.
(C) Connect the hose Vakuum to absolute pressure sensor
manifold.
(D) Connect the manifold absolute pressure sensor.
(A)
A98889
7. MACHINE CLOSE POST SUB - ASSY NO.1

(A) Connect the hood to the bracket.
A98879

battery.

10-24 MACHINE CONTROL SYSTEM -- INJECTOR DRIVER (MACHINE 2KD - FTV)
INJECTOR DRIVER (MACHINE 2KD - FTV)

100SB - 01
REPLACEMENT
2. REMOVABLE DRIVE INJECTOR

(A) Remove the 2 connector. (B) Remove the 2 bolts and
driving the injectors.
A98862
3. INJECTOR DRIVER OFF BRACKET

(A) Remove the 3 screws and bracket mover.
A98863
4. BRACKET INSTALL DRIVER INJECTOR

(A) Attach the drive bracket with 3 screws.
A98863
5. INSTALL DRIVER INJECTOR

(A) Replace the injector drive with 2 screws. (B) Connect to - 2
connector.
A98862

10-25
MACHINE CONTROL SYSTEM -- INJECTOR DRIVER (MACHINE 2KD - FTV)
battery.
8. READING DATA LISTED (See pages 05-266)

10-26 MACHINE CONTROL SYSTEM -- ECM (ENGINE 2KD - FTV)
ECM (ENGINE 2KD - FTV)

100SC - 01
REPLACEMENT
Wait for 90 seconds after removing the cable from the negative terminal (-) battery to prevent the activation of the airbag
2. REMOVABLE DRAWER DOOR ASSY
3. OFF ECM
(A) A / T:
Remove the TCM.
(1) Remove all - 3 connector. (2) Remove the

2 bolts and the ECM.
A98867
(B) Remove the ECM:

(1) Remove all - 4 connector. (2) Remove the
bolts, 2 nuts and the ECM.
A98868
4. ECM OFF BRACKET NO.1

M/T
(A) Remove the 3 screws and bracket.
A/T
A98869

10-27
MACHINE CONTROL SYSTEM -- ECM (ENGINE 2KD - FTV)
M/T
5. BRACKET OFF ECM NO.2
A/T
A98870
M/T
6. ECM BRACKET INSTALL NO.2
A/T
A98870

10-28 MACHINE CONTROL SYSTEM -- ECM (ENGINE 2KD - FTV)
M/T
7. POST BRACKET NO.1 ECM
(A) Attach the bracket with 3 screws.
A/T
A98869
8. PAIRS ECM
(A) Replace the ECM.
(1) Replace the ECM with the bolts and two nuts.
(2) Connect to - 4 connector.
A98868
(B) A / T:
Replace the TCM.
(1) Replace the TCM with 2 screws.

(2) Connect to - 3 connector.
A98867
9. INSTALL DOOR DRAWER ASSY

battery.
12. READING DATA LISTED (See pages 05-181)
13. START MACHINE
CAUTION:
Setelahmengganti ECM, hidupkanmesin and heat with idle rotation until its temperature at normal working temperatures.

10-29
MACHINE CONTROL SYSTEM -- ROD ASSY accelerator pedal (MACHINE 2KD - FTV)
ROD ASSY accelerator pedal (MACHINE 2KD - FTV) REPLACEMENT

100cc - 03
2. TAKE ROD ASSY accelerator pedal

(A) Disconnect the accelerator position sensor. (B) Remove the 2
screws and rod accelerator pedal.
ATTENTION:
S Be - careful not to drop the rod-dal pe accelerator.
S Be - careful janganmembongkar accelerator pedal rod.
A98860
3. PAIRS ROD ASSY accelerator pedal

(A) Replace the accelerator pedal rod with two screws.
(B) Connect the accelerator position sensor.
battery.

FUEL
FUEL SYSTEM COMMON RAIL ASSY

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 11-1 (MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 11-61
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-1 REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-61
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 11-2 FUEL TANK ASSY

ATTENTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-4 (MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 11-65
EXAMINATION ON - VEHICLE ,,,,,,,, 11-7 COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-65
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-9 REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-66
FUEL INJECTOR ASSY
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 11-12
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-12
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-14
FUEL PRESSURE REGULATOR ASSY

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 11-17
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-17
FUEL FILTER ASSY

(MACHINE TR - FE) ,,,,,,,,,,,,,,,,,,,,,,, 11-18
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-18
FUEL PUMPS
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 11-20
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-20
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-21
FUEL TANK ASSY

(MACHINE TR - FE) ,,,,,,,,,,,,,,,,,,,,,,, 11-27
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-27
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-28
FUEL SYSTEM
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 11-33
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-33
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 11-34
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-37
FUEL FILTER ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 11-39
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-39
INJECTOR ASSY
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 11-43
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-43
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-45
SUPPLY FUEL PUMP ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 11-53
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-53
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 11-55

FUEL -- FUEL SYSTEM (ENGINE 1TR - FE) 11-1
FUEL SYSTEM (ENGINE 1TR - FE) LOCATION

1116Y - 01
Ignition Switch Assy Fuel Filter Assy
Fuel Tank
Fuel suction pipe Assy

F Fuel Pump Assy
ECM
Fuel injector Assy

R / B, A / B Space Engineering Fuel Pressure Regulator Assy
F Combined relay
(Unit B: Relay C / OPN, RelayMAIN)
Pulsation damper Pressure
Fuel Assy
A99432

11-2
FUEL -- FUEL SYSTEM (ENGINE 1TR - FE)
1116Z - 01
CHART SYSTEM
Main Pipe Fuel Pulsation damper Pressure

Fuel Assy
Assy
Assy Fuel Delivery Pipe
Fuel Pressure Regulator
Fuel injector Assy
Fuel Filters
valve breakers
Pipe Refueling
Fuel Pump Assy Fuel Tank
A99430

11-3
Sistembahan ECMberdasarkan fuel is determined by the amount of air flow and signals - signals from the various sensors.
I9
A4 MAF Meter ECM
Ignition Switch Assy
30
1 2
+B VG E11
6
E2G 3
AM2 IG2 THA E2
4
E11
INJ
5
E11
5
AM2 IGN F4 Injector No. 1
6 E12
VG
1 2
E11 # 10
BATT P / I
F5 injector No. 2
E11
E2G
5
EFI 5 1 2
E11 #THA
20
F6 injector No. 3 28
1 2 MREL
# 30
relay MAIN
F7 injector No. 4 29
1 2
E11 # 40
FC
12
E12
Relay C / OPN
E12
67 E01 E02
E9
25
E9
4
Fuel F13 38
Suction pipe with Pump & Fuel E12 E1 E2

pumps
Gauge Assy
Battery
A99429

11-4
11170-01
ATTENTION
1. Before working on the fuel system, unplug the negative terminal (-) of the battery.
2. Do not smoke or close to the flame when working on the fuel system.
3. Keep gasoline away from the component to be rubber or leather.
4. EMPTY PRESSURE FUEL SYSTEM WARNING:
S Do not remove the parts of the fuel system until you empty the fuel
system pressure
S Even if you have emptied the fuel pressure, place the fabric
lapdiatas bagianpemasangan part - when you separate the part of
the section to reduce the risk of fuel to spray into you or the engine
room.
(A) Check the DTC (C0210 and / or C0215) before

BA1
do the work described below. If you exit the DTC (see pages 05-417 and
05-423). (B) Remove the front driver's side scuff plates, see page
76-34.
(C) Turn the carpet floor, unplug the connection BA1,
as shown in FIG. (D) Turn on the machine. Once the engine is shut
down,
G35869 turn the ignition switch OFF.
INSTRUCTIONS:
Mungkinakandi - set DTCC0210 / 33 danC0215 / 34 (rear speed sensor circuit).
(E) Check again the DTC (see pages 05-417 and

05-423). If the exit DTC, erase
DTC.
5. FUEL SYSTEM
(A) When the pressure release channel materials
high, gasoline will be overflowing with large numbers. Follow this
procedure.
(1) Empty sistembahanbakar pressure (see hala-
man 4).
(2) Place the container under the point of connection. (3) Remove the fuel
pump pipe (see page
11-28).
(4) Drain the rest of the fuel is in the pipeline
fuel pumps.
(5) fuel pump pipe Untukmelindungi yangdi-
free from damage and contamination, cover with a vinyl bag.
B00679

11-5
RIGHT (B) Take a look at these concerns when it took off and stuffed
the injector. (1)
Do not use back in the ring - O. (2) When installing the ring - O in the
injector, the heart - the heart ja--
FALSE ngan up destroying it in any way. (3) Cover ring - O with grease or
gasoline before
installing it. Do not use engine oil, gear oil or brake fluid.
Ring - New O
A99423
(C) Install the delivery pipe and the injector to the cylinder head, se--
Perti shown in FIG. Sebelummemasang injector, be sure to leave a place
Ring - O
where the fat or fuel delivery pipe touched the ring - O injector.
A99424
(D) Take a look at this concern when removing the pipe connector ba-
han fuel (type fast).
(1) The fuel hose connector types of cover:
Unlock the latch nail by lifting the lid upwards, as shown in FIG.
Slang Fuel cap connector.
A99425
(2) With the fuel pipe clamp types:

Remove the clamps No. 1 the fuel pipe from the fuel pipe
connector.
(3) Check for dirt or mud in the pipe and
around the connector before releasing it. Clean if necessary.
Clamps No. 1
PipaBahanBakar
A99426
(4) If the connector and the pipe sticky, clamp connectors, tap and
nippers drag the pipe to remove the pipe and pull the pipe out. Do not use
any equipment.
(5) Check for dirt or mud on the surfaces of the

Pull
kaan which tighten from the removable pipe. Clean if necessary.
nippers
A62157

11-6
(6) To protect pipes and connectors have in-

Vinyl pockets free from damage and contamination, cover with a vinyl bag.
A99427
(E) Take a look at these concerns when unplugging

the fuel pipe (kind of fast).
(1) Check that no damage or pencema-
ran at the pipe connection (2) Align the axis of the connector and
pressure
wick on
pipe. Press the pipe into the connector until the connector causing
a "click". If the connection has been tight, give a new engine oil at
the end of the pipe.
A71366
(3) Upon completion of the connection, try to pull

untukmemisahkan pipes and connectors and make sure that they
are connected firmly. (4) With fuel pipe clamp types:
Pull
Replace clamps No. 1 the fuel pipe on the connector.
(5) With fuel hose connector types of cover:

Associate locking nail into the connector by pressing down on the
A71366 lid, as shown in FIG.
(6) Check if there is a fuel leak.
6. CHECK THE FUEL LEAK

(A) Check that there are no fuel leaks anywhere in system maintenance setelahmelakukan
fuels (see page 11-7).

11-7
11172-01
Intelligent Tester II 1. Functioning VERIFY FUEL PUMP AND ANY FUEL LEAK.
(A) Prepare intelligent tester II.

(1) Turn the ignition switch ON.
CAUTION: Do not start the
engine.
(2) Press the main switch intelligent tester II ON. (3) Select Active Test and
DLC3
enter the menu - the following menu:
G37661 Powertrain / Engine and ECT / Active Test / Control the Fuel
Pump / Speed.
(B) Check the operation of the fuel pump.
(1) Check the pressure in the inlet connection material ba-
kar of the fuel lines. Check that the sound of the flow of fuel in the
fuel tank could be heard.
If there is no sound, check the combined relay, fuel pump, ECM and wiring
connectors. (C) Check for leaking fuel.
(1) Check that there are no fuel leaks

after treatment systems wherever fuel.
If there is a fuel leak, repair or replace the existing components of fuel leakage.
Slang Fuel No. 1

2. CHECK THE FUEL PRESSURE
Fuel Pipe
(A) Check that the battery positive voltage above 12 V (b) Empty the fuel system
Connector
pressure (see page
11-4).
(C) Unplug this negative terminal (-) of the battery. (D) Purchase a
new fuel pipeline.
Slang fuel No. 1: No. Part 23271--0C010 (e) Cut off the hose and
the fuel pipe connector.
Slang
G35886
(F) Untukmelepaskan connector fuel pipe connected to the fuel filter, jepitlah
nippers and pull the plug.
WARNING:
S Always read the concern (see page 11-4)
pull sebelummelepaskankonektor fuel pipe (kind of fast).
S The fuel pipe may inject fuel as a result of pressure endured the
pinch
A99416 masihada dalampipa. Janganmembiarkan spraying fuel into the
engine room.

11-8 FUEL -- FUEL SYSTEM (ENGINE 1TR - FE)
(G) Install SST (gauge pressure) and the connector pipe ba-
Pipe Fuel han fuel using SST as shown in FIG.
SST (Clip)
SST 09268-41047, 09268-45014 (09268-41250) (h) Remove and
clean all existing gasoline. (I)
Reconnect the negative (-) battery. (J)
SST (Connection - T)
Operate the fuel pump (see step 1 (a)). (K) Measure the fuel
pressure.
Fuel pressure:
SST (Slang)
If the pressure is higher than the specification, replace the fuel pressure
SST (Slang)
regulator.
If the pressure is lower than specification, check the fuel hose-hose and juncture,
Pipe Connector B'Bakar SST fuel pump, fuel filter and fuel pressure regulator. (L)
(Slang)
Start the engine.

(M) Measure the fuel pressure at idle rotation.
A75910 Fuel pressure:
If the pressure is not as specified, check the fuel pump, pressure regulator and /
or the fuel injector. (N) Turn off the machine.
(O) Periksabahwa tekananbahan fuel remain as

determined during 5mn setelahmesindimatikan.
Fuel pressure: 147 kPa (1.5 kgf / cm 2 21psi)
If the pressure is not as specified, check the fuel pump, pressure regulator and /
or the fuel injector. (P) After checking the fuel pressure, release ka-
bel negative (-) battery and remove SST and the fuel pipe connector with
a heart - the heart to prevent the fuel spraying out.
(Q) Reconnect the fuel inlet connection (co-

nektor fuel pipe).
3. LEAK CHECK THE FUEL (See page 11-7)

11-9
11171-01
EXAMINATION
1. CHECK THE FUEL INJECTOR ASSY
(A) Check the injector custody.
(1) Measure prisoners between terminals - terminals.
Standard: 11.6 to 12.4 at 20_C (68_F)
If the result is not as specified, replace the injector assy.
(B) Check the injection of the injector.

K onektor
pressure Regulator WARNING:
PipaB'Bakar
S These tests involve fuel pressure - high and electricity.
SST
S Make every precaution with respect to the safe handling on both
SST components of the fuel and electrical components.
SST
S Perform this test in daerahyangaman, danhindari spark or flame.
injector
A72611
S Do not smoke.
(1) Remove the fuel hose income (konek-
tor the fuel pipe) from the fuel filter. (2) Connect SST (attachment
and hose) to the pipe
fuel.
Slang Fuel No. 1

(3) Purchase a new fuel hose.
Fuel Pipe
Slang fuel No. 1: No. Part 23271--0C010 (4) Cut the hose and
Connector
remove the material pipe connectors
fuel.
Slang
G35886
Fuel Pipe Connector

(5) Connect the SST and the fuel pipe connector to
the fuel pipe. SST
09268-41047
WARNING:
Always read the concern (see page 11-4) before connecting the fuel pipe
connector (type fast).
SST
(Slang)
A74050

11-10
(6) Remove the pressure regulator from the pipeline delivery. (7) Attach the
ring - O to the injector. (8) Connect SST (hose) to the inclusion of materials ba-
pressure Regulator
kar in pressure regulator with SST (union) and 2 screws.
SST (Union) SST 09268-41047 (09268-41110, 09268-41300)

SST (Slang)
(9) Place the injector into the cylinder size.
G35142
(10) Attach the ring - O to the injector. (11) Connect SST (union and hose)
SST (Slang)
to the injectors, and
hold the injector and union with SST (clamp). SST
SST (Union) 09268-41047 (09268-41110, 09268-41300) (12) Place the injector into
Ring - O the cylinder size. INSTRUCTIONS:
SST (Klem) Replace the vinyl pipe from which the injector to spray fuel accommodating.
pipe Vinyl
A99418 (13) Operate the fuel pump (see page
11-7).
(14) Connect SST (cable) to the injector and battery all

longer than 15 seconds, and measuring the volume of injection with
SST
cylinder sizes. Perform tests on each injector 2 or 3 times. SST
09842-30080
Standard:
volume Injection The Difference Between All Cylinders
66 to 77 cm 3 ( 3.9 to 4.7 cu in.)

13 cm 3 ( 0.8 cu in.) Or less
per 15 seconds
A99420
ATTENTION:
Always connect and disconnect the voltage on the battery side, not on the
side of the fuel pump.
(C) Check for leaking fuel.

(1) dalamkondisi above, remove the test probe SST (ka-
bell) from the battery and check for fuel leakage from injector.
Tetesanbahanbakar: 1 tetesataukurangper 12menit
A87750

11-11
2. CHECK THE FUEL PUMP

(A) Check the fuel pump custody.
(1) Using ohmmeter, measure the prisoner between most
minal 4 and 5.
If the result is not as specified, replace the fuel pump assy.
5 4 (B) Check the operation of the fuel pump.

G35143 (1) Circulate the battery voltage to terminal 4 and 5. Perik-
sa that the pump works.
ATTENTION:
S This test must diselesaikandalam10 second injector coil to prevent
the burning and breaking.
S Keep the fuel pump as far as mungkindari battery.
S Always connect and disconnect the voltage on the battery side, not
on the side of the fuel pump.
If the pump does not work, replace the fuel pump assy.

11-12 FUEL -- FUEL INJECTOR ASSY (MACHINE 1TR - FE)
FUEL INJECTOR ASSY (MACHINE 1TR - FE) COMPONENTS

11173-01
8.0 (82, 71 in. Lbf)
Hoses
Entered Channel Connectors Ventilation Air
slang Vakuum
10.8 (110, 8)
Slang By - pass Air

No. 2
Motor Control Throttle and Throttle Position

Sensor Connector Slang By - pass Air
No. 1
Throttle Body Assy z gasket

A99428

11-13
FUEL -- FUEL INJECTOR ASSY (MACHINE 1TR - FE)
12 (122, 9) 12 (122, 9)
Pulsation damper Pressure
Spacer No. 1 Pipe Fuel Assy
Delivery
Delivery Pipe Material BakarSub-- assy
Fuel Pressure Regulator Assy
Slang Fuel No. 1
slang Vakuum
z Ring - O
Fuel injector Assy
Slang Fuel No. 2
z Vibration Insulator injector
spacer
z Ring - O
Clamp wire Harness

G35141

11-14
11174-01
REPLACEMENT
1. EMPTY PRESSURE FUEL SYSTEM (See page 11-4)

4. Slang REMOVE FUEL (See page 11-4)
5. OFF FUEL DELIVERY PIPE SUB - ASSY CAUTION:
Be - careful not to drop the injector when removing the delivery pipe.
(A) Remove the 4 clamps and wire harness from the delivery pipe. (B) Remove
the hose Vakuum.
G35144
(C) Remove all - 4 injector connector. (D) Remove the 2 screws and the delivery
(B)
(C) pipe together - together with
(B)
- 4th injector.
(B)
(C)
(B)
G36024
(E) Using a screwdriver, tipping - 4th out of the cylinder

head.
A87158
6. OFF FUEL INJECTOR ASSY

(A) Pull - 4 injector out of the delivery pipe.
Pull
G34904

11-15
7. INSTALL FUEL INJECTOR ASSY

(A) Install new insulation on the injector. (B) Give a little layer of grease or
gasoline on the ring - O
Ring - O
New
and install a new ring - O to the injector.
New
Penyekat
A99091
(C) Provide a thin layer of grease or gasoline on the spot di-

where the delivery pipe touches the ring - O. (D) To replace the fuel
injector to the delivery pipe
fuel, fuel injector pressure while twisting it back - back and forth
turning
ATTENTION:
S Careful - careful not to twist the ring - O.
S After installing the fuel injector, check that the injector rotates
pressure
A87155 gently. If not, replace the ring - a new O.
(E) Position the injector connector so konektornyameng-

facing down.
8. PASANGPIPADELIVERYBAHANBAKARSUB - ASSY
(A) Attach to - 4 spacers on the cylinder head.
G36023
(B) Connect to - 4 injector connector. (C) Replace the 2 screws and the delivery
(B)
(C) pipe together - together with
(B)
- 4th injector.
(B)
(C) Moment: 12 N m (122 kgf cm long, 9 ft lbf)
(B)
G36024
(D) Connect to - 4 klemdan wire harness to the delivery pipe. (E) Connect the
hose Vakuum.
G35144

11-16
9. Slang CONNECT FUEL

PAIRS 10. THROTTLE BODY ASSY (See page 10-8)
Some specific system need to in - reset from the beginning after removing and replacing the cable negative terminal (-) battery.
13. FUEL LEAK CHECK THE (See page 11-7)

FUEL -- FUEL PRESSURE REGULATOR ASSY (MACHINE 1TR - FE)
11-17
FUEL PRESSURE REGULATOR ASSY (MACHINE 1TR - FE)
11175-01
REPLACEMENT
1. EMPTY PRESSURE FUEL SYSTEM (See halaman11--4)
4. OFF FUEL PRESSURE REGULATOR ASSY
(A) Remove the hose Vakuum. (B) Remove the fuel

hose No. 2.
WARNING:
Put accommodate the appropriate place or rags under the pipe delivery.
(C) 3 Remove the bolt and the fuel pressure regulator.

A99412
5. INSTALL FUEL PRESSURE REGULATOR ASSY

(A) Provide a thin layer of spindle oil or gasoline to the ring - Obaru and install ring - Opada pressure regulator
fuel.
(B) Replace the fuel pressure regulator with three bolts.
(C) Connect the fuel hose. (D) connecting hoses
Vakuum.
6. AIR DUCT CONNECTORS PAIRS SIGN
8. RESET DO WORK STARTS FROM THE BEGINNING (See halaman01--16) CAUTION:
9. LEAK CHECK THE FUEL (See page 11-7)

11-18 FUEL -- FUEL FILTER ASSY (MACHINE 1TR - FE)
FUEL FILTER ASSY (MACHINE 1TR - FE) REPLACEMENT

11176-01

+
3. Slang REMOVE FUEL
pressure
(A) Remove the hose from klemnya. (B)
Pull
Pinch and pull the fuel hose connector to remove it from the pipe above
the fuel filter.
pressure
ATTENTION:
S Check if there is dirt or mud fouling in and around the fuel hose
connector slangbahanbakar. Clean jikaperlu. Kotoranatau sludge
can affect the ability of the ring - O to close the upper pipe
A99133 connectors and fuel filter.
S Do not use the equipment to separate the connector and the pipe
top.
S Do not bend or twist the hose forcibly.
S Keep your connectors and pipes are free of foreign material.
S Put the plug in a vinyl bag to prevent all rusakan and fouling
S If the connector danpipa bagianatas sticky together, flip and swivel

connector with liver - liver to release it.
4. MAIN PIPE REMOVE FUEL

(A) Remove the fuel pipe grommets. (B) Exempt denganmengangkat locking nail
upwards fiancee
tup connectors. Then pinch and pull the plug main fuel pipe to remove it
from the pipe bottom of the fuel filter.
ATTENTION:
pressure pressure
S Periksaapakahada kotoranataupencemaran sludge in the fuel main
Pull A99134 pipe and around the main fuel pipe connector. Clean if necessary.
Dirt or mud can affect the ability of the ring - O to close the
connector and the pipe bottom of the fuel filter.
S Do not use the equipment to separate the connector and the pipe
bottom.
S Do not bend or twist the main pipe by force.

11-19
FUEL -- FUEL FILTER ASSY (MACHINE 1TR - FE)
S Keep your connectors and pipes are free of foreign material.
S Put the plug in a vinyl bag to prevent all rusakan and discoloration.
S If the connector and the pipe at the bottom - the same sticky, flip the
connector danputar denganhati - liver to release it.
5. OFF FUEL FILTER ASSY

(A) Remove the 3 nuts and fuel filters.
A99135
6. INSTALL FUEL FILTER ASSY

(A) Replace the fuel filter with 3 nuts.
7. CONNECT THE MAIN FUEL PIPE CAUTION:
Sebelummemasangkonektor pipautama kepipa bagianatas fuel fuel filter, check for damage to or foreign material in the
connector.
(A) Connect the pipe to the top , pressure both parts together - together firmly until
the sound of a "click". Then attach nail latch on the connector by pressing down on the cap connector.
ATTENTION:
Setelahmenyelesaikan the connection, check whether the connectors and pipes have been connected with the top of the strong
by trying to pull them separately.
(B) Replace the fuel pipe grommets.
8. Slang CONNECT FUEL CAUTION:
Sebelummemasang main fuel pipe connector pipe to the bottom of the fuel filter, pe-Interrogation whether there is damage or
foreign material in the connector.
(A) Connect the pipe to the bottom. pressure both parts together - together firmly until
the sound of a "click".
ATTENTION:
After completing the connection, check whether the pipe connectors and the bottom has been on-again firmly by trying to pull
them separately.
(B) Connect the hose to the clamp.

11-20 FUEL -- FUEL PUMP (ENGINE 1TR - FE)
FUEL PUMP (ENGINE 1TR - FE) COMPONENTS

1116M - 01
pp
Suckers plate Fuel Sub - assy
Suckers buffer Fuel No. 1
Per
Per
z Ring - E
z Ring - O
z Ring - E
Harness Fuel Pumps
Fuel pumps
filter Suckers
Sender Assy Fuel Gage
Close Tank - Fuel Reserves
--Cadangan Fuel Tank No. 1

A99801

11-21
FUEL -- FUEL PUMP (ENGINE 1TR - FE)
1116N - 01
REPLACEMENT
1. OFF FUEL TANK ASSY (See page 11-28)
2. OFF SENDER ASSY FUEL GAGE

(A) Disconnect the fuel sender gage. (B) Press down on the nail to-sender gage
(A) A
labeled A.
mudian sender gage sliding upwards.
Sliding A99812
3. REMOVABLE TANK - FUEL RESERVE NO.1

(A) Remove the fuel pump connector.
A99804
(B) Using a screwdriver, free the nail on the pipe of the knees
bang nails. Remove the pipe from - 2nd klemnya.
clamps
Nails G35043
(C) Remove the lid of the tank - a backup.
(1) Remove the 2 fuel pipes and pumps harness

fuel.
G36667

11-22
(2) Using a screwdriver, free the three nails from the hole
nails and loose tank - fuel reserves.
nail
G36603
(D) Using pliers nose - a pointed, off 2 ring - E. INSTRUCTIONS:
Lower the tank lid slightly - up to release ring--

E.
(E) Remove the 2 per.
Decrease
G36666
(F) Using a screwdriver, free the two nails from the nail hole
and drop tanks - fuel reserves.
ATTENTION:
Do not damage the tank - fuel reserves.
Nail
A99803
4. FUEL PUMP OFF

(A) Using a screwdriver, free the three nails from the nail hole
and remove fuel and filter rakitanpompabahan suckers.
Nail A99805
(B) Remove the fuel pump harness.
A99806

11-23
(C) Remove the ring - O of the fuel pump.
Ring - O
A99808
5. FILTER OFF suckers

(A) Remove the suction filter of the fuel pump.
Fuel pumps
F ilter
Suckers
G35039
6. OFF BUFFER suckers FUEL NO.1

PenyanggaP
engisap fuel
(A) Using a screwdriver, remove two nails from the nail hole
and loose buffer suckers fuel. INSTRUCTIONS:
A99807
7. PAIR BUFFER suckers FUEL NO.1

(A) Relates two nails in the nail holes and plug buffer suckers fuel.

11-24
8. INSTALL FILTERS suckers

(A) Replace the filter suckers to the fuel pump.
Fuel pumps
F ilter
Suckers
G35039
9. INSTALL FUEL PUMP

(A) Replace the fuel pump harness.
A99806
(B) Apply a thin layer of gas in the ring - the new O, and PA-
the ring - O to the fuel pump (c) Relates 3 nail in the nail holes and plug
assemblies
fuel pump and filter suckers
Supporter
Ring - a new O
A99808

11-25
10. PASANGTANGKI - CADANGANBAHANBAKAR NO.1

(A) Relates two nails in the nail holes and attach the tank - ca-
dangan fuel.
G35040
(B) Attach the plate suckers to tank - fuel reserves.

(1) Install 2 per 2nd shaft sucker plate material ba-
kar.
(2) Using a pointed nose pliers, attach 2
ring - the new E at 2 shaft.
Decrease INSTRUCTIONS:
Lower the tank lid slightly - up to install the ring - E.
G36666
(C) Attach the lid of the tank - a backup.

(1) Relates 3 nail in the nail holes and attach the lid
tank - fuel reserves.
Nail
G36603
(2) Connect two fuel pipes and harness pom-

pa fuel.
G36667
(D) Replace the section of pipe to the tank - fuel reserves.

(1) Relates nail on the end of the pipe to the nail hole. PA-
the pipe at 2 clamps on the tank - fuel reserves.
clamps
Nails G35043

11-26
(E) Connect the fuel pump connector.
A99804
11. TIDE GAGE ASSY FUEL SENDER

Sliding
(A) Replace the sender gage to the tank - fuel reserves.
Then slide the sender gage to put her down.
(B) Connect the fuel sender gage.
G36617
12. INSTALL FUEL TANK ASSY (See page 11-28)

FUEL -- FUEL TANK ASSY (MACHINE 1TR - FE) 11-27
FUEL TANK ASSY (MACHINE 1TR - FE) COMPONENTS

1116K - 01
x8
4.0 (41, 35 in.lbf)
Pipe Fuel Tank Filling Sub - assy
Bracket Check Valve
Fuel Evaporation Pipe Sub - assy No. 2
Curved Pipe Fitting Plate Fuel Tank
Clip Connection Pipe

x4
1.5 (15, 13 in.lbf)
Fuel tank with Extra Cover Assy

z gasket
Suction pipe with Pump & Fuel
Gauge Assy
Ventilation pipes Pe
ng u ap an Fuel SlangPernafasan fuel tank
Circuit fuel valve Assy
Tank z gasket
Slang Pipe Fuel Filling keTangki
z Fuel Tank Bearing No

.1 Fuel Tank Assy
Fuel Gauge
Connector
z Fuel Tank Bearing No
.1
Fuel Tank Protector wire Harness
Main pipe Fuel Tank Sub - assy
Inverting pipe Fuel

KlemPipa fuel tank Tank Sub - assy
KlemPipa fuel No. 3 with a grommet

Pin
4.5 (46, 40 in. Lbf)
Sub Band fuel tank - assy Left

Pin
Fuel Tank Band Sub - assy No. 1
Moment of tightening
61 (622, 45) 61 (622, 45)
z Part that can not be reused N · m (kgf · cm, ft · lbf):
G35045

11-33
FUEL -- FUEL SYSTEM (ENGINE 2KD - FTV)
FUEL SYSTEM (ENGINE 2KD - FTV) LOCATION

1117A - 01
DLC3
injector Assy
Fuel Tank Assy
Fuel Supply Pump Assy
Fuel Filter Assy
Common Rail Assy
Control Valves Aspiration
Fuel Temperature Sensor
A98960

11-34
1117B - 01
CHART SYSTEM
With fuel storage at high pressure, common rail system can provide fuel to the fuel injection pressure is stable.
System diagram
Fuel Tank
Control Valves
Supply Fuel Pumps Aspiration
Accelerator Pedal
Position Sensor
Generator
signal
Ignition Switch Signal
delimiter pressure
Starter Signal district.
Common Rail
Vehicle
ECM
DLC3
Battery voltage Fuel Pressure Sensor
Other Signals - 2 relay Communities
Communities EGR Valve Position Sensor
Sensor
Manifold Absolute Pressure
Diesel Throttle Body
VRVuntukEGR
IAT sensor
EGR valve
injector
pump E -
Glow Plug
ECT sensor
Vakuum

relays
GLOW
G34662

11-35
F8 Fuel Pressure Sensor
3
VC
2
PR
S8 1
E2
Control Valves Aspiration
2
BATT
1
E5 +B PCV-- E8
2
E6 ECM
2
E5 MREL 8
MAIN Relay E8
PCV +
10 E5 IREL
28
7
E8 25 E2 E8
IJF I6 INJF
6
Communities Relay
24
IJT # 1 I6 E8 21 1# 1
3 26
23 E8
IJT # 2 I6 E8 #2 PCR1
2
22
IJT # 3 I6 E8 #3
5 18
EFI IJT # 4 I6 E8 #4 VC E8
2
BATT P / I 1
No. 1
4
F4 Injector
2 1 # 1 I5
1
22
3
Communities
INJ # 4 I5
4 1
5
COM1 I5
F7 injector No.
2
GND INJ
INJ # 2 I5
12
No. 2
3 F5 injector
1 F6 Injector No.
INJ # 3 I5
12
6
COM2 I5
1
I6
8
I5 Battery
Battery
G35136

11-36
110M1--03
Intelligent Tester II 1. LEAK CHECK THE FUEL WARNING:
S During the Test Active mode, the engine turns into the combustion
becomes high and loud noise, then be careful - very careful.
S During the Test Active mode, the fuel pressure is high. Be - careful
not to membiarkanmata, hands or your body exposed to the fuel
coming out.
DLC3 A98433
(A) Check that there are no leaks from the mana--

also on the fuel system when the engine has been turned off.
If there is a fuel leak, if necessary, replace the part. (B) At the time of play or start
the engine, check that there is
no leakage from any part of the fuel system.
If there is a fuel leak, if necessary, replace the part. (C)

Remove the tube from the inverting common rail. (D) At the time of
rewinding machine, check the leakage of ba-
kar of inverting pipe.
If there is a fuel leak, replace the common rail (see pages 11-61).
(E) Connect the intelligent tester II to the DLC3. (F)

Start the engine and press the main switch intelligent tester II ON.
(G) Select Fuel Leak test on Active Test mode in intelligent

tester II.
(H) If you do not have intelligent tester II, press the accelerator pedal fully
and quickly. Raise the engine rev up to maximum and maintain the rounds
for 2 seconds. Repeat this operation bebe-rapa times. (I)
Check that there is no leakage from any part of the fuel system.
ATTENTION:
Inverting pipeline leak that is less than 10 cc (0.6 cu in.) Per minute is
acceptable.
If there is a fuel leak, replace the part - the part. (J)
Reconnect slang inverting into the common rail.

11-37
110M2--03
EXAMINATION
1. CHECK THE SUPPLY ASSY PUMP (CONTROL VALVE

Control Valves inhalation)
Aspiration (A) Measure prisoners between terminals - terminal valve.
If the result is not as specified, replace the supply pump assy.
A98438
2. CHECK INJECTOR ASSY

Standard: 0.85 to 1:05 at 20_C (68_F)
2 1
A81503
3. CHECK THE COMMON RAIL ASSY (FUEL PRESSURE SENSOR)
(A) Measure the prisoners on the sensor.
Standard:
relationship Tester Specified Condition
1-2 3 k or less
2-3 16.4 k or less
If the result is not as specified, replace common rail assy.

A62213
4. CHECK THE FUEL FILTER ASSY (SWITCH WARNING HIGH

SURFACE)
(A) Measure the prisoners on the switch.
Standard:
1-2 ON below 1
1-2 OFF 10 k or higher
If the result is not as specified, replace the fuel filter assy.

A98950

11-38
5. PERIKSAFILTERBAHANBAKARASSY (SWITCHPENYUMBATAN)
(A) Measure the prisoners on the switch.
Standard: below 1 at 20_C (68_F)

If the result is not as specified, replace the fuel filter assy.
A98961
6. CHECK THE FUEL TEMPERATURE SENSOR

ohmmeter
(A) Measuring prisoners between terminals - terminals
Standard:
About - about 20_C (68_F) 2:21 to 2.69 k

30
About - about 80_C (176_F) 0287 to 0349 k
20
ATTENTION:
10
If you check the fuel temperature sensor in the water, keep the terminal -
5
Acceptable the terminal remains dry. Upon inspection, delete the sensor to dry.
3
prisoners k
If the result is not as specified, replace sensor.
0.5 2
0.3
0.2
0.1 1
-- 20 0 20 40 60 80 100
(--4) (68) (104) (140) (176) (32) (212)
S01196
S01699
Temperatures ° C (_F) Z17274

11-39
FUEL -- FUEL FILTER ASSY (MACHINE 2KD - FTV)
FUEL FILTER ASSY (MACHINE 2KD - FTV) REPLACEMENT

1117C - 01
INSTRUCTIONS:
When replacing the filter, use original spare parts or equivalent TOYOTA.
2. SHUT OFF FUEL TANK ASSY
3. OFF FUEL FILTER ELEMENT

(A) (A) Remove the clogging sensor connector. (B) Move the clip to release the hose
connected
to the side of the inlet filter.
(C) Connect a hose to the drain valve. Insert the other side
(B)
(C) from the same hose into the shelter. (D) Loosen the drain valve to drain
fuel
as many think - kira50 cc (3.0 cu in.).
A98900
(E) Using a screwdriver as a lever, loosen the nut pe--

ngikatnya until it can be loosened by hand.
A98901
(F) Loosen the fastening nut completely by hand.
A98907

FUEL -- INJECTOR ASSY (MACHINE 2KD - FTV) 11-43
INJECTOR ASSY (MACHINE 2KD - FTV)

110LN - 02
COMPONENTS
The air hose No. 2
20 (204, 15) SlangUdaraNo. 1
18 (184, 13)
Bracket Cover Machine

A98883

11-44
FUEL -- INJECTOR ASSY (MACHINE 2KD - FTV)
9.0 (92, 80 in. Lbf)
x 10
9.0 (92, 80 in. Lbf)
slang Ventilation x2
z Seal nozzle holder

Cover Cylinder Head
Sub - assy
z Cover Cylinder
Head Gasket bolts Union
12.5 (127, 9)
z gasket
z gasket
screw Belubang
16 (163, 12) Leaking pipe injector nozzle Assy
Assy
22 (220, 16)
* 32 (326, 24) 35
(357, 26)
x4
z Back - up Ring
z Ring - O pipe Injection
z washer z nozzle Sheet
5.0 (51, 44 in. Lbf)
No. 2 Pipe Injection

z Clamp
* 32 (326, 24) 35
(357, 26)
z Clamp
The nozzle holder clamps
Injection Pipe Clamps
5.0 (51, 44 in. Lbf)
Clamps No. 3
* 32 (326, 24) 35
(357, 26)
N · m (kgf · cm, ft · lbf) : Moment of tightening

* For use with SST
A98884

11-45
1117D - 01
REPLACEMENT
ATTENTION:
After removing the pipe - a pipe injection, clean everything with brush and air compressor.
2. SHUT OFF FUEL TANK

3. Drain FUEL
5. SHUT OFF ENGINE BRACKET (See pages 14-87)
6. OFF AIR CLEANER PIPE SUB - ASSY NO.2 (See pages 14-87)
The injector side

7. INJECTOR PIPE TAKE
Clamps No. 2
Pipe Injection
CAUTION:
S After removing the fuel pipe, cover the outside of the common rail
SST with adhesive tape to prevent dust from entering into it.
S Setelahmelepaskanpipa fuel, taruhlahkedalam vinyl bag to prevent

foreign objects ngotori me-injector inlet.
(A) Remove the 2 screws and clamps No. 3 pipe injection. (B) Remove the bolts
and clamps No. 2 pipe injection. (C) Using SST, and loose pipe union
Common side Rail kendorkanmur
injection No. 1, No. 2 and No. 3. SST
SST 09023-12701
Clamps No. 3
Pipe Injection
A98967
(1) Remove the two screws and remove the 2 injection pipe clamps.
A98893

11-46
The injector side

(2) Using SST, loosen the union nut and neck
pipe fitting injection No. 4.
SST 09023-12701
SST
Common side Rail
SST
G37743
8. TAKE COVER CYLINDER HEAD SUB - ASSY

(A) small Menggunakanobeng, seal off pemegangnyade--
ngan pry section between the seal holder and a key piece of the cylinder
head. (B) Remove the vent hose.
A60180
(C) Remove all - 4 connector.
G34844
(D) Remove the 10 bolts, 2 nuts and close the cylinder head.
G34877

11-47
9. OFF INJECTOR ASSY

(A) Remove the bolt union, 4 screw holes, 5 gaskets and pipe
nozzle leakage.
ATTENTION:
S When removing the nozzle pipe leaks, put pipe under the pads.
S Note in particular not to change the shape or scratch the surface of

the bolt union pressed.
A61112
S Setelahmelepaskanpipa fuel, taruhlahkedalam vinyl bag to prevent

foreign objects ngotori me-injector inlet.
(B) Remove the 4 screws, 4 washers, 4 clamp holders of nozzles and 4

injector.
INSTRUCTIONS:
Arrange the injector, klempemegang, washer and bolt in the correct order. (C)
Remove the ring - O and back - up ring of the injector. (D) Remove - 4th
pedestal injection nozzle of the cylinder head.
G34876
PAIRS OF INJECTOR ASSY 10. CAUTION:
Pastikanuntukmemasang injector, klempemegang, washer and bolt in its

original position.
(A) Install 4 new pedestal injection nozzles on cylinder
head.
B08252
(B) Apply a clean engine oil on the ring - a new O. (C) Attach the ring - O to each
- each injector as
Ring - a new O
shown in FIG. (D) Enter into - 4 injector into the cylinder head. (E) Record
the injector compensation code (when changing
with new injector) (see page 05-186).

ATTENTION:
S At this time, enter the injector nozzle to touch the board surface.
G36760
S After attaching the injector to the cylinder head, ring - O

bisamenghalangi injector to sit dengansepenuhnya. If so, the
injector pull out and plug it again.
S Restore always injector to the same place as when the injector is

removed.

11-48
washer (F) For a while pairs of new 4washer dan4 klemnozel with 4 bolt clamps.
downwardly INSTRUCTIONS:
Give a little of engine oil on the threads and under the bolt head clamps.
A60177
ATTENTION:
S Part fork on klempemegang injector nozzles should be attached to,
not to other sections.
S Before tightening the bolt - bolts, check that the clamp holder of
The nozzle nozzles have been installed correctly.
holder clamps
S To tighten the screw - clamp bolt, tighten sebagiandemi partly by

hand until it can not be played. Kemudiankencangkanbaut
G37744 denganmomen specified tightening.
S Ketikamengencangkan bolts to the specified torque, special

attention not to tilt bolts and clamps.
S Washernya should not be reused.

S If the leakage pipe nozzles inadvertently tightened beyond
specification pe-ngencangan moment, the pipe must be replaced.
(G) To temporarily attach it to - 4 injector pipe with a nut

union.
INSTRUCTIONS:
To position the injector, tighten the union nut loosely.
(H) Check the plumbing leaks nozzles. Check that there are no
scratches or dents on permukaanmerapatkan to - 5 union.
A62123

11-49
(I) Place the pipe leakage and 5 new gasket. (J)

bolts Union Apply a little oil on to - 4 screw holes and screw union.
screw
Punched
A70538
(K) To temporarily plug the leak pipe with couplers

holes and bolt union. (L)
Tighten to - 4 bolt clamp holder.
Moment: 22 N · m (220 kgf · cm, 16 ft · lbf)
A60184
(M) Tighten the hollow screw dalamurutandari 1 to

bolts Union
4.
CAUTION:
If the screw perforated inadvertently tightened torque exceeds
34 specifications pengencangannya, couplers have to be replaced.
2
screw Belubang 1 (N) Tighten the screw union.

