ENGINE TUNE-UP

ENGINE MECHANICAL - Engine Tune-Up
EM-17
ENGINE TUNE-UP
INSPECTION OF ENGINE COOLANT
(See steps 1 and 2 on page CO-4)
INSPECTION OF ENGINE OIL
(See steps 1 and 2 on page LU-5)
INSPECTION OF BATTERY
(See pages 1 and 2 on page CH-5)
Standard specific gravity:
95D31 R and 95D31L
1.27-1.29 when fully charged at 20°C (68°F)
ex. (95D31 R and 95D31L)
1.25-1.27 when fully charged at 20°C (68°F)
INSPECTION OF AIR FILTER
(Paper Filter Type)
1.
INSPECT AIR FILTER
Visually check that the filter element is not excessively
dirty, damaged or oily.
2.
CLEAN AIR FILTER
Clean the filter element with compressed air.
First blow from the inside thoroughly. Then blow off the
outside of the filter element.
(Washable Type)
1.
INSPECT AIR FILTER
Visually check that the filter element is not excessively
dirty, damaged or oily.
2.
CLEAN AIR FILTER
(a) Blow dirt off in the filter element with compressed air.
EM-18
ENGINE MECHANICAL - Engine Tune-Up
(b) Submerge the filter element in the water and agitate it
up and down more than ten times.
(c) Repeat rinsing in clean water unitil rinse water is clear.
(d) Remove excess water by shaking the filter element or
blowing with compressed air.
NOTICE: Do not beat or drop filter element.
(e) Wipe off dust on the air cleaner case interior.
INSPECTION OF ALTERNATOR DRIVE BELT
(See step 3 on page CH-5)
Drive belt deflection:
New belt 6 - 7 mm (0.24-0.28 in.)
Used belt 8-11 mm (0.31 -0.43 in.)
Drive belt tension (Reference):
New belt 45-55 kg
Used belt 20-35 kg
INSPECTION OF GLOW PLUGS
(See page ST-7)
ENGINE MECHANICAL - Engine Tune-Up
EM-19
ADJUSTMENT OF VALVE CLEARANCE
HINT: Adjust the valve clearance while the engine is cold.
1.
REMOVE INTAKE PIPE
(See step 6 on page EM-34)
2.
REMOVE CYLINDER HEAD COVER
(See step 7 on page EM-35)
3.
SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise, and align its
groove with the timing gear cover groove.
(b) (1PZ)
Check that the valve lifters on the No.1 cylinder are
loose and exhaust valve lifter on the No.5 cylinder is
tight.
(c) (1 HZ and 1HD-T)
Check that the valve lifters on the No.1 cylinder are
loose and valve lifters on the No.6 cylinder are tight.
If not, turn the crankshaft one revolution (360°) and align
the mark as above.
4.
ADJUST VALVE CLEARANCE
(a) Check only those valves indicated in the illustration.
• Using a thickness gauge, measure the clearance
between the valve lifter and camshaft.
• Record the valve clearance measurements which
are out of specification. They will be used later to
determine the required replacement adjusting shim.
Valve clearance (Cold):
Intake
0.15-0.25 mm (0.006-0.010 in.)
Exhaust 0.35-0.45 mm (0.014-0.018 in.)
(b) Turn the crankshaft one revolution (360°), and align
the mark as above (See procedure step 3).
(c) Check only the valves indicated in the illustration.
Measure the valve clearance.
(See procedure step (a))
EM-20
ENGINE MECHANICAL - Engine Tune-Up
(d) Remove the adjusting shim.
• Turn the crankshaft to position the cam lobe of the
camshaft on the adjusting valve upward.
• Using SST, press down the valve lifter.
SST 09248-64011
HINT: Before pressing down the valve lifter, position the
notch on the exhaust manifold side.
• Remove the adjusting shim with a small screwdriver
and magnetic finger.
(e) Determine the replacement adjusting shim size by
using following (Formula or Charts):
• Using a micrometer, measure the thickness of the
removed shim.
• Calculate the thickness of the new shim so the
valve clearance comes within specified value.
T
Thickness of used shim
A
Measured valve clearance
N
Thickness of new shim
Intake N = T + (A-0.20 mm (0.008 in.))
Exhaust N = T + (A-0.40 mm (0.016 in.))
• Select a new shim with a thickness as close as
possible to the calculated values.
HINT: Shims are available in twenty sizes in increments
of 0.05 mm (0.0020 in.), from 2.35 mm (0.0925 in.) to
3.30 mm (0.1299 in.)
(f) Install a new adjusting shim.
• Place a new adjusting shim on the valve lifter.
• Remove SST.
SST 09248-64011
(g) Recheck the valve clearance.
5.
REINSTALL CYLINDER HEAD COVER
(See step 2 on page EM -38)
6.
REINSTALL INTAKE PIPE
(See step 3 on page EM-38)
ENGINE MECHANICAL - Engine Tune-Up
EM-21
Adjusting Shim Selection Using Chart (Intake)
Intake valve clearance (Cold):
0.15-0.25 mm (0.006-0.010 in.)
