Toyota 8FGU15 Manual
  1. Manuals
  2. Brands
  3. Toyota Manuals
  4. Forklifts
  5. 8FGU15
  6. Manual

Toyota 8FGU15 Manual

Hide thumbs Also See for 8FGU15:
1
Table Of Contents
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
Table of Contents

Advertisement

Quick Links

GENERAL
ENGINE - CHASSIS
4Y-E REPAIR
1DZ-II REPAIR
4Y-E LPG DEVICE REPAIR
TRANSMISSION (Pn1•2•3 / Cu2•3)
TRANSMISSION (Cu1 Ton Series)
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
MINI LEVER - JOYSTICK
SAS / OPS
SSTLIST - SERVICE STANDARDS LIST
MULTIFUNCTION DISPLAY DX (OPTIONAL)
ELECTRICAL SYSTEM TROUBLESHOOTING [except Cu1]
ELECTRICAL SYSTEM TROUBLESHOOTING [Cu1 ton series]
WIRING DIAGRAM
SERVICE INFORMATION BULLETINS
SECTION INDEX
NAME
SECTION
0
1
1.1
1.2
1.3
2
2.1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
19.1
E
SIB

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 8FGU15 and is the answer not in the manual?

Questions and answers

Larry Bowman
January 30, 2025

I **** a structural engineer and I **** interested in the maximum operating wheel loads

0
1 comments:
Mr. Anderson
February 10, 2025

The maximum operating wheel loads for the Toyota 8FGU15 are:
- Front axle with maximum load: 14,110 lb (6,400.2 kg)
- Rear axle with maximum load: 2,040 lb (925.3 kg)

This answer is automatically generated

0

Related Manuals for Toyota 8FGU15

Summary of Contents for Toyota 8FGU15

  • Page 1 SECTION INDEX NAME SECTION GENERAL ENGINE - CHASSIS 4Y-E REPAIR 1DZ-II REPAIR 4Y-E LPG DEVICE REPAIR TRANSMISSION (Pn1•2•3 / Cu2•3) TRANSMISSION (Cu1 Ton Series) PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE MINI LEVER - JOYSTICK SAS / OPS...

  • Page 2: Table Of Contents

    GENERAL Page Page EXTERIOR VIEWS ....0-2 PRECOAT BOLTS....0-15 VEHICLE MODEL....0-3 HIGH PRESSURE HOSE FITTING FRAME NUMBER....0-4 TIGHTENING TORQUE..0-15 HOW TO USE WIRE ROPE SUSPENSION THIS MANUAL.......0-5 ANGLE LIST......0-16 ...0-5 EXPLANATION METHOD SAFE LOAD FOR ......0-6 TERMINOLOGY EACH WIRE ROPE SUSPENSION ANGLE ..

  • Page 3: Exterior Views

    0-2a General EXTERIOR VIEWS Section 0...
  • Page 4 0-2b General EXTERIOR VIEWS Section 0...

  • Page 5: Vehicle Model

    General 8FG(D)U15-32 VEHICLE MODEL 8FGCU20-32 Pneumatic Tire Models (Pn) Classification Load Capacity Vehicle Model Transmission Type Engine Series Model 8FGU15 Gasoline Pn15 3000 lbs 8FDU15 1DZ-II Diesel Pn1 ton series 8FGU18 Gasoline Pn18 3500 lbs 8FDU18 1DZ-II Diesel 8FGU20 Gasoline...

  • Page 6: Frame Number

    0-4a General VEHICLE MODEL 8FGCU15,18,SU20 Series Load Capacity Vehicle Model Transmission Type Engine 3000 lbs 8FGCU15 Gasoline Cu1 ton series 1 ton series 3500 lbs 8FGCU18 Gasoline 4000 lbs *8FGCSU20 Gasoline *: USA and CANADA Only FRAME NUMBER Frame No. Punching Position Punching position Series Engine...
  • Page 7 0-4b General FRAME NUMBER 8FG(D)U15-32 8FGCU20-32 Frame No. Punching Position Punching position Series Engine Vehicle model Punching format 8FGU15 8FGU18-10011 8FGU18 1 ton series 8FDU15 1DZ-II 8FDU18-10011 8FDU18 8FGU20 8FGU25-10011 8FGU25 Pneumatic tire 2 ton series 8FDU20 1DZ-II 8FDU25-10011 8FDU25...

  • Page 8: How To Use This Manual

    General HOW TO USE THIS MANUAL EXPLANATION METHOD Operation procedure (1) The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with illustration. Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summarized as point operations.

  • Page 9: Terminology

    General How to read components figures (1) The components figure uses the illustration in the (Example) parts catalog for the vehicle model. Please refer to the catalog for checking the part name. 3201 The number at the right shoulder of each components figure indicates the Fig.

  • Page 10: Operational Tips

    (5) Follow the described procedures for disassembly, inspection and reassembly. (6) Replace, gaskets, packings and O-rings with new ones each time they are disassembled. (7) Use genuine Toyota parts for replacement. (8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
  • Page 11 0-7b General Continued from previous page: 8FGCU15,18,SU20 Jack up points Front side: Jack up at the bottom surface of the frame. Rear side: Jack up at the under the counterweight or the bottom surface of the frame. Section 0...

  • Page 12: Hoisting The Vehicle

    General Hydraulic oil level inspection procedure Checking the oil amount inside tank, as shown below, contact top of cap on retainer. (Do not push it into retainer.) *NOTE: Excludes 7FGCU15,18,SU20 HOISTING THE VEHICLE When hoisting the vehicle, sling with wire rope(s) at the mast hook holes and the rear side of the head guard.

  • Page 13: Attentive Points On Sas

    (valves, piping, etc.). Periodic replacement of the hydraulic oil is very important. Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause faults. Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary equipment, optional parts, etc.). Section 0...

  • Page 14: Circuit Tester

    0-10 General CIRCUIT TESTER Circuit testers are available in both the analog and digital types. They should be used selectively according to the purpose of measurement. Analog type: This type is convenient for observing movement during operation, but the measured value should only be used for reference or rough judgement.
  • Page 15 0-11 General Difference in result of measurement with circuit tester The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used. The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage. The diode characteristics are shown in the figure below.

  • Page 16: Standard Bolt & Nut Tightening Torque

    0-12 General STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and nut tightening torques are not indicated. Judge the standard tightening torque as shown below. For tightening torque of hexagon head bolt, welded bolt and stud bolt with the standard bearing surface, identify bolt class based on the below chart and then determine using the tightening torque table.
  • Page 17 0-13 General Identification by Part No. Part No. Shape Diameter Length (mm) Hexagon head bolt Diameter (mm) Length Class Diameter Length (mm) Stud bolt Diameter (mm) Length Class Tightening Torque Table Specified torque Diameter Pitch Class N·m kgf·cm ft·lbf 1.25 1.25 1.25 1150...
  • Page 18 0-14 General Identification by Bolt Shape (Hexagon flange bolt) Class 4.8T 6.8T 8.8T 10.9T 11.9T No mark Hexagon flange bolt — — No mark Tightening Torque Table (Hexagon flange bolt) Specified torque Diameter Pitch Class N·m kgf·cm ft·lbf 1.25 1.25 4.8T 1.25 1220...

  • Page 19: Precoat Bolts

    0-15 General PRECOAT BOLTS (Bolts with seal lock agent coating on threads) Do not use the precoat bolt as it is in either of the following cases: (1) After it is removed. (2) When the precoat bolt is moved (loosened or tightened) Seal lock agent by tightness check, etc.

  • Page 20: Wire Rope Suspension Angle List

    0-16 General WIRE ROPE SUSPENSION ANGLE LIST Suspension Suspension Lifting angle Tension Compression Lifting angle Tension Compression method method ° ° 1.00 time 0 time 1.41 time 1.00 time 90° 30° ° ° 1.04 time 0.27 time 2.00 time 1.73 time 120°...

  • Page 21: Components Weight

    0-17 General 8FG(D)U15-32 COMPONENTS WEIGHT 8FGCU20-32 8FGCU15,18,SU20 Section 0...

  • Page 22: Recommended Lubricant Quantity & Types

    0-18a General 8FG(D)U15-32 RECOMMENDED LUBRICANT QUANTITY & TYPES 8FGCU20-32 Description Application Quantity l (US gal) Classification Type Motor oil Gasoline 4.0 (1.06) SAE30 SH, SJ, SL, SM SAE10W-30 Engine Diesel engine oil Diesel 1DZ-II 7.9 (2.09) SAE30 CE, CF, CF-4 SAE10W-30 T/C (1 speed) 8.0 (2.11)
  • Page 23 0-18b 0-16 0-16 General RECOMMENDED LUBRICANT QUANTITY & TYPES 8FGCU15,18,SU20 Description Application Quantity l (US gal) Classification Type Motor oil Engine Gasoline 4.0 (1.06) SAE30 SH, SJ, SL, SM SAE10W-30 GM Dexron Transmission 9.5 ~ 10.7 (2.51 ~ 2.82) ® Hypoid gear oil Differential All models...

  • Page 24: Lubrication Chart

    0-19 General LUBRICATION CHART Standard Model (14) (14) (13) (13) (12) (15) (10) (16) (17) (17) (18) (11) (18) *: For the engine oil grades listed below, change oil every 500 hours. Gasoline vehicle: API SL, SM and above Diesel vehicle: API CF-4 and above Inspection Replacement Inspect every 8 hours (daily)
  • Page 25 0-20 0-20 General Wet Brake Model (14) (14) (13) (13) (12) (15) (10) (16) (17) (18) (17) (11) (18) *: For the engine oil grades listed below, change oil every 500 hours. Gasoline vehicle: API SL, SM and above Diesel vehicle: API CF-4 and above Inspection Replacement Inspect every 8 hours (daily)

  • Page 26: Periodic Maintenance

    0-21 General PERIODIC MAINTENANCE INSPECTION METHOD I: Inspection. Repair or replacement if required. M: Measurement. Repair or adjustment if required. T: Retightening C: Cleaning L: Lubrication *: For new vehicle *1: Flaw detector Inspection Period Every Every Every Every 6 weeks 3 months 6 months 12 months...
  • Page 27 0-22 0-22 General Inspection Period Every Every Every Every 6 weeks 3 months 6 months 12 months Every Every Every Every Item 250 hours 500 hours 1000 hours 2000 hours Exhaust gas concentration measurement ← ← ← (carbon monoxide and hydrocarbon) Exhaust system piping looseness and damage ←...
  • Page 28 0-23 General Inspection Period Every Every Every Every 6 weeks 3 months 6 months 12 months Every Every Every Every Item 250 hours 500 hours 1000 hours 2000 hours STEERING SYSTEM ← ← ← Play and looseness Steering wheel ← ←...
  • Page 29 0-24 0-24 General Inspection Period Every Every Every Every 6 weeks 3 months 6 months 12 months Every Every Every Every Item 250 hours 500 hours 1000 hours 2000 hours MATERIAL HANDLING SYSTEM ← ← ← Abnormality of fork and stopper pin ←...
  • Page 30 0-25 General Inspection Period Every Every Every Every 6 weeks 3 months 6 months 12 months Every Every Every Every Item 250 hours 500 hours 1000 hours 2000 hours ELECTRICAL SYSTEM ← ← ← Cracks on distributor cap ← ← ←...
  • Page 31 0-26 0-26 General PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS : Replacement Interval Every Every Every Every 6 weeks 3 months 6 months 12 months Every Every Every Every Item 250 hours 500 hours 1000 hours 2000 hours ← ← ← Engine oil ←...
  • Page 32 ENGINE Page Page ENGINE EXTERIOR VIEW ..1-2 MUFFLER & EXHAUST PIPE ........1-21 ENGINE MAIN ....... 1-21 PARAMETERS.......1-4 COMPONENTS ..1-22 REMOVAL·INSTALLATION ENGINE PERFORMANCE CURVES.........1-6 BATTERY ......1-23 ENGINE ASSY......1-8 ....... 1-23 COMPONENTS ..1-8 REMOVAL·INSTALLATION ....1-24 SPECIFICATIONS AIR BLEEDING OF ......