A51297 Moment: 12.5 N · m (127 kgf · cm, 9 ft · lbf)
CAUTION:
If the union bolt inadvertently tightened beyond specification
pengencangannya moment, the bolts must be replaced.
(O) Remove the 4 injector pipes.

SST
(A) Check that there are no leaks from the junction
leakage pipe nozzles.
(1) Replace the gasket and pipe leakage nozzles No. 2 to
cylinder head with SST (check valve). No. Part 23762-27010
(Pipeline leaks nozzles No.
2)
SST 09280-00010, 09992-00242
G36759 Moment: 21 N m (214 kgf cm, 16 ft lbf)

11-50
(2) Give a little soapy water (or any liquid un-

tuk detecting fuel leaks) at the junction leakage pipe nozzles.
(3) Using SST (gauge pressure turbochar-

SST ger), install the SST on the return of the fuel in the pipe leaks, and
maintain the pressure at 250 kPa (2.5 kgf / cm 2 35.5 psi) for 60
seconds to check that no bubbles coming out. SST 09280-00010,
09992-00242
ATTENTION:
A60186 When checking for leaks, be sure to remove the ball and a check valve in
sebelummengoperasikannya.
(4) After checking the fuel leak, ber-

sihkan soapy water from the pipeline junction leakage.
(5) LepasSST, pipe kebocorannozel No. 2 dangasket. SST 09280-00010,

09992-00242 HINT:
Do not replace the check valve which was demolished in the machine.
12. INSTALL CYLINDER HEAD COVER SUB - ASSY

(A) Clean seal packing (FIPG) the length of the cylinder head. (B) Give seal
packing to a specified place which di-
explain in pictures.
Seal packing: No. Part 08826-00080 or equivalent NOTICE:
S Clean up any oil from the contact surface.

Seal Packing A70541 S Install the cover belt in three minutes after administration of the packing seal.
S Do not start the engine for at least 2 hours after installing the seal
packing.
(C) Install the cover of the cylinder head with 10 screws and two nuts.
(D) Replace the nozzle holder 4 new seal.
G34877

11-51
Paint
13. POST INJECTION PIPE CAUTION:
mark
S When replacing the injector, the injection should replace the pipe.
Approximately
8.0 mm
(0.31 in.) S Keep the injection pipe connections on the net.

(A) To sementarapasang injection pipe No. 1, No. 2 Danno.
3 with the union nut.
2
(B) Replace the injection pipe clamps No. 2 and No. 3 with three screws.
Pipe Injection No.
2
Clamps Injection No. INSTRUCTIONS:
S Be sure to install the injection pipe clamps No. 2 and No. 3 in the correct
position. Check the paint marks on the injection pipe No. 2.
Injection No. 3 Pipe
About - about
12 mm (0:47
S If the paint marks padapipa injection No. 2 has been lost, post injection
in.) pipe clamps No. 2 and No. 3 as seen in the pictures.
Pipe Clamps
Paint mark
A98964
side side (C) Using SST, tighten the nut union injection pipe
on the side of the common rail.
SST 09023-12701
Moment:
SST
32 N m (326 kgf cm, 24 ft lbf) for the use of de-ngan SST
35 N m (357 kgf cm, 26 ft lbf)

INSTRUCTIONS:
Use a torque wrench with a fulcrum length 30 cm (11.81 in.).

30 cm
Common Rail Injector
(D) Using SST, tighten the nut union injection pipe
on the side of the injector SST
SST
09023-12701
Moment:
30 cm 32 N m (326 kgf cm, 24 ft lbf) for the use of de-ngan SST

INSTRUCTIONS:
A98972 Use a torque wrench with a fulcrum length 30 cm (11.81 in.).
(E) For a while post injection pipe No. 4 with a nut

union.
(F) 2 new pairs injection pipe clamps with two bolts.
Moment: 5.0 N m (51 kgf cm, 44 in. Lbf) CAUTION:
S Make sure that the rubber part is inside the clamp dalampas.
S When installing the pipes, check that the rubber part of the clamp
A98893 and are in the correct position.

11-52
side side
(G) Using SST, tighten the nut union injection pipe
SST 09023-12701
SST Moment:

30 cm
INSTRUCTIONS:
Common Rail Injector Use a torque wrench with a fulcrum length 30 cm (11.81 in.).
30 cm (H) Using SST, tighten the nut union injection pipe

on the side of the injector. SST
09023-12701
Moment:
SST 35 N m (357 kgf cm, 26 ft lbf)

INSTRUCTIONS:
A98973 Use a torque wrench with a fulcrum length 30 cm (11.81 in.).
14. POST AIR CLEANER PIPE SUB - ASSY NO.2 (See pages 14-87)
15. POST COVER BRACKET ENGINE (See pages 14-87)
16. INSTALL ENGINE COVER SUB - ASSY NO.1
17. FILLIN FUEL
18. INSTALL FUEL TANK COVER ASSY
19. EXHAUST AIR FROM FUEL SYSTEM (See page 11-39)
22. RECORD CODE INJECTOR COMPENSATION (See pages 05-186)

24. CHECK THE OIL LEAK

FUEL -- SUPPLY PUMP ASSY (MACHINE 2KD - FTV) 11-53
SUPPLY PUMP ASSY (MACHINE 2KD - FTV)

1117E - 01
COMPONENTS
Air Cleaner Assy
14 (143, 10)
Sign Cooling Oil pipelines No. 1 A / T:
5.0 (51, 44 in. Lbf)
A / T:
Cooling oil pipelines Exit No. 1 with A / C: V Belt fans and
Generator
Reservoir tank
Radiator Assy
fans and Generator

x4
12 (122, 9)
radiator Assy
Radiator Outlet Puli fans
Coupling Fan without A / C: V Belt
Radiator hose
fan Shroud
12 (122, 9) Inlet hose
Clip
Grill Radiator

G37488

11-54
FUEL -- SUPPLY PUMP ASSY (MACHINE 2KD - FTV)
Timing Belt Tensioner
Camshaft Timing Puli

flange No. 2
8.0 (82, 71 in. Lbf)
6.0 (61, 53 in. Lbf)
13 (133, 10)
x4
z Ring - O Surface gauges Oli
Guide Gauge Surface
Activator pump pulley shaft Oil
SlangBahanBakar
64 (653, 47)
31 (316, 23)
* 32 (326, 24)
timing Belt
35 (357, 26)
21 (214, 16)
Close No. 1 Timing Belt
z Ring - O
connectors
z Fuel Inlet Pipe Sub -

PompaSupplyAssy
assy

* 32 (326, 24)
z Part that can not be reused 35 (357, 26)
* : For use with SST G37745

11-55
REPLACEMENT
ATTENTION:
1117F - 01
2. RADIATOR GRIL OFF (See page 16-35)

4. Drain FUEL
5. Drain the engine coolant (See pages 16-23)
6. A / T:
Drain AUTOMATIC TRANSMISSION FLUID (See page 40-2)

7. OFF RADIATOR ASSY (See page 16-35)
8. TAKE COVER TIMING BELT NO.1 (See pages 14-105)
9. OFF TIMING BELT (See pages 14-105)
10. PUMP OFFSHORE SUPPLY

(A) Remove the bolts and clamps.
(B) Remove the 2 bolts and the introduction of high measuring surface
oil.
G36615
(C) Using SST, and loose pipe union kendorkanmur

Common Rail
fuel inlet. SST 09023-12701
SST
Supply side side Pump

SST
A98969

11-56
(D) Remove the 2 fuel hose.
A98895
(E) Remove the 2 connector.
A98896
(F) Remove the 4 screws indicated by arrows in FIG.
(G) Remove the camshaft timing pulleys flange No. 2 and pulley shaft
pump drive.
A70710
(H) Remove the nut set and ring - O while holding pulleys crank-
shaft using the SST. SST 09213-58013,
09330-00021
SST A70711
(I) Loosen the two nuts.
A98897

11-57
(J) Remove the injection pump of gear using the SST.
SST SST 09950-50013 (09951-05010, 09952-05010,

09953-05020, 09954-05021)
ATTENTION:
Lubricate the thread and the end of the SST (bolts center) before using the
SST.
(K) Remove the two nuts and pumps.
A70714 ATTENTION:
S Janganmenahan or bring denganmemegang pump pipe.
S The pump must be maintained in order to remain horizontal.
(L) Remove the ring - O.
11. INSTALL PUMP SUPPLY

(A) Ensure that the gear pump supply in the timing
gear case can move back - back gently. (B) Attach the ring - a new O
on the pump. (C) Provide a thin layer of engine oil on the ring - O.
A70715
(D) Align the installation key of the drive shaft

with the groove on the gear injection.
A60835
(E) Install the pump with 2 nuts.

(F) Adjust the position of the ring - O just before tightening the mounting nuts.
A98897

11-58
(G) Using SST, hold the crankshaft pulley and tide

nut installation. SST 09213-58013,
09330-00021
SST A70711
(H) Push the pump shaft pulley to-back and

push ahead to check for gaps in the injection pump drive shaft.
Cracks thrust:
0:15 to 0:55 mm (0.0059 to 0.0217 in.)
If there is no gap a driving, dismantle and reassemble supply pump and pump
drive shaft pulley.
A71144
(I) Connect the two connectors.
A98896
(J) 2 Connect the fuel hose.
A98895

11-59
Common side Rail

(K) To temporarily plug the fuel inlet pipe
union nut.
SST ATTENTION:
S If the supply pump is replaced, the fuel inlet pipe should be replaced as
well.
S Be - careful against dust, dirt or any other foreign objects in the
junction area of the fuel inlet pipe.
30 cm
(L) Using SST, tighten the nut union injection pipe

Pump Supply side
SST 09023-12701
Moment:
SST 35 N m (357 kgf cm, 26 ft lbf)

INSTRUCTIONS:
30 cm (M) Using SST, tighten the nut union injection pipe

A98974
on the side of the supply pump.

SST 09023-12701
Moment:

INSTRUCTIONS:
(N) Replace the oil surface height gauges introduction de--

ngan 2 screws.
(O) Install the clamp bolts.

G36615
12. INSTALL TIMING BELT (See pages 14-105)

13. CLOSE POST NO. 1 TIMING BELT (See pages 14-105)
14. INSTALL RADIATOR ASSY (See page 16-35)
15. A / T:
RADIATOR GRIL PAIRS (See pages 16-35)
16. FILLIN AUTOMATIC TRANSMISSION FLUID (See page 40-2)
17. FILLIN LIQUID COOLING MACHINE (see pages 16-23)
18. FILLIN FUEL

11-60

23. START MACHINE

If the machine does not want to live. See pages 05-192.
24. CHECK THE ENGINE COOLING FLUID LEAK

FUEL -- COMMON RAIL ASSY (MACHINE 2KD - FTV) 11-61
COMMON RAIL ASSY (MACHINE 2KD - FTV)

1117G - 01
REPLACEMENT
ATTENTION:
2. ENGINE OIL Drain (See pages 16-23)

4. Drain FUEL
6. OFF cantilever MANIFOLD (See halaman14--87)
7. OFFSHORE OIL FILTER SUB - ASSY (See halaman17--27)
8. OFFSHORE PIPE INJECTION (See halaman11--45)
9. PIPELINE LEAK OFF NOZZLES ASSY NO.2

check Valve
(A) Remove the 2 fuel hose.
(B) Remove the check valve, 3 bolts, pipe leaks and gasket.
A98898
10. FUEL OFF INLET PIPE SUB - ASSY

(A) Remove the bolts and clamps.
(B) Remove the bolt and the introduction of high measuring surface
oil.
G36615

11-62
FUEL -- COMMON RAIL ASSY (MACHINE 2KD - FTV)
(C) Using SST, and loose pipe union kendorkanmur

Common Rail
fuel inlet. SST 09023-12701
SST
Supply side side Pump

SST
A98969
11. TAKE COMMON RAIL ASSY

(A) Remove the fuel pressure sensor connector. (B) Remove the 2 bolts
and the common rail.
ATTENTION:
Do not remove the pressure limiting and pressure sensors.
PAIR COMMON RAIL ASSY 12. CAUTION:
When replacing the common rail, do not remove the lid pe-ncegahan
A98899 mixing of foreign materials in the common rail until shortly before the inlet
pipe and the pipe is connected to the fuel injection common rail.
(A) Replace the common rail with 2 screws.

(B) Connect the fuel pressure sensor connector.

FUEL -- COMMON RAIL ASSY (MACHINE 2KD - FTV) 11-63
Common side Rail

13. INSTALL FUEL INLET PIPE SUB - ASSY
(A) For the temporary plug the fuel inlet pipe
SST union nut.
ATTENTION:
S If the supply pump is replaced, the fuel inlet pipe should be replaced as
well.
S Be - careful against any dust, dirt or other foreign objects in the
30 cm
junction area of the fuel inlet pipe.
Pump Supply side

(B) Using SST, tighten the nut union inlet pipe
SST 09023-12701
(C) Using SST, tighten the nut union inlet pipe
SST on the side of the supply pump.
SST 09023-12701
(D) Replace the surface with a high gauge introduction
30 cm bolt.
A98974
(E) Install the clamp bolts.

G36615
14. POST PIPELINE LEAK NOZZLES ASSY NO.2

check Valve
(A) For the temporary plug leakage pipe with 3 screws. (B) To temporarily attach
a new gasket with the check
valve.
(C) 3 Tighten the screws and check valve in full.
Moment:
21 N m (214 kgf cm, 16 ft lbf) for the check valve 13 N m (133
kgf cm, 10 ft lbf) to bolt
A98898 (D) Connect two fuel hose.
15. POST INJECTION PIPE (See pages 11-45)

16. INSTALL OIL FILTER SUB - ASSY (See page 17-27)
17. The cantilever MANIFOLD PAIRS (See pages 14-87)
19. FILLIN FUEL

11-64
FUEL -- COMMON RAIL ASSY (MACHINE 2KD - FTV)
21. ENGINE OIL FILLIN

22. CHECK THE SURFACE HIGH OIL
23. EXHAUST AIR FUEL SYSTEM (See page 11-39)
26. CHECK THE ENGINE OIL LEAK


FUEL -- FUEL TANK ASSY (MACHINE 2KD - FTV) 11-65
FUEL TANK ASSY (MACHINE 2KD - FTV) COMPONENTS

1117H - 01
4.0 (41, 35 in. Lbf)
x8 Pipe Fuel Tank Filling Sub - assy

Connector Fuel Tank Plate Set Fuel Tank Pipe
1.5 (15, 13 in. Lbf) Curved Clip Connection Pipe
Sub - assy
Evaporation pipe assy
Fuel Tanks -
Vent pipes ilasi Sub
x4
Aspiration Fuel Pump & Plumbing

z gasket
estimator Assy
Breathing hose Fuel Tank
Slang to Pipe Refueling

Fuel valve Circuit Assy
z gasket
Fuel Tank Assy
assy Fuel Tank Sub - assy

PipaUtama fuel tank Sub - Reversing Pipe
Fuel Pipe
Clamps
Fuel Tank Protector
Left
Pin
Pin
61 (622, 45)
wire Harness
Moment of tightening
z Part that can not be reused N · m (kgf · cm, ft · lbf):
A98943

11-66
FUEL -- FUEL TANK ASSY (MACHINE 2KD - FTV)
1117I - 01
REPLACEMENT

3. Drain FUEL
4. MAIN PIPE REMOVE FUEL TANKS AND FUEL TANK PIPELINE inverting
(A) Move the two clamps to release the two hose.

WARNING:
S To protect the hose, cover with a vinyl bag after inspection.
S If the hose and pipe the same - the same sticky, turn slangnya with liver - liver to release him and then release the fuel
tank hose.
5. LET THE FUEL TANK TO PIPE FILLING slang
6 - (a)
(A) Remove the hose pipe filling of tank filling pipe
fuel.
6. Slang REMOVE FUEL TANK BREATH
5 - (a) (A) Remove the breathing hose from the tank filling pipe
fuel.
A99799
7. OFFSHORE PIPELINE FILLING FUEL TANK SUB - ASSY

(A) Remove the bolt and then remove the fill pipe.
8. OFF FUEL TANK ASSY

(A) Install the jack stand on the fuel tank. (B) Remove the 2 screws, 2 clips, 2
pins and 2 band the fuel tank.
A99137
(C) Lower the jack little buffer. (D) Remove the 7 clamp connector harness and
remove the pump
fuel.
ATTENTION:
S Be - careful not to cut the wiring.
S Before doing this job check the connectors to the presence of dirt,
mud or other fouling.
Clip S Janganmenggunakan peralatanapapun in conducting this work.

G37566

11-67
9. OFF PLATE VENT PIPE FITTING OF FUEL TANKS
(A) Remove the 2 clips and pull out the pipe connections 2 pipe pom-
pa fuel.
A99141
ATTENTION:
Fuel Tube Joint fuel Tube
S Before doing this job check the connectors to the presence of dirt,
mud or other fouling.
S Be - careful of the mud. Ring - O connectors, which are pressed

O - Ring
Tube Joint Clip pipes and connectors, it is easy to become dirty.
S Janganmenggunakan peralatanapapun in conducting this work.

A60575
S Do not bend or twist the fuel pipe. Protect connectors with a cover
using a vinyl bag or a plastic bag.
S If the hose and pipe the same - the same sticky, tap and drag the
connector to release his second. Then pull the connector out of the
pipe.
(B) Remove the 8 bolts and mounting plate.
A99142
10. RELEASE suckers PUMPS AND PIPE MEASURING THE FUEL ASSY
(A) Remove the gauge pipe from the fuel tank.
WARNING:
To be careful - careful not to bend the arm sender fuel gage.
(B) Remove the gasket from the fuel tank.
11. TAKE NO PADS. 1 FUEL TANK
(A) Remove the 4 bearing on the fuel tank.

11-68
12. POST NO PADS. 1 FUEL TANK

(A) Install 4 new pads on the fuel tank.
A99809
13. POST suckers PUMP & PIPE MEASURING THE FUEL ASSY
(A) Provide a thin layer of gasoline or grease on the new gasket and attach the gasket to the fuel tank. (B) Attach the gauge pipe to the
fuel tank.
WARNING:
Be - careful not to bend the arm sender fuel gage.
14. POST PLATE VENT PIPE FITTING OF FUEL TANKS
(A) Attach the mounting plate with eight screws.

A99144
15. INSTALL FUEL TANK ASSY

(A) Install the jack stand on the fuel tank. (B) Raise the jack stand and connect 7
clip possessions
ness and plug the fuel pump to the fuel tank.
Clip
G37567
(C) Replace the fuel tank 2 bands with 2 pins and 2

clip.
(D) Connect the band - band with 2 screws.
Moment: 61 N m (622 kgf cm, 45 ft. Lbf)
A99137
16. INSTALL FUEL TANK FILLING PIPE SUB - ASSY

(A) Replace the filling pipe with screws.
Moment: 19 N m (194 kgf cm, 14 ft. Lbf)

11-69
17. CONNECT THE FUEL TANK TO PIPE FILLING slang
18 - (a)
(A) Connect the hose pipe the filling into the filling pipe of the stairs
ki fuel.
18. CONNECT THE FUEL TANK BREATH slang
17 - (b) (A) Connect the breathing hose to the tank filling pipe
fuel.
A99799
19. HUBUNGKANPIPAUTAMATANGKI BAHANBAKARDANPIPAPEMBALIKTANGKI fuel
(A) Connect the second hose to the second pipe
(B) Move klemnya to the connection.

WARNING:
Check that no damage or foreign objects on the connection pipes.
20. FILLIN FUEL
22. EXHAUST AIR FUEL SYSTEM (See halaman11--39)
24. RESET DO WORK STARTS FROM THE BEGINNING (See pages 01-16) WARNING:

CONTROL EMISSI
CONTROL SYSTEMS EMISSI
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 12-1

EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 12-2
VENTILATION VALVE SUB - ASSY
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 12-3

REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 12-3
CONTROL SYSTEMS EMISSI
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 12-4

LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 12-4
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 12-5
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 12-7
EGR SYSTEM
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 12-8
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 12-9
EGR VALVE ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 12-11
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 12-11

CONTROL EMISSI -- EMISSI CONTROL SYSTEM (ENGINE 1TR - FE) 12-1
EMISSI CONTROL SYSTEM (ENGINE 1TR - FE)

120GM - 01
1. CHECK THE VISUAL ON slang, connexion AND GASKET
(A) Check that there are no cracks, leaks and ke--

rusakan.
ATTENTION:
Release or other problems related dengandipstick engine oil, filling cap, PCV
tubing and other components can cause the engine not running de-ngan
perfect. Connectivity apart, looseness or cracks on components - a
A99255 component of the induction system between the throttle body and the
cylinder head will cause exploitation gangguanmesin danmenyebabkan air or
engine damage and malfunctions on the machine.
If the result is not as specified, replace components if necessary.
2. CHECK THE BREAKER FUEL RPM

(A) Open the throttle valve and keep the engine speed at 3,000 rpm. (B) Use a sound scope to check and listen to the sound operation of
the injector. (C) Check that when the throttle lever is released, the sound operation of the injector paused and the steering
dian started again.

12-2
CONTROL EMISSI -- EMISSI CONTROL SYSTEM (ENGINE 1TR - FE)
120GN - 01
EXAMINATION
1. CHECK THE FUEL TANK COVER ASSY

(A) Visually inspect that the fuel tank cap
and gasketnya not deformed or damaged. If the result is not as specified,
replace the fuel tank cap or gasketnya assy.
gasket
A99761
2. CHECK THE VENTILATION VALVE SUB - ASSY
Cylinder Head side (A) Attach a clean hose to the vent valve. (B) Check the operation
of the vent valve.
(1) blow air into the cylinder head, and pe--
Interrogation that the air passing through the valve with ease.
WARNING: Do not suck air through the valve. Oil chemical substances
Net slang contained in the valve is dangerous.

A59511
(2) blow air into the intake manifold, and

check that udaramengalami difficulty to pass through the valve.
Side Intake Manifold
If the result is not as specified, replace the vent valve. (C)
Remove the clean hose from vent valve.
A59512

CONTROL EMISSI -- VENTILATION VALVE SUB - ASSY (MACHINE 1TR - FE) 12-3
VENTILATION VALVE SUB - ASSY (MACHINE 1TR - FE)

120GO - 01
REPLACEMENT
1. OFF MOTOR & LINK ASSY WIPER FRONT GLASS (See pages 66-13)
2. OFF COWL PANEL SUB - ASSY (See page 66-13)
3. OFF VALVE VENTILATION SUB - ASSY

(A) Remove the ventilation hose from the valve. (B) Remove
the valve.
A99685
4. INSTALL VENTILATION VALVE SUB - ASSY

(A) Replace the valve.
(1) Give the adhesive at 2 or 3 screws.
adhesive:
No. Part 08833-00070, THREE BOND 1342 or equivalent
(2) Replace the valve.

A92670 (B) Connect the vent hose to the vent valve.
5. INSTALL COWL PANEL SUB - ASSY (See page 66-13)

6. PAIRS MOTOR & LINK ASSY WIPER FRONT GLASS (See pages 66-13)

12-4 CONTROL EMISSI -- EMISSI CONTROL SYSTEM (ENGINE 2KD - FTV)
EMISSI CONTROL SYSTEM (ENGINE 2KD - FTV) LOCATION

120GP - 01
Electric Vacuum Regulating Valve (E - VRV) for EGR
EGR valve
EGR Valve Position Sensor
Vakuum pump ECM
G35051

12-5
CONTROL EMISSI -- EMISSI CONTROL SYSTEM (ENGINE 2KD - FTV)
120GQ - 01
CHART SYSTEM
Diesel Throttle Valve Assy
PompaVakuum
EGR valve
Damper Vakuum
E - VRV for EGR
EGR Valve
Position Sensor
Pressure Sensor
Crankshaft Position
ECM
Sensor
Atmospher
Pressure
Position Sensor
Acceleration Pedal Engine Coolant
Temperature (ECT)
Sensor
Intake Air Temperature

Manifold Absolute
(IAT) Sensor
A99956

12-6
120gr - 01
1. CHECK THE VISUAL ON slang, connexion AND GASKET
(A) Check that there are no cracks, leaks and ke--

rusakan.
ATTENTION:
Release or other problems related dengandipstick engine oil, filling cap,
PCV tubing and other components can cause the engine not running
de-ngan perfect. Connectivity apart, looseness or cracks on components -
G35053 a component of the induction system between the throttle body and the
cylinder head will cause air suction danmenyebabkan gangguanmesin or
damage to machinery and malfunctions on the machine.
If the result is not as specified, replace components if necessary.

12-7
120GS - 01
EXAMINATION
1. CHECK THE FUEL TANK COVER ASSY

(A) Visually inspect if there are any changes in shape
or damage to the fuel tank cap and / or gasketnya.
If the result is not as specified, replace the fuel tank cap or gasketnya.
gasket
A99761

12-9
CONTROL EMISSI -- EGR SYSTEM (ENGINE 2KD - FTV)
6. MEASURING OFF VAKUUM

12-10
120GU - 01
EXAMINATION
1. CHECK THE EGR VALVE

(A) Check the EGR valve.
(1) If given Vakuum amounted to 26.7 kPa (200
mmHg, 7.87 in.Hg) into the diaphragm chamber, pe-Interrogation
that its axis went up and the air flow from IN to OUT.
(2) Maintain the above conditions, danperiksa again that

no leaks and that the axis decreases.
(3) Check that the valve is not sticky and no

carbon content by weight.
If the result is not as specified, replace the EGR valve.
B13170
(B) Check the EGR valve position sensor.

(1) Using ohmmeter, check prisoners between
Terminal 1 (VC) and 2 (E2) in the EGR valve position sensor.
23 1
Standard: 4.0 to 6.0 k at 20_C (68_F)

E2 VC
A85764
3 (EGLS) 2 (E2) (C) Give Vakuum into the diaphragm chamber. Check ta-
hanan between terminal 3 (EGLS) and 2 (E2) on the sensor is raised
when the valve is fully opened and also when covered in full.
Standard:
EGR Valve Condition Specified Condition
Open the Full 3.9 k at 20_C (68_F)
ohmmeter Fully sealed 1.0 k at 20_C (68_F)
A99957 INSTRUCTIONS:
Prisoners valve increases in proportion to the opening angle of the EGR valve.

12-11
2 1 2. CHECK THE ELECTRIC VACUUM Regulating VALVE (E - VRV) TO

ohmmeter
EGR
(A) Measure prisoners on E - VRV.
Standard:
1-2 11 to 13 at 20_C (68_F)
1 - The Body 2 -
10 M or higher
The Body
If the result is not as specified, replace the E - VRV.

11 to 13
2 1
ohmmeter
future
Body
10M or higher A99943
(B) Check the operation of E - VRV.

Air
(1) Check that the air flow from the hole E to fil-
ter.
Filter
A99937
Air (2) Circulate the battery voltage at the terminals 1 and 2. (3) Check that
21
the air flow from the hole E to knees
bang F.
If the result is not as specified, replace the E - VRV.
E
Battery A99939
3. CHECK THE PUMP ASSY VAKUUM

Vakuum gauge
(A) Connect Vakuum gauge on the output pipe. (B) Heat the engine and check
that the reading pengu-
kur vakuumberada above 86.7 kPa (650mmHg, 25.59 in. Hg).
If the result is not as specified, replace Vakuum pump assy.
Release
A99955

12-12
CONTROL EMISSI -- EGR VALVE ASSY (MACHINE 2KD - FTV)
EGR VALVE ASSY (MACHINE 2KD - FTV)

120GV - 01
REPLACEMENT
(C) (A) (B) 1. OFF AIR CLEANER PIPE SUB - ASSY NO. 2
(A) Remove the hood No. 1 (see pages 13-11). (B) Remove the turbo
(C)
pressure sensor connector. (C)
Remove the hose Vakuum of turbo pressure sensor. (D) Loosen -
2nd klemnya.
(E) Remove the bolt and pipe cleaner water along with 2
air hose.
(D)
A98889
2. VACUUM SWITCHING OFF VALVE BRACKET

(C) (A) Remove the connector. (B) Remove the hose Vakuum
(A) of 2 places. (C)
(B)
Remove the two screws and bracket.
(B)
(C)
G35434
3. DIESEL OFF THROTTLE BODY ASSY (See page 10-22)
4 - (a) 4 - (a)
4. OFF BRACKET THROTTLE BODY
- (a)
(A) Remove the 3 screws and bracket.

5 - (a) (A) Remove the two nuts, bolts and air inlet connector.
5 - (a)
5 - (a) 4 A99620
6. OFF EGR PIPE SUB - ASSY NO. 1

(A) Remove the 2 screws, 2 nuts and pipes.
7. OFF VALVE ASSY EGR
8. PAIRS EGR VALVE ASSY
(A) Install a new gasket and EGR valve.

12-13
CONTROL EMISSI -- EGR VALVE ASSY (MACHINE 2KD - FTV)
9. PAIRS EGR PIPE SUB - ASSY NO. 1

(A) Install the 2 new gaskets and pipes with 2mur and 2 screws.
INSTRUCTIONS:
Nails gasket must be on the side of the pipe.
G37199
11 - (a) 11 - (a) 10. AIR DUCT CONNECTORS PAIRS SIGN

11 - (a)
(A) Install a new gasket and air inlet connector
with 2 nuts and bolts.
10 - (a) Moment: 20 N m (204 kgf cm, 15 ft lbf)
11. POST BRACKET THROTTLE BODY
10 - (a)
10 - (a)
A99620
12. TIDE DIESEL THROTTLE BODY ASSY (See page 10-22)
13. POST BRACKET VACUUM SWITCHING VALVE

(A) (A) Attach the bracket with 2 screws. (B) Connect the hose
(C) Vakuum in 2 places. (C) Connect the connector.
(B)
(B)
(A)
G35434
(D) (C) 14. POST AIR CLEANER PIPE SUB - ASSY NO. 2
(B)
(B)
the bolt.
(C) Connect the hose Vakuum to turbo pressure sensor. (D) Connect the
turbo pressure sensor. (E) Replace the hood No. 1 (see pages 13-11).
(A)
A98889

INTAKE
SYSTEM TURBOCHARGER
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 13-1
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 13-1
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 13-2
ATTENTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 13-3
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 13-8
TURBOCHARGER SUB - ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 13-9
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 13-9
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 13-12

INTAKE -- SYSTEM TURBOCHARGER (ENGINE 2KD - FTV) 13-1
SYSTEM TURBOCHARGER (ENGINE 2KD - FTV) LOCATION

130A9--01
sensor TekananMutlakManifold ECM
Turbocharger Sub - assy
G35050

13-2
INTAKE -- SYSTEM TURBOCHARGER (ENGINE 2KD - FTV)
130AA - 01
CHART SYSTEM
sensor TekananMutlakManifold
Turbo Charger Sub - assy
ECM
G35054

13-3
130AD - 01
ATTENTION
1. CAUTION REGARDING TREATMENT
(A) Do not turn off the machine immediately after pulling a trailer, or after a
high-speed or hill berkendaraanmenaiki. Let the engine idle for 20 to 120
seconds depending on how hard the vehicle has been driven.
(B) Avoid sudden acceleration or immediately spur Kendal

daraan after starting the engine in a state still cold. (C)
If found damage to the turbocharger and must be replaced, check the

items - these items as well - good: (1) High-level engine oil and oil quality.
(2) In what conditions the turbocharger have
used.
(3) located on the turbocharger oil Repair or replace
items - above items if necessary.
FALSE (D) Be - careful when removing and replacing

turbocharger. Do not drop or hit the turbocharger. Also, the pressure on
local ataumemberi janganmemegang yangmudah broke (for example,
aktuatornya).
(E) Before removing the turbocharger, close the intake hole,

hole exhaust and inlet oil to protect them from dirt or other foreign matter.
G35055
(F) If replacing the turbocharger, check collection particles - particles of sediment
Oil pipe in the oil pipeline, and if necessary, replace the oil pipeline.
sediment (G) Clean thoroughly gasket attached

the oil pipe flanges and flange lubrication oil turbocharger. (H) When
replacing bolts or nuts, use only part
replacement enacted to prevent broken or deformed.
A98799
(I) If replacing the turbocharger, enter 20 cm 3 ( 1.2 cu in.) Of new oil into the
oil inflow hole and turn the turbine wheel turbocharger with oil
untukmenyebarkan hand to bearingnya. (J)
If dismantle or replace the engine, fuel discontinue setelahmerakit back

and startmesin for 30 seconds to distribute the oil to all parts of the
machine. Then let the engine idle for 60 seconds. (K)
G35056
If the machines run without air cleaner, close the case and slangnya, the
entry of particles - of foreign particles will damage the turbocharger.

13-4
130AB - 01
1. CHECK THE AIR IN SYSTEM
(A) Check for leaks or blockages between home air cleaner and turbocharger inlet,
and between the outlet of the turbocharger and cylinder head.
Condition do the Work
Air cleaner clogged Clean or replace the element
Slang deflated or deformed Repair or replace
Leakage of connection Check on each connection and repair
Cracks - cracks in component Check and replace
2. CHECK THE DISPOSAL SYSTEM CHANNEL

(A) Check for leaks or blockages between the cylinder head and inlet turbochar-
ger, and between the outlet of the turbocharger and exhaust pipe.
Condition do the Work
Component change shape Repair or replace
There is a foreign body in the hole channel clean up
Leakage of components Repair or replace
Cracks in component Check and replace
3. PRESSURE CHECK THE TURBOCHARGER

Gas filter
(A) Heat the machine.
SST (B) Using connectors 3 - directions, connect SST (pe--
ngukur pressure turbocharger) to hose between turbo pressure sensor
and filter gas flowing into the air inlet connector. SST 09992-00242 (c) M /
T:
G35299 Press the clutch pedal, and then press the accelerator pedal fully.
Measure the turbocharging pressure at a maximum rotation (about -
about 4,600 rpm). A / T:
Press the accelerator pedal fully. Measure the turbocharging pressure at

a maximum rotation (about - about 4,600 rpm).
Pressure standard:
58.5 to 78.9 kPa (0.60 to 0.80 kgf / cm 2 8.5 to 11.4 psi)
If the pressure is less than specified. check for leaks in the air inlet and the duct
system pembua-ngan. If there are no leaks, replace the turbocharger. If the
pressure is beradadiatas specifications, check slangaktuator the connections are
disconnected or there are cracks. If not, check the turbocharger.

13-5
4. CHECK THE ROUND SHAFT TURBINE

(A) Hold the edge of the turbine shaft and rotated. check
that the turbine shaft to rotate gently. If the turbine shaft can not rotate or
spin with the heavy prisoners, replace the turbocharger.
G35057
5. CHECK THE MANIFOLD ABSOLUTE PRESSURE SENSOR

T6--2 (E2) T6--1 (PIM)
(A) Check the voltage of the electric power source.
(1) Disconnect the pressure sensor connector T6. (2) Turn
the ignition switch ON.
(3) Measure the voltage between terminals T6--2 (PIM) and
T6--1 (E2) on the side of the wiring harness connector.
Standard: 4.5 to 5.5 V
If the result is not as specified, replace the ECM.
G35058 (4) Turn the ignition switch OFF. (5) Reconnect the pressure sensor
connector. (B) Check the power supply.
(1) Turn the ignition switch ON. (2) Remove the hose Vakuum of the
pressure sensor. (3) Connect a voltmeter to terminal E7--28 (PIM) and
E8--28 (E2) at the ECM connector, and measure the voltage out
under the pressure of the surrounding atmospher.
(4) Give vakuumpada dalamkenai- pressure sensor

ECM kan 13.3 kPa (100mmHg, in.Hg 3.94) until the pressure reaches
40.0 kPa (300 mmHg, 11.81 in.Hg).
(5) Measure the voltage reduction of step (3) un-

E7 E8 ECM
tuk any increase in pressure.
Standard:
Vakuum Provided reduced Voltage
E2 (-) PIM (+)
-- 13.3 kPa (100 mmHg, 3.94 in.Hg) 0.1 to 0.4 V
-- 26.6 kPa (199 mmHg, 7.85 in. Hg) 0.2 to 0.6 V
-- 40 kPa (300 mmHg, 11.81 in.Hg) 0.4 to 0.8 V
If the result is not as specified, replace the manifold absolute pressure sensor.
Vacuum
G35059

13-6
(6) Using SST (gauge pressure turbochar-

E7 E8
ECM ECM
ger), put pressure on the pressure sensor in the rise of 19.6 kPa
(0.20 kgf / cm 2 2.84 psi) to the pressure of 98.0 kPa (1.00 kgf / cm 2
14.2 psi).
SST 09992-00242
(7) Measure the voltage increase in the rise te
Right from step (6) for each increment.
Standard:
Given pressure Increased Voltage
19.6 kPa (0.20 kgf / cm 2 2.84psi) 0.1 to 0.4 V
39.2 kPa (0.40 kgf / cm 2 5.69 psi) 0.4 to 0.7 V
58.8 kPa (0.60 kgf / cm 2 8:53 psi) 0.7 to 1.0 V
78.5 kPa (0.80 kgf / cm 2 11.4 psi) 1.0 to 1.3 V
98.0 kPa (1.00 kgf / cm 2 14.2 psi) 1.3 to 1.6 V
If the result is not as specified, replace the manifold absolute pressure sensor.
E2 (-) PIM (+)
Pressure SST
G35060

13-7
130AC - 01
EXAMINATION
1. CHECK THE AXIAL MOVEMENT OF SHAFT TURBINE

(A) Using a dial indicator, insert the needle dial indica-
tor into the sewer. (B) Move the turbine shaft in the axial direction and
measure gera-
kan axially from the turbine shaft.
The maximum axial movement: 0:08 mm (0.031 in.)
If the axial movement is greater than the maximum, replace the turbocharger.
A99510
2. CHECK THE RADIAL MOVEMENTS OF SHAFT TURBINE

(A) Using a dial indicator, insert the needle dial indica-
tor into the hole oil outlet, and set in the middle of the turbine shaft.
(B) Move the turbine shaft in the radial direction and measuring gera-
kan radially from the turbine shaft.
The maximum radial movement: 0.11 mm (0.0043 in.)

Jikagerakan radial lebihbesar darimaksimum, replace the turbocharger.
A99511
3. Functioning VERIFY ACTUATORS AND VALVES DOOR DISPOSAL
(A) Remove the actuator from the home compressor hose. (B) Using SST,
put pressure on the actuator.
Standard: 114 kPa (1:16 kgf cm 2 16.5 psi)
SST 09992-00242
ATTENTION:
Do not put more pressure of 147 kPa (1.50 kgf / cm 2
A99512 21.3 psi) on the actuator.
(C) Check that the push rod and valve actuators move pin-
tu open dumps.
If the push rod does not move, replace actuator or turbocharger. (D) Connect the
actuator to house the compressor hose.

13-8
INTAKE -- TURBOCHARGER SUB - ASSY (MACHINE 2KD - FTV)
TURBOCHARGER SUB - ASSY (MACHINE 2KD - FTV) COMPONENTS

130AE - 01
Intake Air Temperature Sensor / Intake Air Temperature (IAT)
Slang Air Cleaner No. 1
Air Cleaner Assy

14 (143, 10)
Seal Fender Home

6 5
Top Seal Apron Fender Home
Disposal Pipe Assy Home

48 (489, 35)
z gasket
z gasket
Compression springs
Central Disposal pipe
43 (438, 32)
z Part that can not be reused G35206

13-10
Turbocharger Sub - assy
z gasket
13 (133, 10)
Turbo Oil Pipe Sub - assy
z Part that can not be reused A98780

13-12
10. TURBOCHARGER OFF SUB - ASSY

(B) (A) Remove 2baut, dan2 union bolt gaskets, and lepaskanpipa
inlet.
(B) Remove the 2 bolts and the support manifolds.
(A)
(B)
A)
(a A98783
(C) 3 Remove the nut, turbocharger with oil inlet pipe and turbo gasket.
(D) Lepas2mur, oil inlet pipe and turbo gaskets of turbochar-

ger.
A98784
11. CLEAN TURBOCHARGER SUB - ASSY

MECHANICAL MACHINES
MACHINE CYLINDER HEAD GASKET

EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-1 REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-115
DRIVE BELT OIL PUMP SEAL

REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-8 REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-121
PARTIAL ENGINE ASSY REAR ENGINE OIL SEAL

COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-10 REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-123
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-18
CHAIN SUB - ASSY

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 14-36
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-36
CAMSHAFT
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 14-48
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-48
CYLINDER HEAD GASKET

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 14-59
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-59
OIL PUMP SEAL

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 14-63
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-63
REAR ENGINE OIL SEAL retainer

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 14-65
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-65
MACHINE
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 14-67

EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-67
DRIVE BELT
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 14-70
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-70
GAP VALVE
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 14-71
ADJUSTMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-71
PARTIAL ENGINE ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 14-76
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-76
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-87
TIMING BELT
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 14-105
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-105
CAMSHAFT
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 14-110
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 14-110

14-2
MECHANICAL MACHINES -- MACHINE (1TR - FE)
S "Used Belt" is a belt which has been used on the engine for more than 5
minutes.
S After installing a new belt, turn the machine on for about - about 5
minutes and then check back kete-gangannya.
7. CHECK V - Ribbed BELT TENSIONER ASSY

(A) Start the engine in idle rotation and then die
turning
kan. Check that the drive belt is the middle - the middle between the
outskirts of tensioner pulleys. (B) Remove the drive belt tensioner pulleys. (C)
Turn pulinya, and check that the tensioner bearing ber-
motion gently and quietly. If necessary,

replace the tensioner. (D) Replace the drive belt.
G35187
8. CHECK THE PULLEY IDLER SUB - ASSY NO.1

turning
(A) Start the engine in idle rotation and then die
kan. Check that the drive belt is the middle - the middle between the outskirts of
the idler pulley. (B) Remove the drive belt from the idler pulley. (C) Turn the pulleys,
and check that the idler bearing moves den-
gan gentle and quiet. If

necessary, replace the idler pulley. (D)
G35186 Replace the drive belt.
9. SOUND CHECK THE VALVE LASH Adjuster

(A) Raise putaranmesin several times. Check bahwamesin tidakmengeluarkan not sound bia-
sa.
If there is an unusual noise, heat the engine and let it whirl idle for more than 30 minutes. Then repeat step (a). INSTRUCTIONS:
If you find any damage or problemselama examination of the above, give it a lash adjuster valve (see pages 14-48).
10. CHECK THE IGNITION TIMING

(A) Heat the machine and then turn off.
ATTENTION:
Warming the engine should have reached a temperature
cairanpendinginmesin lebihdari 80_C (176_F), telahmencapai engine oil
temperature 60_C (140_F), and the spin machine has become stable
(B) When using intelligent tester II:

Check the ignition timing. (1) Connect the intelligent tester II to
DLC3. (2) Turn the engine on idle rotation. (3) Press the main
switch intelligent tester II ON. (4) Go to the following items:
Powertrain / Engine and ECT / Data list / IGN Advance

DLC3
Intelligent Tester II Ignition timing: 0 to 20_ sebelumTMA @ idle

A98433

MECHANICAL MACHINES -- MACHINE (1TR - FE) 14-3
INSTRUCTIONS:
It is expected to refer to the guidelines for the operation of the intelligent tester II
for further details.
(C) If not using intelligent tester II:

tachometer Check the ignition timing.
(1) Using SST, connect the tachometer probe
terminal to the TAC of DLC3. SST
TAC
09843-18030
ATTENTION:
SST
S Make sure the terminal numbers before connecting. Relations with
the wrong terminal could damage the engine.
DLC3
Battery A99882
S Turn off all electrical systems before menghu-

bungkan terminal.
(2) Clip probe tester of the timing light to the four cable wire cable
wire or green / red in the ignition coil connector for cylinder No. 1. (3)
Cable Green / Red
Turn on the machine.
A99874
(4) Using SST, connect terminals TC and

TC
CG on DLC3. SST
09843-18040
ATTENTION:
CG
Ketikamemeriksa ignition timing, the transmission must be in neutral
position.
SST
DLC3
A99881
INSTRUCTIONS:
Approximately
round S After connecting terminals (TC and CG), engine rpm is changed to about
1,000 to 1,500 rpm
Engine
- about 1,000 to 1,500 rpmselama 5 seconds, then return to the idle
round Idle rotation. Because ECM check that the ISC (idle speed control system /
control system idle rotation) work correctly ..
5 seconds
S Do check the ignition timing after the engine turns back to the idle
rotation.
Connect Terminal TCdanCG
A99876

14-4
(5) Using the timing light, measuring the ignition timing.