EXAMPLE: The 2.800 mm (0.1102 in.)
shim is installed and the measured clearance
is 0.300 mm (0.0118 in.). Replace the 2.800
mm (0.1102 in.) shim with a No.21 shim.
EM-22
ENGINE MECHANICAL - Engine Tune-Up
Adjusting Shim Selection Using Chart (Exhaust)
Exhaust valve clearance:
0.35-0.45 mm (0.014-0.018 in.)
EXAMPLE: The 2.800 mm (0.1102 in.)
shim is installed and the measured clearance
is 0.300 mm (0.0118 in.). Replace the 2.800
mm (0.1102 in.) shim with a No.11 shim.
ENGINE MECHANICAL - Engine Tune-Up
EM-23
ADJUSTMENT OF INJECTION TIMING
1.
(1PZ)
REMOVE TIMING BELT COVER
(See step 1 on page EM-33)
2.
(1PZ)
SET NO.1 CYLINDER TO TDC/COMPRESSION
Turn the crankshaft pulley clockwise, and align each pulley groove with the timing marks (TDC mark) as shown in
the illustration.
3.
(1 HZ and 1HD-T)
SET NO.1 OR NO.6 CYLINDER TO
TDC/COMPRESSION
Turn the crankshaft pulley clockwise, and align its groove
with the timing gear cover groove.
4.
(1HD-T w/BACS)
REMOVE AIR CONTROL VALVE (ACV)
5.
INSTALL SST AND DIAL INDICATOR
(a) (1HD-T)
Loosen the union nut of the No.5 cylinder injection
pipe.
(b) Remove the plug bolt from the distributive head plug
of the injection pump.
(c) Install SST (plunger stroke measuring tool) and a dial
indicator to the plug bolt hole of distributive head
plug.
SST 09275-54011
EM-24
ENGINE MECHANICAL - Engine Tune-Up
6.
(w/ACSD)
RELEASE ACSD ADVANCE
(a) Using a screwdriver, turn the cold starting lever counterclockwise approx. 20°.
(b)
7.
Put a metal plate (thickness of 3.5-7.5 mm
(0.135-0.295 in.)) between the cold starting lever
and thermo wax plunger.
ADJUST INJECTION TIMING
(a)
Slowly rotate the crankshaft pulley counterclockwise
and set the dial indicator at 0 mm (0 in.) when the dial
indicator reaches the minimum value.
NOTICE: Compared with previous four cylinder engines, the 0 mm (0 in.) position (crank angle) is reduced,
so perform the operation carefully, (ex. 1PZ)
(b)
Turn the crankshaft to the left and right and check that
the dial indicator shows the minimum value.
NOTICE: Make sure that the minimum value is set at
0 mm (0 in.).
(c)
Slowly rotate the crankshaft pulley clockwise until
pulley groove is aligned with the timing gear cover
groove.
(d)
Measure the plunger stroke.
Plunger stroke:
1 PZ
0.82-0.88 mm (0.0323-0.0346 in.)
1HZ
1.03-1.09 mm (0.0406-0.0429 in.)
1HD-T
1.29-1.35 mm (0.0508-0.0531 in.)
(e)
Repeat steps (a) to (c) several times.
(f)
Loosen the following nuts and bolt:
(1) (1PZ)
Five union nuts of injection pipes at injection
pump side.
(2) (1HZ)
Six union nuts of injection pipes at injection
pump side.
(3)
(1HD-T)
Five remaining union nuts of injection pipes at
injection pump side.
ENGINE MECHANICAL - Engine Tune-Up
EM-25
(4) Bolt holding injection pump to injection pump
stay.
(5) Two nuts holding injection pump to timing gear
case.
(g) Adjust plunger stroke by slightly tilting the injection
pump body.
If the stroke is less than specification, tilt the pump toward
the engine.
If the stroke is greater than specification, tilt the pump away
from the engine.
(h) Tighten the following nuts and bolt:
(1) Two nuts holding injection pump to timing gear
case.
Torque: 185 kg-cm (13 ft-lb, 18 N m)
(2) Bolt holding injection pump to injection pump
stay.
Torque: 700 kg-cm (51 ft-lb, 69 N m)
• Recheck the plunger stroke.
8.
(w/ ACSD)
REMOVE METAL PLATE
EM-26
ENGINE MECHANICAL - Engine Tune-Up
9.
REMOVE SST AND DIAL INDICATOR
(a) Remove SST and the dial indicator.
SST 09275-54011
(b) Install a new gasket and the plug bolt of the distributive head plug.
Torque:
IPZ and 1HZ 170 kg-cm (12 ft-lb, 17 Nm)
1HD-T
260kg-cm (19 ft-lb, 25 Nm)
10. TORQUE UNION NUTS OF INJECTION PIPES
Torque:
1PZ and 1HZ 150kg-cm (11 ft-lb, 15 Nm)
1HD-T
250kg-cm (18 ft-lb, 25 N-m)
11. (1HD-T w/BACS)
INSTALL AIR CONTROL VALVE (ACV)
12. INSTALL TIMING BELT COVER
(See step 9 on page EM-41)
13. START ENGINE AND CHECK FOR LEAKS
ENGINE MECHANICAL
Engine Tune-Up
EM-27
ADJUSTMENT OF IDLE SPEED AND
MAXIMUM SPEED
1.