  • Page 33: Engine Exterior View

    Engine ENGINE EXTERIOR VIEW 4Y Engine Section 1...
  • Page 34 Engine 1DZ-II Engine Section 1...

  • Page 35: Engine Main Parameters

    1-4a Engine 8FGU15-32 ENGINE MAIN PARAMETERS 8FGCU20-32 Gasoline Engine Vehicle model 8FGU15~25 · 8FGU30 Item 8FGCU20~32 ← Engine model ← Engine type Gasoline · 4 cycle In-line 4 cylinder, ← Number and arrangement of cylinders longitudinally mounted ← Combustion chamber type Wedge ←...
  • Page 36 1-4b Engine ENGINE MAIN PARAMETERS 8FGCU15,18,SU20 Gasoline Engine Engine model Engine type Gasoline · 4 cycle Number and arrangement of cylinders In-line 4 cylinder, longitudinally mounted Combustion chamber type Wedge Valve mechanism OHV·chain drive Bore x stroke mm (in) 91.0 × 86.0 (3.583 × 3.386) Total displacement 2237 (136.51) Compression ratio...
  • Page 37 Engine Diesel Engine Vehicle model · 8FDU15 8FDU20~32 Item ← Engine model 1DZ-II ← Engine type Diesel · 4 cycle In-line 4 cylinder, ← Number and arrangement of cylinders longitudinally mounted ← Combustion chamber type Whirl chamber ← Valve mechanism OHV·gear drive 86.0 ×...

  • Page 38: Engine Performance Curves

    1-6a Engine ENGINE PERFORMANCE CURVES 4Y 8FGU15-25·8FGCU20-32 Gasoline (Exclusive·Convertible) Gasoline (Exclusive·Convertible) LPG (Exclusive·Convertible) Torque Shaft torque Fuel consumption ratio 4Y 8FGU30-32 Gasoline (Exclusive) Gasoline (Convertible with LPG) LPG (Exclusive·Convertible) Torque Gasoline (Exclusive) Gasoline (Convertible with LPG) LPG (Exclusive·Convertible) Shaft torque Gasoline (Exclusive·Convertible)
  • Page 39 1-6b Engine ENGINE PERFORMANCE CURVES 4Y 8FGCU15,18,SU20 Gasoline (Exclusive·Convertible) LPG (Exclusive·Convertible) Torque Shaft torque Fuel consumption ratio Section 1...
  • Page 40 Engine 1DZ-II Engine 8FDU15·18 Torque Shaft torque Fuel consumption ratio 1DZ-II Engine 8FDU20~32 Torque Shaft torque Fuel consumption ratio Section 1...

  • Page 41: Engine Assy

    Engine 8FG(D)U15-32 ENGINE ASSY 8FGCU20-32 REMOVAL·INSTALLATION T = N·m (kgf·cm) [ft·lbf] Engine mount nut T = 53.2~98.0 (542~1000) [39.2~72.4] End plate set bolt T = 49.0~78.4 (500~800) [36.2~57.9] 1DZ- ·2Z: T = 125~186 (1275~1897) [92.2~137.2] Drive plate set bolt (For connecting the engine crank shaft) 4Y: T = 78~98 (795~1000) [57.5~72.4] Drive plate set bolt (For connecting the torque converter) T = 14.7~21.6 (150~220) [10.9~15.9]...
  • Page 42 Engine 8FG(D)U15-32 Removal Procedure 8FGCU20-32 (See Section 11) Remove the engine hood. (See page 11-XX.) Remove the lower panel and toe board. Drain coolant. Remove the battery. Remove the sedimenter bracket set bolt to free the bracket. (1DZ-II engine vehicle) Disconnect the accelerator wire.
  • Page 43 1-10 1-10 Engine 8FG(D)U15-32 Point Operations 8FGCU20-32 [Point 1] Removal: Put match marks on the radiator and torque converter cooler hose. [Point 2] Cover plate Removal: Remove the cover plate. [Point 3] Removal•Installation: Rotate the drive plate using the crank shaft pulley set bolt, and remove the drive plate set bolt.

  • Page 44: Air Bleeding Of The Fuel System

    1-11a 1-11 Engine 8FG(D)U15-32 [Point 5] 8FGCU20-32 Removal: Use a flat-head screwdriver for separation. If the fitting is too tight, change the SST hook position and adjust the engine angle for easier separation. AIR BLEEDING OF THE FUEL SYSTEM 1DZ-II Engine Vehicles Only Perform air bleeding by moving the priming pump knob up and down.
  • Page 45 1-11b Engine ENGINE ASSY 8FGCU15,18,SU20 REMOVAL·INSTALLATION T = N·m (kgf·cm) [ft·lbf] Engine mounting nut T = 53.9 ~ 99.0 (550 ~ 1010) [39.8 ~ 73.1] End plate set bolt T = 49.0 ~ 78.5 (500 ~ 800) [36.2 ~ 57.9] Drive plate set bolt (for connecting engine crankshaft) T = 56.9 ~ 64.7 (580 ~ 660) [42.0 ~ 47.7] Drive plate set bolt (for connecting torque converter)
  • Page 46 1-11c Engine Removal Procedure 8FGCU15,18,SU20 Remove the radiator cover. Remove the engine hood. Remove the lower panel, rear toe board and front toe board. Drain coolant. Remove the relay block and electrical parts plate set bolts to free them. Remove the battery and battery tray. Remove the air cleaner.
  • Page 47 1-11d Engine Point Operations 8FGCU15,18,SU20 [Point 1] Removal: Put match marks on the radiator and torque converter cooler hose. [Point 2] SST(1) Removal•Installation: SST(2) SST 09010-20111-71 ......... (1) 09010-23320-71......... (2) Removal: Temporarily hoist up until the mount bolt completely comes out of the hole in the frame.

  • Page 48: 4Y Engine

    Start the engine, and measure the engine speed (no-load maximum speed) when the accelerator is fully pressed down. 8FGCU15,18,SU20: 2250 ± 30 rpm Standard: 2250 ± 30 rpm (For both gasoline and LPG) 8FGU15-32, 8FGCU20-32: 2570 ± 30 rpm Rev terminal Section 1...

  • Page 49: 1Dz-Ii Engine Vehicle

    1-13 Engine Inspect the relief down amount. Operate the tilt lever fully backward at the maximum engine speed, and measure the engine speed upon full relief. Measure the decrease (relief down) in the engine rpm. Standard: Within 200 rpm Ignition Timing Inspection·Adjustment Attach a rev counter to the terminal for measuring engine speed (Rev terminal).
  • Page 50 1-14 Engine Check the return of the accelerator wire, and also check that Idle adjusting screw the injection pump idle adjusting screw is in contact with the accelerator lever. Inspect the idle speed. Standard 1DZ-II: 750 ± 25 rpm If the standard is not met, loosen the lock nut and adjust with the idle adjusting screw.

  • Page 51: Air Cleaner

    1-15a Engine 8FG(D)U15-32 AIR CLEANER 8FGCU20-32 SPECIFICATIONS Single (STD) Double (OPT) ← Type Cyclone type ← Size 7-inch ← Intake type Fresh air introduction type Outer 18600 (2883) Filtering area 18600 (2883) Inner 510 (79.1) ← Others With evacuator valve COMPONENTS 1703 Section 1...
  • Page 52 1-15b Engine AIR CLEANER 8FGCU15,18,SU20 SPECIFICATIONS Single (STD) Double (OPT) ← Type Cyclone type ← Size 6-inch ← Intake type Fresh air introduction type Outer 14000 (2170) Filtering area 14000 (2170) Inner 570 (88.4) ← Others With evacuator valve COMPONENTS 1703 Section 1...

  • Page 53: Air Cleaner Cleaning·inspection

    1-16 1-16 Engine AIR CLEANER CLEANING·INSPECTION Open the engine hood. Remove the element. Note: In case of the double element type (OPT), do not remove the inner element for other than replacement. Clean the element. (1) For ordinary cleaning, blow with compressed air [690 kPa (7 kgf/cm ) [100 psi] or less] vertically along the pleats from the inside of the element.

  • Page 54: Clogging Warning System Inspection (Opt)

    1-17 Engine Install the element. Install the evacuator valve in the illustrated direction. 25° CLOGGING WARNING SYSTEM INSPECTION (OPT) Warning lamp inspection (1) Check that the air cleaner warning lamp comes on when the ignition key switch is turned ON and goes out when the engine starts.

  • Page 55: Radiator

    1-18 1-18 Engine 8FG(D)U15-32 RADIATOR 8FGCU20-32 COMPONENTS 1603 1DZ-II 1603 Section 1...

  • Page 56: Specifications

    1-19a 1-19 Engine 8FG(D)U15-32 SPECIFICATIONS 8FGCU20-32 Type Crossflow Fin type Corrugated fin Coolant capacity (in radiator) See the table below Cap opening pressure 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1] kPa (kgf/cm ) [psi] Others Built in torque converter cooler (torque converter vehicle) COOLANT CAPACITY AND ANTIFREEZE TABLE Unit: l (US gal) 30% Antifreeze...
  • Page 57 1-19b Engine RADIATOR 8FGCU15,18,SU20 COMPONENTS 1603 Section 1...
  • Page 58 1-19c Engine SPECIFICATIONS 8FGCU15,18,SU20 Type Crossflow Fin type Corrugated fin Coolant capacity (in radiator) See the table below Cap opening pressure 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1] kPa (kgf/cm ) [psi] Others Built in torque converter cooler (torque converter vehicle) COOLANT CAPACITY AND ANTIFREEZE TABLE Unit: l (US gal) 30% Antifreeze mixture...
  • Page 59 1-20 1-20 Engine (2) Find the concentration of the coolant from the table on the left. 50% (approximately -38°C) 40% (approximately -26°C) Note: 30% (approximately -16°C) This graph shows relationship between coolant temperature and specific gravity at concentrations of 30, 40 and 50%.

  • Page 60: Muffler & Exhaust Pipe

    1-21 Engine 8FG(D)U15-32 MUFFLER & EXHAUST PIPE 8FGCU20-32 COMPONENTS 1702 1DZ-II (1·K2·K3 Ton Series) 1702 Section 1...

  • Page 61: Removal·installation

    1-22a 1-22 1-22 Engine 8FG(D)U15-32 REMOVAL·INSTALLATION 8FGCU20-32 Note: The muffler can be removed by either of the two methods shown below. (1)Remove the muffler after removing the counterweight. (2)Remove the muffler after removing the radiator W/ counterweight. Here, method (1) is explained. Removal Procedure Remove the counterweight.
  • Page 62 1-22b Engine MUFFLER & EXHAUST PIPE 8FGCU15,18,SU20 COMPONENTS 1702 EXPORT SPEC 1702 Section 1...
  • Page 63 1-22c Engine REMOVAL·INSTALLATION 8FGCU15,18,SU20 Note: The muffler can be removed by either of the two methods shown below. (1)Remove the muffler after removing the counterweight. (2)Remove the muffler after removing the radiator W/ counterweight. Here, method (1) is explained. Removal Procedure Remove the counterweight.