Ignition Timing: 3 to 7_ before TDC @ idle
(6) Remove the SST from the terminal 13 (TC) and 4 (CG) on
DLC3. SST 09843-18040 (7)
Check the ignition timing.
Ignition timing: 0 to 20_ sebelumTMA @ idle

(8) Ensure that the ignition timing moved to the side
A99880 angle of more advanced when the engine rotation is increased. (9)
Remove the timing light.
11. CHECK THE ENGINE IDLE ROUND

(A) Heat and turn off the engine.
ATTENTION:
temperature 60_C (140_F), and rev the engine has been stabilized.
DLC3
(B) When using intelligent tester II:
Intelligent Tester II Check the idle rotation.
A98433
(1) Connect the intelligent tester II to DLC3.

INSTRUCTIONS:
It is expected to refer to the guidelines for the operation of the intelligent tester II
for further details.
(2) Turn the engine on idle rotation. (3) Press the main switch
intelligent tester II ON. (4) Go to the following items:
Powertrain / Engine and ECT / Data list / Engine SPD
Idle rotation: 650 to 750 rpm CAUTION:
S Ketikamemeriksa idle rotation, the transmission must be in neutral

position.
S Turn off all air conditioners aksessoris and sebe-
lum connect intelligent tester II.
(C) If not using intelligent tester II:

tachometer Check the idle rotation.
(1) Using SST, connect probe tester
tachometer to terminal 9 (TAC) on DLC3. SST
TAC
09843-18030 (2) Turn the engine on idle rotation. (3) Check the
idle rotation.
SST
Idle rotation: 650 to 750 rpm

DLC3
Battery A99882

12. CHECK THE IDLE SPEED CONTROL SYSTEM

(A) Heat the machine and turn off.
ATTENTION:
(B) Check the idle speed control systems.

TC
(1) Using SST, connect terminals TC and
CG of DLC3. SST 09843-18040 (2)
Start the engine in idle rotation.
CG
ATTENTION:
SST S Make sure the terminal numbers before connecting. Relations with
DLC3 the wrong terminal could damage the engine.
A99881
S Turn off all electrical systems before menghu-

bungkan terminal.
S Ketikamemeriksa ISC function, the transmission must be in neutral
position.
(3) After connecting terminals (TC and CG),

Approximately
round rev the engine is changed to about - about 1,000 to
1,000 to 1,500 rpm
Engine
1,500 rpmselama 5 seconds, then return to the idle rotation.
round Idle
If the result is not as specified, check the throttle body (see halaman10--5), DTC
(see pages 05-30) danwire harness.
5 seconds
13. VERIFY compression

Connect Terminals TC and CG
A99876 (A) Heat and turn off the engine.
ATTENTION:
(B) Remove the injector connector. (C)

Remove the ignition coil.
(D) Remove the spark plug.

14-6
(E) Check the cylinder compression pressure.

(1) Insert a compression gauge into the hole
plugs.
(2) Open the throttle fully. (3) While starting the engine, measure the
compression pressure.
Compression pressure:
1,230 kPa (12.5 kgf / cm 2 178 psi) minimum pressure: 0.88 kPa (9
kgf / cm 2 128 psi) The difference between each cylinder: 98 Pa (1.0
A99130 kgf / cm 2 14 psi) CAUTION:
S Always use a fully charged battery untukmendapatkan machine

rotation of 250 rpm or more.
S Check the compression pressure of the other cylinder in the same
way.
S These measurements should be done as soon as possible.
If the compression cylinder pressure is low, pour a little kedalamsilinder engine oil
through the spark plug hole and check again kompressinya pressure.
INSTRUCTIONS:
S If the addition of oil increases the pressure compression, piston rings and
/ or cylinder bore may be worn or damaged.
S If the pressure is low, the valve may be jammed or the holder is not true,
there is a leak in the gasket ataumungkin.
14. CHECK THE CO

INSTRUCTIONS:
This examination is used only to determine whether the levels of CO when the
machine is idle comply with the regulations or not. (A) Initial conditions:
(1) Cash at normal working temperatures. (2) Air

cleaner attached
(3) All pipes and hoses of the air induction system di-
connect. (4) All accessories OFF
switch (5)
all connected Vakuum channel (6) sistemSFI wiring connector is
attached to the sem-
full.
(7) Ignition timing has been set correctly. (8) The transmission is in the
neutral position (9) Tachometer and COmeter calibrated round
idle
ATTENTION:
If the CO meter is not available, do not try to adjust the idle mixture. Use
selaluCOmeter ketikamenyetel idle mixture. Use of the idle mixture screw
for adjustment specifically not required if the vehicle is in good condition.

(B) Heat the engine at constant speed (about - about

50 km / h (31mpj)). Close the throttle valve during 5mn after the engine
coolant temperature becomes stabilized (80 to 90 ° C (176 to 194_F))
and let the spinning machine idle for 5 minutes.
(C) Insert the probe tester at least 40 cm (1.3 ft) into

rear pipe.
CO Meter
(D) Wait for at - least for 1 minute before
COmenjadi concentration measurement as stable. Complete
measurement in 3 minutes.
The concentration of CO at idle: 1.5 0.5%
A99132
If the concentration of CO does not meet the regulations, set by turning the idle
SST mixture screw setter in variable resistor with SST.
SST 09243-00020
variable
Resistors
A01435
INSTRUCTIONS:
Idle mixture screw setter can be set up to span an angle of 180.
S If the concentration of CO has been in the specification,

adjustment is complete.
S If the concentration of CO can not be set correctly by adjusting the
idle mixture, see the table below for possible causes.
180_ A01434 (E) Remove the SST.
CO Problem Cause
1. The air filter is clogged

High rough idle
2. Clogged ventilation valve
(The black smoke out of the sewer)
3. Errors in the system SFI:
S Error on the fuel pressure regulator

S Inverting channels clogged fuel
S Damage to the engine coolant temperature sensor (ECT)
S Errors on ECM
S Error on the injector
S Error on the throttle position sensor
S Errors on MAF meter

14-8 MECHANICAL MACHINES -- DRIVE BELT (MACHINE 1TR - FE)
DRIVE BELT (MACHINE 1TR - FE)

141Y8--01
REPLACEMENT
1. REMOVABLE DRIVE BELT
(A) Use parts shaped - hexagon ditun-

jukkan with an arrow in the image to mengge-rakkan tensioner pulley
down and reduce ketega-ngan drive belt. Then remove the drive belt.
ATTENTION:
When removing the belt drive, do not use the idle pulley bolt.
A99194 INSTRUCTIONS:
After removing the drive belt, tensioner move upward until the maximum step.
2. INSTALL DRIVE BELT

(A) Install the drive belt on the pulley - the pulleys except the tensioner pulley
drive belt.
(B) Use parts shaped - hexagon ditun-
jukkan with an arrow in the image to mengge-rakkan tensioner pulley
down and then plug the drive belt tensioner pulleys to.
ATTENTION:
S Belakangdari side harusmenghadapkepuli drive belt tensioner.
with A / C S Check that the drive belt is correctly installed on each pulley.
Idler Pulley Vane Pump
Generator
Puli
fans
tensioner
Kompressor
Crankshaft pulley Idler Pulley
without A / C Idler Pulley
Generator
Vane Pump
Puli Fans
tensioner
Crankshaft pulley A97752

14-10 MECHANICAL MACHINES -- PARTIAL ENGINE ASSY (MACHINE 1TR - FE)
PARTIAL ENGINE ASSY (MACHINE 1TR - FE)

141Y9--01
COMPONENTS
Kap Machine Sub - assy

Channel connectors and assemblies Air Headgear Arm Wiper Home
Intake Air Cleaner
14 (143, 10) 8.0 (82, 71 in. Lbf) 11.5 (117, 8.5)
19.6 (200, 14)
Wiper arm Right Hose

Left Front Wiper nozzle
Home
Arm
Clip 19.6 (200, 14) Washer
Close Up Box Relay

Clip
Louver Right
Cowl Top
Close the Relay
Top Seal Hood to Cowl Cowl Top Ventilator Ventilator
Box No. 1
8.0 (81, 70 in. Lbf)
Louver Left
Vane Pump Assy

5.5 (56, 49 in. Lbf)
Wiper Motor Connector
Inlet hose Radiator Cowl Panel Sub - assy

25 (255, 18) 25 (255, 18)
5.0 (51.44 in. Lbf)
12 (122, 9) reservoir Motor & Link

Radiator Windshield
25 (255, 18)
Wiper
x4
drive Belt With A / C:

Compressor and
Magnetic Clutch
Puli fans
Fans and
radiator Assy fan Shroud Clutch
Clip
Grill Radiator Assy
N m (kgf cm, ft lbf): Moment of tightening

A99204

14-11
MECHANICAL MACHINES -- PARTIAL ENGINE ASSY (MACHINE 1TR - FE)
Sides Space Engineering
cable
Machinery
ECM connectors
door Drawer
G35138
Slang Inlet Air slang Slang Fuel

Heater Vakuum Slang Fuel No. 2
Slang Outlet A
cables Period
13 (133, 10) Water Heater
(133, 10)
(133, 10) 13
Cable
clamps
variable KlemResistor
Connector A / B Space
Engineering
Cable clamps
31 (316, 23) 13
13 (133, 10)
With A / C
5.4 (55.48 in. Lbf)
suction pipe cables Period
N m (kgf cm, ft lbf): Moment of tightening A99205

(897, 65)
Propeller shaft with Central Bearing
36 (370, 27)
z gasket
48 (489, 35)
Pipe Hangers Disposal No. 1
z gasket
Starter
Compression springs
43 (438, 32) 37 (377, 27) 88
z Part that can not be reused A99207

14-13
M/T
Shift Knob Lever Sub - assy
Console Panel Sub - assy Top
Console Box Assy
Sustainer Exhaust Manifold Shift Lever Boot Assy
Floor Shift Shift Lever Assy
Manual Transmission Unit Assy
72 (738, 53)
30 (306, 22) 44 (449.32) x5
Assy Clutch Release

Cylinder
Frame crossmember Assy
No. 2
12 (120, 9)
Insulator Rear Engine

Mounting No. 1
50 (510, 37) 44 (449, 32)
Frame crossmember Sub -

assy No. 3
27 (275, 20) 50 (510, 37)

G35200

A/T
High gauge PermukaanOli Transmission

Oil Cooler Outlet Pipe No. 1
Sub - assy
5.0 (54, 44 in. Lbf)
Sub Transmission
Oil Filling pipe -
assy
12 (122, 9)
Oil Cooler Inlet Pipe No. 1
z Ring - O
17mmHead: 71 (720, 53) x4x
14mmHead: 37 (377, 27) 4
Automatic Transmission Unit Assy 28 (286, 21)
x6
41 (421, 30)
Transmission Control Cable Bracket
Torque Converter Clutch

Assy
Insulator EngineMountingBelakangNo. 1
Dust seals Flywheel Housing
44 (449, 32)
Frame crossmember Assy No. 2
50 (510, 37)
27 (275, 20) 50 (510, 37)
N m (kgf cm, ft lbf): Moment of Tightening Frame crossmember Sub - assy No. 3
z Part that should not be used anymore

G35087

14-15
/T
Rear End Plate Drive Plate & Ring Gear Sub -

assy
18 (184 13) L 74 (755 55)
x 10
Spacer Home Rear Drive Spacer

Drive Plate Plate
M/N x6
19 (195, 14)
Plat KoplingAssy
18 (184, 13)
x 10
Plat UjungBelakang
Clutch Cover Assy
Dust seals Flywheel Flywheel Sub

Housing - assy L See page 14-18 1st:
26.5 (270, 20) 2nd: Turn
90_
L part padded G34892

wire Harness
Heat insulating
Sewer No. 1
12 (122, 9)
Spacer Pipe Delivery # 1
x5 12 (122, 9) 9.0 (92, 80 in. Lbf)
Delivery pipe BakarSub Materials - assy
z Ring - O
injector
Vibration insulating Throttle Body Assy
injector spacer 25 (255, 18)
z gasket z O - Ring
z gasket
x5
41 (418, 30) 9.0 (92, 80 in. Lbf)
exhaust Manifold Ignition Coil Assy z gasket x5
intake Manifold 25 (255, 18)
plug
20 (204, 15)
18 (184, 13)
Ventilation pipes
Surface gauges
Oil Sub - assy
z Ring - O
Introduction to Surface
Gauge Oil

A99222

14-17
43 (439, 32)
generator Assy
Crankshaft Timing Oil Control

Valve Assy
pulley Plate spacer
Oil Pressure Switch

43 (438, 32) Assy
Sensor Sub - assy 1 L 15 (153, 11)
8.5 (87, 75 in. Lbf)
(438, 32)
43 (438, 32) 43
z Ring - O Temperature Sensor
Engine Coolant
20 (204, 15)
Crankshaft Position
Assy Tensioner V -
8.5 (87, 75 in. Lbf) Ribbed Belt Slang By - pass Air
17.5 (179, 13)

Idler Pulley
Pipe By - pass Air No. 1
z gasket z gasket
Thermostat 20 (204, 15)
z gasket knock Sensor

(459, 18)
Inlet Air
24.5 (, 250, 18)
20 (204, 15)
45 (459, 18)
With A / C: Compressor
Mounting Bracket No. 1
51 (520, 38) 45
51 (520, 38)

Engine Mounting Bracket Home Engine Mounting Bracket Home
No. 1 Right No. 1 Left 8.5 (87, 75 in. Lbf)
z part that not reuse

L part padded
A99223

14-18
141YA - 01
REPLACEMENT
1. EMPTY PRESSURE FUEL SYSTEM (See page 11-4) WARNING:
2. DISCONNECT THE CABLE FROM THE NEGATIVE BATTERY TERMINAL

4. ENGINE OIL Drain
(C) (d) (B) 5. OFF THE AIR IN LINE CONNECTORS

(D) (A) Remove the hose Vakuum. (B) Remove the
ventilation hose No. 2. (c)
Remove the MAF meter connector and wire harness clamps. (D) Loosen the
(D)
hose clamp and remove the four bolts, air cleaner and
(C) (D) (A)
(C)
air inlet connector assembly.
(D)
A99871
6. RADIATOR GRILL OFF (See page 76-2)

7. REMOVE THE RADIATOR INLET hose (See pages 16-13)
8. REMOVE THE RADIATOR OUTLET hose (See pages 16-13)
9. OFF DRIVE BELT (See page 14-8)
10. FAN OFF Shroud (See pages 16-13)
11. PULI OFF FAN
12. TAKE RADIATOR ASSY (See page 16-13)
13. LET slang - slang

(C)
(A) Remove the water heater inlet hose from the unit heater. (B) Remove the
(A) outlet hose from the heater water heater unit. (C)
Remove the hose Vakuum.
(B)
G35079
14. REMOVE FUEL slang

(A) Remove the fuel hose from the fuel filter. (see
pages 11-4).
15. REMOVE FUEL slang NO.2
(A) Remove the fuel hose from the fuel pipe.
G35078

14-19
16. DISCONNECT CABLE MACHINE

(A) Remove the ECM connector from the cabin.
(1) Remove the drawer door. (2) Remove all - 4 ECM
connector. (3) Pull the cord out of the machine cabin.
G35431
(B) Remove the cover on the R / B. (C)
Remove the lid R / B No. 1.

(1) Using a screwdriver, free the four nails and loose
close the R / B.
Pull INSTRUCTIONS:
Pull
Pull
Nail A99884
(D) Remove the nut and remove the cable from the R / B in the engine room. (E) Remove
the 2 connectors A / B in the engine room and release
(D) cable clamps. (F)
Remove the two screws, and remove the cable clamp period and a variable resistor.
(E) (G) Remove the bolt and remove the cable from the block period silin--
der engine.
(E)
(E)
(F)
(F)
G35435
17. REMOVE VANE PUMP ASSY

(A) Remove the oil pressure switch connector Power Steering. (B) Remove all -
two bolts and remove the pump from the engine. (C) prop vane pumpnya
safely.
A99199

14-20
18. With A / C:
REMOVE COMPRESSOR AND MAGNETIC CLUTCH
(A) Disconnect the compressor. (B) Remove the 2 screws and remove the pipe suckers
of the machine.
A99198
(C) Remove the 4 bolts and remove the compressor from the engine.
(D) prop refrigeration compressor safely.
A99200
19. RELEASE LINK ASSY WIPER MOTOR & GLASS FRONT (See page 66-13)
20. TAKE COWL PANEL SUB - ASSY

(A) Remove the 9 bolts and cowl panel.
A99201
21. KAP OFF MACHINE SUB - ASSY

(A) Remove the washer nozzle hose. (B)
Remove the 4 screws and bonnet.
ATTENTION:
To be careful - careful not to damage the vehicle.
A99870
22. DISPOSAL OF OFFSHORE PIPE ASSY FRONT (See page 15-2)

23. RELEASE BEARING WITH CENTRAL PROPELLER SHAFT ASSY (See page 30-4)
24. RELEASE STARTER ASSY (See page 19-7)
25. MANUAL TRANSMISSION:
RELEASE RELEASE CYLINDER CLUTCH ASSY (See page 42-14)

14-21
26. AUTOMATIC TRANSMISSION:

OFFSHORE OIL COOLER INLET PIPE NO.1 (See pages 40-15)
OFFSHORE OIL COOLING PIPE OUTLET NO.1 (See halaman40--15)
OFFSHORE OIL PIPELINE FILLING THE TRANSMISSION SUB - ASSY

DISCONNECT TRANSMISSION CONTROL CABLE ASSY (See page 40-58)
OFF MANUAL TRANSMISSION UNIT ASSY (See page 41-4)
OFF AUTOMATIC TRANSMISSION ASSY (See page 40-15)
32. OFF MACHINE ASSEMBLY

Back side Front side
(A) Install the 2 engine hangers as shown da-
lam pictures.
item No. part
hanger Machine 12281--0C010 or 12281--0C020
Bolt 90 105 - T0129
A99202
(B) Replace the engine lifter chain on a hanger Me-

sin.
(C) Remove the 4 screws and bracket holders 4mur enginemounting and
order.
G36026
(D) Lift the engine out of the vehicle slowly - PE

lan and liver - liver.
Lift ATTENTION:
S Make sure that no wires - cables, hoses - hose or cable - yangmasih
cable is connected to machine.
S Make sure that no wires - cables, hoses - hoses or cables - cables
that impede the machine.
A99869

OFF CLUTCH COVER ASSY (See page 42-16)
OFF PLATE CLUTCH ASSY (See page 42-16)

14-22
35. MANUAL TRANSMISSION: Flywheel OFF

SUB - ASSY
(A) Hold crankshaft with SST.
SST 09213-54015 (91651-60855), 09330-00021
SST
A99210
(B) Remove the 10 bolts and flywheel.
G35062

OFF DRIVE PLATE & RING GEAR SUB - ASSY
(A) Hold crankshaft with SST.
SST 09213-54015 (91651-60855), 09330-00021
SST
A99210
(B) Remove the 10 bolts, spacers rear, drive plate and spacer
front.
A99868
37. TAKE BACK END PLATE

(A) Remove the 2 bolts and rear end plate.
38. INSTALL THE MACHINE STAND MACHINE
(A) Place the engine assembly on the stand.
39. OFF IGNITION COIL ASSY
(A) Remove the bolt and the ignition coil.
40. RELEASE BUSI
41. RELEASE VENT PIPES
(A) Remove the bolt and vent pipe.

14-23
42. TAKE CABLE - CABLE MACHINE

(A) Remove the 2 connectors generator. (B) Remove the oil
pressure sensor connector. (C)
Unplug noise filter.
(D) Remove the camshaft position sensor connector. (E) Remove the
four connectors ignition coil with ignitor. (F)
4 Remove the injector connector. (G) Remove
the ECT sensor connector. (H) Remove the knock
sensor connector. (I)
Remove the wire harness from clamps - klemnya. (J)
Remove the two screws and wire harness from the engine.
43. TAKE slang - slang

(A) Remove the hose from the intake manifold Vakuum. (B) Remove
the hose inlet and outlet heater. (C)
2 Remove the fuel hose from the delivery pipe. (D) Remove the 2
hose by - pass water from the throttle body.
44. RELEASE THROTTLE BODY ASSY (See page 10-8)
45. OFF FUEL DELIVERY PIPE SUB - ASSY (See page 11-14)
46. OFF FUEL INJECTOR ASSY (See page 11-14)

G36020
48. TAKE heat insulator NO.1 EXHAUST MANIFOLD
(A) Remove the 5 bolts and heat insulation.
A99875
49. RELEASE EXHAUST MANIFOLD

(A) Remove the 6 nuts, exhaust manifold and gasket.
A99195

14-24
50. REMOVABLE SURFACE HIGH STANDARD OIL SUB - ASSY
(A) Remove the bolt, introduction and ring gauges - O.

51. INTRODUCTION TO TAKE THE SURFACE HIGH STANDARD OIL
A99877
52. RELEASE GENERATOR ASSY (See page 19-13)
53. With A / C:
KOMPRESSOR OFF MOUNTING BRACKET NO.1
(A) Remove the 5 bolts and mounting bracket compressor.
A99203
54. OFF V - Ribbed BELT TENSIONER ASSY

(A) Remove the 3 screws and belt tensioner.
G35081
55. OFF LINE IN AIR

(A) Remove the bolts, 2 nuts, water inlet and gaskets.
56. OFF THERMOSTAT
(A) Remove the thermostat and gasket.
57. RELEASE PULLEY IDLER SUB - ASSY NO.1

(A) Remove the bolt, plate pulleys, idler pulley and the spacer.
G35185

14-25
58. ENGINE OFF OIL PRESSURE SWITCH ASSY

(A) Using the 24 mm socket wrench, remove the oil pressure switch.
59. OFFSHORE PIPELINE BY - PASS WATER NO.1
(A) Remove the two nuts, pipe by - pass water and gaskets.
G35420
60. OFF KNOCK SENSOR

(A) Remove the bolt and the knock sensor.
61. TAKE TEMPERATURE SENSOR LIQUID COOLING ENGINE / ENGINE COOLANT TEMPERATURE (ECT)
(A) Using a 19 mm socket wrench, remove the ECT sensor.
62. TAKE POSITION SENSOR CAMSHAFT

(A) Remove the bolt and the camshaft position sensor.
G35088
63. TAKE CRANKSHAFT POSITION SENSOR (See page 18-8)
64. OFFSHORE OIL CONTROL VALVE TIMING CAMSHAFT ASSY
(A) Remove the bolt and valve control.
A99883

14-26
65. RELEASE MOUNTING BRACKET ENGINE RIGHT FRONT NO.1
(A) Remove the 4 screws and the mounting bracket.
A99873
66. ENGINE OFF MOUNTING BRACKET LEFT FRONT NO.1
(A) Remove the 4 screws and the mounting bracket.
67. INSTALL ENGINE MOUNTING BRACKET LEFT FRONT NO.1
(A) Attach the mounting bracket with 4 screws.

68. INSTALL ENGINE MOUNTING BRACKET RIGHT FRONT NO.1
A99872

69. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(A) Apply a coating of engine oil to the ring - a new O. (B) Replace
the oil control valve with bolts.
A99883
70. INSTALL CRANKSHAFT POSITION SENSOR (See page 18-8)
71. INSTALL CAMSHAFT POSITION SENSOR

(A) Apply a coating of engine oil to the ring - a new O. (B) Replace
the camshaft position sensor bolts.
G35088

14-27
72. INSTALL ENGINE COOLING LIQUID TEMPERATURE SENSOR / ENGINE COOLANT TEMPERATURE (ECT)
(A) Using a 19 mm socket wrench, install a new gasket and ECT sensor.
73. PAIRS KNOCK SENSOR (See page 10-10)
74. PIPELINE INSTALLATION BY - PASS WATER NO.1
(A) Install a new gasket and pipe by - pass water with 2 nuts.
G35420
75. INSTALL ENGINE OIL PRESSURE SWITCH ASSY (See page 17-1)
76. INSTALL PULLEY IDLER SUB - ASSY NO.1

(A) Install the spacer, idler pulley and the pulley plate with bolts.
G35185
77. INSTALL THERMOSTAT (See page 16-7)

78. POST ENTRY CHANNELS OF WATER (See page 16-7)
79. POST V - Ribbed BELT TENSIONER ASSY

(A) For a while pairs of belt tensioner with 3 screws. INSTRUCTIONS:
3
Ensure that the flange of the bolt - bolt tensioner contact with the surface.
1
(B) Install the tensioner bolt in denganmengencangkan 3
2
the sequence shown in FIG.
G35081

14-28
80. dengana / C:
1 INSTALL MOUNTING BRACKET NO.1 KOMPRESSOR
3
(A) To temporarily attach the mounting bracket to 5
bolt.
INSTRUCTIONS:
Ensure that the flange of the bolt - bolt contacts the surface of the bracket.
2
45A
(B) Attach the mounting bracket bolts denganmengencangkan 5
A99203 in the order shown in the picture.
Moment:
24.5 N m (250 kgf cm, 18 ft lbf) to bolt A 45 N m (459 kgf cm, 33 ft
lbf) except for bolts A CAUTION:
TO AVOID lurusan, which could cause bergeretak belt, tighten the bolt to
be done in the order indicated.
81. POST GENERATOR ASSY (See page 19-13)
82. INTRODUCTION TO MEASURING HIGH TIDE OIL SURFACE
(A) Replace the ring - O gauge with the introduction of new and
bolt.
83. HIGH TIDE MEASURING THE SURFACE OF OIL SUB - ASSY
A99877
84. INSTALL EXHAUST MANIFOLD

(A) Install a new gasket and exhaust manifold with 6
bolt.
A99195
NO.1 heat insulator 85. INSTALL EXHAUST MANIFOLD
(A) Install the heat insulation with 5 bolts.

Moment: 12 N m (122 kgf cm long, 9 ft lbf)
A99875

14-29

and 2 nuts.
G36020
87. INSTALL FUEL INJECTOR ASSY (See page 11-14)

88. INSTALL FUEL DELIVERY PIPE SUB - ASSY (See page 11-14)
89. POST THROTTLE BODY ASSY (See page 10-8)
90. POST slang - slang
(A) Install the 2 hose by - pass water into the throttle body. (B)
Install 2 fuel hose to the delivery pipe. (C) Install the heater inlet
and outlet hose. (D) Attach a hose to the intake manifold Vakuum.
91. PAIRS CABLE - CABLE MACHINE

(A) Connect the two connectors generator. (B) Connect the
oil pressure sensor connector. (C) Connect the noise filter.
(D) Connect the camshaft position sensor. (E) 4 Connect the ignition coil
connector with ignitor. (F) Connect 4 injector connector. (G) Connect the
ECT sensor connector. (H) Connect the knock sensor connector. (I)
Connect the wire harness to klemnya. (J)

Attach the wire harness to the engine by two bolts and clamps.
92. INSTALL VENT PIPES
(A) Install the vent pipe with a screw.
93. POST BUSI
94. INSTALL IGNITION COIL ASSY
(A) Replace the ignition coil bolts.
95. RELEASE OF MACHINES STAND MACHINE
96. INSTALL REAR END PLATE
(A) Install the end plate with two screws.

14-30

INSTALL DRIVE PLATE & RING GEAR SUB - ASSY
adhesive (A) Give the adhesive until 2 or 3 screws at the end of the bolt
binder ..
adhesive:
(B) Replace the front spacer, spacer plate and rear drive
A04869 on the crankshaft.
(C) Hold crankshaft with SST.

SST 09213-54015 (91651-60855), 09330-00021
SST
A99210
2 (D) Replace and tighten the bolts evenly 10 delivery is

7
katnya in several stages in the order shown in the picture.
4 Moment: 74 N m (755 kgf cm, 55 ft lbf)

5
98. MANUAL TRANSMISSION: TIDE flywheel SUB
10 - ASSY
9 INSTRUCTIONS:
6
S Fastening bolts are tightened in 2 progressive step (step (d) and (f)).
1
3 8 A99868
S If there is one of the bolts fastening the broken atauberubah form, replace
the bolt.
(A) Give the adhesive until 2 or 3 screws at the end of the bolt
binder.
adhesive adhesive:
(B) Replace the flywheel.
A04869
(C) Hold crankshaft with SST.

SST 09213-54015 (91651-60855), 09330-00021
SST
A99210

14-31
2 7 (D) Replace and tighten the bolts evenly 10 delivery is

katnya in several stages in the order shown in the picture.
4
5 Moment: 26.5 N m (270 kgf cm, 20 ft lbf)

10
If there is one of the bolts fastening the moment pengencangannya tidakmencapai
specification, replace the bolt fastener.
6
9
1
3 8 G35062
(E) Mark the fastening bolt with paint. (F)

90_ Tighten the screw fastener with 90_ in the order according to the
numbers shown in the image in step (d)).
(G) Check that the paint mark is now at an angle

90_ to step (e).
Paint mark
A87316 G35063

POST PLATE CLUTCH ASSY (See page 42-16)
INSTALL CLUTCH COVER ASSY (See page 42-16)
101. POST ASSEMBLY MACHINE

(A) Replace the engine lifter chain on a hanger Me-
Decrease sin.
(B) Lower the engine assembly slowly - slowly into
machine room.
A99869
(C) Replace the engine mounting bracket with 4 screws and 4

nut.
G36026

INSTALL MANUAL TRANSMISSION UNIT ASSY (See page 41-4)

14-32

INSTALL AUTOMATIC TRANSMISSION ASSY (See page 40-15)
CONNECT THE TRANSMISSION CONTROL CABLE ASSY (See page 40-58)
105. PLUG OIL PIPELINE FILLING THE TRANSMISSION SUB - ASSY (See page 40-15)
OIL COOLING PIPE OUTLET PLUG NO.1
OIL COOLING PIPE INLET PLUG NO.1
POST RELEASE CYLINDER CLUTCH ASSY (See page 42-14)
PROPELLER SHAFT 110 PAIRS WITH CENTRAL BEARING ASSY (See page 30-4)
111. DISPOSAL OF PAIRS PIPE ASSY FRONT (See page 15-2)
112. PAIRS KAP MACHINE SUB - ASSY

(A) Attach the hood with 4 screws and set the hood
in the correct position (see page 75-1).
Moment: 11.5 N m (117 kgf cm, 8.5 in. Lbf)
(B) Connect the washer hose nozzles.
A99870
113. INSTALL COWL PANEL SUB - ASSY

(A) Install the cowl panel with 9 bolts.
A99201
114. PAIRS & LINK ASSY WIPER MOTOR FRONT GLASS (See pages 66-13)
2 115. With A / C:
CONNECT THE COMPRESSOR AND MAGNETIC CLUTCH
4 (A) Replace the screws loosely labeled A to Me-

1 install a compressor.
(B) Replace the compressor complete with mengen-
cangkan 4 screws in the order shown in the picture.
3A
A99200 Moment: 25 N m (255 kgf cm, 18 ft lbf) CAUTION:
TO AVOID lurusan, which could cause bergeretak belt, tighten the bolt to
be done in the order indicated.

14-33
(C) Connect the pipe suckers with 2 screws.

(D) Connect the compressor.
A99198
116. INSTALL VANE PUMP ASSY

(A) Replace the vane pump with 2 screws.
(B) Connect the power steering oil pressure switch.
A99199
117. CONNECT THE CABLE - CABLE MACHINE

(A) Connect the two connectors A / B in the engine room and The relationship
kan clamp the cord.

(B)
(B) Connect the cable to the R / B in the engine room with a nut.
(A) (C) Attach the lid R / B No. 1. (d)

Replace the lid on the R / B.
(A)
(E) Connect the cable clamp period and a variable resistor den-
(A)
gan 2 screws.
(E)
(F) Connect the cable to a period of engine cylinder block with bolts.
(E)
G35435
(G) Connect the ECM connector.

(1) Push the cable into the machine up to the cabin. (2) Connect
4 ECM connector. (3) Attach the drawer door.
G35431

14-34
118. CONNECT FUEL slang NO.2

(A) Connect the fuel hose to the fuel pipe.
119. slang CONNECT FUEL
(A) Connect the fuel hose to the fuel filter (see
pages 11-4).
G35078
120. CONNECT slang - slang

(C) (A) Connect the water inlet hose heater to heater unit. (B) Connect the
(A) water heater outlet hose to the unit heater. (C) Connect the hose
Vakuum.
(B)
G35079

122. PAIRS PULI FAN
123. POST FAN Shroud
124. INSTALL DRIVE BELT (See page 14-8)
125. CONNECT RADIATOR OUTLET slang
126. CONNECT RADIATOR INLET hose
RADIATOR GRIL PAIRS 127. (See page 76-2)
(B) A) (C) 128. POST AIR IN LINE CONNECTORS

(A)
(A) Replace the air cleaner and the air duct connector assemblies
Sign in with 4 screws and tighten the hose clamps.
Moment:
(A)
14 N m (143 kgf cm, 10 ft lbf) for cleaner water
(B) (a (D)
(B) 8.0 N m (82 kgf cm, 71 in. Lbf) for the air inlet connector
(B) Connect the MAF meter connector and harness klemwire. (C) Connect the
(A)
A99871 ventilation hose No. 2. (d) Connect Vakuum slang.

131. FILLIN ENGINE OIL (See page 17-3)

FILLIN AUTOMATIC TRANSMISSION FLUID (See page 40-2)
ENGINE COOLING FLUID FILLIN 133. (See page 16-3)

14-35

CHECK AND / OR ADD OIL MANUAL TRANSMISSION (See page 41-2)
FUEL LEAK CHECK 135. (See page 11-7)
CHECK THE SURFACE HIGH AUTOMATIC TRANSMISSION FLUID (See page 40-2)
139. CHECK THE ROUND IDLE AND IGNITION TIMING (See page 14-1)
140. CHECK THE CONCENTRATION CO (Check page 14-1)
141. CHECK THE FUNCTIONS OF THROTTLE BODY (See page 10-3)

14-36 MECHANICAL MACHINES -- CHAIN SUB - ASSY (MACHINE 1TR - FE)
CHAIN SUB - ASSY (MACHINE 1TR - FE)

141YB - 01
REPLACEMENT
3. OFF MACHINE ASSEMBLY (See page 14-18)

4. MACHINE TO INSTALL STAND MACHINE
(A) Place the engine assembly on the stand.
6. REMOVABLE SPARK PLUGS
G36020
9. SURFACE HIGH STANDARD OFFSHORE OIL SUB - ASSY

10. INTRODUCTION TO OFFSHORE OIL MEASURING SURFACE HIGH
A99877

14-37
MECHANICAL MACHINES -- CHAIN SUB - ASSY (MACHINE 1TR - FE)
12. With the A / C:

OFF COMPRESSOR MOUNTING BRACKET NO.1
(A) Remove the bolt and the mounting bracket.
A99203
13. TAKE TENSIONER V - Ribbed BELT ASSY

G35081
14. OFF LINE IN AIR

15. OFF THERMOSTAT

G35185
G35420
18. SHUT OFF ASSY OIL FILLING

19. RELEASE CYLINDER HEAD COVER SUB - ASSY

(A) Remove the 19 bolts, 2 nuts and headgear and 2 gaskets.
G35202
21. RELEASE PULI CRANKSHAFT

13_47 ' Timing mark (A) Rotate the crankshaft pulley and align its groove with the mark
timing 0 at the close timing chain. (B) Check that the timing marks on the
camshaft timing gear
and sprockets aligned with the timing mark on the cap bea-ring No. 1, as
shown in FIG.
Timing mark
Timing mark
Plot
A97861
(C) Using SST, loosen the pulley bolt.

SST 09213--54015 (91651--60855)
Loosen SST
bear A99211

14-39
(D) Using SST, remove the pulleys and pulley bolt.

SST 09330-00021, 09950-50013 (09951-05010,
bear
09952-05010, 09953-05010, 09954-05021)
SST
G35121
22. BAK OFFSHORE OIL SUB - ASSY NO.2 (See pages 17-14)
23. OFFSHORE OIL STRAINER SUB - ASSY
(A) Remove the bolts, 2 nuts, oil strainer and gasket.
24. BAK OFFSHORE OIL SUB - ASSY (See page 17-14)
25. SHUT OFF THE CHAIN TIMING

(A) Remove the 19 bolts and 2mur as shown dalamgam-
bar.
G36504
Protective tape (B) Remove the cover with the timing chain pry between
close timing chain and cylinder head or cylinder block with a screwdriver.
INSTRUCTIONS:

ATTENTION:
To be careful - careful jangansampai damage permukaankontak of the cylinder
head, cylinder block and close the timing chain.
A97897 (C) 3 Remove the ring - O.
(D) Using a 10 mm socket hexagon key, remove the oath

bat close timing chain.
G36021

26. OFF WATER PUMP ASSY

(A) Remove the 8 bolts, water pump and gasket.
A87223
27. OFF TIMING CHAIN GUIDE

(A) Remove the two screws, timing chain guides and rings - O.
28. RELEASE CHAIN TENSIONER ASSY NO.1 CAUTION:

plunger
Hexagon
S When the chain tensioner telahdilepas, janganmemutar crankshaft.
key
1:27 mm
S When the chain has been removed and the camshaft needs to be played, turn
the crankshaft 90_ to the right.
(A) Move the stopper plate upwards to free the pen-
guncinya, and press the plunger in - in into the tensioner.
Stopper plate (a)
(B) A97899
(B) Move the stopper plate down to install pe--

locked it, and insert the key into the hexagon hole stopper plate. (C)
Remove the bolts, nuts chain tensioner and gasket.

29. RELEASE CHAIN TENSIONER SLIPPER
(A) Remove the bolt and the tensioner slipper.
30. RELEASE CHAIN VIBRATION DAMPER NO.1
(A) Remove the 2 bolts and vibration damper.
31. RELEASE CHAIN SUB - ASSY
32. INSTALL CHAIN VIBRATION DAMPER NO.1
(A) Install vibration damper with two bolts.

14-41
33. INSTALL CHAIN SUB - ASSY

13_47 ' Timing mark
(A) As shown in the picture, plug chain on
sprocket and gear with paint marks aligned with the timing mark on the
sprocket and gear. INSTRUCTIONS:
S Plat camshaft mark is colored yellow.

Timing mark
S Plat crankshaft pins are colored orange.
Timing mark
Plat
Plat
Signs
Signs
Timing mark
Plat Signs A97920
(B) Use a rope to tie the team-chain on the crankshaft

ing sprocket. Tie a piece of rope near the gear.
ATTENTION:
After completion mounted chain tensioner, the rope must be removed.
INSTRUCTIONS:
The rope was tied so that the chain will not jump over the teeth.
A86975
34. INSTALL CHAIN TENSIONER SLIPPER

(A) Replace the bolt tensioner slipper.
35. INSTALL CHAIN TENSIONER ASSY NO.1
(A) Install a new gasket and chain tensioner with bolts and nuts.
36. INSTALL TIMING CHAIN GUIDE
(A) Replace the ring - O new and chain guide with 2 screws.
37. TIDE WATER PUMP ASSY

(A) Install a new gasket and water pump with 8 bolts.
A87223

38. INSTALL TIMING CHAIN CLOSE

(A) Install the 3 rings - a new O to close the timing chain as
visible in the picture.
Pump
Ring - O
O - O Over Water
Pump
Ring - Ring Oil Pump
A97922
(B) Give the adhesive on the lid stopper timing chain.

adhesive adhesive:
A58128
(C) Using a hexagon socket key 10 mm, plug

timing chain stopper cap.
G36021

14-43
(D) Give seal packing into beads - beads to continue - constantly on the indicated place
in the picture.
Seal packing: No. Part 08826-00080 or equivalent width of the seal:
Position Specified Condition
AA 1.5 to 2.5 mm (0.059 to 0.098 in.)
B - B, C - C 3.5 to 4.5 mm (0138 to 0177 in.)
D 2.5 to 3.5 mm (0.098 to 0138 in.)
ATTENTION:
S Clean all the existing oil from the surface of contact.
S Install the crankcase in 3menit and tighten the screws - screws in 15 minutes setelahmemberikan seal packing.
S Do not start the engine for at least 2 hours after installation.
Seal Packing Seal Packing
A
A
C C B
B
D D
20 mm (0787 20 mm (0787
in.) in.)
4 mm (0.157
1.0 mm
in.)
(0.039 in.) Seal width
1.5 to 2.5 mm
AA B-B Seal width:
3.5 to 4.5 mm
2.0 mm
(0.079 in.)
Seal width:
Seal width:
3.5 to 4.5 mm
2.5 to 3.5 mm
C-C D Cylinder
Head
block
Cylinders A97923

(E) Align the rotor spline drive the oil pump and the crankshaft se--
Perti shown in FIG. Install the spline and closed chain on the crankshaft.
Spline Driver
Rotor crankshaft A87226
(F) Replace lid loosely timing chain with 19 bolts and nuts, but do not always tighten bolts - bolts and nuts - nut.
(G) Excludes A fully tighten the bolts - bolts and nuts in this order: Area 1, Area 2 and
Area 3.
HINT: Long bolts:
75 mm (2.95 in.) To bolt A 75 mm (2.95

in.) For the bolt B 87 mm (3.43 in.) To
bolt C 95 mm (3.74 in.) To bolt D
(H) fully tighten the bolts - screws labeled A in this order: Area 2 and Area 3.
(I) Fully tighten the screws - screws labeled E for Area 4.
HINT: Long bolts:
35 mm (1:37 in.) To bolt E
B
A
A
A
Mur Area 3
A
C
Area 1
B
A
A Area 4
A
D Area 2
E E
BA
B
A97924
39. POST BAK OIL SUB - ASSY (See page 17-14)

40. INSTALL OIL STRAINER SUB - ASSY
(A) Install a new gasket and oil strainers with screws and two nuts.
41. POST BAK OIL SUB - ASSY NO.2 (See pages 17-14)

14-45
42. INSTALL CRANKSHAFT PULI

(A) Align the mounting key lock on the pulley grooves
SST pulleys and sliding pulinya added. (B) Using SST, install a new
crankshaft pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Moment: 260 N m (2,651 kgf cm, 192 ft lbf) CAUTION:
Do not reuse the pulley bolt.