  • Page 64: Battery

    1-23 Engine BATTERY COMPONENTS 1901 1DZ-II 1901 Section 1...

  • Page 65: Specifications

    1-24 1-24 Engine SPECIFICATIONS Battery type list (The battery is selected according to the equipped engine). Engine 1DZ-II Specifications GR35 GR24R (JIS 55D23L) (JIS 80D26L) ← Voltage 5 hour rated capacity Specific gravity of battery fluid in use ← 1.280 (at 20°C (68°F)) Battery weight kg (lb)

  • Page 66: Inspection

    1-25 Engine INSPECTION Inspect the battery fluid level. Inspect that the battery fluid level is between the UPPER and LOWER lines. Add distilled water if insufficient. Do not overfill UPPER above the upper fluid limit. LOWER Inspect the specific gravity of the battery fluid. Use a hydrometer to measure the specific gravity of the battery fluid.

  • Page 67: V-Belt Tension Adjustment

    1-26 1-26 Engine V-BELT TENSION ADJUSTMENT Inspect the V-belt tension. Standard [amount of delfection when pressed with 98 N (10 kgf)] 8~13 mm (0.31~0.51 in) 1DZ-II: 8~13 mm (0.31~0.51 in) Standard [When using a tension gauge (SST)] SST 09216-76002-71 (09216-00021) 294~490 N (30~50 kgf) [66~110 lbf] 1DZ-II: 324~559 N (33~57 kgf) [73~126 lbf]...

  • Page 68: Accelerator Pedal

    1-27 Engine ACCELERATOR PEDAL COMPONENTS 2601 1DZ-II 2601 Section 1...

  • Page 69: Inspection·adjustment

    1-28 1-28 Engine INSPECTION·ADJUSTMENT Inspect the angle of the accelerator pedal. 1DZ-II A: When the accelerator is OFF 45° B: At full throttle (reference) 20° Adjust by adjusting the length of the rod. Stopper bolt 1DZ-II engine vehicles 1DZ-II Stopper bolt Adjust the height of the stopper bolt on the floor side so that engine vehicles the link contacts the stopper bolt on the engine side when the...
  • Page 70 1-29 Engine (2) Adjust the sensor voltage when the accelerator is OFF. Display the I/O ENGINE CTRL 4/10 screen on the display. Adjust the installation position of the accelerator sensor so that the VPA1 output (V) comes to the value below, and fix it with a the set screw.

  • Page 71: Ez Pedal (Opt)

    1-30 1-30 Engine EZ PEDAL (OPT) COMPONENTS 2601 Section 1...

  • Page 72: Disassembly·inspection·reassembly

    1-31 Engine DISASSEMBLY·INSPECTION·REASSEMBLY T = N·m (kgf·cm) [ft·lbf] 29 (296) [21.4] Disassembly Procedure Remove the pin and separate the pad W/switch from the pedal. [Point 1] Remove the switch ASSY. [Point 2] Remove the holder W/magnet. [Point 3] Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.
  • Page 73 1-32 1-32 Engine [Point 2] Inspection: Check continuity of direction switches. Forward side: Continuity between when the switch is pressed. Forward Reverse side: Continuity between when the switch is pressed. Reverse Reassembly: Reassemble in the following order: Install the switch on the pedal. Set the switch while fully pressing it onto the pad.

  • Page 74: Adjustment

    1-33 Engine ADJUSTMENT Note: • Adjust the pedal roller height and pedal stopper bolt height in the same way as for the standard pedal. (See page 1-28.) • Direction switch adjustment is explained here. Direction Switch Adjustment Procedure Fully tilt the accelerator pedal pad to either of one side. It shall not contact to the magnet at the time.
  • Page 75 1-34 1-34 Engine Adjusting Accelerator Link Install the accelerator link stopper bolt. After installing the stopper, adjust the bolt so that the clearance is as specified in the illustration. 8 ~ 11 mm (0.31 ~ 0.43 in) After installing the accelerator sensor, loosen the stopper bolt and tighten the lock nut at the position where the link stops.

  • Page 76: Travel And Load Handling Control Device (Opt)

    1-35 Engine TRAVEL AND LOAD HANDLING CONTROL DEVICE (OPT) 1DZ-II Engine Vehicle COMPONENTS 2607 Section 1...

  • Page 77: Removal·installation

    1-36 1-36 Engine REMOVAL·INSTALLATION LBA26-006 Removal Procedure Open the engine hood and disconnect the negative terminal of the battery. Remove the battery. Remove the relay block bracket set bolt and free the relay block. Remove the sedimenter. Remove the battery set plate. Disconnect the injection pump side link.
  • Page 78 1-37 Engine [Point 1] Inspection: Inspect the actuator. Check that the actuator shaft can be manually turned smoothly without sticking. Check the resistance of the actuator. Tester range: Ω × 1 range Standard Between (1) and (3): Approx. 2.5~3.7 Ω Between (2) and (3): Approx.

  • Page 79: Throttle Opening Degree Adjustment

    1-38 1-38 Engine THROTTLE OPENING DEGREE Idle set ADJUSTMENT screw Thickness gauge Idle Switch (Injection Pump Lever Completely Closed) Adjustment Fix the injection pump lever in completely closed state with a LBA26-010 thickness gauge (1.3 mm (0.051 in) thickness) placed between the lever and the idle set screw.
  • Page 80 1-39 Engine TROUBLESHOOTING This page contains troubleshooting advice for the mechanical system of the travel and load handling control device. In the case of an error code being recieved, or trouble with the electrical system, refer to the troubleshooting section. ●...
  • Page 81 1-40 1-40 Engine ● The idle speed deviates from the specified value Check the injection pump specified A defect in the mechanical system of the travel and load Hold pump lever completely closed with your speed handling control device. hand, then start the engine and check whether Check the components of the travel and load handling the engine idles at the specified speed.

  • Page 82: Troubleshooting

    4Y-E Repair...
  • Page 84 4Y-E Repair Section 1.1.0...

  • Page 85: Specifications

    4Y-E Repair Section 1.1.0...

  • Page 86: Engine Exterior View

    4Y-E Repair Section 1.1.0...
  • Page 87 4Y-E Repair Section 1.1.0...

  • Page 88: Engine Sectional View

    4Y-E Repair Section 1.1.0...
  • Page 89 4Y-E Repair Section 1.1.0...

  • Page 90: How To Use This Manual

    4Y-E Repair Section 1.1.0...

  • Page 91: Terminology

    4Y-E Repair Section 1.1.0...

  • Page 92: Abbreviations

    4Y-E Repair Section 1.1.0...

  • Page 93: Operating Tips

    4Y-E Repair Section 1.1.0...
  • Page 94 4Y-E Repair Section 1.1.0...
  • Page 95 4Y-E Repair Section 1.1.0...

  • Page 96: Electrical Parts Inspection

    4Y-E Repair Section 1.1.0...
  • Page 97 4Y-E Repair Section 1.1.0...

  • Page 98: Bolt & Nut Tightening Torques

    4Y-E Repair Section 1.1.0...
  • Page 99 4Y-E Repair Section 1.1.0...
  • Page 100 4Y-E Repair Section 1.1.0...

  • Page 101: Precoated Bolts

    4Y-E Repair Section 1.1.0...

  • Page 102: Handling Flpg (Liquid Gaskets)

    4Y-E Repair Section 1.1.0...
  • Page 104 4Y-E Repair Section 1.1.1...

  • Page 105: Troubleshooting

    4Y-E Repair Section 1.1.1...

  • Page 106: Engine Does Not Crank Normally

    4Y-E Repair Section 1.1.1...

  • Page 107: Or Does Not Start At All

    4Y-E Repair Section 1.1.1...

  • Page 108: During Idling

    4Y-E Repair Section 1.1.1...

  • Page 109: Cannot Accelerate Smoothly

    4Y-E Repair Section 1.1.1...
  • Page 110 4Y-E Repair Section 1.1.1...

  • Page 111: Insufficient Power Output

    4Y-E Repair Section 1.1.1...

  • Page 112: Engine Overheats

    4Y-E Repair Section 1.1.1...

  • Page 113: Excessive Fuel Consumption

    4Y-E Repair Section 1.1.1...

  • Page 114: Abnormal Combustion

    4Y-E Repair Section 1.1.1...
  • Page 115 4Y-E Repair Section 1.1.1...

  • Page 116: Or Noisy Engine

    4Y-E Repair Section 1.1.1...
  • Page 117 4Y-E Repair Section 1.1.1...
  • Page 118 4Y-E Repair Section 1.1.1...

  • Page 119: Excessive Engine Oil Consumption

    4Y-E Repair Section 1.1.1...
  • Page 120 4Y-E Repair Section 1.1.2...

  • Page 121: Sst To Be Used

    4Y-E Repair Section 1.1.2...
  • Page 122 4Y-E Repair Section 1.1.2...

  • Page 123: Engine Attachments

    4Y-E Repair Section 1.1.2...
  • Page 124 4Y-E Repair Section 1.1.2...
  • Page 125 4Y-E Repair Section 1.1.2...

  • Page 126: Cylinder Head

    4Y-E Repair Section 1.1.2...
  • Page 127 4Y-E Repair Section 1.1.2...
  • Page 128 4Y-E Repair Section 1.1.2...
  • Page 129 4Y-E Repair Section 1.1.2...
  • Page 130 4Y-E Repair Section 1.1.2...
  • Page 131 4Y-E Repair Section 1.1.2...
  • Page 132 4Y-E Repair Section 1.1.2...
  • Page 133 4Y-E Repair Section 1.1.2...
  • Page 134 4Y-E Repair Section 1.1.2...
  • Page 135 4Y-E Repair Section 1.1.2...
  • Page 136 4Y-E Repair Section 1.1.2...
  • Page 137 4Y-E Repair Section 1.1.2...
  • Page 138 4Y-E Repair Section 1.1.2...
  • Page 139 4Y-E Repair Section 1.1.2...
  • Page 140 4Y-E Repair Section 1.1.2...

  • Page 141: Disassembly=Inspection=Reassembly

    4Y-E Repair Section 1.1.2...
  • Page 142 4Y-E Repair Section 1.1.2...
  • Page 143 4Y-E Repair Section 1.1.2...
  • Page 144 4Y-E Repair Section 1.1.2...
  • Page 145 4Y-E Repair Section 1.1.2...
  • Page 146 4Y-E Repair Section 1.1.2...
  • Page 147 4Y-E Repair Section 1.1.2...
  • Page 148 4Y-E Repair Section 1.1.2...
  • Page 149 4Y-E Repair Section 1.1.2...

  • Page 150: Components

    4Y-E Repair Section 1.1.2...
  • Page 151 4Y-E Repair Section 1.1.2...
  • Page 152 4Y-E Repair Section 1.1.2...
  • Page 153 4Y-E Repair Section 1.1.2...
  • Page 154 4Y-E Repair Section 1.1.2...
  • Page 155 4Y-E Repair Section 1.1.2...
  • Page 156 4Y-E Repair Section 1.1.2...
  • Page 157 4Y-E Repair Section 1.1.2...
  • Page 158 4Y-E Repair Section 1.1.2...
  • Page 159 4Y-E Repair Section 1.1.2...
  • Page 160 4Y-E Repair Section 1.1.2...

  • Page 161: Engine Adjustment

    4Y-E Repair Section 1.1.2...

  • Page 162: Idle-Up Speed

    4Y-E Repair Section 1.1.2...

  • Page 163: Load Maximum Speed Inspection And

    4Y-E Repair Section 1.1.2...
  • Page 164 4Y-E Repair Section 1.1.2...
  • Page 166 4Y-E Repair Section 1.1.3...

  • Page 167: Sst To Be Used

    4Y-E Repair Section 1.1.3...
  • Page 168 4Y-E Repair Section 1.1.3...

  • Page 169: Engine Attachments

    4Y-E Repair Section 1.1.3...
  • Page 170 4Y-E Repair Section 1.1.3...
  • Page 171 4Y-E Repair Section 1.1.3...
  • Page 172 4Y-E Repair Section 1.1.3...

  • Page 173: Cylinder Head

    4Y-E Repair Section 1.1.3...
  • Page 174 4Y-E Repair Section 1.1.3...
  • Page 175 4Y-E Repair Section 1.1.3...
  • Page 176 4Y-E Repair Section 1.1.3...
  • Page 177 4Y-E Repair Section 1.1.3...
  • Page 178 4Y-E Repair Section 1.1.3...
  • Page 179 4Y-E Repair Section 1.1.3...
  • Page 180 4Y-E Repair Section 1.1.3...
  • Page 181 4Y-E Repair Section 1.1.3...
  • Page 182 4Y-E Repair Section 1.1.3...
  • Page 183 4Y-E Repair Section 1.1.3...
  • Page 184 4Y-E Repair Section 1.1.3...

  • Page 185: Timing Gear

    4Y-E Repair Section 1.1.3...
  • Page 186 4Y-E Repair Section 1.1.3...
  • Page 187 4Y-E Repair Section 1.1.3...
  • Page 188 4Y-E Repair Section 1.1.3...
  • Page 189 4Y-E Repair Section 1.1.3...
  • Page 190 4Y-E Repair Section 1.1.3...
  • Page 191 4Y-E Repair Section 1.1.3...
  • Page 192 4Y-E Repair Section 1.1.3...
  • Page 193 4Y-E Repair Section 1.1.3...
  • Page 194 4Y-E Repair Section 1.1.3...
  • Page 195 4Y-E Repair Section 1.1.3...
  • Page 196 4Y-E Repair Section 1.1.3...

  • Page 197: Cylinder Block

    4Y-E Repair Section 1.1.3...
  • Page 198 4Y-E Repair Section 1.1.3...
  • Page 199 4Y-E Repair Section 1.1.3...
  • Page 200 4Y-E Repair Section 1.1.3...
  • Page 201 4Y-E Repair Section 1.1.3...
  • Page 202 4Y-E Repair Section 1.1.3...
  • Page 203 4Y-E Repair Section 1.1.3...
  • Page 204 4Y-E Repair Section 1.1.3...
  • Page 205 4Y-E Repair Section 1.1.3...
  • Page 206 4Y-E Repair Section 1.1.3...
  • Page 207 4Y-E Repair Section 1.1.3...

  • Page 208: Engine Adjustment

    4Y-E Repair Section 1.1.3...

  • Page 209: Idle Speed Inspection

    4Y-E Repair Section 1.1.3...

  • Page 210: Load Maximum Speed Measurement

    4Y-E Repair Section 1.1.3...
  • Page 211 4Y-E Repair Section 1.1.3...
  • Page 212 4Y-E Repair Section 1.1.4...

  • Page 213: Sst To Be Used

    4Y-E Repair Section 1.1.4...

  • Page 214: Fuel Pump

    4Y-E Repair Section 1.1.4...

  • Page 215: Removal

    4Y-E Repair Section 1.1.4...

  • Page 216: Installation

    4Y-E Repair Section 1.1.4...

  • Page 217: Carburetor

    4Y-E Repair Section 1.1.4...

  • Page 218: Components

    4Y-E Repair Section 1.1.4...

  • Page 219: On-Vehicle Inspection

    4Y-E Repair Section 1.1.4...

  • Page 220: Disassembly

    4Y-E Repair Section 1.1.4...
  • Page 221 4Y-E Repair Section 1.1.4...
  • Page 222 4Y-E Repair Section 1.1.4...
  • Page 223 4Y-E Repair Section 1.1.4...

  • Page 224: Inspection

    4Y-E Repair Section 1.1.4...
  • Page 225 4Y-E Repair Section 1.1.4...

  • Page 226: Reassembly

    4Y-E Repair Section 1.1.4...
  • Page 227 4Y-E Repair Section 1.1.4...

  • Page 228: Carburetor Adjustment

    4Y-E Repair Section 1.1.4...
  • Page 229 4Y-E Repair Section 1.1.4...

  • Page 230: Fast Idle Cam Adjustment

    4Y-E Repair Section 1.1.4...

  • Page 231: Air Governor

    4Y-E Repair Section 1.1.4...

  • Page 232: Removallinstallation

    4Y-E Repair Section 1.1.4...

  • Page 233: Inspection

    4Y-E Repair Section 1.1.4...

  • Page 234: Reassembly

    4Y-E Repair Section 1.1.4...

  • Page 235: Adjustment

    4Y-E Repair Section 1.1.4...
  • Page 236 4Y-E Repair Section 1.1.4...
  • Page 238 4Y-E Repair Section 1.1.5...

  • Page 239: Sst To Be Used

    4Y-E Repair Section 1.1.5...

  • Page 240: Throttle Body

    4Y-E Repair Section 1.1.5...
  • Page 241 4Y-E Repair Section 1.1.5...
  • Page 242 4Y-E Repair Section 1.1.5...

  • Page 243: Injector

    4Y-E Repair Section 1.1.5...

  • Page 244: Removal-Inspection-Installation

    4Y-E Repair Section 1.1.5...
  • Page 245 4Y-E Repair Section 1.1.5...
  • Page 246 4Y-E Repair Section 1.1.5...

  • Page 247: Fuel Pressure Regulator

    4Y-E Repair Section 1.1.5...

  • Page 248: Fuel Pump

    4Y-E Repair Section 1.1.5...
  • Page 249 4Y-E Repair Section 1.1.5...
  • Page 250 4Y-E Repair Section 1.1.5...
  • Page 251 4Y-E Repair Section 1.1.5...

  • Page 252: Intake Temperature Sensor

    4Y-E Repair Section 1.1.5...
  • Page 254 4Y-E Repair Section 1.1.6...

  • Page 255: Ventilation Valve

    4Y-E Repair Section 1.1.6...

  • Page 256: Removal

    4Y-E Repair Section 1.1.6...
  • Page 258 4Y-E Repair Section 1.1.7...
  • Page 259 4Y-E Repair Section 1.1.7...
  • Page 260 4Y-E Repair Section 1.1.7...
  • Page 261 4Y-E Repair Section 1.1.7...
  • Page 262 4Y-E Repair Section 1.1.7...
  • Page 263 4Y-E Repair Section 1.1.7...
  • Page 264 4Y-E Repair Section 1.1.8...

  • Page 265: Sst To Be Used

    4Y-E Repair Section 1.1.8...

  • Page 266: Oil Pressure Inspection

    4Y-E Repair Section 1.1.8...

  • Page 267: Engine Oilmoil Filter Replacement

    4Y-E Repair Section 1.1.8...

  • Page 268: Oil Pumpmstrainer

    4Y-E Repair Section 1.1.8...
  • Page 269 4Y-E Repair Section 1.1.8...
  • Page 270 4Y-E Repair Section 1.1.8...

  • Page 271: Disassemblyminspection.reassembly

    4Y-E Repair Section 1.1.8...
  • Page 272 4Y-E Repair Section 1.1.8...
  • Page 274 4Y-E Repair Section 1.1.9...

  • Page 275: Circuit Diagram

    4Y-E Repair Section 1.1.9...

  • Page 276: Spark Plugs

    4Y-E Repair Section 1.1.9...

  • Page 277: Distributor

    4Y-E Repair Section 1.1.9...

  • Page 278: On-Vehicle Inspection

    4Y-E Repair Section 1.1.9...
  • Page 279 4Y-E Repair Section 1.1.9...
  • Page 280 4Y-E Repair Section 1.1.9...
  • Page 281 4Y-E Repair Section 1.1.9...
  • Page 282 4Y-E Repair Section 1.1.9...
  • Page 283 4Y-E Repair Section 1.1.9...
  • Page 284 4Y-E Repair Section 1.1.9...
  • Page 285 4Y-E Repair Section 1.1.9...
  • Page 286 4Y-E Repair Section 1.1.9...
  • Page 287 4Y-E Repair Section 1.1.9...
  • Page 288 4Y-E Repair Section 1.1.10...

  • Page 289: Spark Plugs

    4Y-E Repair Section 1.1.10...

  • Page 290: Distributor

    4Y-E Repair Section 1.1.10...

  • Page 291: On-Vehicle Inspection

    4Y-E Repair Section 1.1.10...

  • Page 292: Installation

    4Y-E Repair Section 1.1.10...

  • Page 293: Igniter

    4Y-E Repair Section 1.1.10...
  • Page 294 4Y-E Repair Section 1.1.10...
  • Page 296 4Y-E Repair Section 1.1.11...

  • Page 297: Sst To Be Used

    4Y-E Repair Section 1.1.11...

  • Page 298: Starter Motor

    4Y-E Repair Section 1.1.11...
  • Page 299 4Y-E Repair Section 1.1.11...

  • Page 300: Disassembly-Inspection-Reassembly

    4Y-E Repair Section 1.1.11...
  • Page 301 4Y-E Repair Section 1.1.11...
  • Page 302 4Y-E Repair Section 1.1.11...
  • Page 303 4Y-E Repair Section 1.1.11...
  • Page 304 4Y-E Repair Section 1.1.11...

  • Page 305: Starter Motor Assy Unit Inspection

    4Y-E Repair Section 1.1.11...
  • Page 306 4Y-E Repair Section 1.1.12...
  • Page 307 4Y-E Repair Section 1.1.12...
  • Page 308 4Y-E Repair Section 1.1.12...
  • Page 309 4Y-E Repair Section 1.1.12...
  • Page 310 4Y-E Repair Section 1.1.12...
  • Page 311 4Y-E Repair Section 1.1.12...
  • Page 312 4Y-E Repair Section 1.1.12...
  • Page 313 4Y-E Repair Section 1.1.12...
  • Page 314 4Y-E Repair Section 1.1.12...
  • Page 315 4Y-E Repair Section 1.1.12...
  • Page 316 4Y-E Repair Section 1.1.13...
  • Page 317 4Y-E Repair Section 1.1.13...
  • Page 318 4Y-E Repair Section 1.1.13...
  • Page 319 4Y-E Repair Section 1.1.13...
  • Page 320 4Y-E Repair Section 1.1.13...
  • Page 321 4Y-E Repair Section 1.1.13...
  • Page 322 4Y-E Repair Section 1.1.13...
  • Page 323 4Y-E Repair Section 1.1.13...
  • Page 324 4Y-E Repair Section 1.1.13...
  • Page 325 4Y-E Repair Section 1.1.13...
  • Page 326 4Y-E Repair Section 1.1.13...
  • Page 327 …..This Page Intentionally Left Blank…..
  • Page 328 1DZ-II Repair...
  • Page 329 …..This Page Intentionally Left Blank…..
  • Page 330 1DZ-II Repair Section 1.2.0...
  • Page 331 1DZ-II Repair Section 1.2.0...
  • Page 332 1DZ-II Repair Section 1.2.0...
  • Page 333 1DZ-II Repair Section 1.2.0...
  • Page 334 1DZ-II Repair Section 1.2.0...

  • Page 335: How To Read This Manual

    1DZ-II Repair Section 1.2.0...

  • Page 336: Terminology

    1DZ-II Repair Section 1.2.0...
  • Page 337 1DZ-II Repair Section 1.2.0...