A97885

(A) Replace the lid gasket cylinder head and cylinder gasket
head No. 2 on the lid of the cylinder head. (B) Remove all packing
material (FIPG) long. (C) Give the seal packing on the spot as ditunjuk-
right in the picture.

Seal Packing
A99825
S Clean all the oil that is on the surface of contact.

S Install the crankcase within 3 minutes after giving a seal packing.
S Do not start the engine for at least 2 hours after installing.
17 18 (D) Replace the lid is loose cylinder head with 19

19 20
21
screws and two nuts.
(E) Tighten secaramerata to - 19 screws and two nuts in

23 67
16 9
541 8
10
13 12 11
15 14 G35202
45. INSTALL OIL FILLING COVER ASSY

G35420

(A) Install the spacer, idler pulley and the belt pulley plate.
G35185


(A) For a while pairs of belt tensioner with 3 screws. INSTRUCTIONS:
3
Ensure that the flange of the bolt - bolt tensioner contact with the surface.
1
2
G35081
51. With A / C:
1 INSTALL MOUNTING BRACKET COMPRESSOR NO.1
3
(A) To temporarily attach the mounting bracket with 5 ba--
ut.
INSTRUCTIONS:
A Ensure that the flange of the bolt - bolt contacts the surface of the bracket.
2
4 5
(B) Attach the mounting bracket bolts denganmengencangkan 5
A99203 in the order shown in the picture.
Moment:
Untukmencegahketidak lurusan, which bisamenyebabkan bergeretaknya

belt, tighten the bolt to be done in the order shown.

14-47
(A) Replace the ring - O gauge with the introduction of new and
bolt.
A99877

and 2 nuts.
G36020

58. RELEASE FROM ENGINE MACHINE STAND
59. INSTALL ENGINE ASSEMBLY (See page 14-18)

CHECK AND / OR ADD OIL MANUAL TRANSMISSION (See halaman41--2)
CHECK THE SURFACE HIGH AUTOMATIC TRANSMISSION FLUID (See page 40-2)
71. CHECK THE CONCENTRATION CO (Check halaman14--1)
72. CHECK THE FUNCTIONS OF THROTTLE BODY (See page 10-3)

14-48 MECHANICAL MACHINES -- CAMSHAFT (MECHANICAL 1TR - FE)
CAMSHAFT (MECHANICAL 1TR - FE)

141YC - 01
REPLACEMENT

3. OFF DUTY AIR DUCT CONNECTOR (see pages 14-18)
5. TAKE COVER CYLINDER HEAD SUB - ASSY

(A) Remove the wire harness from to - 6 klemnya. (B) Remove the 19 bolts, 2 nuts,
close the cylinder head and 2 gaskets.
G35202
6. OFF TIMING CHAIN GUIDE

(A) Remove the 2 bolts and chain guide.
7. OFF TIMING CAMSHAFT SPROCKET

13_47 ' Timing mark
(A) Rotate the crankshaft pulley and align the groove tandanyadengan
timing mark 0 on the lid of the timing chain. (B) Check that the timing
marks on the camshaft timing gear
and sprockets are aligned with the timing marks on the lid bearing No. 1,
as shown in FIG.
Timing mark
Timing mark
A LUR
Signs
A97861

14-49
MEKANUIKAL MACHINE -- CAMSHAFT (MECHANICAL 1TR - FE)
(C) Give the paint marks on the timing chain and camshaft timing
Paint mark
gear / sprocket.
Timing mark
A97862
(D) Hold camshaft with a key and then loosen

sprocket bolt.
bear Loosen ATTENTION:
Be - careful not to damage the oil delivery pipe.
A97863
(E) Using a 10 mm socket hexagon key, remove the oath

bat close timing chain.
A86539
(F) Using a screwdriver, insert the stopper plate to tension-

er through holes service chain tensioner. Move the stopper plate upwards
to release the latch. Then hold the license plate at the position as shown in
FIG. INSTRUCTIONS:
bear
If the lock plate stopper is difficult to release, rotate slightly triangular sections -
six on the left and to the right camshaft.
Stopper plate
A97864

(G) With the locking plate stopper freed, turn slightly

camshaft right. Then keep it in that position.
turning
ATTENTION:
Be - careful not to damage the oil delivery pipe.
INSTRUCTIONS:
bear Rotate the camshaft to right will cause the pressure was administered on the
plunger tensioner.
plunger
A97865
(H) Remove the screwdriver from the hole service chain tensioner. Gerak-
kan plate stopper into the position shown in FIG. Then insert the hexagon
key into the hole. INSTRUCTIONS:
S If the key can not be inserted into the hole, rotate the camshaft slightly
left and then right. Then insert the key.
Hexagon S To prevent the key from falling out, use adhesive tape to stick the key in
key
place. (I)
1:27 mm
Remove the camshaft timing of the camshaft sprocket.
A86542
8. OFF CAMSHAFT
12 20 16
3 8 (A) Loosen the bolts 21 uniformly in the bearing cap
some stage in the order shown in the picture.
5 17
13 21 9
1 (B) Remove the lid 9 bearing, oil delivery pipe, ring - O and measles
11 19 15 7
4 shafts.
ATTENTION:
2 S Place the camshaft on a flat surface and loosen the bolts - screws
10 18 14 6
A97866 evenly.
S Do not pry camshafts using the tool with excessive force on the
camshaft.
S Do not damage the surface of the drain at the side of the cylinder
head.

14-51
(C) Remove the camshaft with timing chain holding.
A86544
(D) Tie the timing chain with a rope as seen in the pictures.
ATTENTION:
Be - careful not to drop something in close timing chain.
A86545
9. OFF VALVE ROCKER ARM SUB - ASSY NO.1

INSTRUCTIONS:
Make sure the part - removable part is returned to the same place where everything has been removed.
10. Adjuster LASH OFF VALVE ASSY

INSTRUCTIONS:
11. SHUT OFF VALVE STEM

INSTRUCTIONS:

12. CHECK THE VALVE ASSY LASH adjuster CAUTION:

RIGHT FALSE
S Keep lash adjuster clean from dirt and objects - a foreign object.
SST
part of Tire
S Use only clean engine oil.
(A) Place the lash adjuster into a place full
plunger
with engine oil.
Press room late (B) Insert the tip of the lash adjuster plunger into the SST and
Low
use the tip to press the plunger down checkball inside. SST 09276-75010
Checkball
Press room's High

(C) Press the SST and lash adjuster together - together to
moving the plunger up and down 5 to 6 times.
(D) Check the movement of the plunger and the exhaust air.
OK: The plunger moves up and down. ATTENTION:
SST
When dispose of high-pressure air from the compression chamber, making

sure that the tip of the actual pressing checkball SST as shown in the
picture. If checkball not pressed, the air will not come out.
(E) After removing the air, off the SST. then press
plunger with a finger quickly and firmly.
A97867 OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
13. CHECK THE CAMSHAFT TIMING GEAR ASSY

Slowing side (A) Check locking camshaft timing gear.
hole (1) Pinch camshaft in a vise, and make sure that the camshaft timing
gear lock.
ATTENTION:
Side holes To be careful - careful not to damage the camshaft.
Acceleration
(B) Remove the latch pin.
(1) Cover the 4 holes of oil on the cam journal with ribbon
vinyl, as seen in the pictures.
INSTRUCTIONS:
2 holes on the side of the acceleration is located in the groove of the camshaft.
Open
Cover the hole with a piece of rubber.
(2) Stick pieces of tape on the side of the hole perce-
ents and deceleration side hole on the opposite side of the
Closed
groove.
Open Close
Vinyl Ribbon Rubber

A62190

14-53
(3) Give the air pressure about - about 200 kPa (2.0 kgf / cm 2
Slowing side Side holes
28 psi) to a piece of tape affixed hole in step (2).
hole Acceleration
WARNING:
Some oil will spray out. Absorb spray oil with a rag.
A62191
Side holes (4) Check that the camshaft timing gear rotates da-
hole Acceleration lam direction of the acceleration when reducing the air pressure on
Slowing side the hole side of a slowdown.
emphasis. OK: Gear rotates acceleration.

INSTRUCTIONS:
Reduce
This operation releases the locking pin to the position of extreme deceleration.
The pressure-resistant (5) When the camshaft timing gearmencapai perce- position
A62192 ents extreme, off the water gun from side hole deceleration and
acceleration side hole in the sequence.
ATTENTION:
Do not remove the water gun on the acceleration side hole first. Gear can
pindahmendadak towards deceleration and break the latch pin.
(C) Check the tenderness of rotation.

(1) Turn the camshaft timing gear within range
bisabergerakbeberapa times, but janganmemutar to the position
of extreme deceleration. Check that the gear rotates gently.
OK: Gear rotates in the direction of acceleration.

WARNING:
Do not use water gun to perform operations that soft proofing.
(D) Check the locking position of extreme deceleration.

(1) Make sure that the camshaft timing gear lock
the position of the extreme deceleration.
14. TAKE CAMSHAFT TIMING GEAR ASSY

Circles Pin Straightener
(A) Remove the bolt circle edge of the camshaft timing gear.
ATTENTION:
S Be sure not to remove apart from the 3 screws.
S If you plan to use the gear back, be sure to remove the locking pin
alignment before installing gear.
Do removable bolts Edge

A97871

15. INSTALL CAMSHAFT TIMING GEAR ASSY

Pin Straightener
(A) Replace camshaft and camshaft timing gear bersama--
equal to straighten the lock and the alignment pins. (B) Press slightly the
gear to the camshaft, danputar gear. pressure
continue to positions where the pin into the hole.
WARNING:
Make sure not to turn the camshaft timing gear toward deceleration (to the
right corner).
Key hole
A97872 (C) Check that there is no gap between the edge of the circle
gear and camshaft.
(D) Tighten bolts to hold the edge of the circle
camshaft timing gear.
Moment: 78 N m (795 kgf cm 59 ft lbf)
(E) Check that the camshaft timing gear assembly can berge--
rack towards deceleration (right corner), and the lock on the position of
extreme deceleration.
16. POST CLOSE VALVE STEM
(A) Provide a clean engine oil to the tip of the valve stem, and replace the valve stem cap.
WARNING:
Place the lid to the same place from where all had been released.
LASH adjuster 17. INSTALL VALVE ASSY CAUTION:
RIGHT FALSE
S Keep lash adjuster clean from dirt and objects - a foreign object.
SST
part of Tire
S Use only clean engine oil.
(A) Place the lash adjuster into a place full
plunger
with oil.
Press room late (B) Insert the tip of the lash adjuster plunger into the SST and
Low
use the tip to press the plunger down checkball inside. SST 09276-75010
Checkball
Press room's High

(C) Press the SST and lash adjuster together - together to
moving the plunger up and down 5 to 6 times.
(D) Check the movement of the plunger and the exhaust air.
OK: The plunger moves up and down. ATTENTION:
SST
When dispose of high-pressure air from the compression chamber, making

sure that the tip of the actual pressing checkball SST as shown in the
picture. If checkball not pressed, the air will not come out.
(E) After removing the air, off the SST. then press
plunger with a finger quickly and firmly.
A97867 OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster. (F)
Install the lash adjusters.
ATTENTION:
Replace the lash adjuster to the same place as the place from where all had
been released.

14-55
18. INSTALL ROCKER ARM VALVE SUB - ASSY NO.1

(A) Provide a clean engine oil at the end of the valve lash adjuster and the valve stem cap surface. To-
mudian plug valve rocker arm.
WARNING:
Install the valve stem caps and rocker arm valve to the same place as the place from where all had been released.
Timing mark Paint mark 19. INSTALL CAMSHAFT

(A) Provide a clean engine oil on the cam measles
shafts and cylinder head journal.
(B) Replace the timing chain on camshaft timing gear, with
paint marks on the joints aligned with the timing mark on the camshaft
timing gear.
A97873
(C) Attach to - 2 camshaft as shown in the picture.

A C
ATTENTION:
Align the paint marks and signs before setting up the camshaft timing.
B D
B
A
D
C
A97874
Close Edge Stem ATTENTION:

rocker
Before and after installing camshaft and camshaft 2, check that the rocker
Arm
arm arranged precisely on the lash adjuster.
RIGHT FALSE
Lash Adjuster
G35211

(D) Install the camshaft bearing cap is loosened No. 1. (e) Check the correct
location of each - each lid
camshaft bearings and pairs each - each one. (F)
20 Install the ring - O new camshaft bearing cap No. 1. (g) To temporarily
12 4 8 16
plug the oil delivery pipe. (H) Tighten the bolts - the bolts in the order shown
18
15
11 3 7
in the picture.
A 21
9 1 5 Moment:
13
17 12 N m (122 kgf cm long, 9 ft lbf) to bolt A
15.5 N m (158 kgf cm, 11 ft lbf) except for the bolt A
19 10 2 6 14
A97876
20. INSTALL CAMSHAFT TIMING SPROCKET

Timing mark
(A) Turn the camshaft so that the camshaft timing marks and
knock pin camshaft No. 2 is as shown in FIG.
Timing mark
(B) Rotate the crankshaft pulley and align the groove tandanyadengan
timing mark 0 on the lid of the timing chain.
Straightening Pin Timing mark
Plot
A97877
Paint mark (C) Replace the timing chain on camshaft timing sprocket,
with a paint mark is aligned with the timing mark on camshaft timing
sprocket.
(D) Align the camshaft knock pin No. 2 and a pin hole measles
timing shaft sprocket. Then put the camshaft timing sprocket to camshaft
No. 2.
ATTENTION:
Timing mark If the knock pin and pin hole is difficult to be straightened out, turn slightly
A97878 camshaft No. 2 to the left and right using the hexagon-shaped section on
the camshaft. Then try to straighten again.

14-57
(E) Hold camshaft with a key, and then kencang-

bear
kan sprocket bolt.
Tighten Moment: 78 N m (795 kgf cm, 58 ft lbf)
(F) Remove the hexagon key of the chain tensioner.
A97863
(G) Provide adhesive until 2 or 3 screw on lid stopper

adhesive timing chain.
adhesive:
No. Part 08833-00070, THREE BOND 1324 or equivalent quality.
ATTENTION:
Clean the oil that is in the bolt holes.
A58128
(H) Using a hexagon socket key 10 mm, plug

stoppers timing gear case.
A86539

(A) Replace the ring - O new camshaft bearing cap. (B) Replace the
timing chain guide with 2 screws.

(A) Replace the lid gasket cylinder head and cylinder gasket
head No. 2 on the lid of the cylinder head. (B) Clean the packing material
(FIPG) long that is. (C) Give seal packing to 2 locations as shown
in the picture.
Seal Packing
A97879
S Clean oil is on the surface of contact.

S Install the cover of the cylinder head within 3 minutes after administration of the
packing seal.
S Do not give the engine oil for at least 2 hours after installation.

17 18 (D) Replace it loose headgear with 19 bolts and

19 20
21
2 nuts.
(E) Tighten the 19 screws and two nuts evenly with
23 67
16 9
(F) Connect the wire harness on 6 klemnya.
541 8
10
13 12 11
15 14 G35202

24. POST AIR CONNECTOR ENTRY CHANNELS (See page 14-18)
27. RESET DO WORK STARTS FROM THE BEGINNING (See pages 01-16) WARNING:

31. CHECK THE CONCENTRATION CO (See page 14-1)
32. CHECK THE THROTTLE BODY FUNCTION (See page 10-3)

MECHANICAL MACHINES -- GASKET CYLINDER HEAD (MACHINE 1TR - FE) 14-59
GASKET CYLINDER HEAD (MACHINE 1TR - FE)

141YD - 01
REPLACEMENT

(A) Place the engine assembly to stand.

8. REMOVABLE INTAKE MANIFOLD (See pages 14-18)
9. OFF EXHAUST MANIFOLD (See pages 14-18)
(A) Remove the bolt, high-surface and ring gauges - O.
11. INTRODUCTION TO TAKE THE SURFACE HIGH STANDARD OIL
13. With A / C:
OFF COMPRESSOR MOUNTING BRACKET NO.1 (See pages 14-18)
14. TAKE TENSIONER ASSY V - Ribbed BELT (See pages 14-18)
15. OFF LINE IN AIR
(A) Remove the bolt, 2 nuts, gaskets and water inlet.
16. OFF THERMOSTAT (See page 16-7)
(A) Using the 24 mm socket wrench, remove the oil pressure switch.
18. OFFSHORE PIPELINE BY - PASS WATER NO.1 (See pages 14-18)
20. RELEASE CYLINDER HEAD COVER SUB - ASSY (See page 14-36)
22. TAKE PULI CRANKSHAFT (See halaman14--36)
23. BAK OFFSHORE OIL SUB - ASSY NO.2 (See pages 14-36)
25. BAK OFFSHORE OIL SUB - ASSY (See page 14-36)
26. SHUT OFF THE CHAIN TIMING (See page 14-36)
27. OFF WATER PUMP ASSY (See page 14-36)
28. RELEASE CHAIN TENSIONER ASSY NO.1 (See pages 14-36)
29. RELEASE CHAIN TENSIONER SLIPPER
(A) Remove the bolt and the tensioner slipper.
30. RELEASE CHAIN VIBRATION DAMPER NO.1
(A) Remove the 2 bolts and vibration damper.
31. RELEASE CHAIN SUB - ASSY
32. TAKE CAMSHAFT (See pages 14-48)

14-60
MECHANICAL MACHINES -- GASKET CYLINDER HEAD (MACHINE 1TR - FE)
33. RELEASE CYLINDER HEAD SUB - ASSY

3 5 10 8 2 (A) Using a 10 mm hexagon key, loosen it
evenly - 10 bolt in the order shown in the picture. Disconnect to - 10
cylinder head bolts and plate washer.
WARNING:
S Be careful - careful janganmenjatuhkan washer into the cylinder
1 7 9 6 4 head.
A97901 S Crookedness or cylinder head cracks can result from releasing the
bolt in the wrong order.
34. RELEASE CYLINDER HEAD GASKET
35. INSTALL CYLINDER HEAD GASKET

15 (0591)
(A) Give seal packing to the side of the cylinder and the top side atasblok
cylinder head gasket continue - constantly as shown in FIG.
15 (0591)
Seal packing: No. Part 08826-00100 or equivalent
15 (0591)
Seal width: 4 to 7 mm (0:15 until 0:28 in.) WARNING:
mm (in.) 15 (0591) S Clean the existing oil from the surface of the contacts.
A97915
S Replace the cylinder head gasket in 3 minutes after giving a seal

packing.
S Install the cylinder head bolts in 15 minutes after giving the seal
packing.
S Do not put engine oil thereto within 2 hours of installation time.
On the side of the Cylinder Head Gasket

(B) Place the new cylinder head gasket on the surface
a cylinder block with a stamp Lot No. facing upwards.
Lot No.
WARNING:
S Note the direction of installation.
S Place the cylinder head gently so as not to damage the cylinder
head gasket denganbagianbawah.
36. INSTALL CYLINDER HEAD SUB - ASSY
INSTRUCTIONS:
Front
A97916 Cylinder head bolts are tightened in the second phase of the implementation of tightening.
(A) Place the cylinder head on the cylinder block. (B) Provide a thin layer of
engine oil on and below the to-screw
nutmeg cylinder head bolts.

MECHANICAL MACHINES -- GASKET CYLINDER HEAD (MACHINE 1TR - FE) 14-61
(C) Using a 10 mm hexagon key, plug and Kendal

8 6 1 3 9 cangkan evenly - 10 bolt cylinder head with a plate washer,
dalambeberapa stage, with the sequence shown.
10 4 2 5 7
A97901
(D) Mark the front of the cylinder head bolt head de--
90_ ngan paint.

90_
(E) Tighten the screw cylinder head with 90_ da-
lam order according to the number indicated in step (c). (F)
Home
Machine Tighten the screw cylinder head with additional 90_.
Paint mark (G) Check that the paint marks now facing towards
A97917 back.
(H) Seal packing will leak out on the side depanmesin.

Front side Machine
Cylinder Head Clean thoroughly all existing packing seal.
Gasket
Cylinder Head
Clear
Cylinder Block
Until clean
A97918
37. INSTALL CAMSHAFT (See pages 14-48)

38. INSTALL CHAIN VIBRATION DAMPER NO.1
(A) Install vibration damper with two bolts.
39. INSTALL CHAIN SUB - ASSY (See page 14-36)
40. INSTALL CHAIN TENSIONER SLIPPER
(A) Replace the bolt tensioner slipper.
41. INSTALL CHAIN TENSIONER ASSY NO.1
(A) Install a new gasket and chain tensioner with bolts and nuts.
(A) Replace your chain with bolt.
43. TIDE WATER PUMP ASSY (See page 14-36)
44. INSTALL TIMING CHAIN COVER (See page 14-36)
45. POST BAK OIL SUB - ASSY (See page 14-36)

14-62
MECHANICAL MACHINES -- GASKET CYLINDER HEAD (MACHINE 1TR - FE)
47. POST BAK OIL SUB - ASSY NO.2 (See pages 14-36)
48. POST PULI CRANKSHAFT ( See pages 14-36)
50. INSTALL CYLINDER HEAD COVER SUB - ASSY (See page 14-36)
51. INSTALL OIL FILLING CLOSE
52. PIPELINE INSTALLATION BY - PASS WATER NO.1 (See pages 14-36)
54. POST TENSIONER ASSY V - Ribbed BELT (See pages 14-36)
57. With A / C:
INSTALL MOUNTING BRACKET COMPRESSOR NO.1 (See pages 14-18)
(A) Replace the ring - a new O and introduction of high gauge oil surface with bolts.
61. INSTALL EXHAUST MANIFOLD (See pages 14-18)
62. INSTALL EXHAUST MANIFOLD NO.1 heat insulator (See pages 14-18)
63. INSTALL INTAKE MANIFOLD (See pages 14-18)
(A) Replace the ignition coil with the bolt.
70. ADD ENGINE OIL (See page 17-3)

ADD AUTOMATIC TRANSMISSION FLUID (See page 40-2)
72. ADD LIQUID COOLING ENGINE (See page 16-3)
CHECK AND / OR ADD OIL MANUAL TRANSMISSION (See page 41-2)
CHECK THE FLUID LEVEL IN AUTOMATIC TRANSMISSION (See page 40-2)

MECHANICAL MACHINES -- OIL PUMP SEAL (ENGINE 1TR - FE) 14-63
OIL PUMP SEAL (ENGINE 1TR - FE)

141YE - 01
REPLACEMENT

5. OFF FAN Shroud (See pages 16-13)
6. PULI OFF FAN
7. OFF PULI CRANKSHAFT

(A) Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Loosen SST
bear A99211
(B) Using SST, remove the pulleys and pulley bolt.

SST 09950-50013 (09951-05010, 09952-05010, 09953-05010,
09954-05021)
bear
Loosen SST
SST
A97882
8. OFFSHORE OIL PUMP SEAL

(A) Using a screwdriver with the edges covered, tipping
seal oil out.
ATTENTION:
After the release, check the damage on the crankshaft. If damaged, puree
the surface with sandpaper 400 - grit.
Tape
protector Pinch
A97883

14-64
MECHANICAL MACHINES -- OIL PUMP SEAL (ENGINE 1TR - FE)
9. OIL PUMP SEAL POST

(A) MenggunakanSSTdan hammer, knock the oil seal kedalamsam-
pie flat surface with the rear oil seal retaining periphery. SST
09223-50010
ATTENTION:
S Keep your mouth clean from foreign objects.
SST
S Do not knock the oil seal at an angle ..
A97884 (B) Give the MP on the lips plump new oil seal.
10. PULI INSTALL CRANKSHAFT

SST pulleys and sliding pulinya added. (B) Using SST, install a new
SST 09213-54015 (91651-60855), 09330-00021
Do not reuse the pulley bolt.

A97885
11. POST PULI FAN

12. POST FAN Shroud (See pages 16-13)
14. CONNECT RADIATOR INLET hose (See page 14-8)


14-65
MECHANICAL MACHINES -- RETAINING SEAL REAR ENGINE OIL (MACHINE 1TR - FE)
RETAINING SEAL REAR ENGINE OIL (MACHINE 1TR - FE) REPLACEMENT

141YF - 01

4. OFF DRIVE BELT (See pages 14-70)
6. PULI OFF FAN
OFF MANUAL TRANSMISSION UNIT ASSY (See page 41-4)
OFF AUTOMATIC TRANSMISSION ASSY (See page 40-15)

OFF PLATE CLUTCH DISC ASSY (See page 42-16)
Flywheel OFF SUB - ASSY (See page 14-18)
OFF DRIVE PLATE & RING GEAR SUB - ASSY (See page 14-18)
Protective
13. OFFSHORE OIL SEAL RETAINING REAR ENGINE
ribbon (A) Using a knife, cut depleted oil seal lip. (B) Using a screwdriver with tape
wrapped edges,
tipping seal oil out.
ATTENTION:
After the release, check the damage on the crankshaft. If damaged, puree
Position
the surface with sandpaper 400 - grit.
Cut Position Cut A99212
14. INSTALL REAR ENGINE OIL SEAL RETAINING

(A) Give chubby MP on new oil seal lip.
SST
ATTENTION:
Keep the oil seal lips clean of foreign objects.
(B) MenggunakanSSTdan hammer, knock the oil seal kedalamsam-
pie flat surface with the rear oil seal retaining periphery.
SST 09223-15030, 09950--70010 (09951--07150)

A99213 ATTENTION:
Clean the excess grease from the crankshaft.

14-66
MECHANICAL MACHINES -- RETAINING SEAL REAR ENGINE OIL (MACHINE 1TR - FE)

INSTALL DRIVE PLATE & RING GEAR SUB - ASSY (See page 14-18)
Flywheel POST SUB - ASSY (See page 14-18)
INSTALL AUTOMATIC TRANSMISSION ASSY (See page 40-15)
INSTALL MANUAL TRANSMISSION UNIT ASSY (See page 41-4)
21. POST PULI FAN
24. CONNECT RADIATOR INLET hose (See pages 16-13)


MECHANICAL MACHINES -- MACHINE (MACHINES 2KD - FTV) 14-67
MACHINE (MACHINES 2KD - FTV)

141Z5--01
EXAMINATION
1. CHECK THE ENGINE COOLING FLUIDS (See pages 16-21)
2. CHECK THE ENGINE OIL (See pages 17-25)
3. CHECK THE BATTERY (See pages 19-23)
4. CHECK THE AIR CLEANER FILTER ELEMENT SUB - ASSY
5. CHECK THE FAN AND GENERATOR V BELT CAUTION:

AB
It is not necessary to measure the tension and flexibility of the V belt for
use on V belt automatic tensioner.
(A) Ensure that the tensioner indicators are in ren-

pliers B.
If the marks do not fall within the range B, replace the V belt. INSTRUCTIONS:
A74374
After replacement of V belt, make sure that the indicator bolt tensioner is within
the range A.
INSTRUCTIONS:
S After installing the V belt, check that V belt right located in the ribs with a
perfect groove. Check the de-ngan your hands to ensure that the belt does
not slip out of the groove in the bottom of the crankshaft pulley
RIGHT FALSE
S "New Belt" is a belt that has been used for less than 5 minutes on engine
life.
A87787 S "Used Belt" is a belt which has been used on the engine for 5 minutes or
more.
S After installing a new belt, turn the machine on for about - about 5
minutes and then check back kete-gangannya.
6. CHECK ROUND AND ROUND THE MAXIMUM ENGINE IDLE
INSTRUCTIONS:
S For more detailed information about the intelligent tester II, refer to the
operation guidelines.
S If there are no intelligent tester II, use a probe tester tachometer instead.

14-68
MECHANICAL MACHINES -- MACHINE (MACHINES 2KD - FTV)
Intelligent Tester II (A) Connect the intelligent tester II to DLC3.
DLC3 A98433
(B) If not available tester, connect the tester probes tachometer to terminal 9
(TAC) of DLC3 with SST. SST 09843-18030 (c) Check the idle rotation.
12345678 (1) Start the engine and measure the idle rotation.
Idle rotation: 700 to 800 rpm
9 10111213141516 If the idle rotation is not as specified, check diagnostic troubleshooting chapter.
(D) Check the maximum rotation.
TAC
A82779
(1) Start the engine. (2) Press the accelerator pedal fully.
(3) Measure the maximum rotation.
Maximum round: 4.450 to 4.750 rpm

If the maximum rotation is not as specified, pe-Interrogation diagnostic
troubleshooting chapter. (E) Dalamkeadaan tachometer probe tester is
connected to
DLC3, remove the probe tester with SST from terminal 9 on DLC3. (F)
Disconnect the intelligent tester II of DLC3.

7. CHECK THE CYLINDER PRESSURE compression
INSTRUCTIONS:
Measure the compression pressure if tenagamesin tidakmencukupi, excessive oil

consumption and / or fuel wasteful. (A) Remove all - 4th glow plug (see pages
19-32). (B) Remove all to - 4 injector connector. (C) Turn the ignition switch to
START untukmemaksa out je-
games and other foreign objects from inside the cylinder.
(D) Install the SST (attachment) into the glow plug hole.
SST
SST 09992--00025 (09992--00121)
(Gauge Compression)
(E) Connect SST (measuring compression) to the SST (attach-
ment).
SST 09992-00025 (09992-00211) (f)
Measure the compression pressure while turn on / start the engine.
SST (Attachment)
A38771

MECHANICAL MACHINES -- MACHINE (MACHINES 2KD - FTV) 14-69
INSTRUCTIONS:
Always use a fully charged battery to get the engine rotation of 250 rpm or more.
(G) Repeat steps (d) through (f) for each silin-

der.
ATTENTION:
These measurements should be done in the shortest possible time.
Compression pressure:
2,700 kPa (27.5 kgf / cm 2 391 psi) or more minimum
pressure:
2,200 kPa (22.5 kgf / cm 2 320 psi) The difference
between each cylinder: 500 kPa (5.0 kgf / cm 2 71 psi)
or less
If the compression in one cylinder or more is low, give a little engine oil into the
glow plug hole. Then repeat the above steps (d) through (f) for the cylinder -
cylinder pressure kompressinya - low). INSTRUCTIONS:
S If the pressure increases slightly after giving kompressinya engine oil,

piston rings and / or hole-der SILIN may have worn out or damaged.
S If the pressure is low, the valve may be stuck or improperly seated. Or

the pressure may leak through the gasket.
(H) Remove the SST (attachment and gauge compressed). (I)

Connect all to - 4 injector connector. (J)
Replace all - 4th glow plug (see pages 19-32).

14-70
MECHANICAL MACHINES -- DRIVE BELT (MACHINE 2KD - FTV)
DRIVE BELT (MACHINE 2KD - FTV)

1411I - 03
REPLACEMENT
1. OFF FAN AND GENERATOR V BELT
(A) Using the tensioner pulley bolt set, tensioner pulleys rotate clockwise to-untukmengendorkan
voltage V belt. Then remove the V belt.
2. TIDE FAN AND GENERATOR V BELT

With A / C
Idler No. 3
(A) Use the bolt tensioner pulley set, turn the tensioner pulley Sea-
Kompressor A / rah clockwise, and then attach the V belt.
C Puli fans ATTENTION:
Make sure that the V belt has been installed correctly on each pulley.
Idler No. 2
Generator
crankshaft
tensioner
Without A / C
Puli fans
Generator
crankshaft
tensioner
G35153
(B) Ensure that the indicator mark on the tensioner is located

A
in the range of A in the picture.
A72433

14-71
MECHANICAL MACHINES -- GAP VALVE (MACHINE 2KD - FTV)
GAP VALVE (MACHINE 2KD - FTV)

1411J - 03
ADJUSTMENT

3. Drain FUEL
4. SHUT OFF MACHINE SUB - ASSY NO.1 (See pages 14-87)
7. OFFSHORE PIPE INJECTION (See pages 11-45)
8. TAKE COVER CYLINDER HEAD SUB - ASSY (See page 14-115)
9. OFF INJECTOR ASSY (See page 11-45)
10. CYLINDER SET NO. 1 TO TDC / compression

(A) Align the mark matching the crankshaft pulley and
close timing gear case to rotate the crankshaft clockwise.
INSTRUCTIONS:
Make sure that both the nose - cam (side intake and exhaust side) on the
cylinder No. 1 facing upwards.
Matching mark
A72847
11. CHECK THE VALVE GAP
EX EX EX EX (A) Check only the valve - the valve shown.

(1) Using a feeler gauge, measure the gap between the lifter
valves and camshaft.
Slit valve (Cold):
intake 0:20 to 0.30 mm (0.008 to 0.012 in.)
exhaust 0:35 to 0:45 mm (0.014 to 0.018 in.)

IN IN IN IN
Record the size of the valve gap which exists outside of the specified range. This
A60176
size will be used later to determine the size of the adjusting shim that will be
installed. (B) Rotate the crankshaft dalam360_ untukmengatur cylinder No.
4 to TDC / compression.

14-72
(C) Check valve shown only.

EX
EX EX EX (1) Using a feeler gauge, measure the gap between the lifter
valves and camshaft.
Slit valve (Cold):
intake 0:20 to 0.30 mm (0.008 to 0.012 in.)
exhaust 0:35 to 0:45 mm (0.014 to 0.018 in.)
Record the size of the valve gap which exists outside of the specified range. This
IN IN IN IN
size will be used later to determine the size of the adjusting shim that will be
A60175
installed.
12. Set GAP VALVE
(A) Drain the coolant (see pages 16-23). (B) Remove the fan shroud
(see pages 16-26). (C)
Remove the cover No. 1 timing belt (see pages 14-105). (D) Remove
the timing belt (see pages 14-105). (E) Remove the camshaft timing pulley
(see page 14-110). (F)
Remove the timing belt idler sub - assy No. 1 (see page 14-105). (G) Remove the
cover No. 2 timing belt (see pages 14-110). (H) Remove the camshaft and camshaft No. 2
(see pages 14-110).
(I) Remove the valve lifters.
(J) Using a micrometer, measure the thickness of the lifter that te

was released.
(K) Calculate new thickness so that slit valve lifter entry
within a specified value.
A The thickness of the new lifters
B The thickness of the old lifter
C The size of the valve gap
A01082 Slit valve (Cold): Intake A = B + (C - 0:25 mm (0.0098 in.))

Exhaust A = B + (C - 0:40 mm (0.00158 in.))
(L) Choose a new lifter with thickness as close as possible to the value of the
calculation. INSTRUCTIONS:
Valve Lifter is available in 35 sizes with the addition

0.020mm (0.0008 in.), Of 5.060mm (0.1992 in.) To 5,740 mm (0.2260 in.).
(M) Install the valve lifter selected.

Tables Valve Lifter Options (Valves Sign)
The thickness of the lifter

Installed
mm (in.)
Size
Cracks mm (in.)
MECHANICAL MACHINES
--
New Lifter thickness mm (in.)
No. The thickness No. The thickness No. Thickness

Slit valves Log (Cold):

0:20 to 0.30mm (0.008 to 0.012 in.)
EXAMPLE:
Installed lifter 5.250mm (0.2067 in.), And the size of the valve gap
is 0.400 mm (0.0158 in.). Replace shim 5.250mm (0.2067 in.)

With Lifter No. 40 new ones.
A72846
14-73
14-74
Tables Valve Lifter Options (Valves Remove)
The thickness of the lifter

Installed
mm (in.)
Size
Cracks mm (in.)

MECHANICAL MACHINES
--
New Lifter thickness mm (in.)
No. The thickness No. The thickness No. Thickness

Remove the valve slit (Cold):

0:35 to 0:45 mm (0.014 to 0.018 in.)
EXAMPLE:
Installed lifter 5.340mm (0.2102 in.), And the size of the valve gap
is 0480 mm (0.0189 in.). Change shim5.340mm (0.2102 in.) With
a new Lifter No. 42.
A72845
14-75
(N) Install camshaft and camshaft No. 2 (see page

14-110).
(O) Install the cover No. 2 timing belt (see pages 14-110). (P) Replace timing
belt idler No. 1 (see page 14-105). (Q) Replace camshaft timing pulleys (see
pages 14-110). (R)
Replace the timing belt (see pages 14-105). (S) Install the cover No. 1
timing belt (see pages 14-105). (T)
Install the fan shroud (see pages 16-26). (U)
Fill the coolant (see pages 16-23).
13. POST INJECTOR ASSY (See page 11-45)
14. FUEL LEAK CHECK THE (See pages 11-45)
19. INSTALL ENGINE COVER SUB - ASSY NO.1 (See pages 14-87)
20. CONTENTS OF FUEL
22. POST AIR CLEANER PIPE SUB - ASSY NO. 2 (See pages 14-87)


14-76 MECHANICAL MACHINES -- PARTIAL ENGINE ASSY (MACHINE 2KD - FTV)
PARTIAL ENGINE ASSY (MACHINE 2KD - FTV) COMPONENTS

141Z6--01
11.5 (117, 8.5)

Left Front Wiper
Arm
Wiper arm Right
Home
Air Cleaner Assy
Headgear Arm Wiper Home Hose
nozzle
14 (143, 10)
Washer
Right Cowl Louver TopVentilator
Seal Kap Machine to Cowl Top

Left Clips
Ventilator Louver
Cowl Top
8.0 (81, 70 in. Lbf)
5.0 (51, 44 in. Lbf)
5.0 (51, 44 in. Lbf)

Inlet Pipe No. 1 Cooling Oil A / T: Cowl Panel Sub - assy
Oil reservoir
Pipe Outlet No. 1 Cooling Oil A / T:

Without A / C: V Belt
fans and Generator
adiator
25 (255, 18)
Tank Assy Assy R 5.0 (51, 44 in. Lbf)
x4
Radiator Reservoir
coupling Fan
Puli Fan Fan

Radiator Outlet With A / C: VBelt danGenerator
fan Shroud
Inlet hose Radiator hose

12 (122, 9)
5.0 (51, 44 in. Lbf)
bracket Clip
Battery
Battery
Alas Battery
Grill Radiator

G37592

14-77
MECHANICAL MACHINES -- PARTIAL ENGINE ASSY (MACHINE 2KD - FTV)
The air hose No. 2
20 (204, 15) The air hose No.

1
18 (184, 13)

A98883

cables Period
Close Up R / B
13 (133, 10)
No. 1
connector Communities
Starter cable
Engineering Close R / B
Connector A / B at Space
connector Starter Cable A / B at Space
Engineering
30 (306, 22)
cables Period

G37240

14-79
Drawer Connector Assy
*2
*1
*2
*1 *2
*1 *2
* 1: A / T: TCM Close
* 2: ECM connectors
G37571

SlangBahanBakar
51 (520, 38)
Giving Pipe
Pressure
Reservoir to Pump Slang Slang

A98995

14-81
MANUAL TRANSMISSION (G58) Shift Knob Lever Sub

- assy
Console Top Panel Assy
Console Box Assy
z gasket
Boot Shift Lever Assy
z gasket
48 (490, 35)
72 (738, 53)
68 (694, 50)
x8
43 (438, 32)
37 (377, 27)
starter Assy
* 1 68 (694, 50)
Rear Propeller Shaft Assy
Assy Clutch Release Cylinder
12 (120, 9) Insulator Rear Engine

Frame crossmember Sub - Mounting No. 1
assy No. 3
50 (510, 37)
44 (449, 32)
50 (510, 37)
27 (275, 20)


TRANSMISSION AUTOMATIC ( A340E)
Propeller shaft with Central Bearing Assy
(897, 64)
Pipe Outlet No. 1

5.0 (50, 43)
Cooling Oil
12 (122, 9)
71 (720, 53)
Inlet Pipe No. 1

x5
Cooling Oil Torque Converter
28 (286, 21)
Clutch Assy
Transmission Control Cable
41 (421, 30) Bracket
Plat Tip No. 2 Sub Transmission Oil Surface

gauges - assy
x6 starter Assy
Insulator No. 4 Block
Assy
Cylinders
(720, 53) 68 (693, 50)
Right Plate stiffener

Plate stiffener Left Sub Transmission Oil
71 (720, 53) 68 (693, 50)
71 (720, 53) 71 Filling pipe - assy
Oil Cooling pipe with clamps Sub - Insulator Rear Engine Mounting
assy No. 1 12 (122, 9) 88
Disposal Pipe Assy
z gasket assy No. 2 Automatic Transmission
Home 48 (490, 35) z Ring - O
65 (660, 48)
z gasket
50 (510, 37)
50 (510, 37)

assy No. 3
43 (439, 32)
27 (275, 20)
G34846

14-83
MANUAL TRANSMISSION
Rear End Plate
Clutch Plate Assy

178 (1,815, 132)
x8
19 (195, 14)
Flywheel Sub - assy
x8
Clutch Cover Assy
N m (kgf cm, ft lbf) : Moment of tightening G35126
AUTOMATIC TRANSMISSION
Rear End Plate
drive Plate
Sub - assy Drive Plate Spacer
x8
178 (1,815, 132)
N m (kgf cm, ft lbf) : Moment of tightening Flywheel

G35207

Fluid Temperature Sensor PendinginMesin / Engine Coolant Temperature (ECT)

20 (204, 15)
Timing Belt Idler Sub

- assy No. 1
washer
35 (357, 26)
x6 13 (133, 10)
timing Belt
Chain Tensioner Assy No. 1
z Ring - O 39 (398, 29)
Timing Belt Cover Crankshaft pulley
6.0 (61, 53 in. Lbf) 365 (3.722, 270)
z Ring - O
Vane Pump Assy

21 (214, 16)
Vakuum Pump Assy
z Part that should not be used anymore G35421

20 (204, 15)
z gasket
Air Line Connector Sign
2.2 (22, 19 in. Lbf) Diesel Throttle
Body Assy
Glow Plug Connector No. 1
Vacuum Switching Bracket
screw grommet
20 (204, 15)
20 (204, 15) z gasket

13 (133, 10)
EGR Pipe Sub - assy No. 1

Introduction
Surface gauges Oli
EGR Valve Assy
z gasket
Glow Plug Assy
z gasket
13 (133, 10)
Line Out Water
8.0 (82, 71 in. Lbf)

intake Manifold
19 (195, 14)
29 (296, 21)
z gasket Surface gauges Oli 19 (195, 14)
21 (214, 16)
z Ring - O
* 32 (326, 24) 35
(357, 26)
PompaSupplyAssy
crutch
5.0 (51, 44 in. Lbf)
z Ring - O
Clamps No. 2 * 32 (326, 24) 35

(357, 26)
Pipe Injection
* 32 (326, 24) 35 z Clamp

(357, 26)
21 (214, 16)
Leaking pipe nozzle Assy No. 2

Clamps No. 3
Pipe Injection
13 (133, 10)
5.0 (51, 44 in. Lbf)
Common Rail Assy

38 (387, 28)
z gasket
68 (694, 50)
Sub Oil Filter - assy Left Engine

Mounting Bracket
Close Cooling Oil Sub - assy

13 (133, 10)
* For use with SST G37609

14-87
141Z7--01
REPLACEMENT

3. Drain OIL TRANSMISSION AND TRANSMISSION FLUID (See page 41-2 or 40-2)
6. Drain FUEL
(A) Remove the washer nozzle hose. (B)
Remove the 4 screws and bonnet.
9. OFF COWL PANEL SUB - ASSY
10. RADIATOR GRILL OFF (See page 16-35)
11. TAKE BATTERY BRACKET
12. RELEASE AND BACKING BATTERY BATTERY
13. OFF AIR CLEANER ASSY
(A) Remove the IAT sensor connector. (B)
Loosen the hose clamp. (C)
3 Remove the bolts and air cleaner.
14. TAKE RADIATOR ASSY (See page 16-35)
17. TAKE PROPELLER SHAFT ASSY (See page 30-4)
18. TAKE THE TRANSMISSION ASSY (See page 41-2 or 40-2)

14-88
19. LET slang - slang and CONNECTORS - CONNECTORS

(A)
(A) Remove the lid on the R / B. (B)

Remove the cover No. 1 R / B (c)
Remove the nut and remove the cable A / B engine room. (D) Remove the
2 connectors J / B and the engine room. (E) Remove the bolt and remove the
(C)
cables period.
(D)
(B)
(E)
G35294
(F) 2 Remove the injector driver connector.
G35296

14-89
(G) Automatic Transmission:

3 Remove the TCM connector. (H)
Remove the four connectors ECM.
(H)
(G)
(H)
(G) (H)
(G) (H)
G35427
(I) 2 Remove the fuel hose. (J)

Remove the pump hose Vakuum. (K)
(I)
Remove the pump hose from the oil reservoir.
(I)
(K)
(J)
G35298
(L) Using SST, remove the giver pressure pipe.