  • Page 338: Operation Precautions

    1DZ-II Repair Section 1.2.0...
  • Page 339 1DZ-II Repair Section 1.2.0...
  • Page 340 1DZ-II Repair Section 1.2.0...

  • Page 341: Inspection Of Electric Parts

    1DZ-II Repair Section 1.2.0...
  • Page 342 1DZ-II Repair Section 1.2.0...

  • Page 343: Bolt And Nut Tightening Torque

    1DZ-II Repair Section 1.2.0...
  • Page 344 1DZ-II Repair Section 1.2.0...
  • Page 345 1DZ-II Repair Section 1.2.0...

  • Page 346: Precoat Bolts

    1DZ-II Repair Section 1.2.0...

  • Page 347: Handling The Flpg (Liquid Gasket)

    1DZ-II Repair Section 1.2.0...
  • Page 348 1DZ-II Repair Section 1.2.1...
  • Page 349 1DZ-II Repair Section 1.2.1...

  • Page 350: Engine Does Not Crank Normally

    1DZ-II Repair Section 1.2.1...

  • Page 351: Engine Does Not Start Easily Or Does Not Start At All

    1DZ-II Repair Section 1.2.1...

  • Page 352: Engine Malfunctions Or Stops While Idling

    1DZ-II Repair Section 1.2.1...

  • Page 353: Insufficient Output

    1DZ-II Repair Section 1.2.1...

  • Page 354: High Fuel Consumption

    1DZ-II Repair Section 1.2.1...

  • Page 355: Frequent Diesel Knocking

    1DZ-II Repair Section 1.2.1...

  • Page 356: Unusual Engine Sounds And Noises

    1DZ-II Repair Section 1.2.1...
  • Page 357 1DZ-II Repair Section 1.2.1...
  • Page 358 1DZ-II Repair Section 1.2.1...

  • Page 359: High Engine Oil Consumption

    1DZ-II Repair Section 1.2.1...
  • Page 360 1DZ-II Repair Section 1.2.2...

  • Page 361: Used Ssts

    1DZ-II Repair Section 1.2.2...
  • Page 362 1DZ-II Repair Section 1.2.2...

  • Page 363: Engine Accessories

    1DZ-II Repair Section 1.2.2...
  • Page 364 1DZ-II Repair Section 1.2.2...
  • Page 365 1DZ-II Repair Section 1.2.2...
  • Page 366 1DZ-II Repair Section 1.2.2...
  • Page 367 1DZ-II Repair Section 1.2.2...

  • Page 368: Cylinder Head

    1DZ-II Repair Section 1.2.2...
  • Page 369 1DZ-II Repair Section 1.2.2...

  • Page 370: Disassembly. Inspection And Reassembly

    1DZ-II Repair Section 1.2.2...
  • Page 371 1DZ-II Repair Section 1.2.2...
  • Page 372 1DZ-II Repair Section 1.2.2...
  • Page 373 1DZ-II Repair Section 1.2.2...
  • Page 374 1DZ-II Repair Section 1.2.2...
  • Page 375 1DZ-II Repair Section 1.2.2...
  • Page 376 1DZ-II Repair Section 1.2.2...
  • Page 377 1DZ-II Repair Section 1.2.2...
  • Page 378 1DZ-II Repair Section 1.2.2...

  • Page 379: Timing Gear Components

    1DZ-II Repair Section 1.2.2...
  • Page 380 1DZ-II Repair Section 1.2.2...

  • Page 381: Disassembly. Inspection And Reassembly

    1DZ-II Repair Section 1.2.2...
  • Page 382 1DZ-II Repair Section 1.2.2...
  • Page 383 1DZ-II Repair Section 1.2.2...
  • Page 384 1DZ-II Repair Section 1.2.2...
  • Page 385 1DZ-II Repair Section 1.2.2...
  • Page 386 1DZ-II Repair Section 1.2.2...
  • Page 387 1DZ-II Repair Section 1.2.2...
  • Page 388 1DZ-II Repair Section 1.2.2...
  • Page 389 1DZ-II Repair Section 1.2.2...
  • Page 390 1DZ-II Repair Section 1.2.2...
  • Page 391 1DZ-II Repair Section 1.2.2...

  • Page 392: Cylinder Block Components

    1DZ-II Repair Section 1.2.2...
  • Page 393 1DZ-II Repair Section 1.2.2...

  • Page 394: Disassembly. Inspection And Reassembly

    1DZ-II Repair Section 1.2.2...
  • Page 395 1DZ-II Repair Section 1.2.2...
  • Page 396 1DZ-II Repair Section 1.2.2...
  • Page 397 1DZ-II Repair Section 1.2.2...
  • Page 398 1DZ-II Repair Section 1.2.2...
  • Page 399 1DZ-II Repair Section 1.2.2...
  • Page 400 1DZ-II Repair Section 1.2.2...
  • Page 401 1DZ-II Repair Section 1.2.2...
  • Page 402 1DZ-II Repair Section 1.2.2...
  • Page 403 1DZ-II Repair Section 1.2.2...
  • Page 404 1DZ-II Repair Section 1.2.2...
  • Page 405 1DZ-II Repair Section 1.2.2...

  • Page 406: Cylinder Block Bore Dimensions

    1DZ-II Repair Section 1.2.2...

  • Page 407: Engine Tune-Up

    1DZ-II Repair Section 1.2.2...

  • Page 408: Valve Clearance Inspection And Adjustment

    1DZ-II Repair Section 1.2.2...

  • Page 409: Maximum Engine Speed Inspection And Adjustment

    1DZ-II Repair Section 1.2.2...
  • Page 410 1DZ-II Repair Section 1.2.2...

  • Page 411: Compression Inspection

    1DZ-II Repair Section 1.2.2...
  • Page 412 1DZ-II Repair Section 1.2.3...

  • Page 413: Used Ssts

    1DZ-II Repair Section 1.2.3...
  • Page 414 1DZ-II Repair Section 1.2.3...

  • Page 415: Fuel Filter

    1DZ-II Repair Section 1.2.3...
  • Page 416 1DZ-II Repair Section 1.2.3...

  • Page 417: Disassembly, Inspection And Reassembly

    1DZ-II Repair Section 1.2.3...
  • Page 418 1DZ-II Repair Section 1.2.3...

  • Page 419: Injection Nozzle

    1DZ-II Repair Section 1.2.3...

  • Page 420: Removal And Installation

    1DZ-II Repair Section 1.2.3...
  • Page 421 1DZ-II Repair Section 1.2.3...
  • Page 422 1DZ-II Repair Section 1.2.3...
  • Page 423 1DZ-II Repair Section 1.2.3...

  • Page 424: Injection Pump

    1DZ-II Repair Section 1.2.3...
  • Page 425 1DZ-II Repair Section 1.2.3...

  • Page 426: Removal And Installation

    1DZ-II Repair Section 1.2.3...

  • Page 427: Disassembly

    1DZ-II Repair Section 1.2.3...
  • Page 428 1DZ-II Repair Section 1.2.3...
  • Page 429 1DZ-II Repair Section 1.2.3...
  • Page 430 1DZ-II Repair Section 1.2.3...
  • Page 431 1DZ-II Repair Section 1.2.3...
  • Page 432 1DZ-II Repair Section 1.2.3...

  • Page 433: Inspection

    1DZ-II Repair Section 1.2.3...
  • Page 434 1DZ-II Repair Section 1.2.3...
  • Page 435 1DZ-II Repair Section 1.2.3...
  • Page 436 1DZ-II Repair Section 1.2.3...

  • Page 437: Reassembly

    1DZ-II Repair Section 1.2.3...
  • Page 438 1DZ-II Repair Section 1.2.3...
  • Page 439 1DZ-II Repair Section 1.2.3...
  • Page 440 1DZ-II Repair Section 1.2.3...
  • Page 441 1DZ-II Repair Section 1.2.3...
  • Page 442 1DZ-II Repair Section 1.2.3...
  • Page 443 1DZ-II Repair Section 1.2.3...
  • Page 444 1DZ-II Repair Section 1.2.3...
  • Page 445 1DZ-II Repair Section 1.2.3...
  • Page 446 1DZ-II Repair Section 1.2.3...
  • Page 447 1DZ-II Repair Section 1.2.3...
  • Page 448 1DZ-II Repair Section 1.2.3...

  • Page 449: Airtightness Test

    1DZ-II Repair Section 1.2.3...

  • Page 450: Adjustment

    1DZ-II Repair Section 1.2.3...
  • Page 451 1DZ-II Repair Section 1.2.3...
  • Page 452 1DZ-II Repair Section 1.2.3...
  • Page 453 1DZ-II Repair Section 1.2.3...
  • Page 454 1DZ-II Repair Section 1.2.3...
  • Page 455 1DZ-II Repair Section 1.2.3...
  • Page 456 1DZ-II Repair Section 1.2.3...
  • Page 457 1DZ-II Repair Section 1.2.3...
  • Page 458 1DZ-II Repair Section 1.2.3...
  • Page 459 1DZ-II Repair Section 1.2.3...
  • Page 460 1DZ-II Repair Section 1.2.3...
  • Page 461 1DZ-II Repair Section 1.2.3...
  • Page 462 1DZ-II Repair Section 1.2.3...
  • Page 463 1DZ-II Repair Section 1.2.3...
  • Page 464 1DZ-II Repair Section 1.2.4...
  • Page 465 1DZ-II Repair Section 1.2.4...
  • Page 466 1DZ-II Repair Section 1.2.4...
  • Page 467 1DZ-II Repair Section 1.2.4...
  • Page 468 1DZ-II Repair Section 1.2.4...
  • Page 469 1DZ-II Repair Section 1.2.4...
  • Page 470 1DZ-II Repair Section 1.2.5...

  • Page 471: Used Ssts

    1DZ-II Repair Section 1.2.5...

  • Page 472: Oil Pressure Inspection

    1DZ-II Repair Section 1.2.5...

  • Page 473: Oil Strainer

    1DZ-II Repair Section 1.2.5...

  • Page 474: Oil Pump

    1DZ-II Repair Section 1.2.5...
  • Page 475 1DZ-II Repair Section 1.2.5...
  • Page 476 1DZ-II Repair Section 1.2.5...
  • Page 477 1DZ-II Repair Section 1.2.5...
  • Page 478 1DZ-II Repair Section 1.2.6...

  • Page 479: Used Ssts

    1DZ-II Repair Section 1.2.6...

  • Page 480: Preheating System

    1DZ-II Repair Section 1.2.6...

  • Page 481: Inspection Of Glow Plug

    1DZ-II Repair Section 1.2.6...

  • Page 482: Inspection Of Water Temperature Sensor

    1DZ-II Repair Section 1.2.6...

  • Page 483: Starter Motor

    1DZ-II Repair Section 1.2.6...

  • Page 484: Removal, Inspection And Installation

    1DZ-II Repair Section 1.2.6...

  • Page 485: Disassembly. Inspection And Reassembly

    1DZ-II Repair Section 1.2.6...
  • Page 486 1DZ-II Repair Section 1.2.6...
  • Page 487 1DZ-II Repair Section 1.2.6...
  • Page 488 1DZ-II Repair Section 1.2.6...
  • Page 489 1DZ-II Repair Section 1.2.6...
  • Page 490 1DZ-II Repair Section 1.2.6...

  • Page 491: Starter Assembly Individual Inspection

    1DZ-II Repair Section 1.2.6...
  • Page 492 1DZ-II Repair Section 1.2.6...
  • Page 493 1DZ-II Repair Section 1.2.6...
  • Page 494 1DZ-II Repair Section 1.2.7...
  • Page 495 1DZ-II Repair Section 1.2.7...
  • Page 496 1DZ-II Repair Section 1.2.7...
  • Page 497 1DZ-II Repair Section 1.2.7...
  • Page 498 1DZ-II Repair Section 1.2.7...
  • Page 499 1DZ-II Repair Section 1.2.7...
  • Page 500 1DZ-II Repair Section 1.2.7...
  • Page 501 1DZ-II Repair Section 1.2.7...
  • Page 502 1DZ-II Repair Section 1.2.7...
  • Page 503 1DZ-II Repair Section 1.2.7...
  • Page 504 1DZ-II Repair Section 1.2.8...

  • Page 505: Sst List

    1DZ-II Repair Section 1.2.8...
  • Page 506 1DZ-II Repair Section 1.2.8...
  • Page 507 1DZ-II Repair Section 1.2.8...
  • Page 508 1DZ-II Repair Section 1.2.8...

  • Page 509: Service Standards

    1DZ-II Repair Section 1.2.8...
  • Page 510 1DZ-II Repair Section 1.2.8...
  • Page 511 1DZ-II Repair Section 1.2.8...
  • Page 512 1DZ-II Repair Section 1.2.8...
  • Page 513 1DZ-II Repair Section 1.2.8...
  • Page 514 1DZ-II Repair Section 1.2.8...

  • Page 515: Fuel System

    1DZ-II Repair Section 1.2.8...
  • Page 516 1DZ-II Repair Section 1.2.8...
  • Page 517 1DZ-II Repair Section 1.2.8...
  • Page 518 1DZ-II Repair Section 1.2.8...

  • Page 519: Cooling System

    1DZ-II Repair Section 1.2.8...

  • Page 520: Starting System

    1DZ-II Repair Section 1.2.8...
  • Page 521 1DZ-II Repair Section 1.2.8...
  • Page 522 SECTION INDEX NAME SECTION 1.3.0 GENERAL 1.3.1 OPERATION DESCRIPTION 1.3.2 LPG REGULATOR OVERHAUL 1.3.3 ELECTRICAL TROUBLESHOOTING 1.3.4 APPENDIX 4Y-E LPG Device Repair...
  • Page 523 …..This Page Intentionally Left Blank…..
  • Page 524 LPG Device for 4Y-E Engine GENERAL Page TYPE OF LPG DEVICES........0-2 ENGINE PERFORMANCE CURVES .....0-3 ENGINE SPECIFICATIONS ........0-6 PRINCIPAL DIFFERENCES FROM GASOLINE VEHICLE .......0-7 ABBREVIATIONS...........0-7 GENERAL RULES OF SERVICING WORK ..0-8 BOLT & NUT TIGHTENING TORQUES....0-9 BOLT STRENGTH CLASS IDENTIFICATION ....0-9 METHOD AND TIGHTENING TORQUE PRECOATED BOLTS...

  • Page 525: Type Of Lpg Devices

    LPG Device for 4Y-E Engine TYPE OF LPG DEVICES Types of LPG cylinders Pneumatic Cushion Gas weight Cylinder length Specification models models General purpose — 15 kg (33.1 lb) 637 mm (25.1 in) With level gauge and quick coupling — General purpose —...

  • Page 526: Engine Performance Curves

    LPG Device for 4Y-E Engine ENGINE PERFORMANCE CURVES 4Y Engine (8FGU15 to 25, 8FGCU20 to 32) Gasoline (Exclusive, Convertible) LPG (Exclusive, Convertible) Engine speed Section 1.3.0...
  • Page 527 LPG Device for 4Y-E Engine 4Y Engine (8FGU30, 32) Gasoline (Exclusive) Gasoline (Convertible with LPG) LPG (Exclusive, Convertible) Gasoline (Exclusive, Convertible) LPG (Exclusive, Convertible) Engine speed Section 1.3.0...
  • Page 528 LPG Device for 4Y-E Engine 4Y Engine (8FGU15 to 32 series, 8FGCU15, 18 and 8FGCSU20) Gasoline (Exclusive, Convertible) (Exclusive, Convertible) Engine speed Section 1.3.0...

  • Page 529: Engine Specifications

    LPG Device for 4Y-E Engine ENGINE SPECIFICATIONS 8FGU15 to 25 8FGU30, 32 8FGCU15, 18 and 8FGCSU20 8FGCU20 to 32 N·m Maximum shaft (kgf·m) (16.3) (16.8) (16.5) (16.3) (16.3) torque 2100 2570 2200 2100 Maximum shaft (PS) (51) (59) (58) (57)

  • Page 530: Principal Differences From Gasoline Vehicle

    LPG Device for 4Y-E Engine PRINCIPAL DIFFERENCES FROM GASOLINE VEHICLE Gasoline vehicle Exclusive vehicle Convertible vehicle Gasoline tank and Fuel tank LPG cylinder Gasoline tank LPG cylinder Adapter For LPG For LPG Not provided Regulator For LPG For LPG Not Provided Fuel pump Not provided For gasoline...

  • Page 531: General Rules Of Servicing Work

    LPG Device for 4Y-E Engine GENERAL RULES OF SERVICING WORK Preparation before disassembly • Prepare necessary mechanic tools, measuring instruments and SST before starting operation. • When disassembling a complicated assembly, put punch or matching marks at places not affecting the function to facilitate reassembly operation.

  • Page 532: Bolt & Nut Tightening Torques

    LPG Device for 4Y-E Engine BOLT & NUT TIGHTENING TORQUES Standard Bolt & Nut Tightening Torque Tightening torques of standard bolts and nuts are not indicated throughout the manual. Use the procedures and table below to judge the standard tightening torque. Judge the tightening torque for the hexagon head bolt, welded bolt or stud bolt having the standard bearing surface according to the tightening torque table by identifying the bolt strength class from the table below.
  • Page 533 0-10 0-10 LPG Device for 4Y-E Engine Identification by Part No. Type Part No. Shape 91 611-4 0 62 5 Nominal Nominal length (mm) diameter Hexagon bolt Nominal diameter (mm) Strength class Nominal length 92 1 32 -4 06 14 Nominal Nominal length (mm) diameter...
  • Page 534 0-11 LPG Device for 4Y-E Engine Identification by Bolt Shape (Hexagon flange bolt) Class 4.8T 6.8T 8.8T 10.9T 11.9T No mark Hexagon flange bolt No mark Tightening Torque Table (Hexagon flange bolt) Standard tightening torque Nominal diameter Pitch Strength class N·m kgf·cm ft·lbf...

  • Page 535: Precoated Bolts (Bolts With Seal Lock Agent Coating On Threads)

    0-12 0-12 LPG Device for 4Y-E Engine PRECOATED BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON THREADS) Do not use the precoat bolt as it is in either of the following cases: (1) After it has been removed. (2) When it has been moved by tightness check, etc. (loosened or tightened) Note: For torque check, tighten the bolt at the lower limit of the...

  • Page 536: Periodic Maintenance

    0-13 LPG Device for 4Y-E Engine PERIODIC MAINTENANCE INSPECTION METHOD I: Inspection. Repair or replacement if required. C: Cleaning *1: Soapy water *2: Detector Inspection Period Months Item Hours 1000 2000 Gas leak from piping and joint Damage of piping and joint Tar removal from regulator Regulator adjustment status Regulator function...
  • Page 537 …..This Page Intentionally Left Blank…..
  • Page 538 LPG Device for 4Y-E Engine OPERATION DESCRIPTION Page OUTLINE OF LPG DEVICE........1-2 FUEL FILTER FOR LPG ........1-3 SOLENOID VALVE ..........1-3 ADAPTER...............1-4 REGULATOR............1-5 ............1-5 SPECIFICATIONS ....1-11 REGULATORS SYSTEM COMPONENTS Section 1.3.1...

  • Page 539: Outline Of Lpg Device

    LPG Device for 4Y-E Engine OUTLINE OF LPG DEVICE LPG (in liquid form supplied from the cylinder) passes through the LPG filter in the engine room to remove foreign matter and reaches to the regulator through the main solenoid valve. LPG is reduced and gasified in the regulator, and supplied to engine with its pressure kept at a certain rate.

  • Page 540: Fuel Filter For Lpg

    LPG Device for 4Y-E Engine FUEL FILTER FOR LPG The filter is mounted between the LPG cylinder and the right before the solenoid valve to remove various kinds of foreign materials in From LPG. It consists of a filter element and permanent magnet, and the Main filter element is detachable for easy cleaning and has sufficiently cylinder...

  • Page 541: Adapter

    LPG Device for 4Y-E Engine ADAPTER The adapter is installed on the right upper position of the electric governor, and mixes air with gaseous LPG decompressed in the regulator. The air-mixed fuel is led to the engine. The adapter has a Seat FCM (Fuel/air Control Motor) at the ventury part and the FCM diameter...
  • Page 542 LPG Device for 4Y-E Engine REGULATOR The regulator supplies vaporized LPG after pressure reduction to the engine while maintaining the pressure at a fixed level. SPECIFICATIONS First chamber pressure kPa (psi) 24.5 to 34.3 (3.6 to 5.0) First seat inner diameter mm (in) 3.2 (0.1) Secondary seat inner diameter...
  • Page 543 LPG Device for 4Y-E Engine Regulator Function The LPG is gasified by depriving the engine coolant, led into the regulator, of heat. The regulator consists of chamber A where LPG vaporization starts, chamber B (first reducing chamber) where the gasified LPG pressure is reduced, chamber C (second reducing chamber) for reducing the pressure down to almost atmospheric level to supply fuel using the adopter venturi vacuum, and chamber D for forced fuel supply during engine start and idling.
  • Page 544 LPG Device for 4Y-E Engine When starting the engine When the ignition switch and LPG switch are both turned to ON, the LPG led from the IN port flows into chamber A. Upon entering chamber A, the LPG pushes open the elastic face valve 1 by its own vapor pressure, and enters the primary pressure reduction chamber B for pressure reduction and vaporization.
  • Page 545 LPG Device for 4Y-E Engine During idling When the engine is idling, current flows to the slow solenoid valve coil to operate the valve, resulting in opening of the closed path to connect chambers B with D. Since the pressure in chamber B is high enough, the depressurized LPG flows chamber D.
  • Page 546 LPG Device for 4Y-E Engine During normal operation When the throttle valve is opened, vacuum arises at the adapter venturi nozzle, which is applied to chamber C through the main path. This vacuum pulls second diaphragm to open elastic face valve 2. As a result, LPG flows from chamber B to chamber C, and enters the adapter venturi nozzle through the main path.
  • Page 547 1-10 1-10 LPG Device for 4Y-E Engine When stopping the engine When the engine stopped, the current to the slow solenoid valve is cut off to close the path between chambers B and D, resulting in suspension of LPG supply through the slow path. Since the vacuum at the adapter venturi does not exist, LPG supply through the slow path also stops.