SST 09023-12701
SST
G34367

14-90
20. KOMPRESSOR OFF COOLING ASSY

(A) Remove the 4 screws and refrigeration compressors.
INSTRUCTIONS:
Hanging kompressornya rather than releasing it.

23. Flywheel OFF SUB - ASSY (See page 14-123)
24. TAKE BACK END PLATE
(A) Remove the bolt and the rear end plate.
25. OFF MACHINE ASSY

Engine Hanger No. 1Engine Hanger No. 2
(A) Install the engine hanger No. 1 above and gantunganme-
Sin No. 2 in the place shown in FIG.
Moment:
25 N m (255 kgf cm, 18 ft lbf) for hanging the machine No. 1
68 N m (693 kgf cm, 50 ft lbf) for hanging the machine No. 2
A98932 HINT: No. part:
Part name No. part
Bolt 12284-30020
Hangers machine No. 1 on
(91512-61014)
Bolt 12282-67020
Hangers machine No. 2
(91642-81030)
ATTENTION:
Use new bolts for mounting the engine hanger.
(B) Hold the machine with the engine and chain lifter. (C)
Remove the 4 screws and 4 nuts.
(D) Remove the engine by operating the lifter

machinery and chains.
G36026
26. RELEASE engine cradle

14-91
A98879
28. SHUT OFF ENGINE BRACKET

(A) Remove the two screws and bracket hood.
(A) (B) 29. OFF AIR CLEANER PIPE SUB - ASSY NO.2
(C)
(A) Remove the manifold absolute pressure sensor connector. (B) Remove
(C)
the hose Vakuum. (C) Loosen the two clamps.
(D) Remove the bolt and pipe cleaner water along with 2
air hose.
(D)
A98889
30. TAKE CABLE - CABLE MACHINE

(A) Remove the cable - the cable machine from the machine.
31. SHUT OFF NO. 1 TIMING BELT

(A) Remove the bolt and clamp the hose. (B)
Remove wire harness clamps. (C)
6 Remove the bolt and close timing belt.
A15094

33. CHECK THE TIMING BELT IDLER SUB - ASSY NO.1 (See pages 14-105)
34. CHECK THE CHAIN TENSIONER ASSY NO.1 (See pages 14-105)
35. CHECK THE TIMING BELT (See pages 14-105)

14-92

SST
(A) Using SST, remove the pulley bolt.
SST 09213-58013, 09330-00021
A72413
(B) Using SST, remove the pulleys.

SST
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
ATTENTION:
Give the oil or grease on the thread and the end of the SST (bolts te-ngah)
before using it.
A72414
37. OFF TIMING CAMSHAFT PULLEY (See pages 14-110)

38. LET slang Ventilation (See pages 13-11)
39. TAKE VENT PIPES (See halaman13--11)
40. OFF TURBO insulator NO.1 (See pages 13-11)
41. OFFSHORE OIL TURBO INLET PIPE SUB - ASSY (See page 13-11)
42. RELEASE EXHAUST MANIFOLD
(A) Remove the 8 bolts and exhaust manifold with turbocharger
as shown in the picture.
G37633
43. CHECK THE EXHAUST MANIFOLD

(A) Using a straight edge and feeler gauge precision,
crookedness measuring surfaces in contact with the cylinder head.
The maximum crookedness: 0:40 mm (0.0157 in.)

If kebengkokannya greater than the maximum, replace the exhaust manifold.
A98949
44. RELEASE BRACKET GENERATOR

(A) Remove the 2 bolts and brackets.

14-93

A98937
47. RELEASE MOUNTING BRACKET NO.1 KOMPRESSOR

(A) Remove the connector. (B) Remove the 2
bolts and brackets.
48. OFF THERMOSTAT (See pages 16-29)
49. TAKE OUT OF WATER CHANNEL

(A) Remove the 2 screws and drain out the water.
A98933
50. TAKE GLOW PLUG ASSY (See page 19-32)
51. RELEASE cantilever MANIFOLD

(A) Remove the 2 bolts and support.
G37596
(C) 52. VACUUM SWITCHING OFF VALVE BRACKET

(A) Remove the connector. (B) Remove the hose Vakuum
of 2 places. (C)
(B)
Remove the two screws and brackets.
(A)
(C)
(B)
G37630

14-94
53. RELEASE DIESEL THROTTLE BODY ASSY

(A) Remove the 2 connector.
A98877
(B) Remove the 2 screws, 2 nuts, throttle body and gasket.
G37748
54 - (a) 54 - (a) 54. RELEASE BRACKET DIESEL THROTTLE BODY

54 - (a)
(A) Remove the 3 bolts and brackets.
55. TAKE THE AIR IN LINE CONNECTORS
55 - (a) (A) Remove the two nuts, bolts and air inlet connector.
55 - (a)
55 - (a) A99620
56. OFF EGR PIPE SUB - ASSY NO. 1 (See pages 12-12)
57. OFFSHORE OIL FILTER SUB - ASSY (See page 17-27)
58. RELEASE INJECTION PIPE (See pages 11-45)
59. PIPELINE LEAK OFF NOZZLES ASSY NO.2 (See pages 11-61)
60. OFF FUEL INLET PIPE SUB - ASSY (See page 11-55)
61. TAKE COMMON RAIL ASSY (See page 11-61)
62. OFFSHORE SUPPLY PUMP ASSY (See page 11-55)
63. INTRODUCTION TO MEASURING SURFACE OFFSHORE OIL
(A) Remove the bolt, introductory oil surface and ring gauges - O.

(A) Remove the four bolts, two nuts, manifold and gasket.
G37631

14-95
65. CHECK THE INTAKE MANIFOLD

(A) Using a straight edge and feeler gauge precision,
crookedness measuring surfaces in contact with the cylinder head.
The maximum crookedness: 0:50 mm (0.0197 in.)

If kebengkokannya greater than the maximum, replace the intake manifold.
A98945
66. SHUT OFF COOLING OIL SUB - ASSY (See page 17-52)
67. TAKE PUMP ASSY VAKUUM

(A) Remove the two nuts, and 2 ring Vakuum pump - O.
A98930
68. OFF VANE PUMP ASSY

(A) Remove the two nuts, vane pump and ring - O.
A98935
69. TAKE POSITION SENSOR CRANKSHAFT

(A) Remove the bolt, crankshaft position sensor and the ring - O.
(A) Remove the bolt and the camshaft position sensor.
71. TEMPERATURE SENSOR LIQUID COOLING OFF MACHINE (ECT)
(A) Using a 17 mm socket wrench, remove the ECT sensor.

14-96
Right Left
72. RELEASE MOUNTING BRACKET ENGINE RIGHT AND LEFT
(A) Remove the 4 bolts and brackets. mounting
A98936
73. PARTIAL CHANGE ENGINE ASSY
Right Left
74. INSTALL ENGINE MOUNTING BRACKET RIGHT AND LEFT

A98936
75. INSTALL ENGINE COOLING FLUID TEMPERATURE SENSOR (ECT)

(A) Using a 17 mm socket wrench, replace the ECT sensor.
(A) Install the sensor with the bolt.
77. INSTALL CRANKSHAFT POSITION SENSOR
(A) Provide a clean engine oil on the ring - a new O. (B) Attach the ring
- O to the sensor. (C) Install the sensor with the bolt.

(A) Replace the ring - a new O on vane pump. (B)
Replace the vane pump with two nuts.
A98935

14-97
79. POST VAKUUM PUMP ASSY

(A) Replace the ring - O new Vakuum pump. (B) Replace
Vakuum pump with two nuts.
A98930
80. INSTALL OIL COOLER COVER SUB - ASSY (See page 17-52)

(A) Install a new gasket and manifold to the cylinder head de--
ngan four screws and two nuts.
G37631
82. INTRODUCTION TO MEASURING SURFACE OIL POST

(A) Provide a clean engine oil into the ring - a new O. (B) Attach the
ring - O gauge to the oil surface. (C) Install the oil level gauge with
the screw.
83. POST SUPPLY PUMP ASSY (See page 11-55)
84. POST COMMON RAIL ASSY (See page 11-61)
85. INSTALL FUEL INLET PIPE SUB - ASSY (See page 11-55)
86. POST ASSY NO.2 PIPELINE LEAK NOZZLES (See pages 11-61)
89. POST EGR PIPE SUB - ASSY NO. 1 (See pages 12-12)
91 - (a) 90. POST AIR IN LINE CONNECTORS

91 - (a)
91 - (a)
(A) Install a new gasket and air inlet connector
with 2 nuts and bolts.
90 - (a) Moment: 20 N m (204 kgf cm, 15 ft lbf)
91. TIDE DIESEL THROTTLE BODY BRACKET
90 - (a)
90 - (a) A99620

14-98
92. TIDE DIESEL THROTTLE BODY ASSY

(A) Install a new gasket and throttle body with 2 screws and
2 nuts ..
G37748
(B) Connect the two connectors.
A98877
(A) 93. POST BRACKET VACUUM SWITCHING VALVE

(B)
(B) Connect the hose Vakuum in 2 places. (C) Connect the
(C)
connector.
(A)
(B)
G37630
94. The cantilever MANIFOLD PAIRS

(A) Replace the support with 2 screws.
INSTRUCTIONS:
A
Cantilever indentation area (labeled A) should be facing manifold.
G37635
95. POST GLOW PLUG ASSY (See page 19-32)

14-99
96. INSTALL WATER LINE OUT

(A) Install a new gasket to the cylinder head, as shown da-
lam pictures.
A98977
(B) Replace the water outlet with 2 screws.

A98933
97. INSTALL THERMOSTAT (See pages 16-29)

98. POST MOUNTING BRACKET NO.1 KOMPRESSOR
(B) Connect the connector.
block Cylinders (A) Install the tensioner with 4 screws.
A Moment: 21 N m (214 kgf cm, 15 ft lbf)
INSTRUCTIONS:
A Press firmly and hold the tensioner to the cylinder block to eliminate loopholes in
the area A in FIG. Then tighten to - 4 screws evenly.
tensioner
A97638

101. POST BRACKET GENERATOR
INSTRUCTIONS:
Do not tighten the screws before installing the generator.

14-100
102. INSTALL EXHAUST MANIFOLD

(A) Replace the 8 bolts and exhaust manifold with turbochar-
ger as shown in FIG.
G37633
103. TURBO OIL INLET PIPELINE POST SUB - ASSY (See page 13-11)
104. INSTALL VENT PIPES (See pages 13-11)
105. PAIRS slang Ventilation (See pages 13-11)
106. INSTALL CAMSHAFT TIMING PULLEY (See pages 13-11)

SST (A) Align the mounting key lock on the pulley grooves
puli.
(B) Using SST, install the pulley bolt.
SST 09213-58013
Moment: 365 N m (3.722 kgf cm, 270 ft lbf)
A72417
109. NO.1 POST COVER TIMING BELT

(A) Install the cover of the timing belt with 6 bolts.
A15094
110. PAIRS CABLE MACHINE

(A) Connect the machine to machine.

14-101
(B) (D) (C) 111. POST AIR CLEANER PIPE SUB - ASSY NO.2
(B)
bolt.
(C) Connect the hose Vakuum to absolute pressure sensor
manifold.
(A) (D) Connect the manifold absolute pressure sensor.

A98889
112. POST COVER BRACKET MACHINE

(A) Install the engine cover bracket with 2 screws.
113. POST COVER MACHINE SUB - ASSY NO.1
A98879
114. OFF MACHINE OF ENGINE STAND
115. INSTALL ENGINE ASSY

(A) Replace the chain and lifting equipment to engine hanger
machine.
(B) Lower the machine slowly - slowly into the engine room. (C) Replace the
engine mounting bracket with bolts and nuts.
(D) Remove all - 2 engine hangers.
G36026
116. POST PLATE REAR END

(A) Replace the rear end plate with bolts.
117. Flywheel POST SUB - ASSY (See page 14-123)
120. PAIRS KOMPRESSOR COOLING ASSY
(A) Replace compressor with 4 screws.

14-102
121. PAIRS slang - slang and CONNECTORS - CONNECTORS
(A) Using SST, install a pressure pipe provider.

SST 09023-12701
SST
G34367
(B) Connect the fuel hose 2. (C) Connect the hose pump
Vakuum. (D) Connect hose to pump oil reservoir.
(B)
(B)
(D)
(C)
G35298
(E) The automatic transmission:
3 Connect the TCM connectors. (F)

4 Connect the ECM connectors.
(F)
(E)
(F)
(E) (F)
(E) (F)
G35427
(G) Connect second injector driver connector.
G35296

14-103
(H) Plug the cable bolts period.

(L)
(I) Connect the two connectors A / B engine room. (J)
Plug the cable A / B engine room with a nut.
(K) Install the cover of the R / B No. 1. (l)
(J)
Replace the lid on the R / B.
(I)
(K)
(H)
G35294
122. PAIR TRANSMISSION ASSY (See page 40-6 or 41-4)

123. PAIRS PROPELLER SHAFT ASSY (See page 30-4)
127. POST AIR CLEANER ASSY
(A) Replace air cleaner with 2 screws.
(B) Connect the connector to the MAF meter. (C)
Connect a hose clamp.
128. INSTALL THE BATTERY AND BATTERY ALAS
129. POST BRACKET BATTERY
130. INSTALL RADIATOR GRILL
Moment: 8.0N m (81 kgf cm, 70 ft lbf)
132. PAIRS & LINK ASSY WIPER MOTOR FRONT GLASS
(A) Attach the hood with 4 screws.
Moment: 11.5 N m (117 kgf cm, 8.4 ft lbf)

14-104
(B) Connect the washer hose nozzles. (C) Set the bonnet
(see page 75-1).
134. CONTENTS OF FUEL
135. POST COVER FUEL TANK ASSY
136. FILLIN LIQUID COOLING MACHINE
137. FILLIN TRANSMISSION OIL AND FLUID TRANSMISSION
138. FILLIN ENGINE OIL
139. REMOVE AIR FROM FUEL SYSTEM (See page 11-39)

145. CHECK THE ROUND AND ROUND THE MAXIMUM ENGINE IDLE

MECHANICAL MACHINES -- TIMING BELT (MACHINE 2KD - FTV) 14-105
TIMING BELT (MACHINE 2KD - FTV)

141Z8--01
REPLACEMENT
3. PULI OFF FAN (See pages 16-26)
4. Lepat CLOSE NO. 1 TIMING BELT

(A) Remove the bolt and clamp the hose. (B)
Remove wire harness clamps. (C)
6 Remove the bolt and close timing belt.
A15094
5. OFF TIMING BELT

Timing mark
Timing mark (A) Turn the crankshaft clockwise and align tanda--
timing mark as shown in the picture.
A70549
(B) Loosen the 2 screws evenly and remove the tensioner ti--
ming belt. (C)
Remove the timing belt.
(D) Using a hexagon key 10mm, loose bolts, timing

belt idler and washer.
A70550

14-106
MECHANICAL MACHINES -- TIMING BELT (MACHINE 2KD - FTV)
INSTRUCTIONS:
90_
S Ketikamemutar camshaft when the timing belt has been removed, turn
90_
the crankshaft 90_ counter-clockwise.
S When installing the timing belt, it is necessary to return to the camshaft
timing mark and then turn the crankshaft clockwise, is to align with the
timing marks as shown in the picture.
A70551
6. CHECK THE TIMING BELT

FALSE
Water CAUTION:
Oil S Janganmenekuk, twisted ataumemutar bagiandalam timing belt out.
S Do not let the timing belt is exposed to oil, water or steam.
S Janganmempergunakanketegangan timingbelt when inserting or

removing camshaft timing pulley bolt fastener.
A54953
If there is damage to the above, check the following: (a)

Damage to spare before their time.
(1) Check to the proper installation. (2) Check the lid gasket timing belt if
there keru-
sakan or pemasanganya correct.
(B) If a tooth is cracked or broken timing belt, check for me-Knowing whether
there is one camshaft locked. (C)
If there is any wear or cracks that seem obvious on the face of the timing
belt, check if there are scratches on the lock side idler pulleys and water
pump. (D)
If there is any wear or damage is only on one side of the timing belt,
check your timing belt and straightness of each pulley. (E)
If there is any visible wear on teeth timing belts, timing cap check for
damage, check that gasketnya has been installed correctly, and check for
foreign objects in the tooth pulleys. If necessary, replace the timing belt.
7. CHECK THE TIMING BELT IDLER SUB - ASSY NO.1

(A) Check by hand that the idler pulley rotates de--
ngan soft.
P22783

(B) Visually inspect that part of the seal on the idler

Pulley no fat ..
ATTENTION:
S Janganmenekuk, twisted ataumemutar bagiandalam timing belt out.
S Do not let the timing belt and each - each pulley exposed to oil,
water or steam.
S Before installing, make sure to clean up any pulleys with a rag.
P22782
S Do not remove the timing belt idler No. 1 except reveal any damage.
8. CHECK THE CHAIN TENSIONER ASSY NO.1

(A) Visually inspect the oil leak in the
seal of the tensioner. If no leaks are found, replace the
tensioner. INSTRUCTIONS:
There was a little oil seepage on the sealing side of the push rod tensioner is
unacceptable.
P22742
(B) Hold the tensioner with both hands as shown da-

lam pictures. Press firmly push rod and check that the push rod is not
moving. If the push rod to move, replace the tensioner.
ATTENTION:
Do not hold the tensioner push rod facing downwards.
P22690
(C) Measure the push rod protrusion from the end housing.
Bulge Bulge: 8.1 to 8.9 mm (0.319 to 0350 in.)
If the bulge is not as specified, replace the tensioner.
P22743

14-108
MECHANICAL MACHINES -- TIMING BELT (MACHINE 2KD - FTV)
9. INSTALL TIMING BELT

Timing mark
Timing mark (A) Check that the mark - the timing marks are aligned like most
see in the pictures.
INSTRUCTIONS:
If reusing timing belt, align the point - the point marked at the time of release,
and attach the belt with an arrow pointing to the direction of rotation of the
engine.
ATTENTION:
S The engine should be cool.
S When turning the crankshaft, valve head akanmembenturmengenai
top position of the piston. Then the crankshaft janganmemutar more
than necessary.
(B) Using a 10 mm hexagon key, plug washer
A70691 and a timing belt idler pulley bolt ..
(C) Check that the idler pulley moves gently. If it does not run smoothly, check
idler sub - assy and washers (see step 7).
(D) Replace timing belt pulley to pump drive shaft, measles

shaft timing pulley and timing belt idler No. 1 in the circuit.
(E) Install the tensioner perpendicular. Then adjust the pressure

at the top of the tensioner.
ATTENTION:
S Do not scratch or damage the rod tip.
S Press rod tensioner entered above.
S Protect the end of the push rod with a cloth to prevent damage.
(F) Using a press, press the push rod into the PE

A70548 lan - quietly using the power of 981 to 9.807 N (100 to 1,000 kgf, 220 to
2.205 lbf).
ATTENTION:
Do not let the burden of more than 9.807 N (100 to
1,000 kgf, 220 to 2.205 lbf) on the push rod.
(G) Align the holes push rod and housing. then MA-
be incorporated 1:27 mm hexagon key through the hole to keep the
position of the push rod arrangement. (H) Replace timing belt tensioner with 2
screws while Men-
thrust towards the timing belt idler pulley. (I)
Tighten to - 2 screws.
Moment: 13 N m (133 kgf cm, 10 ft lbf) CAUTION:
Tighten - 2nd denganmerata and install the bolt tensioner.

(J) Remove the 1.5 mm hexagon key of the tensioner.
A59983
(K) Rotate the crankshaft clockwise jam720_ and check bah-

Timing mark
Timing mark wa mark - the timing marks are aligned as shown in FIG.
A70549
10. CLOSE POST TIMING BELT NO.1

(A) Install the cover of the timing belt with 6 bolts.
(B) Attach the wire harness clamp. (C) Attach the hose
clamp with bolt.
11. POST PULI FAN (See pages 16-26)
13. POST V BELT FAN AND GENERATOR

14-110 MECHANICAL MACHINES -- CAMSHAFT (MECHANICAL 2KD - FTV)
CAMSHAFT (MECHANICAL 2KD - FTV)

141Z9--01
REPLACEMENT

10. SHUT OFF TIMING BELT NO.1 (See pages 14-105)

(A) Using a small screwdriver, remove the retaining seal de--
ngan pry section between the seal holder and a key piece of the cylinder
head.
A60180
(B) Remove the 10 bolts, 2 nuts, close the cylinder head and gasket.
G36584
13. TAKE CAMSHAFT TIMING PULLEY

(A) Remove the bolt for the camshaft timing pulley with appends
han camshaft with a key. (B) Remove
the camshaft timing pulley.
A60182
14. OFF TIMING BELT IDLER SUB - ASSY NO.1 (See pages 14-105)
15. SHUT OFF TIMING BELT NO.2

14-111
MECHANICAL MACHINES -- CAMSHAFT (MECHANICAL 2KD - FTV)
(A) Remove the 4 bolts, nuts and close timing belt.

To the top
17. RELEASE CAMSHAFT
(A) Expose the key groove on the camshaft above with Me-
turning the camshaft with a key.
The key
groove
A60148
(B) Loosen the 15 bolts evenly in the bearing cap

56
11
4 some stage in the order shown in the picture. (C)
14 12
10
15
8
13 Disconnect to - 5 cap bearing, seal oil and to - 2 camshaft. (D) Pull out
9
2
7 the oil seal.
3
A60147
18. INSTALL CAMSHAFT

(A) Using the crankshaft pulley bolt, adjust the cylinder No. 1 ber-
there are at 90_ before TDC / compression.
INSTRUCTIONS:
Cylinder arrangement No. 1 in 90 ˚ before TDC / compression is to avoid a top of
90 ˚
the piston and the valve head clash.
lock Installation G36616
To the top (B) Replace the camshaft.

The key groove
(1) Apply grease MP on the part that gets power
thrust on the camshaft.
(2) Install the camshaft in the cylinder head, by means
The key groove faced upwards.
A60149

(3) Align the mark - the timing mark (1 point) on

The main gear and the camshaft drive gears are in motion with,
and install camshaft No. 2.
A60150
(C) Clean the old gasket (FIPG) of the lid bearing measles
Seal Packing 8 mm
(0.31 in.) shafts.
(D) Give the seal packing on the spot - a specific place
oil channel described in the picture.
Seal packing: No. Part 08826-00080 or equivalent quality seal Width:
4 mm (0:16 in.) CAUTION:
Seal width: 4 mm
A60283 S Do not let FIPG the hole in the lid bearing oil channel.
S After giving FIPG, replace the camshaft bearing cap bolts

dalam3menit dankencangkan in 15 minutes.
(1) Attach it to - 5 bearing cap in place which BE-

nar.
A60146
(2) Give tipisoli layer and below the to-threaded mesinpada

10 11
5
12 nutmeg bearing cap bolts.
2
4
(3) Replace and tighten to - 10 bolt bearing caps
6
8
1
3
evenly in several stages in the order shown in the picture.
14 79
13
15
A60147

14-113
MECHANICAL MACHINES -- CAMSHAFT (MECHANICAL 2KD - FTV)
(E) Install the camshaft oil seal.

(1) Give chubby MP on new oil seal lip. (2) Using SST and a hammer, tap
SST
the depths of the oil seal
lamsampai flat surface with the edge of the retaining seal oil. SST
09608-06041
A60145

21. INSTALL TIMING BELT COVER NO.2 Seal packing: No. Part
08826-00080 or equivalent quality CAUTION:
Install the cover of the timing belt No. 2 in 3menit and tighten the bolt and
nut in the 15 minutes immediately after the completion FIPG.
(A) Install the cover of the timing belt No. 2 with four bolts and nuts.
Seal Packing A60279
22. INSTALL CAMSHAFT TIMING PULLEY

(A) Replace camshaft timing pulley.
(B) Tighten the bolts to camshaft timing pulley with
hold the camshaft using a key.
Moment: 98 N m (1,000 kgf cm, 72 ft lbf)
A60182

(A) Remove all packing material (FIPG) long. (B) Give the seal packing on the
cylinder head as the most
Seal packing: No. Part 08826-00080 or equivalent quality.
(C) Replace the cylinder head gasket on the cap.
Seal Packing A60179

(D) Install the cover of the cylinder head with 10 screws and two nuts.
Tighten bolts - bolt and nut evenly in several stages.
Moment: 9.0 N · m (92 kgf · cm, 80 in. Lbf)

(E) Replace the seal barrier 4 new ones.
G36584
24. INSTALL TIMING BELT IDLER SUB - ASSY NO.1 (See pages 14-105)
26. POST COVER TIMING BELT NO.1 (See pages 14-105)
27. POST PULI FAN (see pages 16-26)


14-115
MECHANICAL MACHINES -- GASKET CYLINDER HEAD (MACHINE 2KD - FTV)
GASKET CYLINDER HEAD (MACHINE 2KD - FTV)

141ZA - 01
REPLACEMENT
2. ENGINE OIL Drain

4. Drain FUEL
6. OFF AIR CLEANER ASSY (See page 14-87)
10. VENTILATION PIPE REMOVABLE

13. KOMPRESSOR SEPARATE COOLING ASSY (See page 14-87)
14. RELEASE MOUNTING BRACKET NO.1 KOMPRESSOR (See pages 14-87)
15. OFF TURBOCHARGER SUB - ASSY (See page 13-11)
16. TAKE MANIFOLD cantilever (See pages 14-87)
17. REMOVE WIRE HARNESS
19. PIPELINE LEAK OFF NOZZLES ASSY NO.2 (See pages 11-61)
20. RELEASE VALVE ASSY EGR (See pages 12-12)

(A) Using a small screwdriver, remove the retaining seal
pry section between the seal holder with a key piece of the cylinder head.
A60180

14-116
(B) Remove the 10 bolts, 2 nuts, close the cylinder head and gasket.
G36584

28. TAKE CAMSHAFT (See pages 14-110)
29. RELEASE CYLINDER HEAD SUB - ASSY

8 16 13 5
2 10 18 11 3 (A) Loosen and remove the cylinder head bolts 18 secaramera-
ta in several stages in the order shown in the picture.
ATTENTION:
Removing the bolt - bolt dalamurutanyangsalah bisamengakibatkan
crookedness or cylinder head cracks.
46 12 9 (B) Remove the cylinder head of the stake in the cylinder block, and put
14 17 15 71
A59194 cylinder head on a wooden beam above the bench
INSTRUCTIONS:
If the cylinder head is difficult to be removed, use a screwdriver to
pry between the cylinder head and cylinder block.
ATTENTION:
Be careful - careful not to damage the contact surface on the cylinder head
and cylinder block.
30. RELEASE CYLINDER HEAD GASKET
Point 31. CHECK THE CYLINDER HEAD BOLTS

Measurement (A) Using calipers , outer diameter measuring mini-
mumdari screw compressed at the measurement point (A).
extension Screw
Outside diameter standard:
11.8 to 12.0 mm (0465 to 0.472 in.) Outer diameter
minimum: 11.6 mm (0457 in.)
If the diameter is less than the minimum, replace the bolts.
A: 30 mm (1.1811 in.) A A62121

14-117
32. INSTALL CYLINDER HEAD GASKET

Measurement tip
(1) Find where the most prominent of the piston head
by turning the crankshaft slowly - slowly in the same direction and
counter-clockwise.
Bulge
A60143 A57646 A60285
(2) Measure each cylinder in two places as shown

in the image, which makes the number of measurements No 8
(3) For the value of each cylinder piston protrusion, guna-

kannilai - average of 2 pengukuranpada each cylinder.
Piston protrusion:
0.005 to 0.254 mm (0.0002 to 0.0100 in.)
X: Point Measurement A58134 INSTRUCTIONS:
When removing the piston and connecting rod assemblies: If the bulge is not as
specified, remove the piston and connecting rod assemblies and then reinstall
them.
Signs Pieces D (A) Select new cylinder head gasket.

BA E INSTRUCTIONS:
C
New cylinder head gasket has 5 sizes and marked
A, B, C, D or E.
The thickness of the new cylinder head gasket is installed:
A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)

Signs Pieces
B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
C Until 1:00 0.90 mm (0.0354 to 0.0394 in.)

Front A60174
D Until 1:05 0.95 mm (0.0374 to 0.0413 in.)
E 1:00 to 1:10 mm (0.0394 to 0.0433 in.)
(1) Choose the largest piston protrusion value of pengu-

kuran done, and then select a new gasket that is suitable
according to the table below.
Piston protrusion Gasket size
0005 up to 0054 mm (0.0002 to 0.0021 in.) Use A
0.055 to 0.104 mm (0.0022 to 0.0041 in.) Use B
0105 up to 0154 mm (0.0041 to 0.0061 in.) Use C
0.155 to 0.204 mm (0.0061 to 0.0080 in.) Use D
0205 up to 0255 mm (0.0081 to 0.0100 in.) Use E

14-118
(B) Place the cylinder head on the cylinder block.

(1) Place the cylinder head gasket in a position above
Front cylinder block.

ATTENTION:
Be - careful on the direction of installation.
(2) Place the cylinder head at a position above the gasket
cylinder head.
A60144
33. INSTALL CYLINDER HEAD SUB - ASSY

INSTRUCTIONS:
(B) (B) (B) (B) S Cylinder head bolts are tightened in three progressive stages (step (b),
(A) (A) (A) (A) (A)
11 3 6 14
17 9 1 8 16 (d) and (f)).
S If there is a bolt is broken or damaged, replace the bolts. (A) Provide a thin
layer of engine oil on and below the to-screw
nutmeg cylinder head bolts.
(B) Attach to - 18 cylinder head bolts and tighten de--
ngan uneven, in recent times in the order shown in the picture.
15 7 2 10 18
13 5 (A) (A) (B) (A)
4 (B) (A) 12 Moment: 85 N · m (867 kgf · cm, 63 ft · lbf)
(A)
(B) (B) HINT: Bolt length: 110 mm (4:33
in.) For a 167 mm (6:57 in.) To B
A59194 A60284
If any of the bolts - cylinder head bolt torque specifications pengencangannya not
reached, replace the cylinder head bolts.
(C) Mark the front of the cylinder head bolts with paint. (D) Tighten the screw -
90 ˚
bolt cylinder head with
90 ˚ 90 ˚ in the order shown in the picture. (E) Tighten the screw - bolt cylinder
90 ˚
head with
Home Mark With 90 ˚ an additional 90 ˚.
Cat (F) Check that the paint mark is now facing backward.
A60141
34. INSTALL CAMSHAFT (See halaman14--110)


14-119

(A) Remove all packing material (FIPG) long. (B) Give the packing seal to the
cylinder head as shown da-
lam pictures.
Seal packing: No. Part 08826-00080 or equivalent quality
(C) Replace the cylinder head gasket on the cap.
Seal Packing A60179
(D) Install the cover of the cylinder head with 10 bolts and nuts.
Tighten bolts - bolts and nuts evenly in recent times.
Moment: 9.0 N · m (92 kgf · cm, 80 in. Lbf)

(E) Replace the seal barrier 4.
G36584
38. INSTALL TIMING BELT COVER NO.2 (See pages 14-110)

43. POST EGR VALVE ASSY (See page 12-12)
44. POST ASSY NO.2 PIPELINE LEAK NOZZLES (See pages 11-61)
46. CONNECT WIRE HARNESS
47. The cantilever MANIFOLD PAIRS (See pages 14-87)
48. INSTALL TURBOCHARGER SUB - ASSY (See page 13-11)
49. POST MOUNTING BRACKET NO.1 KOMPRESSOR (See pages 14-87)
50. POST KOMPRESSOR COOLING ASSY (See page 14-87)
51. POST PULI FAN (See pages 16-26)
53. INSTALL VENT PIPES
57. POST AIR CLEANER ASSY (See page 14-87)
59. FILLIN FUEL

14-120


MECHANICAL MACHINES -- OIL PUMP SEAL (ENGINE 2KD - FTV) 14-121
OIL PUMP SEAL (ENGINE 2KD - FTV)

1411Q - 03
REPLACEMENT

Drain AUTOMATIC TRANSMISSION FLUID (See page 40-2)

5. PULI OFF FAN
6. OFF RADIATOR ASSY (See page 16-35)
7. OFF PULI CRANKSHAFT

SST
(A) Using SST, remove the pulley bolt.
SST 09213-58013, 09330-00021
A72413
(B) Using SST, remove the pulleys.

SST
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
ATTENTION:
Give the oil or grease on the thread and the end of the SST (bolts te-ngah)
before using it.
A72414
8. OFFSHORE OIL PUMP SEAL
SST (A) If the close timing gear mounted on the cylinder block. (1) Using SST,
remove the oil seal. SST 09308-10010, 09950-50013 (09957-04010),
09950--60010 (09951--00350)
A58124

14-122
MECHANICAL MACHINES -- OIL PUMP SEAL (ENGINE 2KD - FTV)
9. OIL PUMP SEAL POST

(A) Give chubby MP on new oil seal lip. (B) Using SST and a hammer, tap new
oil seal into
until the surface is flat with the edge of the lid timing gear. SST
09214-76011
SST
A58125

SST (A) Align the installation lock with the key groove
puli.
(B) Using SST, install the pulley bolt.
SST 09213-58013
A72417

12. POST PULI FAN
13. POST FAN Shroud (see pages 16-26)


14-123
MECHANICAL MACHINES -- OIL SEAL REAR ENGINE (ENGINE 2KD - FTV)
OIL SEAL REAR ENGINE (ENGINE 2KD - FTV) REPLACEMENT

141ZB - 01
2. OFF STARTER ASSY (see pages 19-18)

3. ENGINE OIL Drain
4. Drain OIL TRANSMISSION AND AUTOMATIC TRANSMISSION FLUID (See page 41-2 or 40-2)
5. OFFSHORE TRANSMISSION ASSY (See page 40-6 or 41-4)
7. Flywheel OFF SUB - ASSY

SST (A) Using SST, hold the crankshaft.
SST 09213-58013, 09330-00021
A72851
M/T (B) The manual transmission:

Remove the 8 bolts and flywheel. (C)
Automatic transmission:
Remove the 8 bolts and spacers off the drive plate, drive plate and flywheel.
A/T
A98971
8. OFF PLATE REAR END

(A) Remove the bolt and the rear end plate.

14-124
9. OFFSHORE OIL SEAL RETAINING REAR ENGINE

(A) Remove the 7 bolts and retaining the oil seal.
A38736
10. SEAL OFF THE REAR ENGINE OIL

(A) Using a screwdriver and a hammer, tap out the oil seal. INSTRUCTIONS:
A72422
11. INSTALL REAR ENGINE OIL SEAL

(A) Using SST and a hammer, tap new oil kedalamseal
until the surface is flat denganpinggir anchoring the rear oil seal.
SST
SST 09223-15030, 09950-70010 (09951-07100) (b) Give the MP fat
lip oil seal.
A72423
12. INSTALL REAR ENGINE OIL SEAL RETAINING

(A) Clean seal packing (FIPG) the length of the oil sump and block
Seal Packing
cylinder.
(B) Give the seal packing on the specific places that be explained
Seal packing: No. Part 08826-00080 or equivalent quality.
Seal width: 3 to 5 mm (0:12 until 0:20 in.) CAUTION:
S After giving FIPG, replace the oil seal retaining-bolt

belakangmesindalam3menit dankencangkanbaut in 15 minutes.
S Do not start the engine for 2 hours after installation.
Seal Packing
Seal width: 3 to 5 mm
A75507

14-125
A (C) Replace the oil seal holder with 7 screws. Tighten

A to - 7 bolts alternately in recent times.
Moment:
13 N m (133 kgf cm, 9.6 ft lbf) to bolt A 16 N m (163 kgf
A cm, 12 ft lbf) to bolt B
B
A72856
13. INSTALL REAR END PLATE

(A) Install the plate with screws.
14. POST flywheel SUB - ASSY

(A) Clean the bolt and the hole.
adhesive
(B) Give the adhesive at 2 or 3 screws at the end of the bolt pe--
ngikat.
adhesive:
No. Part 08833-00070, THREE BOND 1324 or equivalent quality.
A54047
(C) Using SST, hold the crankshaft.

SST SST 09213-58013, 09330-00021
(D) The manual transmission:
Install the flywheel on the crankshaft. (E) The

automatic transmission:
Replace the flywheel, drive plate and spacer plate on the crankshaft drive.
A72424

14-126
M/T (F) Connect and fasten to - 8 bolts evenly in the sequence shown in FIG.
2
5
4 Do not start the engine during the first hour after installation.
3
67
8
1
A/T
2
7
5
4
3
6
8
1
A98971

16. INSTALL TRANSMISSION ASSY (See page 40-6 or 41-4)
18. FILLIN OIL TRANSMISSION AND AUTOMATIC TRANSMISSION FLUID (See page 41-2 or 40-2)

23. CHECK THE ENGINE OIL HIGH SURFACE

EXHAUST
EXHAUST PIPE ASSY

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 15-1
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 15-1
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 15-2
EXHAUST PIPE ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 15-4
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 15-4
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 15-5

15-1
EXHAUST -- EXHAUST PIPE ASSY (MACHINE 1TR - FE)
EXHAUST PIPE ASSY (MACHINE 1TR - FE)

150DP - 01
COMPONENTS
Rear Muffler Heat insulating Top Top
Heat insulating Dash Panel Heat insulating Main Muffler
Heat insulating floors Home No. 1
Exhaust Pipe Middle Assy
Hangers Exhaust Pipe No. 2
Pipe Outlet z gasket
48 (489, 35)
z gasket
Hangers Exhaust Pipe No.

2
z gasket Hangers Exhaust Pipe No. 2
48 (489, 35)
43 (438, 32)
Exhaust Pipe Assy Home
Rear Exhaust Pipe Assy
Per Compression Hangers Exhaust Pipe No. 3

A97628

15-2
150DQ - 01
REPLACEMENT
ATTENTION:
Exhaust pipe assy adalahsangat hot, setelahmesin immediately turned off. Sebelummelepas exhaust pipe assy, make sure that
the exhaust pipe has to be cool and wear gloves.
1. TAKE BACK EXHAUST PIPE ASSY
(A) Remove the two screws and two nuts.
(B) Remove the rear pipe of the central pipe and loose gasketnya. (C)
Remove the pipe from the rear exhaust pipe hanger No. 3.
2. OFF CENTRAL EXHAUST PIPE ASSY
(B) Remove the central pipe of the front pipe and loose gasketnya. (C)
Remove the middle pipe from 3rd - exhaust pipe hanger No. 2.
3. OFF FRONT EXHAUST PIPE ASSY
(A) Remove the 2 screws and 2 per compression.
(B) Remove the front pipe of the outlet pipe and loose gasketnya. (C)
Remove the front pipe of the exhaust pipe hanger No. 1.
4. INSTALL EXHAUST PIPE ASSY FRONT

(A) Using calipers, measure the free length of
per compression.
Minimum length: 40 mm (1:57 in.)
If the free length is less than the minimum, replace per compression.
(B) Attach the front pipe to pipe hanger No. 1.
EM0801
Outlet pipe gasket (C) Install a new gasket to the outlet pipe.
INSTRUCTIONS:
Using a hammer-faced - plastic, gaskets at secarame average so that the gasket
and the outlet pipe into fitting perfectly.
ATTENTION:
S Heart - heart with directions gaskets.
Outlet pipe S Do not reuse gaskets that have been released.
A99436
S When installing, pipes and gaskets must be installed separately. Do

not push the gasket to press into the installed pipe.
(D) Install the front pipe with 2 per compression and 2 screws.
Tighten bolts alternately in several stages.

5. EXHAUST PIPE ASSY CENTRAL POST
(A) Attach the center pipe to pipe hanger No. 3 2.
(B) Install a new gasket and pipe middle to next pipe with 2 screws and two nuts. Tighten the bolt
alternately in several stages.

15-3
ATTENTION:
S Do not reuse gaskets that have been released.
S Ketikamemasang, pipadangasket must separate dipasangsecara. Janganmendoronggasket to suppress entered into by
fitting.
6. INSTALL EXHAUST PIPE ASSY REAR
(A) Install the rear pipe to pipe hanger No. 3.
(B) barudanpipa Pasanggasket back to the middle pipe bolts and 2mur dengan2. Kencangkanbautnya

fitting.
7. LEAK CHECK THE EXHAUST.
If there gasbuang yangbocor, kencangkandaerah yangdiperlukan untukmenghentikan kebocoran.Ganti damaged parts if necessary.

15-4
EXHAUST -- EXHAUST PIPE ASSY (MACHINE 2KD - FTV)
EXHAUST PIPE ASSY (MACHINE 2KD - FTV)

150DR - 01
COMPONENTS
Rear Muffler Heat insulating Top Top
Heat insulating Main Muffler
Heat insulating floors Home No. 1
Exhaust Pipe Middle Assy z gasket

Outlet pipe Hangers Exhaust Pipe No. 1
Exhaust Pipe Assy 48 (489, 35)

Home
z gasket Hangers Exhaust Pipe No. 2
43 (438, 32)
z gasket
per Compression
48 (489, 35)
Rear Exhaust Pipe Assy

A97629

15-5
150DS - 01
REPLACEMENT
ATTENTION:
Exhaust pipe assy adalahsangat hot, setelahmesin immediately turned off. Sebelummelepas exhaust pipe assy, make sure that
the exhaust pipe has to be cool and wear gloves.
1. TAKE BACK EXHAUST PIPE ASSY
(B) Remove the rear pipe of the central pipe and loose gasketnya. (C)
Remove the pipe from the rear exhaust pipe hanger No. 3.
2. OFF CENTRAL EXHAUST PIPE ASSY
(B) Remove the central pipe of the front pipe and loose gasketnya. (C)
Remove the middle pipe from 3rd - exhaust pipe hanger No. 2.
3. OFF FRONT EXHAUST PIPE ASSY
(A) Remove the 2 screws and 2 per compression.
(B) Remove the front pipe of the outlet pipe and loose gasketnya. (C)
Remove the front pipe of the exhaust pipe hanger No. 1.
4. INSTALL EXHAUST PIPE ASSY FRONT

(A) Using calipers, measure the free length of
per compression.
Minimum length: 40 mm (1:57 in.)
If the free length is less than the minimum, replace per compression.
(B) Attach the front pipe to pipe hanger No. 1.
EM0801
outlet Pipe gasket (C) Install a new gasket to the outlet pipe.
INSTRUCTIONS:
Using a hammer-faced - plastic, gaskets at secarame average so that the gasket
and the outlet pipe into fitting perfectly.
ATTENTION:
S Heart - heart with directions gaskets.
outlet Pipe S Do not reuse gaskets that have been released.
A99436
S When installing, pipes and gaskets must be installed separately. Do

not push the gasket untukmenekan entered into by fitting.
(D) Install the front pipe with 2 per compression and 2 screws.
Tighten bolts alternately in several stages.