  • Page 548: Regulators System Components

    1-11 LPG Device for 4Y-E Engine REGULATORS SYSTEM COMPONENTS LPG Cutoff Device The solenoid valve for slow path control is integrated with the regulator. The solenoid valve is opened and closed according to the engine speed, starter signal etc. detected by means of engine ECU. When the ignition switch is ON, with the engine not running, the valve is closed not to flow LPG to the adapter.
  • Page 549 …..This Page Intentionally Left Blank…..
  • Page 550 LPG Device for 4Y-E Engine LPG REGULATOR OVERHAUL Page PRECAUTION FOR LPG FORKLIFT OPERATION AND REPAIR ............2-2 REGULATOR............2-3 ........2-10 REMOVAL·INSTALLATION .......2-12 DISASSEMBLY·REASSEMBLY LPG LEAK INSPECTION ........2-17 ENGINE ADJUSTMENT........2-18 Section 1.3.2...
  • Page 551 LPG Device for 4Y-E Engine PRECAUTION FOR LPG FORKLIFT OPERATION AND REPAIR Handle LPG with special attention, because it is inflammable and may cause explosion resulting in the fatal accident. Never smoke tobacco, strike a match and light a lighter near the LPG forklift. Never park and stop the LPG forklift near a stove, gas burner, electric heater, electric apparatus (a motor, etc), bonfire, etc.
  • Page 552 LPG Device for 4Y-E Engine REGULATOR General Section 1.3.2...
  • Page 553 LPG Device for 4Y-E Engine Components First valve ASSY Idle adjust screw O-ring Solenoid valve Second cover Second Second diaphragm valve ASSY First diaphragm First cover Section 1.3.2...
  • Page 554 LPG Device for 4Y-E Engine SSTs for LPG Regulator Overhaul Part No. Part Name 09813-26600-71 Gauge 09814-22000-71 Tool 09815-22000-71 Tool 80339-76026-71 Automatic choke pipe plug 09817-23600-71 Union 09819-23600-71 Gauge 09819-22000-71 Gauge 23627-22000-71 Spring 09820-23600-71 Tester SUB-ASSY 09823-23600-71 Union 09822-22000-71 Gauge 09821-22000-71 Bellows Section 1.3.2...
  • Page 555 LPG Device for 4Y-E Engine How to Deal with Tamper Proof Ring General It is not basically necessary to adjust VF voltage and regulator primary pressure, but at regulator overhauling, remove the tamper proof rings to adjust them. Follow the procedure described below to treat the tamper proof rings.
  • Page 556 LPG Device for 4Y-E Engine Troubleshooting Inspection 1 Remove the idle adjusting screw and install the SST. SST (Union) tightening torque: T=0.2 to 0.3 N·m (2 to 3 kgf·cm) [0.14 to 0.19 ft·lbf] Supply compressed air at 400 kPa (4 kgf/cm ) [57 psi] through the IN port and maintain the air pressure.
  • Page 557 LPG Device for 4Y-E Engine From Inspection 3 Inspection 4 Stop supplying the compressed air in the state of Inspection 2. Breathe air into the inner vent port and read the SST gauge. The pointer moves to 0 position. The pointer stays at the position. Normal •...
  • Page 558 LPG Device for 4Y-E Engine Individual Inspection Inspect the slow solenoid. Check that the operating sound is heard when applying 12 V to the slow solenoid. 12 V Inspect the main solenoid. Check that the operating sound is heard when applying 12 V to the main solenoid.
  • Page 559 2-10 2-10 LPG Device for 4Y-E Engine REMOVAL·INSTALLATION Caution: • Perform working at a well-ventilated job site and never put fire sources around the vehicle. • Perfectly discharge LPG from the piping before starting removal. • Disconnect the battery negative terminal before handling the fuel system. •...
  • Page 560 2-11 LPG Device for 4Y-E Engine Point Operations [Point 1] Removal: Discharge LPG from the piping according to the procedure below. (1) Close the LPG supply piping valve 1 (green). (2) Close the LPG outlet valve 2 (amber). (3) Start the engine, and run the engine in the idling state until it stops naturally.
  • Page 561 2-12 2-12 LPG Device for 4Y-E Engine DISASSEMBLY·REASSEMBLY Caution: Perform working at a well-ventilated job site and never put fire sources around the vehicle. Note: • Wash the outer surface of the regulator and keep the work bench clean. • First, perform individual check of the filter for clogging and the solenoid valve for any abnormality, and then disassemble the regulator only when its internal abnormality is found by the inspection according to the troubleshooting given in this manual.
  • Page 562 2-13 LPG Device for 4Y-E Engine [Point 1] Reassembly: Install the diaphragm by matching its pin with the concave portion of the second valve lever. Tighten the screws in the illustrated order. Tightening torque: T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.5 ft·lbf] Concave portion [Point 2] Reassembly:...
  • Page 563 2-14 2-14 LPG Device for 4Y-E Engine If not satisfied, use the SST to bend the lever for adjustment. SST (2) SST 09814-22000-71......... (1) 09815-22000-71......... (2) During lever height adjustment, do not push the valve seat against the port. SST (1) [Point 3] Disassembly: Since the spring force is applied at each portion, do not try...
  • Page 564 2-15 LPG Device for 4Y-E Engine Check the first valve air-tightness. (1) Put the SST (spring) between the lever tip and regulator body. SST 23627-22000-71 (2) Connect the SST (gauge) to the fuel inlet. SST 09820-23600-71 (3) Check that the air does not leak from the valve until air pressure become in the range of 49.0 to 58.8 kPa (0.5 to 0.6 kg/cm ) [2.7 to 7.0 psi].
  • Page 565 2-16 2-16 LPG Device for 4Y-E Engine Adjust the first diaphragm adjust screw. (1) Loosen the adjust screw nut. (2) Using SST, adjust the protrusion of the screw. SST 09819-22000-71 Reference height: 13.9 mm (0.5 in) Adjust the pressure of first reducing chamber. (See page 2-17) [Point 5] Reassembly: Idle adjusting screw...
  • Page 566 2-17 LPG Device for 4Y-E Engine LPG LEAK INSPECTION Caution: • After repairing each part of the LPG system, use soapy water to check no LPG leakage from any part before starting the engine. • Never use fire for inspecting gas leakage. •...
  • Page 567 2-18 2-18 LPG Device for 4Y-E Engine ENGINE ADJUSTMENT Note: To measure values described below, use the multifunction display or plug-in analyzer. Warm up the engine until the coolant temperature be 80GC (176GF) or higher. Check the engine idle speed. Standard: 750 ±...
  • Page 568 2-19 LPG Device for 4Y-E Engine Adjust LPG regurator primary pressure (1) Start the engine. (2) Loosen the adjust screw nut and adjust the primary pressure by turning the screw. Standard: 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm ) [3.5 to 5.0 psi] Check and adjust VF voltage (1) Warm up the heated oxygen sensor by maintaining the engine speed at 1800 rpm for approximately 2 minutes.
  • Page 569 …..This Page Intentionally Left Blank…..
  • Page 570 LPG Device for 4Y-E Engine ELECTRICAL TROUBLESHOOTING Page BEFORE TROUBLESHOOTING......3-2 .........3-2 CONNECTOR HANDLING WIRE HARNESS AND CONNECTOR INSPECTION ............3-2 PROCEDURE BEFORE BEGINNING TROUBLESHOOTING ..3-4 DIAGNOSIS (SELF DIAGNOSIS FUNCTION)..3-5 ...............3-5 GENERAL HOW TO INTERPRET THE FLOW-CHARTS ..3-6 ANALYZER .............3-7 ............3-7 EXPLANATION ......3-8 ANALYZER MENU SCREEN LIST ABOUT TROUBLE SHOOTING...

  • Page 571: Before Troubleshooting

    LPG Device for 4Y-E Engine BEFORE TROUBLESHOOTING CONNECTOR HANDLING Disconnect battery plug before connecting disconnecting each connector or terminal. When unplugging a connector, first remove the lock then, without pulling the harness, pull out the connector while holding the main unit. To connect, push the connector fully until it is locked in position.
  • Page 572 LPG Device for 4Y-E Engine Measure the resistance between the relative terminals of the appricable connector. Standard: 1 M: or above Note: The wiring may short-circuit due to pinching by the body or defective clamping. Visual and Contact Pressure Checks Disconnect connectors at both ends of the relevant harness.

  • Page 573: Before Beginning Troubleshooting

    LPG Device for 4Y-E Engine BEFORE BEGINNING TROUBLESHOOTING It is not appropriate to begin trouble shooting for the 4Y engine on the basis of results only. It can lead to mistaken corrective action, wasted time, and sometimes to an increase in abnormalities. Therefore, please pay careful attention to the details surrounding the time when a fault occurs, to be supplied by the customer based on the following.

  • Page 574: Diagnosis (Self Diagnosis Function)

    LPG Device for 4Y-E Engine DIAGNOSIS (SELF DIAGNOSIS FUNCTION) GENERAL When the computer detects a problem in the system, the fault is made known by a lighting a warning lamp and displaying an error code on the combination meter, while at the same time failsafe functions operate to stop the engine or control the engine to a low speed.

  • Page 575: How To Interpret The Flow-Charts

    LPG Device for 4Y-E Engine HOW TO INTERPRET THE FLOW-CHARTS Turn the key switch OFF and ON again Is there an error code 31-1? Inspect the VF voltage. Drive controller defect ± Standard: 2.5 0.5 V To next procedure depending on result Single frames indicate measurement using a circuit tester and normal procedures.

  • Page 576: Analyzer

    LPG Device for 4Y-E Engine ANALYZER EXPLANATION Analyzer function supports operations for inspecting/investigating faulty section by displaying the condition of the control system, using communication between each controller and the multifunction display or plug-in analyzer. By switching the multifunction display to analyzer mode, or connect the plug-in analyzer to the diagnosis connector, operative conditions of the sensor actuator that is used for traveling functions, or the error information detected by the controller can be read.

  • Page 577: Analyzer Menu Screen List

    LPG Device for 4Y-E Engine ANALYZER MENU SCREEN LIST ANALYZER MENU screen Display item Description DIAG MEMORY 1. - 10. Indications of errors occurred I/O ENGINE CTRL IGSW Key switch (IG) Key switch (ST) BATT Battery voltage G/LP Fuel changeover switch Fuel specification discrimination signal Engine specification discrimination signal MREL...

  • Page 578: About Trouble Shooting By Error Codes

    LPG Device for 4Y-E Engine ABOUT TROUBLE SHOOTING BY ERROR CODES Defective contact of connectors may cause error codes to appear and disappear. Therefore before performing troubleshooting, check the battery cable connection, turn the key switch ON, and check that the error code appears.
  • Page 579 3-10 LPG Device for 4Y-E Engine Section 1.3.3...
  • Page 580 3-11 LPG Device for 4Y-E Engine Section 1.3.3...

  • Page 581: Troubleshooting By Symptoms

    3-12 3-12 LPG Device for 4Y-E Engine TROUBLESHOOTING BY SYMPTOMS Symptom Chart Symptom Page for reference Does not start Starting motor turns over but engine does not start 3-13 Unstable idle speed 3-15 Poor idle adjustment Idle speed low and unstable 3-17 Idle speed high 3-18...
  • Page 582 3-13 LPG Device for 4Y-E Engine z <DOES NOT START> STARTING MOTOR TURNS OVER BUT ENGINE DOES NOT START Probable cause • Ignition system defect (When combustion does not start) • Fuel system defect (When combustion does start, but does not continue.) •...
  • Page 583 3-14 3-14 LPG Device for 4Y-E Engine Repair or replace LPG regulator Inspect LPG regulator primary pressure Adjust primary pressure of LPG regulator. (Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2) Defect of ignitor or engine ECU Check starting ability Finish Section 1.3.3...
  • Page 584 3-15 LPG Device for 4Y-E Engine z <POOR IDLE ADJUSTMENT> UNSTABLE IDLE SPEED Probable cause • Air leakage • 1 or more cylinders misfiring • VF voltage abnormality during idling • Ignition timing off Note: When fuel of a low vapor pressure is used in winter, insufficient vaporization may cause unstable idle speed. Only a particular Inspect spark plugs...
  • Page 585 3-16 3-16 LPG Device for 4Y-E Engine Inspect VF voltage (Refer to parts inspection and adjustment 14) Adjust VF voltage Standard: 2.5 ± 0.5V To injector system Inspect injector function (Refer to 3-32) (Refer to parts inspection and adjustment 6) Inspect compression Inspect and repair engine (Refer to parts inspection and adjustment 15)
  • Page 586 3-17 LPG Device for 4Y-E Engine z <POOR IDLE ADJUSTMENT> IDLE SPEED LOW AND UNSTABLE Probable cause • Air-fuel ratio over-lean • Blockage around the electric throttle valve Inspect the VF voltage. (Refer to parts inspection and adjustment 14) Standard: 2.5 ± 0.5 V Adjust VF voltage Note: A over-lean air-fuel ratio may result in a low...
  • Page 587 3-18 3-18 LPG Device for 4Y-E Engine z <POOR IDLE ADJUSTMENT> IDLE SPEED HIGH Probable cause • Throttle valve return defect • Air leakage • VF voltage abnormality Note: Inspect parts related to the items listed above. Section 1.3.3...
  • Page 588 3-19 LPG Device for 4Y-E Engine z <POOR DRIVABILITY> KNOCKING Probable cause • Excess deposition in combustion chamber or on spark plug electrode • Ignition timing off Adjust initial advance timing Check initial advance timing (Refer to page 2-16) (Refer to page 2-16) Inspect spark plugs (1) Check that there is no obvious deposition.
  • Page 589 3-20 3-20 LPG Device for 4Y-E Engine z <POOR DRIVABILITY> HESITATION Probable cause • Electronic throttle abnormality • VF voltage abnormality • Initial advance timing off • O sensor abnormality Caution: Since pulsating combustion occurs on fuel cut operation at high rpm, operate in a range below the rpm at which hesitation occurs.
  • Page 590 3-21 LPG Device for 4Y-E Engine Inspect LPG regulator primary pressure Adjust primary pressure of LPG regulator (Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2) Inspect injector operation and inspect for blockages To injector system (3-33) (Refer to parts inspection and adjustment 6, 7) Inspect O sensor feedback...
  • Page 591 3-22 3-22 LPG Device for 4Y-E Engine z <POOR DRIVABILITY> INSUFFICIENT POWER OUTPUT Probable cause • Air-fuel ratio abnormality (over-lean) • Initial advance timing off Note: • After disconnecting the battery terminal or removing the LPG fuse, the fuel system learning value will be cleared.
  • Page 592 3-23 LPG Device for 4Y-E Engine Inspect VF voltage (Refer to parts inspection and adjustment 14) Inspect changes in VF voltage and OX value (0 or 1) at 1800 r/min. (idle OFF). Standard: 2.5 ± 0.5 V* *: 0 V, 2.50 V, or 5.0 V will be displayed when the plug-in Inspect, repair, or replace the feedback-related...
  • Page 593 3-24 3-24 LPG Device for 4Y-E Engine Inspect wire harness and connectors between engine ECU and vacuum Repair wire harness sensor connectors (Refer to the wiring diagram at the back of the book) Replace engine ECU NG (Standard value or more, or not airtight) Inspect LPG regulator primary pressure Repair LPG regulator...
  • Page 594 3-25 LPG Device for 4Y-E Engine z <ENGINE STALL> ENGINE STALLING IN GENERAL Probable cause • Charging system • LPG regulator primary pressure adjustment defect • Air leak in (over-lean) intake system • Ignition timing defect • Idling air-fuel ratio adjustment defect •...
  • Page 595 3-26 3-26 LPG Device for 4Y-E Engine Adjust primary pressure of LPG regulator. Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2) NG (Does not start at all) Check the vehicle re-starts Inspect ignition Recreation test LPG regulator defect or...
  • Page 596 3-27 LPG Device for 4Y-E Engine LPG regulator (secondary system) defect or Inspect LPG regulator primary pressure unsuitable specification fuel (winter only) (Refer to parts inspection and adjustment 1) NG (Airtightness defect) Repair LPG regulator (Outside (Refer to section 2) standard value) Inspect and repair blockages in fuel piping...
  • Page 597 3-28 3-28 LPG Device for 4Y-E Engine z <ENGINE STALL> ENGINE STALLING A SHORT TIME AFTER START UP Probable cause • LPG regulator primary pressure adjustment defect • Blocked injector, air control valve, or by-pass route • Charging system defect •...
  • Page 598 3-29 LPG Device for 4Y-E Engine Inspect initial advance timing Adjust initial advance timing (Refer to page 2-16) Inspect VF voltage (Refer to parts inspection and adjustment 14) Inspect changes in VF voltage and OX value (0 or 1) at 1800 r/min. (idle OFF). Standard: 2.5 ±...
  • Page 599 3-30 3-30 LPG Device for 4Y-E Engine z <ENGINE STALL> ENGINE STALLING WHEN A/C, LIGHTS, OR DEFOGGER ARE TURNED ON, OR WHEN THE STEERING IS OPERATED Probable cause • LPG regulator primary pressure adjustment defect • Pay attention to air-fuel ratio abnormalities (injector blocked, idle adjustment defect) •...
  • Page 600 3-31 LPG Device for 4Y-E Engine z <ENGINE STALL> ENGINE STALLING ON RELEASING THE ACCELERATOR Probable cause • Idling air-fuel ratio adjustment defect • Ignition timing off • Air leakage • Injector defect • LPG filter defect Inspect VF voltage (Refer to parts inspection and adjustment 14) Inspect changes in VF voltage and OX value Inspect, repair, or replace the feedback-related...
  • Page 601 3-32 3-32 LPG Device for 4Y-E Engine Replace LPG filter Inspect LPG filter Inspect injector system operation and inspect To LPG injector system for blockages (Refer to page 3-33) (Refer to parts inspection and adjustment 6, 7) Inspect LPG regulator primary pressure Adjust LPG regulator primary pressure (Refer to parts inspection and adjustment 1) Engine ECU defect...
  • Page 602 3-33 LPG Device for 4Y-E Engine z LPG INJECTOR SYSTEM Inspect the injectors for air-tightness Clean or replace injectors Clean or replace injectors (Refer to parts inspection and adjustment 6) Perform startup operation inspection and NG (Only during startup) idle operation inspection of injectors. To *A (Refer to parts inspection and adjustment 6) To *B...
  • Page 603 3-34 3-34 LPG Device for 4Y-E Engine Inspect injector operation with the coolant Measure the voltage between temperature sensor connector disconnected. Replace engine ECU the THW - E1 terminals of the engine ECU. (1) Disconnect the connector from the coolant Standard: 4.5 to 5.5 V temperature sensor.
  • Page 604 3-35 LPG Device for 4Y-E Engine z AIR-FUEL RATIO CONTROL MOTOR SYSTEM Inspect air-fuel ratio control motor operation System normal (Refer to parts inspection and adjustment 5) Measure the voltage between THA - E2 Disconnect the intake temperature Inspect and replace terminals of the engine control computer sensor and carry out the above engine control computer...
  • Page 605 3-36 3-36 LPG Device for 4Y-E Engine z SLOW SOLENOID VALVE SYSTEM Inspect slow solenoid valve for airtightness Replace slow solenoid valve (Refer to parts inspection and adjustment 4) Inspect slow solenoid valve operation System normal (Refer to parts inspection and adjustment 4) Inspect voltage between connector terminal 2 and terminal 1 on Inspect and replace the slow solenoid valve the slow solenoid valve wire harness side.
  • Page 606 3-37 LPG Device for 4Y-E Engine PARTS INSPECTION AND ADJUSTMENT SST (2) Check LPG regurator primary pressure. SST (1) (1) Remove the tamper proof ring. (Refer to 2-5-1) (2) Install the SST to the LPG regulator. SST 09817-23600-71 ......(1) 09820-23600-71 ......
  • Page 607 3-38 3-38 LPG Device for 4Y-E Engine Inspect slow solenoid valve (1) Disconnect the injector hose from the LPG injector. (2) Turn the ignition switch ON and OFF promptly. (3) Check that the LPG blows. Standard: LPG blows for a split second. (4) Turn the ignition switch OFF.
  • Page 608 3-39 LPG Device for 4Y-E Engine (7) Disconnect the connector from the FCM. (8) Measure the resistance between the terminals. Standard: Terminals Resistance 15 to 25 : at cold temp. 2-1, 3 20 to 30 : at hot temp. 15 to 25 : at cold temp. 5-4, 6 20 to 30 : at hot temp.
  • Page 609 3-40 3-40 LPG Device for 4Y-E Engine Inspect LPG injector (1) Put a sound scope on the LPG injector. (2) Check the injector operating sound while cranking the engine. Standard: Injector makes operating sound. Reference: Injector injects fuel twice per engine revolution while cranking.
  • Page 610 3-41 LPG Device for 4Y-E Engine Clean LPG injector (1) With a clean shop rag, wipe off the carbon around the nozzle. (2) Insert and desert a wire with diameter of less than 1.2 mm (0.047 in), while applying compressed air of 343 to 490 kPa (3.5 to 5.0 kgf/cm , 49.8 to 71.1 psi) from the intake port.
  • Page 611 3-42 3-42 LPG Device for 4Y-E Engine 10. Inspect distributor cap (1) Check the distributor cap and center piece contact visually. Standard: • There is no crack on the distributor cap. • There is no damage on the center piece. •...
  • Page 612 3-43 LPG Device for 4Y-E Engine 13. Inspect signal generator (1) Disconnect the pickup coil connector. (2) Measure the resistance between the terminals. Standard: Condition Resistance 370 to 550 : Cold 20qC (68qF) 475 to 650 : Hot 80qC (176qF) (3) Remove the distributor cap, rotor, and dust-proof cover.
  • Page 613 3-44 3-44 LPG Device for 4Y-E Engine 15. Check cylinder compression pressure (1) Warm up the engine to the normal operating temperature. (2) Disconnect the distributor connectors. (3) Disconnect the resistive codes from the spark plugs. (4) Remove the spark plugs. (5) Check the cylinder compression pressure.
  • Page 614 LPG Device for 4Y-E Engine APPENDIX Page SST LIST ..............4-2 SERVICE STANDARDS .........4-4 WIRING DIAGRAM..........4-5 Section 1.3.4...
  • Page 615 LPG Device for 4Y-E Engine SST LIST Section Illustration Part number Part name 09238-13130-71 Sub harness 09814-22000-71 Tool 09815-22000-71 Tool 09813-26600-71 Gauge 80339-76026-71 Automatic choke pipe plug 09817-23600-71 Union 09819-22000-71 Gauge Section 1.3.4...
  • Page 616 LPG Device for 4Y-E Engine Section Illustration Part number Part name 09819-23600-71 Gauge 23627-22000-71 Spring 09820-23600-71 Tester SUB-ASSY 09240-26600-71 Plug-in Analyzer Section 1.3.4...
  • Page 617 LPG Device for 4Y-E Engine SERVICE STANDARDS FILTER Tightening Torque T=N·m (kgf·cm) [ft·lbf] Cover set bolt 6.4 to 7.8 (65 to 80) [4.7 to 5.8] Element tightening nut 1.0 to 1.2 (100 to 150) [0.7 to 1.1] REGULATOR Protrusron of the idle adjust screw 11.8 to 15.0 (120 to 150) [8.7 to 11.0] (Distance from the body face to the screw tip) Mounting height of the first spring adjuster...

This manual is also suitable for:

8fdu158fgu188fdu188fgu208fdu208fgu25 ... Show all

Table of Contents

Save PDF