5. EXHAUST PIPE ASSY CENTRAL POST
(A) Attach the center pipe to pipe hanger No. 3 2.
(B) Install a new gasket and pipe middle to next pipe with 2 screws and two nuts. Tighten the bolt

15-6
ATTENTION:
fitting.
6. INSTALL EXHAUST PIPE ASSY REAR
(A) Install the rear pipe to pipe hanger No. 3.
(B) barudanpipa Pasanggasket back to the middle pipe bolts and 2mur dengan2. Kencangkanbautnya

S Ketikamemasang, pipadan gaskets must dipasangsecara separately. Janganmendoronggasket to suppress entered into by
fitting.
7. LEAK CHECK THE EXHAUST
If there gasbuang yangbocor, kencangkandaerah yangdiperlukan untukmenghentikan kebocoran.Ganti damaged parts if necessary.

COOLING
COOLING SYSTEMS
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 16-1
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-2
LIQUID COOLING
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 16-3
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-3
WATER PUMP ASSY
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 16-5

REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-5
THERMOSTAT
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 16-7
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-7
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-9
RADIATOR ASSY
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 16-10
CLEANING IN - VEHICLE ,,,,,, 16-10
KOMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-11
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-13
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-15
OVERHAUL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-16
COOLING SYSTEMS
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 16-21
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-22
LIQUID COOLING
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 16-23
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-23
WATER PUMP ASSY
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 16-26

REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-26
THERMOSTAT
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 16-29
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-29
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-31
RADIATOR ASSY
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 16-32
CLEANING IN - VEHICLE ,,,,,, 16-32
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-33
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-35
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-37
OVERHAUL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 16-38

16-2
COOLING -- COOLING SYSTEMS (MACHINE 1TR - FE)
160ZJ - 01
EXAMINATION
1. CHECK THE FLUID CLUTCH ASSY

(A) Check that the fluid coupling is not damaged and no oil
silicon leaking. If necessary,
change the clutch fluid.
A97646

16-3
COOLING -- LIQUID COOLING (MACHINE 1TR - FE)
LIQUID COOLING (MACHINE 1TR - FE)

160Z0--01
REPLACEMENT
(A) Remove the drain plug tap on the cylinder block and radiator drain plug. (B) Drain the coolant by
removing the radiator cap.
WARNING:
Janganmelepas the radiator cap and radiator saatmesin masihpanas. Cairanpendingin high-pressure hot danuap
bisamenyembur out danmenyebabkan occurrence of serious burns.
INSTRUCTIONS:
Collect the cooling liquid into the container and discard place in accordance with the regulations in your area.
Close Radiator
Cylinder Blocks faucet drain stopper
Radiator drain stopper
A99249

(A) Secure all plugs and fill the radiator with Coolant Durable Super Toyota /
TOYOTA Super Long Life Coolant (SLLC).
Moment: 25 N m (255 kgf cm, 18 ft lbf) to plug the tap of the cylinder block
(B) Fill the engine coolant.
Standard:
item Capacity
Automatic transmission 7.3 liters (7.7 US qts, 6.4 lmp.qts)
Manual transmission 7.0 liters (7.4 US qts, 6.2 lmp.qts)
INSTRUCTIONS:
S Using improper cooling fluid can damage the engine cooling system.
S Use only Coolant Durable Super Toyota (TOYOTA SLLC) or similar high quality ethylene glycol based non - silicate, non - amine,
non - nitrite, non - borate coolant with long technology - life hybrid organic acid , (Liquid cooling technology with long - life hybrid
orga - nic acid consisting of a combination of low phosphate and organic acids.)
S TOYOTAanda didalamkendaraan TOYOTASLLC is loaded at the factory. To avoid a damage to the engine cooling system and
other technical problems, only use Coolant

16-4 COOLING -- COOLING SYSTEMS (MACHINE 1TR - FE)
Hold LamaSuper Toyota (TOYOTASLLC) or similar high quality ethylene glycol based non - silicate, non - amine, non - nitrite, non
- borate coolant with long technology - life hybrid organic acid.
S Press the hose - radiator inlet and outlet hoses several times by hand, and then check the coolant level high. If the coolant level is
low, add coolant.
S Please contact your TOYOTA dealer for further details.

ATTENTION:
Do not use water as a substitute for engine coolant.
(C) Press the hose - radiator inlet and outlet hoses several times by hand, and then check
High coolant liquid surface. (D) Remove air from
the cooling system.
(1) Preheat the engine until the thermostat opens. By the time the thermostat opens, the circulation
coolant few minutes.
(2) Maintain the engine speed at 2,000 to 2,500 rpm.
(3) Press the hose - radiator inlet and outlet hoses several times by hand to throw
air.
WARNING:
When pressing slang - slang radiator:
S Wear protective gloves.
S In order to be - careful because the heat radiator hose.
S Keep your hands away from the radiator fan.
(E) Turn off the engine and wait until the coolant to cool to the temperature lingku--
ngan.
WARNING:
Janganmelepas the radiator cap and radiator saatmesin masihpanas. Cairanpendingin high-pressure hot danuap
bisamenyembur out danmenyebabkan occurrence of serious burns.
(F) Check the coolant level in the radiator.

If the coolant level is low, add SLLC to the radiator until the coolant level is equal to the surface of the coolant in the reservoir tank. (G)
Replace the radiator cap.
3. FLUID LEAK CHECK THE COOLING (See page 16-1)

16-5
COOLING -- WATER PUMP ASSY (MACHINE 1TR - FE)
WATER PUMP ASSY (MACHINE 1TR - FE)

160Z1--01
REPLACEMENT
1. Drain the engine coolant (See page 16-3)
2. OFF slang RADIATOR INLET
3. Slang OFF OUTLET RADIATOR
4. RELEASE CLUTCH FLUID ASSY
(A) Remove the 4 nuts and couplings.
ATTENTION:
Do not remove the coupling of the fan shroud, because it can cause damage to the radiator core.
5. OFF FAN AND GENERATOR V BELT (See page 14-8)

6. PULI OFF FAN
7. OFF FAN Shroud

(B)
(A) Remove the reservoir hose from the radiator. (B) Remove the
two screws and shroud.
(A)
(B)
A99634
8. OFF GENERATOR ASSY (See page 19-13)

9. OFFSHORE OIL INTRODUCTION TO MEASURING SURFACE
(A) Remove the bolt and the introduction gauges.
INSTRUCTIONS:
To prevent foreign matter from entering into the oil pan, cover the hole gauges.
10. IDLER PULLEY OFF
(A) Remove the bolts and pulleys.
A99635

(A) Remove the 3 bolts and the tensioner.
A99636

16-6
COOLING -- WATER PUMP ASSY (MACHINE 1TR - FE)

B B (A) Remove the two screws labeled A and 8 screws labeled
AB B. Then off the pump and gaskets.
B
A (A) Install a new gasket and pump with 10 bolts.
Moment:
21 N m (214 kgf cm, 155 kgf cm) to bolt A
BBBB
9.0 N m (92 kgf cm, 79 in. Lbf) to bolt B
A99639
14. POST TENSIONER ASSY V - Ribbed BELT

(A) Install the tensioner with 3 bolt.
15. POST IDLER PULLEY
(A) Replace pulleys with bolt.
(A) Install the introduction by bolts.
18. POST FAN Shroud
(A) Replace the radiator shroud nails as shown da-
(B)
lam pictures. Make sure that the shroud and radiator are connected
(B) firmly.
(B) When installing the shroud to the radiator, replace the fan
coupling to shroud with two screws.
(A)
(C) Connect the reservoir tank hose on the radiator.
A99679
19. POST PULI FAN

20. INSTALL CLUTCH ASSY FLUID
(A) coupling to the water pump pulley with 4 screws.
21. POST V BELT FAN AND GENERATOR (See page 14-8)
22. POST slang OUTLET RADIATOR
23. INSTALL RADIATOR INLET hose

16-7
COOLING -- THERMOSTAT (MACHINE 1TR - FE)
THERMOSTAT (MACHINE 1TR - FE)

160Z3--01
REPLACEMENT
2. REMOVE THE RADIATOR INLET hose
3. OFF LINE IN AIR

(A) Remove the connector.
A99676
(B) Remove the two nuts, bolts and inlet.
A99677
4. OFF THERMOSTAT
5. INSTALL THERMOSTAT
RIGHT (A) Install a new gasket and thermostat. (B) Insert the thermostat into the
cylinder block with ka-
gasket Jiggle tup overlooking perpendicular to the top.
INSTRUCTIONS:
30_
30_
S Jiggle valve can be set in a position 30_ from one side of a
predetermined position.
FALSE S When installing the gasket to the thermostat, be careful - careful not to
A99678 damage the gasket. Make sure that the thermostat is installed gasket fits
properly into the hole, as shown in FIG.
6. CHANNEL PAIR IN AIR

(A) Install the inlet with two nuts and bolts.
(B) Connect the connector.
7. CONNECT THE RADIATOR INLET hose

16-8


16-9
160Z2--01
EXAMINATION
1. CHECK THE THERMOSTAT

INSTRUCTIONS:
Thermostat valve opening temperature is written on the thermostat.
P13560
(A) Immerse the thermostat in water, then panaskanair-

it is gradually - gradually. (B) Check the thermostat valve opening
temperature.
The valve opening temperature: 80 to 84_C
(176 to 183_F)
If the temperature of the valve opening is not as specified, replace the
thermostat.
P00436
(C) Check the lifting valve.

Lifted valves: 8.5mm (0.33 in.) Or lebihpada 95_C (203_F)
Jikamengangkatnya valve is not as specified, replace the thermostat.
(D) Check that the valve is fully closed at the time of thermo-
Statistics are at low temperatures (below 77_C (171_F)).
8.5 mm
A85445 If it is not fully closed, replace the thermostat.

16-10 COOLING -- RADIATOR ASSY (MACHINE 1TR - FE)
RADIATOR ASSY (MACHINE 1TR - FE)

160Z4--01
CLEANING IN - VEHICLE
1. CHECK THE BARRIER TO THE FIN - FIN
(A) If the fins - fins clogged, wash with water or steam cleaner.
Standard:
distance Spraying Spraying pressure
2.942 to 4.903 kPa

300 mm (11.81 in.)
(30 to 50 kg / cm 2, 427 to 711 psi)
4.903 to 7.845 kPa

500 mm (19.69 in.)
(50 to 80 kg / cm 2, 711 to 1.138 psi)
A99252
ATTENTION:
S If the distance between steamcleaner and radiator core is too close,
the fins - fins could be damaged.
S If the fins - fins bent, straighten all with a screwdriver or pliers.
S Janganmemberi water directly on the component - electronic

component.
(B) Dry with an air compressor.

16-11
COOLING -- RADIATOR ASSY (MACHINE 1TR - FE)
160Z5--01
COMPONENT
Backup Radiator hose
radiator Assy
5.0 (51, 44 in. Lbf)
Backup tank grommet Radiator Assy
A/T Oil Cooler Inlet Pipe No. 1
5.0 (51, 44 in. Lbf)
fan Shroud Oil Cooler Outlet Pipe No. 1

Stoppers Taps PengurasRadiator
25 (255, 18)
x4
Inlet hose Radiator
6.0 (61, 53 in. Lbf)
x4
Puli fans
Slang Radiator Fan Clutch Fluid

Outlet
Radiator grille 12 (122, 9)

A99680

16-12
13 (133, 10)
Close Radiator
Radiator Tank Top
z Ring - O
13 (133, 10)
Radiator Bracket Left
Tank Bottom Right

z Ring - O
M/T A/T 8:34 (85, 74 in. Lbf)

pipe Cooling
Oil Cooling Assy 14.7 (150, 11)
Faucets drain stoppers z Ring - O

z Ring - O Radiator
z Ring - O
z Ring - O
Radiator Radiator Stoppers 14.7 (150, 11)
8:34 (85, 74 in. Lbf)

Radiator Bracket Radiator
Tank Bottom drain taps

A99697

16-13
160Z7--01
REPLACEMENT
3. REMOVE THE ENTRY CHANNELS slang RADIATOR
4. Slang REMOVE RADIATOR LINE OUT
5. PULI OFF FAN
(A) Remove the 4 nuts and fan pulleys.
ATTENTION:
After removing the four bolts, the fan clutch will not be long stick to something. However, do not remove the fan clutch because
it can cause damage to the radiator core. Fan clutch will be released with the shroud in step 7.
7. OFF FAN Shroud

(B)
(A) Remove the reservoir tank hose from the radiator. (B) Remove the
two screws, and the fan clutch.
(A)
ATTENTION:
Be - careful not to damage the radiator core.
(B)
A99634
REMOVE OIL COOLING PIPE LINE ENTRY NO. 1

REMOVE OIL COOLING PIPE LINE OUT NO. 1
10. RADIATOR ASSY RELEASE

(A) Using a clip release, off 2 connectors and 2 nails
of the radiator as shown in FIG. INSTRUCTIONS:
Wrap the end of the release clip with adhesive tape before use.
A99633

16-14
(B) Remove the 4 bolts and the radiator.
INSTRUCTIONS:
Use the radiator grille to enter the 4 screws.
A99640
11. INSTALL RADIATOR ASSY

(A) Install radiator with 4 screws.
CONNECT THE OIL COOLING PIPE LINE ENTRY NO. 1
CONNECT THE OIL COOLING PIPE LINE OUT NO. 1
14. POST FAN Shroud

(A) Replace the radiator shroud nails as shown in
(B)
picture. Make sure that the shroud and radiator are connected firmly.
(B)
(B) Putting the shroud to the radiator, replace the fan ko--
pling to shroud with two screws.
(A)
CAUTION:
A99679 Both the shroud and fan clutch should be installed prior to installing 2
screws into the radiator. Otherwise, the radiator core could be damaged.
(C) Connect the tank to the reserve tank hose on radiator

tor.
15. INSTALL CLUTCH FAN
(A) coupling to the water pump pulley with 4 bolts.
16. POST V BELT FAN AND GENERATOR (See page 14-8)
17. ENTRY CHANNELS slang CONNECT RADIATOR
18. LINE OUT CONNECT RADIATOR slang
21. INSTALL RADIATOR GRIL (See page 76-2)

16-15
160Z6--01
EXAMINATION
1. CHECK THE RADIATOR COVER SUB - ASSY
CAUTION:
S If the radiator cap contaminated with dirt, wash with water.
S Before using the radiator cap tester, wet relief valve and pressure
relief valve with the early pension fluid-ngin machine or water.
S When performing the steps - steps (a) and (b), hold the tester at an
angle above 30_ or more above the horizontal.
(A) Using a radiator cap tester, tester pompalah PE

Tester Close Radiator lan - slowly, then check that the air entering from the valve Vakuum.
Pumping speed: 1 pressure / 3 seconds or more CAUTION:
30_ or more
Press the pump in a constant speed.
If the air does not enter from the valve Vakuum, replace the radiator cap. (B)
Close Radiator Pompalah tester, then measuring the opening pressure re-
A85446 lief valve.
Pumping speed: 1 pressure in 1 second CAUTION:
Pumping speed for pumping the above is only the first (to close the valve
Vakuum). After the first pumping, pumping speed can be reduced.
Standard opening pressure: 74 to 103 kPa (0.75 to 1:05 kgf / cm 2 10.7

to 14.9 psi) minimum opening pressure: 59 kPa (0.6 kgf / cm 2 8.6 psi)
INSTRUCTIONS:
Use the maximum pressure reading as an opening pressure tester.
If the opening pressure is less than the minimum, replace the radiator cap.

16-16
160Z8--01
OVERHAUL
1. OFF BRACKET RADIATOR SUB - ASSY

(A) Remove the 4 screws and 2 brackets.
A99961
2. OFF drain stopper

(A) Remove the drain plug. (B) Remove
the ring - O.
3. ASSEMBLE SST
bagiana
(A) Replace the nails to part A of the handle overhaul, such as
seen in the diagram. SST
09230-01010
size B (B) Gripping the handle, set the stopper bolt all
Stopper bolt SST
to arrive at a size B.
Size B: 0.2 to 0.3mm (0.008 to 0.012 in.)
Claw
Handel Overhaul A87082
Lock plate
4. RELEASE PLATE locking
Tank
(A) Using SST to release the lock,
press the handle until stopped by the stopper bolt. SST 09230-01010
SST
A99698
5. OFFSHORE TANKS AND TANK UNDER THE RADIATOR
(A) word-softly - softly radiator bracket (or hose inlet or

radiator outlet) with a plastic hammer and remove the tank. (B) Remove the
ring - O.
Knock
A99699

16-17
6. OFFSHORE OIL COOLER ASSY

(A) Remove the 2 pipe cooling. (B) Remove the 2 nuts, 2 plate
washer and oil cooler. (C)
2 Remove the ring - O of the oil cooler.
A99700
7. INSTALL OIL COOLER ASSY

(A) Install two ring - O new to the oil cooler. (B) Set the cooling pipes at the
location and angle of the visible
in the picture.
(C) Replace the oil cooler to the tank bottom with 2 plate
washer and two nuts.
Moment: 8:34 N m (85 kgf cm, 74 in. Lbf)
(D) Posting - 2nd coolant pipe.
8. CHECK THE DAMAGE TO PLAT lock

Lock plate
(A) Check the damage to the locking plate. If the sides of the groove locking
plate deformed, not akanmemungkinkan to be able to assemble the tank back.
Fix any changes shape with pliers. Water leakage will occur if the bottom groove
the locking plate is damaged or dented. Repair or replace if necessary.
Core Plate Lock

ATTENTION:
A99690 The radiator can only be re-seba locking Much of this twice. After the
second time, the core radiator must be replaced.
9. PASANGTANGKI ATASDANTANGKI UNDER RADIATOR
(A) Check that there are no foreign objects in the groove plate
normal O twisted X lock, and plug the ring - a new O. Make sure that the ring - O is not
twisted. INSTRUCTIONS:
Ketikamembersihkan groove locking plate, rub slightly scratched with sandpaper

Ring - O
twisted X no. (B) Replace the tank without damaging the ring - O
A87088
(C) the word of the locking plate with a plastic hammer so as not
RIGHT there is a gap between the locking plate and the tank.
FALSE
Tank
Lock plate
A99702

16-18
10. SST ASSEMBLE

part A
(A) Replace the beater assembly (punch) to section A on han--
del overhaul, as shown in FIG. SST 09230-01010, 09231-14010 (b)
Gripping the handle, set the stopper bolt all
size B SST
Stopper bolts
up to size B as defined below.
Size B: 8.4 mm (0.34 in.)
punch Assembly Handel Overhaul A87090
11. LOCKING PLATE locking

(A) Press the SST bit against the locking plate in order
5 3 7
it looks in the picture. After repeating this be-how many times, the key to
1 2 the lock plate entirely by gripping the handle until stopped by the locking
plate. SST 09230-01010
6 4 8
Stopper bolts SST
Tank
Lock plate
A99703
ATTENTION:
S Janganmemukul bulge area around the hole (1) and the bracket (2).
(2) (1)
(1) (1)
(1)
A99704

16-19
S The area indicated by the circle marks dalamgambar can not diketok
with SST. Use pliers and so careful - careful not to damage the core
plate.
A99705
(B) Check the height of the locking plate H after menyelesai-

kan locking.
High-plate H: 8.8 mm (0.346 in.)
If not within the specified altitude, set again on the stopper bolt locking handle
and do again on the locking plate.
A99706
12. insert the cap drain

(A) Replace the ring - a new O plug to drain. (B) Replace the
drain plug.
13. CHECK THE COOLING FLUID LEAK

SST (A) Sumbatlah radiator inlet and outlet pipe with SST.
SST 09230-01010
(B) Using a radiator cap tester, apply pressure
on the radiator.
Testing pressure: 177 kPa (1.8 kgf / cm 2 26 psi)
(C) Soak in the water radiator.
A99707
(D) Check for leaks.

INSTRUCTIONS:
Tank
In the resin radiator tank, there is a gap between the tank and the locking plate
which will be lagging a little air, which demonstrates that there are air leaks when
Plate
the radiator direndamdidalamair. Sebelummelakukan water leak testing, first
Lockout blend the radiator in the water to get out air bubbles.
Ring - O
A90282

16-20
14. INSTALL RADIATOR BRACKET SUB - ASSY

(A) Replace - 2nd bracket with 4 screws.
A99961

16-22
COOLING -- COOLING SYSTEMS (MACHINE 2KD - FTV)
160ZK - 01
EXAMINATION
1. CHECK THE FLUID CLUTCH ASSY

(A) Check that the fluid coupling is not damaged and no oil
silicon leaking. If necessary,
change the clutch fluid.
A97646

16-23
COOLING -- LIQUID COOLING (MACHINE 2KD - FTV)
LIQUID COOLING (MACHINE 2KD - FTV)

160Z9--01
REPLACEMENT
(A) Remove the stopper cylinder block drain taps and plugs
radiator drain tap.
(B) Discharge TOYOTA Super Long Life Coolant (SLLC) / Fluid

Cooling Durable Super TOYOTA denganmelepas reservoir cap, and
remove the lid vent using a key.
WARNING:
Do not remove the radiator cap when the engine reservoir and
radiatormasihpanas. Cairanpendingindanuappanas high pressure can
spurt out and cause serious burns.
A98990
INSTRUCTIONS:
Collect the coolant (TOYOTA SLLC) into shelters and dispose in accordance
with regulations in your area.
Close Ventilation
Close Reservoir Radiator
Reservoir tank Radiator
Cylinder Blocks faucet drain stopper
Stoppers Taps Radiators Penguran
A99250

(A) Tighten the radiator drain plug taps with
hand.
(B) Tighten the cylinder block drain plug tap.
Moment:
8.0 N m (82 kgf cm, 71 in. Lbf) for the stopper cylinder block drain
taps

16-24
(C) Fill radiator with TOYOTA SLLC to the reservoir tank until the line - B.
Line - B
Standard:
item Capacity
AUTOMATIC TRANSMISSION 10.3 liters (10.9 US qts, 9.1 Imp. Qts)
MANUAL TRANSMISSION 9.0 liters (9.5 US qts, 7.9 Imp. Qts)
INSTRUCTIONS:
S TOYOTA SLLC have loaded in your TOYOTA vehicles in the factory. To

A98989 avoid damage to the engine cooling system and other technical
problems, only use Coolant Durable Super Toyota (TOYOTA SLLC) or
similar high quality ethylene glycol based non - silicate, non - amine, non
- nitrite, non-- borate coolant with techno-logy long - life hybrid organic
acid. (Coolant de-ngan technology Long - life hybrid organic acid
comprises a combination of a low phosphate and organic acids.)
S Please contact your TOYOTA dealer for further details.
ATTENTION:
Do not use water as a substitute for TOYOTA SLLC.
(D) Press the hose - radiator inlet and outlet hoses several
times by hand, and then check the coolant level high.
If the coolant level falls below the line - B, add TOYOTA SLLC, until the line - B.
(E) Replace the radiator reservoir cap. (F) Using the key, plug the vent cap.

(G) Remove the air from the cooling system.
(1) Preheat the engine until the thermostat opens. On
when the thermostat opens, circulate coolant few minutes. (2)
Maintain the engine speed at 2,000 to
2,500 rpm.
(3) Press slang - slang radiator inlet and outlet bebera-
pa times by hand to throw out the air.
WARNING:
When pressing slang - slang radiator:
S Wear protective gloves.
S In order to be - careful because the heat radiator hose.
S Keep your hands away from the radiator fan.
(4) Matikanmesindan wait until cairanpendingin
to cool to the temperature lingku-ngan.

16-25
WARNING:
Do not remove the radiator cap when the engine reservoir and
radiatormasihpanas. Cairanpendingindanuappanas high pressure can
spurt out and cause serious burns.
(H) Check the coolant level.

(1) Check that the coolant liquid surface dida-
lam radiator are on the line - B.
If the coolant level is not on the line - B, add up to a line SLLC TOYOTA - B.
Then repeat the steps - steps (d) to (h) until the exhaust air does not cause the
surface of the coolant decreases.
(I) TOYOTA SLLC drain from the cap reservoir to regulate the coolant liquid
surface on the line - F.
Line - F
G36768
3. FLUID LEAK CHECK THE COOLING (See pages 16-21)

16-26
COOLING -- WATER PUMP ASSY (MACHINE 2KD - FTV)
WATER PUMP ASSY (MACHINE 2KD - FTV)

160ZA - 01
REPLACEMENT

3. Slang CHANNEL OFF DUTY RADIATOR
4. OFF FAN Shroud

(C) (A) Remove the 3 bolts and oil reservoir.
(B) Remove the hose by - pass water No. 1 and No. 2 of the tank
(B)
(A)
(F) up and down. (C)
Remove the two screws and the radiator reservoir. (D)
(A)
Loosen the nut holder 4 fan clutch. (E) Remove the V belt fan
(C)
and generator
(See pages 14-70). (F)
Remove the fan shroud 2 screw holder. (G) Remove the 4 nuts in step
(F) (A) (d), and then release
Shroud together - together with the fan clutch.
ATTENTION:
(H) Remove the fan from the water pump pulley.
(B)
A97631
5. OFF KOMPRESSOR A / C
(A) Remove the 4 screws and compressors.
6. OFF GENERATOR ASSY (See page 19-25)
7. OFF TENSIONER ASSY V - Ribbed BELT
(A) Remove the 4 bolts and the tensioner.
8. TAKE COVER TIMING BELT NO. 1 (See pages 14-105)
10. OFF TIMING BELT IDLER SUB - ASSY NO. 1 (See pages 14-105)
13. SHUT OFF TIMING BELT NO. 2 (See pages 14-87)

16-27

(A) Remove the two nuts, bolts 5, and the water pump gasket.
Mur
Mur
A97632

(A) Install new gaskets and water pumps with five screws and two nuts.
16. POST NO COVER TIMING BELT. 2 (See pages 14-87)
19. INSTALL TIMING BELT IDLER SUB - ASSY NO. 1 (See pages 14-105)
21. POST NO COVER TIMING BELT. 1 (See pages 14-105)

block Cylinders (A) Install the tensioner with 4 screws.
A Moment: 21 N m (214 kgf cm, 15 ft lbf)
INSTRUCTIONS:
A Press and hold the tensioner firmly against the cylinder block to eliminate the
loopholes that exist in the area A in FIG. Then tighten to - 4 bolts evenly.
tensioner
A97638

24. POST KOMPRESSOR A / C
(A) Replace compressor with 4 screws.

16-28
(H)
25. POST FAN Shroud
(A) Install the fan to the water pump pulley.
(i)
(J) (B) Replace the shroud together - together with the fan clutch in
(E) between the radiator and engine components.
(J)
ATTENTION:
(H) Be - careful not to damage the radiator core.
(C) Attach the fan clutch to the water pump and fan pulleys with
4 nuts.
(E) (J) INSTRUCTIONS:
Tighten the nut - nut as much as possible by hand. (D) Replace the radiator
shroud nails as shown da-
lam pictures.
(E) Install shroud with two screws.
(F) PasangVbelt kipasdan generator (see halaman14--70). (G) Tighten 4
(I) bolts of step (c).
(D) Moment: 18 N m (184 kgf cm, 13 ft lbf)
(H) Replace the radiator reservoir tank with 2 screws.
A99447 Moment: 5.0 N m (51 kgf cm, 44 in. Lbf)
(I) Connect the hose by - pass water No. 1 and No. 2 to the tank top and
bottom. (J)
Replace the oil reservoir with 3 screws.
26. POST ENTRY CHANNELS slang RADIATOR
27. FILLIN LIQUID COOLING ENGINE (See pages 16-23)
31. DO WORK FROM START RESET (See pages 01-16) CAUTION:
battery.

16-29
COOLING -- THERMOSTAT (MACHINE 2KD - FTV)
THERMOSTAT (MACHINE 2KD - FTV)

160ZC - 01
REPLACEMENT
INSTRUCTIONS:
Bolts without tightening torque specifications shown in table bolts standards (see page 03-2).

REMOVE BRACKET
(A) Remove the bolt and remove the bracket.
A97634
6. OFF LINE IN AIR

(A) Remove the 3 bolts and the inlet.
A97637
7. OFF THERMOSTAT

16-30
8. INSTALL THERMOSTAT
RIGHT FALSE
(A) Install a new gasket to the thermostat. (B) Insert the thermostat into the
cylinder block with ka-
Jiggle tup perpendicular facing upwards.
gasket INSTRUCTIONS:
S Jiggle valve can be installed in a 30_ angle from one side of a
predetermined position.
S When installing the gasket to the thermostat, be careful - careful not to
damage the gasket. Make sure that the thermostat fits into the hole
Top gaskets correctly, as shown in FIG.
30_ 30_
Jiggle valve To
A97636
9. CHANNEL PAIR IN AIR

CONNECT THE BRACKET
(A) Install the inlet with 3baut.
12. POST AIR CLEANER ASSY
15. CHECK THE ENGINE COOLING FLUID LEAK (See pages 16-21)
battery.

16-31
160ZB - 01
EXAMINATION
1. CHECK THE THERMOSTAT

INSTRUCTIONS:
Thermostat valve opening temperature is written on the thermostat.
G35577
(A) Immerse the thermostat in water, then panaskanair-

it is gradually - gradually. (B) Check the thermostat valve opening
temperature.
The valve opening temperature: 80 to 84_C (176 to 183_F)
If the temperature of the valve opening is not as specified, replace the

thermostat.
G37486
(C) Check the lifting valve.

Lifted Valve: 10 mm (0:39 in.) Or more at 95_C (203_F)
Jikamengangkatnya valve is not as specified, replace the thermostat.
(D) Check that the valve is fully closed at the time of thermo-
Statistics are at low temperatures (below 40_C (104_F)).
10 mm
S05683 If not closed, replace the thermostat.

16-32
COOLING -- RADIATOR ASSY (MACHINE 2KD - FTV)
RADIATOR ASSY (MACHINE 2KD - FTV)

160ZD - 01
CLEANING IN - VEHICLE
1. CHECK THE BARRIER TO THE FIN - FIN
(A) If the fins - fins clogged, wash with water or steam cleaner.
Standard:
distance Spraying Spraying pressure
2.942 to 4.903 kPa

300 mm (11.81 in.)
(30 to 50 kg / cm 2, 427 to 711 psi)
4.903 to 7.845 kPa

500 mm (19.69 in.)
(50 to 80 kg / cm 2, 711 to 1.138 psi)
A99251
ATTENTION:
S If the distance between steamcleaner and radiator core is too close,
the fins - fins could be damaged.
S If the fins - fins bent, straighten all with a screwdriver or pliers.
S Janganmemberi water directly on the component - electronic

component.
(B) Dry with an air compressor.

16-33
160ZE - 01
COMPONENT
Slang By - pass Air 1 5.0 (51, 44 in. Lbf)
T utup Close Reservoir Radiator

Ventilation
Reservoir tank Radiator Assy
5.0 (51, 44 in. Lbf)
fan Shroud
grommet
A/T Oil Cooler Inlet Pipe No. 1
radiator Assy
Oil Cooler Outlet Pipe No. 1
Faucets drain stoppers Radiator Slang By - pass Air No. 2
Oil reservoir 18 (184, 13)

x4
5.0 (51, 44 in. Lbf)
radiator Assy
Puli fans
x4 Fan Clutch Fluid

6.0 (61, 53 in. Lbf)
Inlet hose
Radiator
Slang Radiator
Outlet
Radiator grille
12 (122, 9)

A99517

16-34
Radiator Tank Top
13 (133, 10)
z Ring - O
Left Bracket Radiator
Right Bracket Radiator
z Ring - O
M/T A/T 14.7 (150, 11) pipe Cooling

8:34 (85, 74 in. Lbf)
z Ring - O
z Ring - O
Oil Cooling Assy
K eran drain
z Ring - O
stoppers
Radiator
z Ring - O
8:34 (85, 74 in. Lbf)

plugs K eran Radiator
Radiator Tank Bottom
14.7 (150, 11)
Lower Radiator tank drain

A99686

16-35
160ZG - 01
REPLACEMENT
4. Slang REMOVE RADIATOR LINE OUT
5. OFF FAN Shroud

(C) (A) Remove the 3 bolts and oil reservoir.
(B) Remove the hose by - pass water No. 1 and No. 2 of the tank
(B)
(A)
(F) up and down. (C)
Remove the two screws and the radiator reservoir. (D)
(A)
Loosen the nut holder 4 fan clutch. (E) Remove the V belt fan
(C)
and generator
(See pages 14-70). (F)
Remove the fan shroud 2 screw holder. (G) Remove all 4 - myrrh in step
(F) (A) (d), and then release
Shroud in conjunction with the fan clutch.
ATTENTION:
(H) Remove the fan from the water pump pulley.
(B)
A97631
REMOVE OIL COOLING PIPE LINE ENTRY NO. 1

REMOVE OIL COOLING PIPE LINE OUT NO. 1
8. OFF RADIATOR ASSY

(A) Remove the 4 bolts and the radiator.
INSTRUCTIONS:
Use the air inlet to enter the lower bolt.
A97639
9. INSTALL RADIATOR ASSY

(A) Install radiator with 4 screws.
CONNECT THE OIL COOLING PIPE LINE ENTRY NO. 1

16-36

CONNECT THE OIL COOLING PIPE LINE OUT NO. 1
(H)
12. POST FAN Shroud
(A) Install the fan to the water pump pulley.
(i)
(J) (B) Replace the fan shroud in conjunction with clutch dianta-
(E) ra radiator and engine components.
(J)
ATTENTION:
(H) Be - careful not to damage the radiator core.
(C) Attach the fan clutch to the water pump pulley with 4 bolts. INSTRUCTIONS:
(E) (J) Tighten the nut - the nut until the nut - nut can not be rotated by hand.
(D) Replace the radiator shroud nails as shown in

picture.
(E) Install shroud with two screws.
(F) PasangVbelt kipasdan generator (see halaman14--70). (G) Tighten to 4 -
(I) myrrh in step (c).
(D) Moment: 18 N m (184 kgf cm, 13 ft lbf)
(H) reservoi Install radiator with 2 screws.
A99447 Moment: 5.0 N m (51 kgf cm, 44 in. Lbf)
(I) Connect the hose by - pass water No. 1 and No. 2 to the tank top and
bottom. (J)
Replace the oil reservoir with 3 screws.
14. LINE OUT CONNECT RADIATOR slang
16. CHECK THE ENGINE COOLING FLUID LEAK (See pages 16-21)
17. INSTALL RADIATOR GRIL (See page 76-2)

16-37
160ZF - 01
EXAMINATION
1. CHECK THE RESERVOIR RADIATOR CLOSE
Close Reservoir Radiator
Radiator Cap Tester ATTENTION:
S If the radiator cap contaminated with dirt, wash water selaludengan.
S Before using the radiator cap tester, wet relief valve and pressure
relief valve with the early pension fluid-ngin machine or water.
30_ or more
S When performing the steps - steps (a) and (b), hold the tester at an
B08802 angle of 30_ above horizontal.
(A) Pompalah radiator cap tester slowly - slowly, and

check that the air is removed from the valve Vakuum.
Pump speed: 1 pressure every 3 seconds or more CAUTION:
Press the pump at a constant speed.

If the air is not removed from the valve Vakuum, re-servoir replace radiator cap.
(B) Pompalah tester and measure pressure relief opening

valve.
Pump speed: 1 pressure in 1 second CAUTION:
The pump speed is set to be followed only for the first pumping. It
akanmenutup katupvakuum. Once the valve vakuumtertutup,
kecepatanpompa can be reduced.
Standard opening pressure: 93 to 123 kPa (0.95 to 1.25 kgf / cm 2 13.4

to 17.6 psi) minimum opening pressure: 78 kPa (0.8 kgf / cm 2 11.4
psi)
INSTRUCTIONS:
Use pembacaanmaksimum on the tester as the opening pressure.
If the maximum reading is less than the minimum opening pressure, replace the
reservoir cap radiator.

16-38
160ZH - 01
OVERHAUL
1. OFF BRACKET RADIATOR SUB - ASSY

(A) Remove the 4 screws and 2 brackets.
A99949
2. OFF drain stopper

(A) Remove the drain plug. (B) Remove
the ring - O.
3. ASSEMBLE SST
part A
(A) Replace the nails to part A of the handle overhaul, such as
seen in the diagram. SST
09230-01010
size B (B) Gripping the handle, set the stopper bolt all
Stopper bolt SST
to arrive at a size B.
Size B: 0.2 to 0.3 mm (0.008 to 0.012 in.)
Nail
Handel Overhaul A87082
Lock plate Tank

4. RELEASE PLATE locking
(A) Using SST to release the lock,
grip the handle until stopped by the stopper bolt. SST 09230-01010
SST
A99687
5. OFFSHORE TANKS AND TANK UNDER THE RADIATOR
(A) word-bit bracket radiator (or hose inlet or outlet

radiator) with a plastic hammer and remove the tank. (B) Remove the
ring - O.
Knock
A99688

16-39

(A) Remove the 2 pipe cooling. (B) Remove the 2 nuts, 2 plate
washer and oil cooler. (C)
2 Remove the ring - O of the oil cooler.
A99689

(A) Install two ring - O new to the oil cooler. (B) Set the cooling pipes at the
location and angle diperlihat-
(C) Replace the oil cooler to the tank bottom with 2 plate
washer and two nuts.
Moment: 8:34 N m (85 kgf cm, 74 in. Lbf)
(D) Posting - 2nd coolant pipe.
8. CHECK THE DAMAGE TO PLAT lock

Lock plate
(A) Check the damage to the locking plate. If the sides of the groove locking
plate deformed, not akanmemungkinkan to be able to assemble the tank back.
Fix any changes shape with pliers. Water leakage will occur if the bottom of the
groove-locked license plate pe damaged or dented. Repair or replace if
necessary.
Core Plate Lock

ATTENTION:
A99690 The radiator can only be re-seba locking Much of this twice. After the
second time, the core radiator must be replaced.
9. PASANGTANGKI ATASDANTANGKI UNDER RADIATOR
(A) Check that there are no foreign objects inside the groove plate
normal O twisted X lock, and install ring - O new, and pairs of ring - O new. Make sure that
the ring - O is not twisted. INSTRUCTIONS:
When cleaning groove locking plate, rub a bit of de-ngan sandpaper without
Ring - O twisted X
scratched. (B) Replace the tank without damaging the ring - O.
A87088
(C) the word of the locking plate with a plastic hammer so as not
RIGHT there is a gap between the locking plate and the tank.
FALSE
Tank
Lock plate
A99691

16-40
10. SST ASSEMBLE

part A
(A) Replace the beater assembly (punch) to part A of han--
del overhaul, as shown in FIG. SST 09230-01010, 09231-14010 (b)
Gripping the handle, set the stopper bolt all
size B SST
Stopper bolts
up to size B as defined below.
Size B: 8.4 mm (0.34 in.)
assembled Beater Handel Overhaul A87090
11. LOCK locking PLAT
5 3 7
(A) Press the SST bit against the locking plate in order
it looks in the picture. After repeating this be-how many times, the key to
1 2 the lock plate entirely by gripping the handle until stopped by the stopper
plate.
6 4 8
SST 09230-01010
Stopper bolts SST
Tank
Lock plate
A99692
ATTENTION:
S Janganmemukul bulge area around the hole (1) and the bracket (2).
(1)
(2)
(1)
(1) (1) (1)
A99693

16-41
S The area indicated by the circle marks dalamgambar can not diketok
with SST. Use tangdanberhati - warned jangansampaimerusak core
plate.
A99694
(B) Check the height of the locking plate H after menyelesai-

kan locking.
High-plate H: 8.8 mm (0.346 in.)
If not within the specified altitude, set again on the stopper bolt locking handle
and do more on the locking plate.
A99695
12. insert the cap drain

(A) Replace the ring - a new O plug to drain. (B) Replace the
drain plug.
13. CHECK THE COOLING FLUID LEAK

SST
(A) Sumbatlah pipe inlet and outlet of the radiator
tor with SST. SST
09230-01010
(B) Using a radiator cap tester, apply pressure
on the radiator.
Testing pressure: 177 kPa (1.8 kgf / cm 2 26 psi)
(C) Soak in the water radiator.
A99696
(D) Check for leaks.

INSTRUCTIONS:
Tank
In the resin radiator tank, there is a gap between the tank and the locking plate
which will be lagging a little air, which demonstrates that there are air leaks when
Plate
the radiator direndamdidalamair. Sebelummelakukan water leak testing, first
Lockout blend the radiator in the water until air bubbles disappear.
Ring - O
A90282

16-42
14. INSTALL RADIATOR BRACKET SUB - ASSY

(A) Replace - 2nd bracket with 4 screws.
A99949

lubrication
lubrication system
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 17-1
OIL FILTER SUB - ASSY

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 17-3
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 17-3
OIL PUMP ASSY

(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 17-5
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 17-5
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 17-14
lubrication system
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 17-25
OIL FILTER SUB - ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 17-27
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 17-27
OIL PUMP ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 17-29
COMPONENT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 17-29
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 17-42
OIL COOLER ASSY

(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 17-52
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 17-52

17-1
lubrication -- Lubrication system (MACHINE 1TR - FE)
Lubrication system (MACHINE 1TR - FE)

170MK - 01
(A) Heat the engine until the normal working temperature, then turn it off and wait for 5 Me-
nit. Surface oil should be between the low level mark and mark the dipstick penuhpada surface.
If the surface is low, check the oil leak and add oil until the full surface of the sign.
ATTENTION:
Do not fill the engine oil to the surface above the full mark.
Recommended Viscosity (SAE) 2. CHECK THE ENGINE OIL QUALITY

(A) Check the oil against the ugliness, the penetration of water, per-
20W - 50
changes color or keencerannya.
15W - 40
Oil grade: 20W - 50 and
10W - 30
5W - 40
5W - 30 API grade SJ or multigrade engine oil SL 10W - 30 and
_ C --29 --18 --7 4 16 27 38 5W - 30
_ F --20 0 20 40 60 80 100
API gradeSJ "Energy - conserving", SLEnergy - conserving "or
Temperature Range of Anticipated Before Next Oil Change.
G36499 ILSAC multigrade engine oil
3. CHECK THE OIL PRESSURE

(A) Remove the oil pressure switch connector. (B)
Remove the oil pressure switch. (C) Install the oil
pressure gauge. (D) Heat the machine.
Oil Pressure Switch A86844
(E) Measure the oil pressure.
Standard:
idle 29 kPa (0.3 kgf / cm 2 4.2 psi) or more
3,000 rpm 160 to 490 kPa (1.6 to 5.0 kgf / cm 2, 23 to 71 psi) or more
(F) Remove the oil pressure gauge

17-2
lubrication -- Lubrication system (MACHINE 1TR - FE)
4. TIDE OIL PRESSURE SWITCH

adhesive
(A) Give the adhesive at 2 or 3 screws of the pressure switch
oil.
adhesive:
No. Part 08833-00080, THREE BOND 1344, Loctite 242 or equivalent
(B) Replace the oil pressure switch.

G36762
Do not start the engine for at least 1 hour after the installation of the
switch.
(C) Connect the oil pressure switch. (D) Start the engine and
check for oil leaks.

17-3
lubrication -- OIL FILTER SUB - ASSY (MACHINE 1TR - FE)
OIL FILTER SUB - ASSY (MACHINE 1TR - FE)

170ml - 01
REPLACEMENT
WARNING:
S Contact with mineral oil dalamwaktuyang Prolonged or repeated - ulangakanmenyebabkanhilangnya natural fat from the
skin, dry skin, irritation and inflammation of the skin. In addition, used engine oils contain harmful pollution that can
cause skin cancer.
S Wear protective clothing and gloves to minimize the duration and frequency of contact between the skin and used oil. If
contact occurs, wash your skin carefully with soap and water or waterless hand sanitizer. Do not use gasoline, thinner or
solvents to wash the skin.
S Untukmemelihara environment, dispose of used oil and used oil filter only on landfills which have been determined.
1. ENGINE OIL Drain

(A) Remove the engine oil filler cap.
(B) Remove the oil drain plug and drain the oil into a shelter used oil.
2. OFFSHORE OIL FILTER SUB - ASSY

(A) Using SST, remove the oil filter.
SST 09228-07501
3. INSTALL OIL FILTER SUB - ASSY
(A) Check and clean the oil filter mounting surface. (B) Provide a clean engine oil
on the new oil filter gasket.
SST
A99196
(C) Skrupkan little oil filter into place by hand.

Then tighten up gasketnya touch the filter holder.
(D) Using SST, tighten the oil filter.

SST 09228-07501
(1) Depending on the workplace that are available, select
SST
of the following circumstances.
If the available space is sufficient, use a torque wrench to tighten the filter.
A99197

If the space provided is not sufficient to use a torque wrench, tighten the oil filter
3/4 rounds with a hand or a regular key.

17-4
lubrication -- OIL FILTER SUB - ASSY (MACHINE 1TR - FE)

(A) Clean the oil drain plug and the plug with a new gasket.
(B) Fill with new engine oil.
Standard:
item Capacity
Drained and refilled With oil filter change 5.6 liters (5.9 US qts, 4.9 Imp. Qts)
Drained and refilled Without oil filter change 5.3 liters (5.6 US qts, 4.6 Imp. Qts)
charging dry 6.3 liters (6.7 US qts, 5.5 Imp. Qts)
(C) Replace the oil filler cap.


17-5
lubrication -- OIL PUMP ASSY (MACHINE 1TR - FE)
OIL PUMP ASSY (MACHINE 1TR - FE)

170mm - 01
COMPONENTS

Channel connector assemblies and Air Headgear Arm Wiper Home
Cleaner Air Intake
14 (143, 10) 8.0 (82, 71 in. Lbf) 11.5 (117, 8.5)
19.6 (200, 14)

Hose
Wiper arm Right Home Left Front Wiper nozzle
Arm
Clip 19.6 (200, 14) Washer
Close Up Relay Block

clip
Cowl Top Ventilator Louver Right
Cowl Top
Close Relay
Top Seal KapMesin keCowl Ventilator
Block No. 1
8.0 (81, 70 in. Lbf)
Louver Left
Vane Pump Assy

5.5 (56, 49 in. Lbf)
Wiper Motor Connector
Inlet hose Radiator Cowl Panel Sub - assy

25 (255, 18) 25 (255, 18)
5.0 (51.44 in. Lbf)
12 (122, 9) reservoir Motor &

Radiator Windshield
25 (255, 18)
Wiper Link Assy
x4
drive Belt With A / C:

Compressor and
Magnetic Clutch
Puli fans
Fans and
radiator Assy fan Shroud Clutch
clip
Radiator grille Assy
N m (kgf cm, ft lbf) : The moment specified tightening

A99204

17-6
Sides Space Engineering
cable
Machinery
ECM connectors
Close Drawers
G35138
Slang Inlet Water slang Slang Fuel

Heater Vakuum Slang Fuel No. 2
Slang Outlet A cables Period

13 (133, 10)
Water Heater
(133, 10)
(133, 10) 13
Cable
clamps
Clamps Variable Resistors

Engineering
Cable clamps
31 (316, 23) 13
13 (133, 10)
dengana / C
5.4 (55.48 in. Lbf)
suction pipe cables Period
N m (kgf cm, ft lbf) : The moment specified tightening A99205

17-7
(897, 65)
Propeller shaft with Central Bearing
36 (370, 27)
z gasket
48 (489, 35)
Exhaust Pipe No. 1
z gasket
Starter
Compression spring Hangers
43 (438, 32) 37 (377, 27) 88

A99207

17-8
MANUAL TRANSMISSION:
KnobTongkat PerpindahanSub - assy
Console Panel Sub - assy Top
Console Box Assy
Sustainer Exhaust Manifold Switching Boot Stick Assy
Switching sticks Floor Shift Assy
72 (738, 53)
30 (306, 22) 44 (449.32) x5
Assy Clutch Release

Cylinder
Frame crossmember Assy
No. 2
12 (120, 9)

Mounting No. 1
50 (510, 37) 44 (449, 32)

assy No. 3
27 (275, 20) 50 (510, 37)

G35200

17-9
AUTOMATIC TRANSMISSION:
Oil Cooler Outlet Pipe No. 1 Sub Transmission Oil Surface gauges - assy
5.0 (54, 44 in. Lbf)
Sub Transmission
Oil Filling pipe -
assy
12 (122, 9)
Oil Cooler Inlet Pipe No. 1
z Ring - O
17mm head: 71 (720, 53) Head x4x
14mm: 37 (377, 27) 4
Automatic Transmission Unit Assy 28 (286, 21)
x6
41 (421, 30)
Transmission Control Cable Bracket
Torque Converter
Clutch Assy
Engine Mounting No. 1
Dust Seal Flywheel Housing
44 (449, 32)
50 (510, 37)
27 (275, 20) 50 (510, 37)
Frame crossmember Sub - assy No. 3 Insulator Rear

N m (kgf cm, ft lbf): The moment specified tightening

G35087

17-10
/T
Rear End Plate Drive Plate & Ring Gear Sub -

assy
18 (184 13) L 74 (755 55)
x 10
Drive Plate Spacer Spacer Drive Rear

Home Plate
M/N x6
19 (195, 14)
Plat KoplingAssy
18 (184, 13)
x 10
Rear End Plate
Clutch Cover Assy
Dust Seal Flywheel Flywheel Sub

L See It. To 14-18 - 1: 26.5
Housing - assy
(270, 20) to - 2: Rotate
90_
L part padded G34892

17-11
intake Manifold
9.0 (92, 80 in. Lbf) 25 (255, 18)
Throttle Body Assy
z gasket
z gasket
43 (439, 32) generator Assy

x5
9.0 (92, 80 in. Lbf)
25 (255, 18)
Idler Pulley
Ignition Coil Assy
Sub - assy 1
plug
Pulley plate Crankshaft Position

Sensor
spacer Pipe By - pass Air No. 1

(438, 32)
(438, 32)
43 (438, 32) 43 z gasket

21 (214, 15) 43
V - Ribbed Belt Tensioner Assy
20 (204, 15)
17.5 (179, 13)
z gasket
Surface gauges Guide Gauge Surface
Oil Sub - assy Thermostat
Oil
z gasket
With A / C: Compressor
Line-In Air
Mounting Bracket No. 1
20 (204, 15)
(459, 33)
45 (459, 33)
24.5 (250, 18) 45

17-12
9.0 (92, 80 in. Lbf)
x8
Filling cap assy
9.0 (92, 80 in. Lbf)
9.0 (92, 80 in. Lbf) x 11
Cover Cylinder Head Sub - Assy Oil
Cover Cylinder
Head Gasket
Cover Cylinder Head Gasket No. 2
Water Pump Assy z gasket
9.0 (92, 80 in. Lbf)
z 260 (2,651, 192) z Ring - O
Oil Bak Sub -

assy
Crankshaft pulley
x8
x7 (265, 19)
z gasket
20 (204, 15)
20 (204, 15)
Oil Sub - assy
x 20
Oil Bak Sub - assy 2 Strainer
9.0 (92, 79 in. Lbf) 26
drain stopper
37.5 (382, 28)
z gasket

G35572

17-13
Close Timing Chain (Oil

Pump Assy)
x6 z Ring - O
36 (167, 27) 21 (214, 15)

x8
21 (214, 15) z Ring - O
L 16.6 (169, 12)
21 (214, 15) z Ring - O
21 (214, 15)

L part padded
G35573

17-14
170MN - 01
REPLACEMENT

(A) Place the engine assembly to engine stand.
G36020

10. INTRODUCTION TO OFFSHORE OIL MEASURING SURFACE HIGH
12. With the A / C:

A99203
13. TAKE TENSIONER V - Ribbed BELT ASSY

G35081

17-15
14. OFF LINE IN AIR

15. OFF THERMOSTAT

(A) Remove the 19 bolts, 2 nuts and cylinder head cover and 2 gaskets.

13_47 ' Timing mark (A) Rotate the crankshaft pulley and align its groove with the mark
timing 0 at the close timing chain. (B) Check that the timing marks on the
camshaft timing gear
and sprockets are aligned with the timing marks on the lid bearing No. 1,
as shown in FIG.
Timing mark
Timing mark
Plot
A97861
(C) Using SST, loosen the pulley bolt.

SST 09213--54015 (91651--60855)
Loosen SST
Fix A99211

17-16
(D) Using SST, remove the pulleys and pulley bolt.

SST 09330-00021, 09950-50013 (09951-05010, 09952-05010,
bear
09953-05010, 09954-05021)
SST
Loosen
G35121
SST
22. BAK OFFSHORE OIL SUB - ASSY NO.2
SST
(A) Remove the drain plug and gasketnya. (B) Remove 20
(C) Insert the blade of SST in the oil pan. Cut continues
given sealer and release oil sump. SST
09032-00100
ATTENTION:
Be - careful not to damage the contact surface of the oil sump.
A99215

24. BAK OFFSHORE OIL SUB - ASSY

(A) Remove 16 screws and two nuts. (B) Remove the oil pan with pry between
the oil sump and
cylinder block with a screwdriver.
INSTRUCTIONS:

Tape ATTENTION:
protector
Be - careful not to damage the contact surface of the cylinder block and oil
G36411 pan.
(C) Remove the ring - O.

(A) Remove the bolt and sensor.

17-17
26. SHUT OFF THE CHAIN TIMING (OIL PUMP ASSY)

(A) Remove the 19 bolts and 2mur as shown dalamgam-
bar.
G36504
Protective ribbon (B) Remove the cover with the timing chain pry between
close timing chain and cylinder head or cylinder block with a screwdriver.
INSTRUCTIONS:

ATTENTION:
To be careful - careful jangansampai damage permukaankontak of the cylinder
head, cylinder block and close the timing chain.
A97897 (C) 3 Remove the ring - O.
(D) Using a 10 mm socket hexagon key, remove the oath

bat where timing gear.
G36021

(A) Remove the 8 bolts, water pump and gasket.
(A) Install a new gasket and water pump with 8 bolts.
A87223

17-18
29. INSTALL TIMING CHAIN CLOSE

(A) Install the 3 rings - a new O to close the timing chain as terli-
hat in the picture.
Pump
Ring - O
Pump
O - O Over Water
Ring - Ring Oil Pump
A97922
(B) Give the adhesive in place timing gear stopper.

adhesive adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
A58128
(C) Using a hexagon socket key 10 mm, plug

stoppers place (case) timing gear.
G36021

17-19
(D) Provide continuous seal bead packing in the places shown in the picture.
Seal packing: No. Part 08826-00080 or equivalent width of the seal:
Position Specified Condition
A A, 1.5 to 2.5 mm (0.059 to 0.098 in.)
B - B, C - C 3.5 to 4.5 mm (0138 to 0177 in.)
D 2.5 to 3.5 mm (0.098 to 0138 in.)
ATTENTION:
S Clean all the existing oil from the surface of contact
S Install the crankcase in 3menit and tighten the screws - screws in 15 minutes setelahmemberikan seal packing.
Seal Packing Seal Packing
A
A
C C B
B
D D
20 mm (0787 20 mm (0787
in.) in.)
4 mm (0.157
1.0 mm
in.)
(0.039 in.) Seal width:
1.5 to 2.5 mm
AA B-B Seal width:
3.5 to 4.5 mm
2.0 mm
(0.079 in.)
Seal width:
Seal width:
3.5 to 4.5 mm
2.5 to 3.5 mm
C-C D Cylinder
Head
block
Cylinders A97923

17-20
(E) Align the rotor spline drive the oil pump and the crankshaft se--
Perti shown in FIG. Replace the lid plate spline and chain on the
crankshaft.
Spline Drive
Rotor crankshaft A87226
(F) Replace lid loosely timing chain with 19 bolts and nuts, but do not always tighten bolts - bolts and nuts - nut.
(G) Not including bolts A, fully tighten the bolts - bolts and nuts in this order: Area 1, Area
2 and Area 3.
HINT: Long bolts:
75 mm (2.95 in.) To bolt A 75 mm (2.95

in.) For the bolt B 87 mm (3.43 in.) To
bolt C 95 mm (3.74 in.) To bolt D
(H) fully tighten the bolts - bolts A in this order: Area 2 and Area 3.
(I) Fully tighten the screws - bolts E for Area 4.
HINT: Long bolts:
35 mm (1:37 in.) To bolt E
B
A
A
A
Mur Area 3
A
C
Area 1
B
A
A Area 4
A
D Area 2
E E
BA
B
A97924

(A) Apply engine oil to the ring - the new O (b) Replace the
sensor with the bolt.

17-21
31. POST BAK OIL SUB - ASSY

(A) Give the seal packing on the continuous bead on
place shown in the picture ..
A A
Width of seal: 2 to 3 mm (0.079 to 0118 in.) CAUTION:
S Clean the existing oil from the surface of the contacts.

S Install the crankcase within 3 minutes after administration of the packing seal.
BB
Seal Packing
AA B-B
8.0 mm 6.5 mm
(0.315 in.) (0.256 in.) 2-3 mm
2-3 mm
A99219
Mur (B) Replace the oil pan loosely with 16 bolts and 2mur. HINT: Bolt length: 20 mm
Mur B
A A (0.79 in.) To bolt A 40 mm (1:57 in.) For the bolt B
10 11 12 13 14
A
15
16
3456789 (C) Tighten all - 16 screws and two nuts evenly de--
2 18 17
ngan sequence shown in FIG.
B Moment : 26 N m (265 kgf cm, 19 ft lbf)

A1 B A99220

33. POST BAK OIL SUB - ASSY NO.2

(A) Give the seal packing on the continuous bead on
place shown in FIG.
The width of the seal: 2.5 to 3.5 mm (0.098 to 0138 in.) CAUTION:
6.0 mm
(0.236 in.) Seal width: S Clean the existing oil from the surface of the contacts.
2.5 - 3.5 mm S Install the crankcase within 3 minutes after administration of the packing seal.
AA
Packing Seal AA
A99221

17-22
(B) Replace the oil pan loosely with 20 bolts and 2mur. (C) Tighten all - 20
20
4 5 6 21 22 screws and two nuts evenly de--
7 ngan sequence shown in FIG.
1 Moment: 9.0 N m (92 kgf cm, 80 in. Lbf)
(D) Install new gasket and drain plug.
8
12 2 13 14 15 16 17 3 18 19 9
11 10
A99214
34. INSTALL CRANKSHAFT PULI

SST pulleys, and slide into the pulley. (B) Using SST, install the
SST 09213-54015 (91651-60855), 09330-00021
Do not reuse the old pulley bolt.

A97885

(A) Replace 2 cylinder head gasket lid to close the cylinder
head.
(B) Give the seal packing on the spot as ditunjuk-
Seal Packing S Clean the existing oil from the surface of the contacts.
A99825
S Install the crankcase within 3 minutes after administration of the packing seal.
17 18 (C) Install the cover loosely with a cylinder head 19

19 20
21
(D) Tighten all - 19 screws and two nuts evenly de--

23 67
ngan sequence shown in FIG.
16 9
541 8
13 12 11 10
15 14 A88646

17-23
37. INSTALL OIL FILLING COVER ASSY


(A) For a while pairs of tensioners v - ribbed belt with
3
3 screws.
INSTRUCTIONS:
1 Ensure that the flange of the bolt tensioner contact with the surface

2
G35081 Moment: 43 N m (438 kgf cm, 32 ft lbf)

42. INSTALL WATER LINE ENTRY. (See page 16-7)
43. With A / C:
1 PASANGBRACKETMOUNTINGKOMPRESSORNO.1
3
(A) For a while pairs of mounting brackets compressor
with 5 bolts.
INSTRUCTIONS:
Ensure that the flange of the bolt contacts the surface brac-ket.
2
45A
(B) Replace the compressor mounting bracket with mengen-
A99203 cangkan 5 bolts in the order shown in the picture.
Moment:
To prevent non lurusan, which causes bergeretak belt, tighten the screws -
the screws should be done in the order shown.

(A) Replace the ring - a new and introductory O gauge oil surface with bolts.
46. INSTALL OIL MEASURING SURFACE SUB - ASSY

17-24

and 2 nuts.
G36020

battery.
ADD AUTOMATIC TRANSMISSION FLUID (See page 40-2)
56. ADD LIQUID COOLING ENGINE (See page 16-3)
ADDED OIL CHECK AND MANUAL TRANSMISSION (see page 41-2)
CHECK THE FLUID LEVEL IN AUTOMATIC TRANSMISSION (See page 40-2)

lubrication -- Lubrication system (MACHINE 2KD - FTV) 17-25
Lubrication system (MACHINE 2KD - FTV)

170C9--03
(A) Heat the engine until the normal working temperature, then turn it off and wait for 5 Me-
nit. Surface oil should be between the low level mark and mark the dipstick penuhpada surface.
If the oil level is low, check the oil leak and add oil until the full surface of the sign.
ATTENTION:
Do not fill the engine oil to the surface above the full mark.
Recommended Viscosity (SAE) 2. CHECK THE ENGINE OIL QUALITY

(A) Check the oil against the ugliness, the penetration of water, per-
20 W - 50
changes color or keencerannya. If lower quality is
15 W - 40
visible, replace the engine oil. INSTRUCTIONS:
10 W - 30
5 W - 30 This vehicle is filled with TOYOTA Genuine Motor factory. Use an approved oil
_ C -- 29 -- 18 -- 7 4 16 27 38 TOYOTA, TOYOTA Genuine Motor Oil or equivalent quality to ensure
_ F -- 20 0 20 40 60 80 100
Temperature Range Anticipated Before Next Oil Change consistency level and below.
G35132
Oil level:
G - DLD1 or grade API CF - 4, CF (you can also use the API CE
or CD)
If you use engine oil SAE 10W - 30 or higher viscosity in extreme temperatures
low, hard mesinbisamenjadi untukdihidupkan. For low temperatures it is
recommended to use engine oil SAE 5W - 30.
3. OFFSHORE OIL PRESSURE SWITCH ASSY

(A) Remove the oil pressure switch connector.
(B) Using the 24 mm socket wrench, remove the oil pressure switch.
4. POST STANDARD OIL PRESSURE

estimator TekananOli
B11501
5. HEAT ENGINE

17-26
lubrication -- Lubrication system (MACHINE 2KD - FTV)
6. CHECK THE OIL PRESSURE oil

pressure:
idle 29 kPa (0.3 kgf cm 2 4.2 psi) or more
3,000 rpm 245 kPa (2.5 kgf cm 2, 36 psi) or more
If the oil pressure is not as specified, check the oil pump (see pages 17-42).
7. TIDE OIL PRESSURE SWITCH

adhesive
(A) Remove the oil pressure gauge.
(B) Give the adhesive at 2 or 3 screws of the pressure switch
oil.
adhesive:
Part No. 08833-00080, THREE BOND 1344, Loctite 242 or
equivalent
(C) Using a socket wrench dalam24mm, plug switch
P13638 oil pressure.
Do not start the engine within one hour after installation.
(D) Connect the oil pressure switch.

8. TURN ON MACHINE AND CHECK THE ENGINE OIL LEAK

lubrication -- OIL FILTER SUB - ASSY (MACHINE 2KD - FTV) 17-27
OIL FILTER SUB - ASSY (MACHINE 2KD - FTV)

170BZ - 03
REPLACEMENT
WARNING:
S Contact with mineral oil dalamwaktu long and / or repetitive - again akanmengakibatkan removal of natural fat from the
skin, the skin terjadinyamasalah danmemudahkan se-Perti dry skin, irritation and inflammation of the skin. In addition,
used engine oil can cause skin cancer, because it may contain harmful pollution.
S Be - careful so as not exposed to used engine oils on your skin when doing replacement of engine oil. Wear protective
clothing and gloves that can protect against oil leakage. If skin contact with oil, wash thoroughly with soap and water or
waterless hand sanitizer. Do not use gasoline, thinners and solvents.
S For environmental protection, dispose of used oil and oil filter at the specified disposal site or in accordance with
instructions given by the local government.
1. ENGINE OIL Drain

(A) Remove the oil filler cap.
(B) Remove the oil drain plug and drain the engine oil from the oil sump.
ATTENTION:
Contain oil with shelters to dispose of used oil.
2. OFFSHORE OIL FILTER SUB - ASSY

SST
(A) Using SST, remove the oil filter.
SST 09228-07501 HINT:
Enter the oil filter drain hose. Place the drained oil accomodating place under the
drain hose to contain the oil in the oil filter.
slang drain
B11502
3. INSTALL OIL FILTER SUB - ASSY

(A) Check and clean the oil filter mounting surface. (B) Provide a clean engine oil
on the new oil filter gasket. (C) Skrupkan little oil filter into place by ta--
ngan. Tighten up gasketnya touch the filter holder.
(D) Tighten the oil filter using the SST.

SST 09228-07501
SST A60101

17-28
lubrication -- OIL FILTER SUB - ASSY (MACHINE 2KD - FTV)
(1) Depending on the workplace provided, select-

the one of the following circumstances.
S If the available space is sufficient, use kuncimomen

untukmengencangkan oil filter.
S If the space provided is not sufficient to use a torque
wrench, tighten the oil filter 3/4 rounds with a hand or a
regular key.

(A) Clean the oil sump and drain plug before installing it. (B) Install a new gasket and drain
plug.
(C) Fill the new oil.
Specification:
item Capacity
Drain and refill it By replacing the oil filter 6.9 liters (7.3 US qts, 6.1 Imp. Qts)
Drain and refill it Without replacing the oil filter 6.6 liters (7.0 US qts, 5.8 Imp. Qts)
charging dry 7.4 liters (7.8 US qts, 6.5 Imp. Qts)
(D) Replace the oil filler cap.


17-29
lubrication -- OIL PUMP ASSY (MACHINE 2KD - FTV)
OIL PUMP ASSY (MACHINE 2KD - FTV)

170MO - 01
COMPONENTS
11.5 (117, 8.5) Left Front Wiper
Wiper arm Right Arm
Home
Air Cleaner Assy
Headgear Arm Wiper Home Hose
nozzle
14 (143, 10)
Washer
Cowl Top Ventilator Louver Right
Seal Kap Machine Into Top Cowl

Left Clips
Ventilator Louver
Cowl Top
8.0 (81, 70 in. Lbf)
5.0 (51, 44 in. Lbf)
5.0 (51, 44 in. Lbf)

Oil Cooler Inlet Pipe No. 1 A / T: Cowl Panel Sub - assy
Oil reservoir
A / T:
PipaOutlet PendinginOli No. 1
RadiatorAssy Without A / C: V
Belt fans and
Reservoir Tank 25 (255, 18) Generator

5.0 (51, 44 in. Lbf)
x4
Assy Radiator
fan Clutch
Puli Fan Fan

Radiator Outlet With A / C: VBelt danGenerator
fan Shroud
Inlet hose Radiator hose

12 (122, 9)
5.0 (51, 44 in. Lbf)
Battery Clip
Bracket
Battery
Alas Battery
Radiator grille

G37592

17-30
The air hose No. 2
20 (204, 15) The air hose No. 1
18 (184, 13)

A98883

17-31
cables Period
Close Up R / B
13 (133, 10)
No. 1
connector Communities
starter Wire
Engineering Close R / B
connector Starter Cable A / B Space
Engineering
30 (306, 22)
cables Period

G37240

17-32
Drawer Connector Assy
*2
*1
*2
*1 *2
*1 *2
* 1: A / T: TCM Door
* 2: ECM connectors
G37571

17-33
Slang Fuel
51 (520, 38)
Giving Pipe Pressure
Oil Reservoir Pump hose to hose

A98995

Manual transmission (G58) 17-34 Shift Knob Lever Sub

- assy
Console Top Panel Assy
Console Box Assy
z gasket
Shift Boot LeverAssy
z gasket
48 (490, 35)
72 (738, 53)
68 (694, 50)
x8
43 (438, 32)
37 (377, 27)
starter Assy
* 1 68 (694, 50)
Rear Propeller Shaft Assy
Assy Clutch Release Cylinder
12 (120, 9)
Mounting No. 1
assy No. 3
50 (510, 37)
44 (449, 32)
50 (510, 37)
27 (275, 20)


17-35
Automatic transmission (A340E)
Propeller shaft with Central

Bearing Assy
(897, 64)
Outlet pipe PendinginOli

5.0 (50, 43)
No. 1
12 (122, 9)
Automatic
Transmission Assy
Inlet pipe 71 (720, 53)
PendinginOli No. 1
x5
Torque Converter
28 (286, 21)
Clutch Assy
Transmission Control Cable
41 (421, 30) Bracket
Plat Tip No. 2 Sub Transmission Oil Surface

gauges - assy
x6 starter Assy
Insulator Block
Cylinder No. 4
(720, 53) 68 (693, 50)
Right Plate stiffener

Plate stiffener Left Sub Transmission Oil
71 (720, 53) 68 (693, 50)
71 (720, 53) 71 Filling pipe - assy
Cooling oil with pipe clamps Insulator Engine
sub - assy MountingBelakang No. 1 12 (122, 9) 88
Exhaust Pipe
z gasket Assy Home 48 (490, 35) z Ring - O
65 (660, 48)
z gasket
50 (510, 37)
50 (510, 37)

assy No. 3
43 (439, 32)
assy No. 2
27 (275, 20)
G34846

17-36
Manual transmission
Rear End Plate
178 (1,815, 132)

x8
19 (195, 14)
Flywheel Sub - assy
x8
Clutch Cover Assy
N m (kgf cm, ft lbf) : Moment of tightening Clutch Plate Assy G35126
Automatic transmission
Rear End Plate
drive Plate
Sub - assy Drive Plate Spacer
x8
178 (1,815, 132)
N m (kgf cm, ft lbf) : Moment of tightening Flywheel

G35207

17-37
Idler Sub - assy No. 1

Timing Belt Cover
timing Belt
35 (357, 26)
washer
8.5 (87, 75 in. Lbf)
8.5 (87, 75 in. Lbf) Camshaft Position Sensor

x6
13 (133, 10)
Chain Tensioner Assy No. 1

Crankshaft pulley
6.0 (61, 53 in. Lbf)
365 (3.722, 270)
N m (kgf cm, ft lbf) : Moment of tightening Timing Belt
z Part that can not be used again G36614

17-38
Cooling Compressor Assy
21 (214, 16)
62 (632, 46)
generator Assy
25 (255, 18)
Compressor Mounting Bracket
bracket Generator
V - Ribbed Belt Tensioner Assy No. 1

Idle Pulley Assy
Key
Camshaft Timing Pulley
98 (1000, 72)
10 (102, 7)
10 (102, 7)
Timing Belt Cover
13 (133, 10)
z gasket
(133, 10)
13 (133, 10) 13
Water Pump Assy


17-39
9.0 (92, 80 in. Lbf)
9.0 (92, 80 in. Lbf)
2 x 10 x
z Seal nozzle holder

Cover Cylinder Head
Sub - assy
Pipe Clamps
* 32 (326, 24) 35
Injection No. 2 (357, 26)
z Cover Cylinder
Head Gasket pipe Injection
5.0 (51, 44 in. Lbf)
* 32 (326, 24) 35
(357, 26)
z Clamp
z Clamp
5.0 (51, 44 in. Lbf)

Pipe Clamps
Injection No. 3
8.0 (82, 71 in. Lbf)
* 32 (326, 24) 35
(357, 26)
Introduction to Surface
Gauge Oil
Surface gauges Oli
z Ring - O
crutch

19 (194, 14)
* For use with SST G35208

17-40
Slang Fuel
Slang Fuel * 32 (326, 24) 35

(357, 26)
21 (214, 16)
Activator pump pulley shaft
z Ring - O
z Ring - O
(653, 47)
z Fuel Inlet Pipe Sub -
assy
PompaSupplyAssy
* 32 (326, 24) 35
(357, 26)
x4
Flange Camshaft Timing

Pulley No. 2
31 (316, 23) 64
39 (398, 29)
z Ring - O
21 (214, 16)
z Ring - O
Vane Pump Assy
Vakuum Pump Assy

* For use with SST
G37594

17-41
z gasket
Points Timing Gear Assy
16 (160, 12)
Idle Gear No. 1
13 (133, 9)
Pusher plate
x8
8.0 (82, 71 in. Lbf)
z O - Ring z gasket
Oli
Idle Gear Shafts No. 1

50 (510, 37) Crankshaft Timing Gear
Crankshaft Sensor plate 1
13 (133, 9)
8.0 (82, 71 in. Lbf)

13 (133, 9)
x 14
Cover Timing Gear
Injection Gear
Oil Bak Sub - assy
x4
x 22
16 (163, 12)
Surface Sensor Strainer Oli
16 (163, 12)

17-42
170MP - 01
REPLACEMENT

3. Drain OIL TRANSMISSION AND TRANSMISSION FLUID (See page 41-2 or 40-2)
6. Drain FUEL
8. OFF COWL PANEL SUB - ASSY
(A) Remove the washer nozzle hose from the washer nozzles. (B) Remove
the 4 screws and bonnet.
11. TAKE BATTERY BRACKET
12. RELEASE AND BACKING BATTERY BATTERY
13. OFF AIR CLEANER ASSY (See page 14-87)
16. LET slang - slang and CONNECTORS - CONNECTORS (See pages 14-87)
17. KOMPRESSOR OFF COOLING ASSY (See page 14-87)
19. TAKE EXHAUST PIPE ASSY FRONT (See page 15-5)
20. TAKE PROPELLER SHAFT ASSY (See page 30-4)
21. TAKE THE TRANSMISSION ASSY (See page 40-6 or 41-4)
22. Flywheel OFF SUB - ASSY (See page 14-123)
23. RELEASE REAR END PLATE (See page 14-87)
24. OFF ENGINE ASSY (See page 14-87)
25. INSTALL THE MACHINE STAND MACHINE
28. RELEASE CHAIN TENSIONER ASSY NO.1 (See pages 14-105)
29. OFF V - Ribbed BELT TENSIONER ASSY (See page 14-87)
30. RELEASE BRACKET GENERATOR (See pages 19-25)
32. RELEASE MOUNTING BRACKET NO.1 KOMPRESSOR (See pages 14-87)

17-43
35. RELEASE cantilever MANIFOLD

(A) Remove the 2 bolts and support.
G37596
42. OFF WATER PUMP ASSY (see pages 16-26)
43. TAKE PUMP ASSY VAKUUM

(A) Remove the hose Vakuum.
(B) Remove the two nuts, and 2 ring Vakuum pump - O.
A98930
44. OFF VANE PUMP ASSY

(A) Remove the two nuts, vane pump and ring - O.
INSTRUCTIONS:
It tidakdiperlukanuntukmelepas slangdari vanepump. Untukprosedur pelepasanpart left, you can put part assemblies that have been
removed on the side at a suitable location.
45. TAKE PULI PUMP DRIVE SHAFT
(A) Remove the 4 bolts, flanges No. 2 camshaft timing pulley and pulleys
pump drive shaft.
A38747

17-44
(B) Using SST, hold the crankshaft pulley untukmelepas

Nuts and ring - O.
SST 09213-58013, 09330-00021
SST A70711
46. TAKE PULI CRANKSHAFT (See pages 14-121)

(A) Remove the bolt and sensor. (B) Remove
the ring - O of the sensor.
48. TAKE POSITION SENSOR CRANKSHAFT
(A) Remove the bolt and sensor. (B) Remove
the ring - O of the sensor.
49. SHUT OFF TIMING GEAR

(A) Remove the wire harness clamp. (B)
Remove 14 screws and two nuts.
(C) Separate the lid from the timing gear with lem-
but using a flat-head screwdriver.
INSTRUCTIONS:
There're some gaps - small cracks could andamasuki with minus screwdriver tip
to separate the timing gear and stopper. Look at the picture to the location of the
gap.
ATTENTION:
Be - careful not to damage the contact surface from the timing gear and
stopper.
A38748 (D) Remove the lid and ring - O.
50. HOLD IDLE GEAR NO.1

(A) Hold sub idle gear at idle gear with bolts service.
CAUTION:
If the position of the screw holes on the rear sub idle gear is not right, turn
the crankshaft counter-clockwise to fix the position of the hole. Then put
the screws service.
bolts Service
G37597 INSTRUCTIONS:
Untukmenghilangkan bolt couplers mounted torsion force caused by the spring

idle gear, which is located between the idle gear and each sub idle gear. Style
twist will cause tooth sub idle gear and idle gear teeth become misaligned.

17-45
51. CRANKSHAFT TIMING GEAR OR OFF-KET SPROC
(A) Remove the crankshaft sensor plate No. 1. (b) Replace

the service bolt on the crankshaft.
(C) Using SST, remove the crankshaft timing gear.

SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05010)
SST
G37598
52. OFF IDLE GEAR NO.1

(A) Remove the two screws, plate driver of the idle gear and idle gear. (B) Remove
the idle gear shaft No. 1.
G37600
53. RELEASE GEAR INJECTION

(A) Using SST, remove the injection gear.
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
SST
G37599
54. OFFSHORE SUPPLY PUMP ASSY (See page 11-55)

55. OFFSHORE OIL MEASURING SURFACE SUB - ASSY
(A) Remove the bolt and the oil level gauge. (B) Remove the ring -
O of the measuring surface of the oil.
56. BAK OFFSHORE OIL SUB - ASSY
(A) Remove the 4 bolts, oil level sensor and gasket. (B) Remove 22

17-46
SST SST (C) Insert SST knife between the cylinder block and oil pan.
Cut kept sealer provided and loose oil sump. SST 09032-00100
ATTENTION:
S Do not use the SST to the oil pump body side and anchoring the
rear oil seal.
S Be careful - careful not to damage the oil pan flange.
Z04119 (D) Remove the oil pan gasket. (E) Remove the 2 bolts, nuts, oil
strainer and gasket.
57. TAKE THE TIMING GEAR ASSY
(A) Remove the 8 bolts and union bolts, and then remove spot
timing gear and - 2nd ring - O her.
ATTENTION:
Do not drop the oil pump rotors.
G37601
58. INSTALL THE TIMING GEAR ASSY

Ring -
(A) Replace the two rings - a new O on the cylinder block.
New O
G37603
Width: 5 mm
(B) Remove the seal packing (FIPG) long from the timing gear
and the cylinder block.
Gasket
(C) Install new oil pump gasket to the timing gear. (D) Give seal packing into
place - the most specific place
Seal Packing Seal width: 5 mm (0.20 in.)

A75511 CAUTION:
S After giving FIPG, where timing gear pairs in 3 minutes and tighten
the screws - screws in 15 minutes.
S Do not start the engine within 2 hours after installation.

17-47
(E) Tighten to - 8 bolts and bolt union.

Moment:
13 N m (133 kgf cm long, 9 ft lbf) to bolt 16 N m (160 kgf cm,
12 ft lbf) to bolt union
(F) Ensure that the oil pump drive gear rotates gently.
ATTENTION:
If the gear can not rotate with soft, loose to - 8 bolts and union bolts to
G37601 remove the gear. Then put another bolt - bolt and gear.
(G) Replace the sender pipe Vakuum No. 1 with a nut.

59. POST BAK OIL SUB - ASSY
(A) Install a new gasket and oil strainer with two screws and
nut.
(B) Clean seal packing (FIPG) long from oil sump sub - assy
and the cylinder block.
(C) Give the seal packing on the spot - a special place

Packing Seal
visible in the picture.
Seal width: 5 mm (0.20 in.)

CAUTION:
S After giving FIPG, where timing gear pairs in 3 minutes and tighten
Width: 5 mm A74129
(D) Replace the oil sump with 22 screws and two nuts.
(E) Install a new gasket on the sensor surface of the oil. (F)
Replace the oil surface sensor with 4 screws.
ring - O gauge to the oil surface. (C) Install the oil level gauge with
the screw.
61. INSTALL GEAR INJECTION
63. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
(A) Align the timing mark "1" on the crankshaft timing gear and
the oil pump drive gear, and install crankshaft timing gear using the SST.
SST 09223-00010
SST 64. IDLE GEAR PAIRS NO.1

(A) Give the engine oil in place - a special place in sight
G37604 in the picture. Install the idle gear shaft No. 1 block to the cylinder block.

17-48
(B) Align the timing mark "4" from the idle gear No. 1 and injec-
tion gear. (C)
Align the timing mark "5" from the idle gear No. 1 and the crankshaft
timing gear and idle gear pairs No. 1. (d) Replace the idle gear No. 1 with the
plunger plate idle gear
and 2 screws.
(E) Remove the bolt service. (F)
Replace the crankshaft angle sensor plate No. 1.
bolts Service
G37605
65. INSTALL TIMING GEAR COVER

(A) Replace the ring - a new O on where timing gear.
Ring - New O
A72411
(B) Clean seal packing (FIPG) long from close timing

Width: 5 mm
gear.
(C) Give the packing seal into place - special place di--
show in the picture.
Seal width: 5 mm (0.20 in.)

CAUTION:
Seal Packing A75513 S After giving FIPG, attach the lid timing gear in 3 minutes and tighten
(D) Install the cover of the timing gear with 14 screws and two nuts.
ring - o on the sensor. (C) Install the sensor with the bolt.

17-49

(A) Install the sensor with the bolt.
68. INSTALL CRANKSHAFT PULI (See pages 14-87)
69. POST PULI PUMP DRIVE SHAFT

(A) Replace the ring - a new O on the pump supply. (B) Replace the supply
pump portion with a nut. (C) MenggunakanSST, hold the crankshaft pulley
untukmengen-
cangkan nut.
SST 09213-58013, 09330-00021
SST A70711
(D) Replace camshaft timing pulley flange No. 2 and pulley shaft
pump drive with 4 screws.
A38747
(E) Check slit thrust of the drive shaft pump supply by moving the camshaft
timing pulleys No. 2 Use your hand.
Cracks thrust:
0:15 to 0:55 mm (0.0059 to 0.0217 in)
INSTRUCTIONS:
If there is no gap thrust, unloading part - the part is untukmelepas close timing
gear. Then reassemble everything.
A36609

(A) Replace the ring - a new O on vane pump. (B)
Replace the vane pump with two nuts.
71. POST VAKUUM PUMP ASSY
(A) Replace the ring - O new Vakuum pump. (B) Replace
Vakuum pump with two nuts.
72. TIDE WATER PUMP ASSY (See page 16-26)
73. INSTALL TIMING BELT COVER NO.2 (See pages 14-110)

17-50
79. The cantilever MANIFOLD PAIRS
(A) Replace the support manifold with 2 screws.
G37596
81. POST MOUNTING BRACKET NO.1 KOMPRESSOR (See pages 14-87)
83. POST BRACKET GENERATOR (See pages 19-25)
84. POST V - Ribbed BELT TENSIONER ASSY (See page 14-87)
86. INSTALL CHAIN TENSIONER ASSY NO.1 (See pages 14-105)
89. INSTALL ENGINE ASSY (See page 14-87)
90. INSTALL REAR END PLATE (See page 14-87)
91. POST flywheel SUB - ASSY (See page 14-123)
92. INSTALL TRANSMISSION ASSY (See page 40-6 or 41-4)
93. POST PROPELLER SHAFT ASSY (See page 30-4)
94. INSTALL FRONT EXHAUST PIPE ASSY (See page 15-5)
96. POST KOMPRESSOR ASSY (See page 14-87)
97. CONNECT slang - slang and CONNECTORS - CONNECTORS (See pages 14-87)
100. POST AIR CLEANER ASSY (See page 14-87)
101. INSTALL THE BATTERY AND BATTERY ALAS
102. POST BRACKET BATTERY
RADIATOR GRIL PAIRS 103. (See pages 16-35)
(A) Attach the hood with 4 screws.
Moment: 11.5 N m (117 kgf cm, 8.5 ft lbf)
(B) Connect the washer hose to the nozzle washer nozzles.
106. PAIRS & LINK ASSY WIPER MOTOR FRONT GLASS (See pages 66-13)
107. FILLIN FUEL
108. POST COVER FUEL TANK ASSY

17-51
110. FILLIN TRANSMISSION OIL AND FLUID TRANSMISSION (See pages 41-2 or 40-2)
111. FILLIN ENGINE OIL
112. REMOVE AIR FROM FUEL SYSTEM (See page 11-39)
battery.

17-52
lubrication -- OIL COOLER ASSY (MACHINE 2KD - FTV)
OIL COOLER ASSY (MACHINE 2KD - FTV)

170MQ - 01
REPLACEMENT
2. ENGINE OIL Drain

4. Drain FUEL
5. OFF cantilever MANIFOLD

(A) Remove the 2 bolts and the support manifolds.
G37596
6. OFFSHORE OIL MEASURING SURFACE SUB - ASSY

(A) Remove the bolt and the oil level gauge. (B) Remove the ring -
O of the measuring surface of the oil.
9. OFFSHORE OIL FILTER SUB - ASSY (See page 17-27)
10. STARTER OFF ASSY (See page 19-18)
11. OFFSHORE SUPPLY PUMP ASSY (see pages 11-55)
12. TAKE COMMON RAIL ASSY (See page 11-61)
13. SHUT OFF COOLING OIL SUB - ASSY

(A) Remove the oil pressure switch connector and wire harness. (B) Remove the
13 bolts, 2 nuts and oil cooler lid.
A38741

17-53

(A) Loosen the first - 4th nut ..
(B) the word-out partly by knocking the oil cooler
each head nut with a plastic-faced hammer. (C)
Remove the 4 nuts, oil cooler and two gaskets.
(A) Install two new gasket to the oil cooler. (B) Replace the oil cooler to the oil
cooler lid with 4
A38742 nut.
16. INSTALL OIL COOLER COVER SUB - ASSY

(A) Install a new gasket and close the oil cooler with 13

(B) Connect the oil pressure switch and plug wire
harness.
A38741
17. POST COMMON RAIL ASSY (See page 11-61)

(A) Provide a clean engine oil on the ring - a new O. (B) Attach the ring
- O gauge to the oil surface. (C) Install the oil level gauge with the
screw.
24. POST cantilever MANIFOLD

(A) Replace the support manifold with 2 screws.
G37596
25. FILLIN FUEL


17-54
battery.

IGNITION
IGNITION SYSTEM
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 18-1
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 18-1
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 18-2
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 18-5
CAMSHAFT POSITION SENSOR
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 18-7

REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 18-7
CRANKSHAFT POSITION SENSOR
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 18-8

REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 18-8

18-1
IGNITION -- IGNITION SYSTEM (ENGINE 1TR - FE)
IGNITION SYSTEM (ENGINE 1TR - FE) LOCATION

180DL - 01
ECM
Ignition Coil Assy

(With Igniter)
plug
A99800

18-2
180DM - 01
CHART SYSTEM
The ignition timing is determined by ECM based on signals - signals from the various sensors.
I1 Ignition Coil Assy

I8
(With Igniter) 1 ECM
IgnitionSwitch
INJ 17 E12 IGT1

5 6 +B
IG2 AM2 IGT 3
plug 23 E12 IGF1

2
IGF
GND
4
(With Igniter) 1
16
+B IGT 3
E12 IGT2
plug
IGF 2
GND
4
(With Igniter) 1
15
+B IGT 3
E12 IGT3
plug
IGF 2
GND
4
(With Igniter) 1
1 14
+B IGT 3
N2 Noise E12 IGT4
plug
Filter IGF 2
GND
4
C1 Camshaft
Position Sensor
Shielded
1 26 E12 G2
Rotor of +
Camshaft 2
AM2
Shielded
27
Crankshaft 1
E12 NE +
Position Sensor
plate No. 1 34
2
Battery E12 NE--
3
3
C5 Crankshaft E12 E1
Position Sensor
G35046

18-3
180DN - 01
ATTENTION:
In the next chapter, the term - the term "cold" and "hot" refers to the temperature of the coil. "In-ngin" means the temperature is
about - about --10 to 50_C (14 to 122_F). "Hot" means the temperature is about - about 50 to 100_C (122 to 212_F).
1. CHECK THE IGNITION COIL ASSY (WITH Igniter) SPARKS INTEREST AND DO TESTING API
(A) Check the DTC.

ATTENTION:
If a DTC, perform troubleshooting in accordance with the procedures of DTC.
(B) Check if sparks.
(1) Remove the ignition coil.
(2) Using a 16 mm spark plug key, remove all the spark plugs.
(3) Replace the spark plugs to each ignition coil and the ignition coil connector plug. (4) Remove all - 4
injector connector. (5) Connect the spark plug with a future.
(6) Check to see if sparks on each spark plug when the engine distart.
ATTENTION:
Do not start the engine for more than 2 seconds.
If no sparks, do the following test:
TEST SPARKS INTEREST API

UGLY
CHECK FOR WIRE HARNESS CONNECTOR SIDE OF IGNITIONCOIL (D
Connect securely.
/ G Igniter) LOCKED SAFE UGLY
OK
If sparks, replace the ignition coil with a good ugly.
DO TEST WITH THE IGNITION COIL (WITH Igniter) OTHER
OK
1. Replace the ignition coil (with Igniter) which now, with Igni tion coil (with Igniter)
which are functioning well.
2. Perform a spark test again.
UGLY
POWER SOURCE TO CHECK THE IGNITION COIL (WITH Igniter)

Check the wiring between the ignition switch to the ignition
UGLY coil.
1. Turn the ignition switch ON.
2. Check that there is voltage from the battery to the positive terminal (+) ignition coil
OK
RESISTANCE TO VERIFY CAMSHAFT POSITION SENSOR
(See page 18-5) Replace camshaft position sensor.
Cold Hot UGLY
Standard: 835 to 1,400 1,060 to 1,645
OK
Continued on next page

18-4
Continued from previous page
OK
RESISTANCE TO VERIFY POSITION SENSOR CRANKSHAFT

(See page 18-5)
Replace the crankshaft position sensor.
Cold Hot UGLY
Standard: 1,630 to 2,740 2,065 to 3,225
OK
CHECK THE SIGNAL FROM ECM (See pages 05-91) Check the ECM (see pages 01-31).
UGLY
OK
IMPROVE BETWEEN THE IGNITION COIL WIRING AND ECM
(7) Using a 16 mm spark plug key, plug all plugs.

(8) Install all of the ignition coil.

18-5
180DO - 01
EXAMINATION
ATTENTION:
In the next chapter, the term - the term "cold" and "hot" refers to the temperature of the coil. "Cold" means the temperature is
about - about --10 to 50_C (14 to 122_F). "Hot" means the temperature is about - about 50 to 100_C (122 to 212_F).
1. CHECK SPARK PLUG

CAUTION:
S Janganmenggunakan to cleaning the spark plug wire brush.
S Do not attempt to adjust the electrode gap of the spark plugs that
have been used.
(A) Check the spark plug electrodes.

Megaohmmeter
(1) Menggunakanmegaohmmeter, measuring custody isola-
sinya.
The correct insulation resistance: 10 M or more
If the prisoner is less than the value specified, continue to step (d).
INSTRUCTIONS:
Otherwise tersediamegaohmmeter, perform the following simple checks.

time I39522
(B) the alternative inspection method:

(1) The engine really accelerated rapidly to 4,000
rpm for 5 times. (2) Remove the spark plug. (3) Check the spark
plugs visually. If elektrodenya dry, the spark plug is functioning properly. If
elektrodenya wet, proceed to step (c), (d) and (e).
(4) Replace the spark plugs.
B02629 (C) Check the spark plug if there is damage to the screw and penyekat-
his.
If there is any damage, replace the spark plug.
The spark plugs are recommended:
Made in DENSO K20HRU11

18-6
(D) Check the spark plug electrode gap.

Maximum electrodes for spark plug loopholes that have been used:
1.3 mm (0.051 in.)

If the gap is greater than the maximum, replace the spark plugs.
Fix / set the electrode gap for the new spark plugs:
1.1 mm (0.043 in.)
1.1 mm
ATTENTION:
B02630 If set a new spark plug electrode gap, bend only at the foot of the electrode
period. Do not touch the edges. Janganmencobauntukmenyetel celahdari
plugs that have been used.
(E) Clean the spark plug.

If the electrode is no trace of carbon wet, wipe elektrodenya with cleaning plugs
and then dried.
Air pressure: 588 kPa (6 kgf / cm 2 85 psi) Duration: 20
seconds or less
INSTRUCTIONS:
Use only with a spark plug cleaner if elektrodenya free of oil. If the electrodes are
no traces of oil, use gasoline to clean the oil before using cleaning spark plugs.
B62019
2. CHECK THE POSITION SENSOR CAMSHAFT

Standard:
temperatures Specified Condition
Cold 835 to 1,400
Hot 1,060 to 1,645
If the result is not as specified, replace the camshaft position sensor.
3. CHECK THE POSITION SENSOR CRANKSHAFT

(A) Measure prisoners between NE + and NE-- terminal.
Standard:
temperatures Specified Condition
Cold 1,630 to 2,740
Hot 2,065 to 3,225
If the result is not as specified, replace the crankshaft position sensor.
2 1
P16211

IGNITION -- CAMSHAFT POSITION SENSOR (MACHINE 1TR - FE) 18-7
CAMSHAFT POSITION SENSOR (MACHINE 1TR - FE)

180DJ - 01
REPLACEMENT
2. CAMSHAFT POSITION SENSOR OFF

(A) Remove the sensor connector. (B)
A99146
3. CAMSHAFT POSITION SENSOR PAIRS

(A) Give a little layer of engine oil to the ring - O on the sensor. (B) Replace the
sensor with the bolt.
5. RESET DO WORK FROM THE EARLY CAUTION:
battery.

18-8
IGNITION -- CRANKSHAFT POSITION SENSOR (MACHINE 1TR - FE)
CRANKSHAFT POSITION SENSOR (MACHINE 1TR - FE)

180DK - 01
REPLACEMENT
Wait for 90 seconds after removing the cable from the negative terminal (-) battery to prevent the activation of the airbag
2. With A / C:
OFF DRIVE BELT (See page 14-8)
3. With A / C:
REMOVE AIR KOMPRESSOR ASSY
(A) Remove the two screws and remove the hose exploiters.
(B) Disconnect the cooling compressor.
A99198
(C) Remove the 4 screws and remove the refrigerant compressor.
A99200
4. With A / C:
A99203

18-9
5. CRANKSHAFT POSITION SENSOR OFF

(A) (b) (A) Remove the sensor connector. (B) Remove the connectors from
the connector bracket. (C)
Remove the harness clamps. (D)
(C)
(D) A99147

(C) (E) (A) Provide a thin layer of engine oil to the ring - O of the sensor. (B) Replace
the sensor with the bolt.
(D)
(C) Plug the connector into the connector bracket. (D)
Install the harness clamp. (E) Connect the sensor
connector.
(B)
A99147
7. With A / C
1 PASANGBRACKETMOUNTINGKOMPRESSORNO.1
3
(A) For temporary use only screws labeled A
to install the compressor mounting bracket. (B) Attach the mounting
A
brackets are complete compressor
B to tighten to - 5 bolt in the order shown in the picture.
2 4 5
Moment:
A99203 25 N m (255 kgf cm, 18 ft lbf) to bolt B 45 N m (459 kgf cm, 33 ft lbf)
for bolts except bolt B CAUTION:
To prevent non lurusan, which causes bergeretaknya belt, tightening the

bolt to be done in the correct order.
2 8. With A / C:
PAIRS KOMPRESSOR COOLING ASSY
(A) For temporary use only screws labeled A
4 to install the compressor.
1
(B) Replace the compressor complete with mengen-
cangkan - 4th bolt in the order shown in the picture.
3A
A99200
To prevent non lurusan, which causes bergeretaknya belt, tightening the

bolt to be done in the correct order.
(C) Connect the suction hose with 2 screws.

Moment: 5.4 N m (55 kgf cm, 48 in lbf)

18-10
9. With A / C:
INSTALL DRIVE BELT (See page 14-8)
11. DO RESET INITIAL WORK OF CAUTION:
battery.

START & FILLING
IGNITION SWITCH OR GLOW PLUG ASSY

STARTER SWITCH ASSY ,,,,,,,,,,,,,, 19-1 (MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 19-32
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-1 REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-32
START SYSTEM
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 19-3
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-3
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 19-4
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-5
STARTER ASSY
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 19-7
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-7
CHARGING SYSTEM
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 19-8
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-8
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 19-9
PREVENTIVE MEASURE ,,,,,,,,,,,,,,,,, 19-10
GENERATOR ASSY
(MACHINE 1TR - FE) ,,,,,,,,,,,,,,,,,,,,,, 19-13
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-13
START SYSTEM
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 19-14
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-14
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 19-15
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-16
STARTER ASSY
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 19-18
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-18
CHARGING SYSTEM
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 19-20
LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-20
eXPLANATION SYSTEM ,,,,,,,,,,,,,,,,,,,,, 19-21
PREVENTIVE MEASURE ,,,,,,,,,,,,,,,,, 19-22
EXAMINATION OF VEHICLES ,,,,,,,,, 19-23
GENERATOR ASSY
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 19-25
REPLACEMENT ,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-25
HEATING SYSTEMS - PRELIMINARY (PRE - HEATING)
(MACHINE 2KD - FTV) ,,,,,,,,,,,,,,,,,,,,, 19-27

LOCATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-27
CHART SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,, 19-28
EXAMINATION ,,,,,,,,,,,,,,,,,,,,,,,,,,, 19-31

19-1
START & FILLING -- SWITCH IGNITION SWITCH OR STARTER ASSY
SWITCH IGNITION SWITCH STARTER OR REPLACEMENT ASSY

19115-01
2. TAKE COVER UNDER THE STEERING COLUMN

(A) Remove the 3 screws and bottom cover.
INSTRUCTIONS:
Turn the steering wheel to the right and to the left as necessary to remove 3rd -
screw the lid down.
H45606
3. DISCONNECT CONNECTOR - connectors

(A) Remove the 7 connector and harness of the steering klemwire
column.
G34341
4. SWITCH OFF SWITCH IGNITION OR STARTER ASSY
(A) Remove the 2 nails and off switch on the top bracket
steering column.
: Nails A99992

19-2
STARTER & FILLING -- SWITCH IGNITION SWITCH OR STARTER ASSY
5. INSTALL OR SWITCH IGNITION SWITCH STARTER ASSY

(A) Install the switch on top of the steering column bracket with two nails.
6. PLUG CONNECTOR - connectors

(A) Connect to - 7 connector as shown da-
lam pictures.
G34341
7. INSTALL STEERING COLUMN CLOSE DOWN

(A) Replace the bottom cover with 3 screws.
INSTRUCTIONS:
Turn the steering wheel to the right and to the left as necessary to install 3
couplers and shut down the steering column.
H45606

battery.

19-4
START & FILLING -- SYSTEM START (MACHINE 1TR - FE)
19117-02
CHART SYSTEM
System start rotating the motor starter based on the signal - signal from the ignition switch.
I9
ST
AM2 ST2 A/T
5 7
M/T
N1 Switch PNP
5 4
ECU warning PencurianAssy
relay ST
12
*1
T9
2 1
5 3 *2
1
T9
AM2
1 S7 1 S6
30 50
Pull - in Coil Holding Coil
Primary
contact
C plunger
armature Coil
* 1: With Theft Deterrent System
battery * 2: Without Theft Prevention System
starter Assy
G36460

19-5
19118-01
EXAMINATION
1. CHECK THE STARTER ASSY

Terminal 50
CAUTION:
This test should be done dalamwaktu 3 to 5 seconds in order to prevent
Functioning the coil from burning.
(A) Perform pull tests - in / holding.
(1) Disconnect the field coil wire from terminal C. (2) Connect battery to
magnetic switch as
it looks in the picture. Then check that the clutch pinion gear to
Terminal C move out.
A99965
(3) The battery is connected as above and

terminal 50 clutch pinion gear out, disconnect the negative cable (-) from
terminal C. Check that the pinion gear stick out.
terminal C
Release A99966
(4) Disconnect the negative cable (-) from the switch body. Perik-
Release terminal 50
sa that the clutch pinion gear back into.
If the result is not as specified, replace starter assy.
Functioning
Release A99967
Terminal 30 (B) Test operation with no load.

(1) Connect the cable field coil wire to terminal C.
Moment: 9.8 N m (100 kgf cm, 86.7 in. Lbf)
(2) Hold the starter with a vise. (3) Connect battery and ammeter to the
starter as
it looks in the picture. (4) Check that the starter rotates smoothly
ammeter and
Terminal 50 steady while pinion gear to move out. Then measure the large
A99968 current.
Large currents specified: 90 A or less at
11.5 V
If the result is not as specified, replace starter assy.

19-6
2. CHECK THE RELAY (Marked: ST)

1 2
(A) Measure the custody of the relay ST.
Standard:
5 3 relationship Tester Predefined conditions
3-5 10 k or higher
5
below 1
1 2 3-5
(When the battery voltage is supplied to terminal 1 and 2)
3
If the result is not as specified, replace the relay ST.
B60778
3. CHECK THE IGNITION SWITCH OR SWITCH STARTER ASSY

ACC IG1
(A) Measure the custody of the switch.
Standard:
AM1 234 1
relationship Tester conditions Switch Predefined conditions
8765 AM2 -- LOCK 10 k or higher
2 (ACC) - 4 (AM1) ACC below 1
1 (IG1) - 4 (AM1) 2
ST2 IG2 (ACC) - 4 (AM1) 5 (AM2) ON below 1
G35048
- 6 (IG2)
1 (IG1) - 4 (AM1) 2
(ACC) - 4 (AM1) 5
START under 1
(AM2) - 6 (IG2) 5 (AM2)
- 7 (ST2)
If the result is not as specified, replace the ignition switch assy.

19-7
START & FILLING -- STARTER ASSY (MACHINE 1TR - FE)
STARTER ASSY (MACHINE 1TR - FE)

19119-01
REPLACEMENT
2. SEAL OFF FRONT FENDER

(A) Remove the 5 clips and seals.
(A) 3. OFF STARTER ASSY

(b) (A) Remove the starter connector. (B) Remove the nut and
remove the starter cord. (C) Automatic Transmission:
(E)
Remove the two screws and automatic transmission oil level gauge. (See
pages 40-15). (D) Manual Transmission:
(E)
A99682 Remove the clutch cylinder release (see page 41-4). (E) Remove the
2 bolts and starter.
4. INSTALL STARTER ASSY

(A) Install the starter with two bolts.
(B) Attach the starter cable to the terminal 30 with a nut.
(C) Connect the starter. (D) Automatic
Transmission:
Replace automatic transmission oil level gauge with two screws (see pages 40-15). (E) Transmission Manual:
Replace the clutch cylinder release (see page 41-4).

5. SEAL INSTALL FRONT FENDER
(A) Replace the seal with 5 clips.
battery.

19-9
START & FILLING -- CHARGING SYSTEM (ENGINE 1TR - FE)
1911B - 01
CHART SYSTEM
Charging system using a voltage regulator to regulate the electricity generated from the rotation of the rotor coil and store this electricity in
batteries.
I9
ECM
AM1 IG1
4 1
AM2 IG2
5 6
ECU - IG &
MET
GAUGE
AM1
21
Warning
Meter Lamp)
C10 (Charging
Combination
E12 10
ALT
ALT ALT - SAM2
37
1 A7 1 A8 4 A8 2 A8 3 A8
B S L IG M
S L IG M
Coil Coil
voltage Regulator
Rotor Stator
EFP
Battery
generator Assy
A99924

19-10
1911C - 01
PREVENTIVE MEASURE
1. Check that the battery cables have been connected to the correct terminal.
2. Disconnect the battery cables when the batteries are charging fast.
3. Do not perform tests with high voltage insulation resistance tester.
4. Do not remove the battery when the engine is turned on.
5. Check that the charging cable is connected firmly to the terminal B of the generator and the fuse box.
6. If the generator is connected to the vehicle, janganmelakukan examination at terminal F.

19-11
1911D - 01
WARNING:
If the battery is weak or difficult to distart engine, recharge the battery and perform the checks again before returning the
vehicle to the customer.
1. CHECK THE BATTERY CONDITION
(A) Check the battery against damage and deformation. If damaged, it was found there's-
its deformation or leaks, replace the battery. (B) Check the electrolyte
quantity of each cell. For battery-free - treatment:
If the quantity of electrolyte is below the recommended amount, replace the battery. For batteries that are
not free - treatment:
If the quantity of electrolyte is below the recommended amount, add distilled water.
2. CHECK THE BATTERY TERMINAL, fusible LINK AND FUSE
(A) Check that the battery terminals are not loose or exposed to corrosion. If the terminal - the terminal exposed to
corrosion, clean the terminals - terminals. (B) Check the fusible link, fuse - H and fuse - fuse for prisoners under 1. If the
fusible link or fuse - fuse is not as specified, replace as necessary.
3. CHECK THE DRIVE BELT

FALSE (A) Check the belt against the wear and tear, cracks - cracks and
sign - a sign of other damage. If you find any damage,
replace the drive belt. INSTRUCTIONS:
Replace the drive belt if found damage to the following:

S If the belt is worn until the wires can be seen.
S If the rift reaches the wire and exists in more than one place.
B00543
S If the belt has no missing pieces of his ribs.
(B) Check that the belt is perfectly fitting in

groove ribs.
INSTRUCTIONS:
Periksamenggunakan your hands, toensure that the belt does not slip out of the
groove on the bottom of the pulleys.
RIGHT FALSE
B75171
4. CHECK THE WIRING GENERATOR FOR VISUAL

(A) Check that wiring is in good condition.
5. LISTEN TO THE SOUND THAT IS NOT NORMAL OF GENERATOR
(A) Check that no abnormal noise from the generator when the engine is turned on.
6. CHECK THE WARNING LAMP CIRCUIT FILLING
(A) Turn the ignition switch ON. Check that the charging warning lamp lights up. (B) Start the engine and check
that the lights are extinguished.
If the lights do not work as specified, do troubleshoot the charging warning lamp circuit.

19-12
ammeter 7. CHECK THE CHARGING CIRCUIT WITHOUT LOAD

Remove the cables (A) Connect a voltmeter and ammeter to the charging circuit
from Terminal B
as follows.
INSTRUCTIONS:
Battery If available battery tester / generator, connect the tester to the charging circuit in
accordance with the manufacturers' instructions.
Generator (1) Disconnect the cable from the generator terminal B and Hu
voltmeter
bungkan cable to the negative (-) of the ammeter. (2) Connect the
A91071 positive cable (+) ammeter to terminal B
on the generator.
(3) Connect the positive cable (+) voltmeter to terminal B
on the generator.
(4) Connect the negative cable (-) voltmeter time. (B) Check the
charging circuit.
(1) Hold the engine speed at 2,000 rpm. check
readings on the ammeter and voltmeter.
Standard amperage: 10 A or less Voltage:
13.2 to 14.8 V
If the result is not as specified, replace the generator.
8. CHECK THE CHARGING CIRCUIT WITH LOAD
(A) The engine speed at 2,000 rpm, turn on the lights away at the big lights and turn the switch
heater blower to HI position. (B) Check the
reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than standard amperage, replace the generator. INSTRUCTIONS:
If the battery is fully charged, the ammeter reading sometimes - sometimes will be less than standard amperage.

19-13
START & FILLING -- GENERATOR ASSY (MACHINE 1TR - FE)
GENERATOR ASSY (MACHINE 1TR - FE)

1911E - 01
REPLACEMENT

(B) 4. OFF GENERATOR ASSY

(A) (A) Remove the nut, bolt and generator cables. (B)
Remove the generator connector. (C)
(C)
Remove the two bolts and generator.
(A)
(C) A99681
(C) 5. INSTALL GENERATOR ASSY

(B) (A) Install the generator with 2 screws.
Moment:
(a A
62 N m (630 kgf cm, 46 ft lbf) to bolt A 25 N m (254 kgf
(B)
cm, 19 ft lbf) to bolt B
(B) Attach the cord generator with bolts and nuts.
Moment: 6.0 N m (61 kgf cm, 53 ft lbf) for the nut.
(C) Connect the connector.
(A) - B A99681
6. TIDE FAN AND GENERATOR V BELT (See page 14-8)

7. INSTALL AIR CLEANER ASSY
battery.

19-14
START & FILLING -- SYSTEM START (MACHINE 2KD - FTV)
SYSTEM START (MACHINE 2KD - FTV) LOCATION

1911F - 01
T:
Switch Park / Neutral Position (PNP)
ECUPeringatanPencurianAssy
A / B Instrument Panel Assy

(A / B Side Driver)
F fuse ST
F Fuse - AM2 H
F relay ST
Starter Assy A /
A99716

19-15
1911G - 01
CHART SYSTEM
System start rotating the motor starter based on the signal - signal from the ignition switch.
I9
AM2 ST2 ST A/T
5 7
M/T
N1 Switch PNP
5 4
ECUPeringatan PencurianAssy
relay ST
12
*1
T9
2 1
5 3 *2
1
T9
AM2
1 S7 1 S6
30 50
Pull - in Coil Holding Coil
Primary
contact
C plunger
armature Coil
* 1: With Theft Deterrent System
Battery * 2: Without Theft Prevention System
starter Assy
G36460

19-16
1911H - 01
EXAMINATION
2.7 kW terminal C 2.0 kW terminal C
Terminal 50 Terminal 30 Terminal 50 Terminal 30
A97648
1. CHECK THE STARTER ASSY

Functioning terminal C
CAUTION:
This test should be dilakukandalamwaktu3 to 5 detikuntuk prevent the coil
from burning.
(A) Perform pull tests - in / holding.
(1) Disconnect the field coil wire from terminal C. (2) Connect battery to
magnetic switch as
terminal 50 it looks in the picture. Then check that the clutch pinion gear
A97649 moves outward.
Release (3) The battery is connected as above and
Terminal C
with clutch pinion gear stick out, disconnect the negative cable (-)
from terminal C. Check that the pinion gear stick out.
terminal 50
A97650
(4) Disconnect the negative cable (-) from the switch body. Perik-
Release
Functioning
sa that the clutch pinion gear back into.
Release
Terminal 50
A97651

19-17
(B) Test operation with no load.

(1) Connect the cable field coil wire to terminal C.
Connect
(2) Hold the starter with a vise. (3) Connect battery and ammeter to the
starter as
it looks in the picture. (4) Check that the starter rotates smoothly
and
terminal 50
steady while pinion gear to move out. Then measure the large
current.
ammeter
terminal 30 Much current is specified:
item Prescribed conditions
Starter kinds of 2.7 kW 180 A or less at 11 V
Starter kinds of 2.0 kW 100 A or less at 11.5 V
A97652 If the result is not as specified, replace starter assy.
2. CHECK THE RELAY (Marked: ST)

(A) Measure the custody of the relay ST.
Standard:
relationship Tester Specified conditions
3-5 10 k or higher
below 1
3-5
If the result is not as specified, replace the relay ST.
A92673
3. CHECK THE IGNITION SWITCH OR SWITCH STARTER ASSY

ACC IG1
(A) Measure the custody of the switch.
Standard:
AM1 234 1
relationship Tester conditions Switch Specified Condition
8765 AM2 -- LOCK 10 k or higher
2 (ACC) - 4 (AM1) ACC below 1
1 (IG1) - 4 (AM1) 2
ST2 IG2 (ACC) - 4 (AM1) 5 (AM2) ON below 1
G35048
- 6 (IG2)
1 (IG1) - 4 (AM1) 2
(ACC) - 4 (AM1) 5
START below 1
(AM2) - 6 (IG2) 5 (AM2)
- 7 (ST2)
If the result is not as specified, replace the ignition switch assy.

19-18
START & FILLING -- STARTER ASSY (MACHINE 2KD - FTV)
STARTER ASSY (MACHINE 2KD - FTV)

1911I - 01
REPLACEMENT
2. SEAL OFF FRONT FENDER

(A) Remove the 5 clips and seals.
3. OFF STARTER ASSY

(b)
(A) Remove the starter connector. (B) Remove the nut and
remove the starter cord. (C) Automatic Transmission:
(A) Remove the automatic transmission oil level gauge. (See page 40-6). (D)
Manual Transmission:
Remove the clutch cylinder release (see page 41-4).

A97641
(E) Remove the two nuts, bolts, cables and starter period.
(E)
(E)
Bolt A97647
4. INSTALL STARTER ASSY

(A) Install the starter and wiring time with two nuts and bolts.
(B) Attach the starter cable to the terminal 30 with a nut.
Moment:
21 N m (214 kgf cm, 15 ft lbf) to 2.7 kW 10 N m (102 kgf
cm, 7 ft lbf) to 2.0 kW
(C) Connect the starter. (D) Automatic
Transmission:
Replace automatic transmission oil level gauge with two screws (see page 40-6). (E) Transmission Manual:
Replace the clutch cylinder release (see page 41-4).

5. SEAL INSTALL FRONT FENDER

19-19
START & FILLING -- STARTER ASSY (MACHINE 2KD - FTV)
battery.

19-20
START & FILLING -- CHARGING SYSTEM (ENGINE 2KD - FTV)
CHARGING SYSTEM (ENGINE 2KD - FTV) LOCATION

1911J - 01
A / B Instrument Panel Assy (J / B ECM

Combination Meter Assy
Side Driver)
F LampuPeringatanPengisian
F Fuse - AM1 H
F fuse MET
F Fuse ECU - IG & GAUGE
generator Assy
F Fuse - ALT H
F Fuse - AM2 H
F Fuse ALT - S
A99929

19-21
1911K - 01
eXPLANATION SYSTEM
Charging system using a voltage regulator to regulate the power produced by perputa-
ran from the rotor coil and store this electricity in the battery.
I9
ECM
AM1 IG1
4 1
AM2 IG2
5 6
ECU - IG &
MET
GAUGE
AM1
Warning
Meter Lamp)
C10 Assy 21
(Charging
Combination
E8 8
ALT
ALT ALT - SAM2
37
1 A7 1 A8 4 A8 2 A8 3 A8
B S L IG M
S L IG M
Coil Coil
voltage Regulator
Rotor Stator
EFP
Battery
generator Assy
A99924

19-22
1911L - 01
PREVENTIVE MEASURE
1. Check that the battery cables have been connected to the correct terminal.
2. Disconnect the battery cables when the batteries are charging fast.
3. Do not perform tests with high voltage insulation resistance tester.
4. Do not remove the battery when the engine is turned
5. Check that the charging cable is connected firmly to the terminal B of the generator and the fuse box.
6. If the generator is connected to the vehicle, do not perform checks on the terminal F.

19-23
1911M - 01
WARNING:
If the battery is weak or difficult to distart engine, recharge the battery and perform the checks again before returning the
vehicle to the customer.
1. CHECK THE BATTERY CONDITION
(A) Check the battery against damage and deformation. If damaged, it was found there's-
its deformation or leaks, replace the battery. (B) Check the electrolyte
quantity of each cell. For battery-free - treatment:
If the quantity of electrolyte is below the recommended amount, replace the battery. For batteries that are
not free - treatment:
If the quantity of electrolyte is below the recommended amount, add distilled water.
2. CHECK THE BATTERY TERMINAL, fusible LINK AND FUSE
(A) Check that the battery terminals are not loose or exposed to corrosion. If the terminal - the terminal exposed to
corrosion, clean the terminals - terminals. (B) Check the fusible link, fuse - H and fuse - fuse for prisoners under 1. If the
fusible link or fuse - fuse is not as specified, replace as necessary.
3. CHECK THE DRIVE BELT

CHANGE BELT
(A) Check the belt against the wear and tear, cracks - cracks and
sign - a sign of other damage. If you find any damage,
replace the drive belt. INSTRUCTIONS:
Replace the drive belt if found damage to the following:

S If the belt is worn until the wires can be seen.
S If the rift reaches the wire and exists in more than one place.
B00543
S If the belt has no missing pieces of his ribs.
(B) Check that the belt is perfectly fitting in

groove ribs.
INSTRUCTIONS:
Periksamenggunakan your hands, toensure that the belt does not slip out of the
groove on the bottom of the pulleys.
RIGHT FALSE
B75171
4. CHECK THE WIRING GENERATOR FOR VISUAL

(A) Check that wiring is in good condition.
5. LISTEN TO THE SOUND THAT IS NOT NORMAL OF GENERATOR
(A) Check that no abnormal noise from the generator when the engine is turned on.
6. CHECK THE WARNING LAMP CIRCUIT FILLING
(A) Turn the ignition switch ON. Check that the charging warning lamp lights up. (B) Start the engine and check
that the lights are extinguished.
If the lights do not work as specified, do troubleshoot the charging warning lamp circuit.

19-24 STARTING & CHARGING -- CHARGING SYSTEM (KIJANG INNOVA / 2KD - FTV (TMMIN
MADE FOR INDONESIA))
ammeter 7. Perikasa CHARGING CIRCUIT WITHOUT LOAD

Remove the cables (A) Connect a voltmeter and ammeter to the charging circuit
from Terminal B
as follows.
INSTRUCTIONS:
Battery If available battery tester / generator, connect the tester to the charging circuit in
accordance with the manufacturers' instructions.
Generator (1) Disconnect the cable from the generator terminal B and Hu
voltmeter
bungkan cable to the negative (-) of the ammeter. (2) Connect the
A91071 positive cable (+) ammeter to terminal B
on the generator.
(3) Connect the positive cable (+) voltmeter to terminal B
on the generator.
(4) Connect the negative cable (-) voltmeter time. (B) Check the
charging circuit.
(1) Hold the engine speed at 2,000 rpm. check
readings on the ammeter and voltmeter.
Standard amperage: 10 A or less Voltage Standard:
13.2 to 14.8 V
If the result is not as specified, replace the generator.
8. CHECK THE CHARGING CIRCUIT WITH LOAD
(A) The engine speed at 2,000 rpm, turn on the lights away at the big lights and turn the switch
heater blower to HI position. (B) Check the
reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than standard amperage, replace the generator. INSTRUCTIONS:
If the battery is fully charged, the ammeter reading sometimes - sometimes will be less than standard amperage.

19-25
START & FILLING -- GENERATOR ASSY (MACHINE 2KD - FTV)
GENERATOR ASSY (MACHINE 2KD - FTV)

1911N - 01
REPLACEMENT

3. OFF FAN AND GENERATOR V BELT (See pages 14-70)
4. OFF GENERATOR ASSY

(b) (A) Remove the nut, bolt and generator cables. (B)
Remove the generator connector. (C)
Remove the two bolts and generator.
(C)
(C)
(A)
A97653
5. INSTALL GENERATOR ASSY

(c) (A) Install the generator and stem penyetelnya with 2
bolt.
Moment:
62 N m (630 kgf cm, 46 ft lbf) to bolt A 25 N m (254 kgf
cm, 19 ft lbf) to bolt B
(B) Attach the cord generator with bolts and nuts.
(a A
(C) Connect the generator connector.
(A) - B
(B)
A97653
6. TIDE FAN AND GENERATOR V BELT (See pages 14-70)

7. INSTALL AIR CLEANER ASSY

19-26
START & FILLING -- GENERATOR ASSY (MACHINE 2KD - FTV)
battery.

19-28
START & FILLING -- HEATING SYSTEM BEGINNING (MACHINE 2KD - FTV)
1911P - 01
CHART SYSTEM
C10
Assy Combination Meter (Indicator
Lamp Incandescent) ECM
MET 14
E5 GIND
21 40
I9
IG2 AM2
5
AM2 6
1 2
GLOW
1 2
relays GLOW
3 5
G1 15
Glow Plug E5 GREL
1 2
ECT sensor W1
19
THW
E8 THW
2
28
E2
E8 E2
1
Battery
A99984

19-29
1911Q - 01
ATTENTION:
Turn the ignition switch OFF for 60 seconds before performing the following checks.
(Seconds) 1. INDICATOR LIGHT PERIKSALAMANYAMENYALADARI PIJAR

On the length of Lights
10
(A) Check the length of the light is on.

6.5
(1) Turn the ignition switch ON, and then measuring the long-
its lights on.
3.5
Length of lights: See chart
0.5 0-23 (2) Turn the ignition switch OFF.
-- 13 30 C)
If the result is not as specified, check the ECM, ECT sensor, glow plug and relay
-- 4 8.5 0 32 86 (_F) (°
Engine Coolant Temperature G36553 GLOW. INSTRUCTIONS:
The length of the actual lights can be little changed from the graph.
2. CHECK THE WARMING - THE BEGINNING
(A) Check the initial heating time.
10.5 (1) Turn the ignition switch ON, then measuring how
10 long it takes for the battery voltage supplied to the glow plug.
8.4 8 Standard:
Engine Coolant Temperature Heating Time - Initial
7.4 40_C (104_F) or higher 1 second
6.8
Heating Time - Initial (sec)
See chart (longest 15

Less than 40_C (104_F)
6 seconds)
(2) Turn the ignition switch OFF.

4.7 4 If the result is not as specified, check the ECM, ECT sensor, glow plug and relay
GLOW.
(B) Turn the ignition switch keSTA, then check that te
gangan battery is supplied to the glow plug. (C) While the start / rewinding
0
machine, measuring how long di--
need to drain the battery voltage to the glow plug.
0 12 12.5 13 13.5 14 14.5
Battery Voltage (V)

A96717
Standard:
Engine Coolant Temperature Heating time - Beginning
40_C (104_F) or higher 1 second
See chart (longest 15

Less than 40_C (104_F)
seconds)
GLOW.

19-30
3. CHECK THE TIME AFTER PIJAR

E8 E5
(A) Check the time after the flare.
ECM ECM
(1) Setelahmesin life, measuring how long diper-
Lukan untukmengalirkan E5--15 terminal to the battery voltage
(GREL) and E8--28 (E2) of ECM.
Standard:
E5--15 (GREL) - E8--28 (E2) See graph

28 (E2) (-) 15 (GREL) (+)
GLOW.
After Glow Time (sec)
0120
0 20 40 (° C)
68 104 (_F)
Fluid Temperature PendinginMesin
G37755
4. CHECK THE GLOW PLUG (SPARK PIJAR)

screw grommet (A) Remove the screw grommet. (B) Measure the
prisoners in the glow plug.
Standard:
Glow plug terminal - The Body About - about 0.95 at 20_C (68_F)
If the result is not as specified, replace the glow plug.

ATTENTION:
ohmmeter
S Be - careful not to damage the pipe glow plug because it can cause
an open circuit or shorten the life of the glow plug.
S Be - careful to prevent oil and gas spraying in the glow plug when
cleaning.
A97654 S Clean the oil that is in the terminal and bakelitewasher with a dry
cloth.
S Be - careful not to give more than 11 V voltage on the glow plug
because it can cause an open circuit.

19-31
1911R - 01
EXAMINATION
1. CHECK THE RELAY (Marked: GLOW)

(A) Measure the custody of the relay GLOW.
Standard:
1-2 10 k or higher
below 1
3-5
If the result is not as specified, replace the relay GLOW.
A92673
2. CHECK THE TEMPERATURE SENSOR-Ngin early retirement FLUID MACHINE

ohmmeter

Standard:
30
20
10
5
3
Kalaumemeriksa ECTdi sensor in water, keep the terminal - the terminal
remains dry. After examination of all ringkan sensor.
prisoners k
0.5 2
0.3
0.2
0.1 1
-- 20 0 20 40 60 80 100
(--4) (68) (104) (140) (176) (32) (212)
S01196
Temperatures ° C (_F)
S01699 Z17274

19-32 START & FILLING -- GLOW PLUG ASSY (MACHINE 2KD - FTV)
SPARK PIJAR (GLOW PLUG) ASSY (MACHINE 2KD - FTV)

1911S - 01
REPLACEMENT
2. OFF AIR CLEANER PIPE SUB - ASSY NO. 2 (See pages 13-11)
3. DIESEL OFF THROTTLE BODY ASSY (See page 10-22)
4. OFF BRACKET THROTTLE BODY (See pages 12-12)
5. OFF DUTY AIR DUCT CONNECTOR (See pages 12-12)
6. OFF EGR PIPE SUB - ASSY NO. 1 (See pages 12-12)
7. OFF VALVE ASSY EGR (See pages 12-12)
8. GLOW PLUG CONNECTOR RELEASE NO. 1
(A) Remove the nut and wire harness.
(B) Remove the 4 grommet screws, 4 nuts and glow plug connector.
9. TAKE GLOW PLUG ASSY

(A) Using a 12 mm socket wrench, remove to - 4
glow plug.
A98830
10. GLOW PLUG ASSY PAIRS

11 - (c)
(A) Using a 12 mm socket wrench, attach it to - 4
11 - (a)
glow plug.
11 - (d) Moment: 13 N m (133 kgf cm, 10 ft lbf)
11. GLOW PLUG CONNECTOR PAIR NO. 1
10 - (a) (A) Connect the glow plug to install 4 nuts
and tighten evenly.
G35140 (B) Attach to - 4 grommets couplers. (C) Attach the
wire harness with a nut.
12. POST EGR VALVE ASSY (See page 12-12)
13. POST EGR PIPE SUB - ASSY NO. 1 (See pages 12-12)
14. POST AIR CONNECTOR CHANNEL SIGN (See pages 12-12)
15. TIDE DIESEL THROTTLE BODY ASSY (See page 10-22)
16. POST BRACKET THROTTLE BODY (See pages 12-12)
17. POST AIR CLEANER PIPE SUB - ASSY NO. 2 (See pages 13-11)

19-33
START & FILLING -- GLOW PLUG ASSY (MACHINE 2KD - FTV)
battery.


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Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

PT. ASTRA TOYOTA MOTOR,

National Service Division, Training Department Jl. South

Motor Style No. 5 North Jakarta 14330 Fax No. 021-6521363

Phone. No. 021-6515551 extension 2902

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

MACHINE CONTROL SYSTEM ,,,,,,,,,,,,,,, 02-1

FUEL ,,,,,,,,,,,,,,,,,,,,,,,,,, 02-2

CONTROL EMISSI ,,,,,,,,,,,,,,,,,,,,,,, 02-5

INTAKE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-6

MECHANICAL MACHINES ,,,,,,,,,,,,,,,,,,,,,, 02-7

EXHAUST ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-12

COOLING ,,,,,,,,,,,,,,,,,,,,,,,,,, 02-13

lubrication ,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-14

IGNITION ,,,,,,,,,,,,,,,,,,,,,,,,,,,, 02-17

START & FILLING ,,,,,,,,,,,,,,,,,,,, 02-18

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

PREPARATION MACHINE CONTROL

TOYOTA electrical tester ECD (MACHINE 2KD - FTV)

ECD (MACHINE 2KD - FTV)

Service wire harness - harness Wire service Torque wrench

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

09023-12701 Union Nut Wrench 17 mm INJECTOR ASSY (MACHINE 2KD - FTV)

(09268-41091) NO.7 Union FUEL SYSTEM (ENGINE 1TR - FE)

(09268-41110) Adapter FUEL SYSTEM (ENGINE 1TR - FE)

(09268-41120) 3 Way FUEL SYSTEM (ENGINE 1TR - FE)

(09268-41300) Clamp FUEL SYSTEM (ENGINE 1TR - FE)

(95336-08070) Hose FUEL SYSTEM (ENGINE 1TR - FE)

(95333-06030) Hose FUEL SYSTEM (ENGINE 1TR - FE)

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

09950-50013 Puller C Set SUPPLY PUMP ASSY (MACHINE 2KD - FTV)

(09951-05010) Hanger 150 SUPPLY PUMP ASSY (MACHINE 2KD - FTV)

(09952-05010) slide Arm SUPPLY PUMP ASSY (MACHINE 2KD - FTV)

(09954-05021) Claw No. 2 SUPPLY PUMP ASSY (MACHINE 2KD - FTV)

09992-00242 Turbocharger Pressure Gauge INJECTOR ASSY (MACHINE 2KD - FTV)

Turbocharger pressure gauge

Hexagon wrench (10 mm) - Hexagon keys (10 mm)

Hose - Slang Intelligent

Measuring flask Press -

Radiator cap tester - Tester Close Radiator Service wire

harness - Wire Harness Service

Square Steel - Steel Quadrangle

Service wire harness - Wire Harness Service

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

Torque wrench - Key Moments

Vernier caliper - Term Sorong

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

09992-00242 Turbocharger Pressure Gauge EGR SYSTEM (ENGINE 2KD - FTV)

Turbocharger pressure gauge

09082-00040 TOYOTA Electrical Tester EGR SYSTEM (ENGINE 2KD - FTV)

TOYOTA electrical tester

(09083-00150) Test Lead Set EGR SYSTEM (ENGINE 2KD - FTV)

Cable Test Set

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

09992-00242 Turbocharger Pressure Gauge SYSTEM TURBOCHARGER (ENGINE 2KD -

Innova Repair Guidelines - Volume 3 (PRK I 179- I- J3)

Union nut key 17 mm ENGINE ASSY (MACHINE 2KD - FTV) CAMSHAFT

(MECHANICAL 2KD - FTV) GASKET CYLINDER

HEAD (MACHINE 2KD - FTV)

09032-00100 Oil Pan Seal Cutter CHAIN SUB - ASSY (MACHINE

09213-54015 Crankshaft Pulley Holding Tool CHAIN SUB - ASSY (MACHINE