INITIAL CONDITIONS
(a) Engine at reach normal operating temperature
(b) Air cleaner installed
(c) All accessories switched OFF
(d) All vacuum lines properly connected
(e) Valve clearance set correctly
(f) Injection timing set correctly
(g) Transmission in N range
2.
CONNECT TACHOMETER
3.
ADJUST IDLE SPEED
(a) Check that the adjusting lever touches the idle speed
adjusting screw when the accelerator pedal is released.
If not, adjust the accelerator linkage.
(b) Start the engine.
(c) Check the idle speed.
Idle speed:
1PZ
600-700 rpm
1HZ M/T
600-700 rpm
1HZ A/T
660-760 rpm
1HD-T M/T 600-700 rpm
1HD-T A/T
750-850 rpm
(d) Adjust the idle speed.
• Disconnect the accelerator linkage.
• Loosen the lock nut of the idle speed adjusting
screw.
• Adjust the idle speed by turning the IDLE SPEED
ADJUSTING SCREW.
Idle speed:
1PZ
650 rpm
1HZ M/T
650 rpm
1HZ A/T
710 rpm
1HD-T M/T 650 rpm
1HD-T A/T 800 rpm
• Securely tighten the lock nut, and recheck the idle
speed.
• Reconnect the accelerator linkage.
• After adjustment, adjust the accelerator linkage.
4.
ADJUST MAXIMUM SPEED
(a) Check that the adjusting lever touches the maximum
speed adjusting screw when the accelerator pedal is
depressed all the way.
If not, adjust the accelerator linkage.
EM-28
ENGINE MECHANICAL
Engine Tune-Up
(b) Start the engine.
(c) Depress the accelerator pedal all the way.
(d) Check the maximum speed.
Maximum speed:
1PZ and 1 HZ 4,500 - 4,700 rpm
1HD-T
4,300-4,500 rpm
(e) Adjust the maximum speed.
• Disconnect the accelerator linkage.
• Cut out the seal wire of the maximum speed adjusting screw.
• (w/ HAC and 1HD-T)
Using SST, loosen the lock nut of the maximum
speed adjusting screw.
SST 09275-54020
• (w/o HAC)
Loosen the lock nut of the maximum speed adjusting screw.
• Adjust the maximum speed by turning the MAXIMUM SPEED ADJUSTING SCREW.
Maximum speed:
1 PZ and 1 HZ 4,600 rpm
1HD-T
4,400 rpm
HINT: Adjust at idle speed. Then, raise engine speed and
recheck the maximum speed.
• (w/ HAC and 1HD-T)
Using SST, securely tighten the lock nut.
SST 09275-54020
• (w/o HAC)
Securely tighten the lock nut.
• Recheck the maximum speed.
• Reconnect the accelerator linkage.
• After adjustment, adjust the accelerator linkage.
• Seal the maximum speed adjusting screw with a
new seal wire.
ENGINE MECHANICAL - Engine Tune-Up
EM-29
ADJUSTMENT OF AIR CONDITIONER IDLE-UP
SETTING SPEED
1.
INITIAL CONDITIONS
(a) Engine at reach normal operating temperature
(b) Air cleaner installed
(c) All vacuum lines properly connected
(d) Valve clearance set correctly
(e) Injection timing set correctly
(f) Transmission in N range
(g) Idle speed set correctly
2.
CONNECT TACHOMETER
3.
ADJUST AIR CONDITIONER IDLE-UP SETTING SPEED
(a) Start the engine.
(b) A/C switches ON.
(c) Disconnect the vacuum hose from the idle-up actuator.
(d) Apply vacuum to the idle-up actuator.
(e) Race the engine to 2,500 rpm for a few seconds,
release the throttle and check the idle-up setting
speed.
A/C idle-up setting speed: 950 rpm
(f)
Adjust the idle-up setting speed by turning the IDLEUP SETTING SPEED ADJUSTING SCREW.
(g) Race the engine to 2,500 rpm for a few seconds,
release the throttle and recheck the A/C idle-up
setting speed.
(h) Reconnect the vacuum hose to the idle-up actuator.
EM-30
ENGINE MECHANICAL
Compression Check
COMPRESSION CHECK
HINT: If there is lack of power, excessive oil consumption
or poor fuel economy, measure the compression pressure.
1.
WARM UP AND STOP ENGINE
Allow the engine to reach normal operating temperature.
2.
DISCONNECT INJECTION PUMP (FUEL CUT
SOLENOID) CONNECTOR
3.
REMOVE GLOW PLUGS
(See step 9 on page EM-57)
4.
CHECK CYLINDER COMPRESSION PRESSURE
(a) Install SST (attachment) to the glow plug hole.
SST 09992-00024 (09992-00160)
(b) Connect SST (compression gauge) to SST (attachment).
SST 09992-00024 (09992-001 60, 09992-00211)
ENGINE MECHANICAL - Compression Check
EM-31
(c) Fully open the throttle valve.
(d) While cranking the engine, measure the compression
pressure.
HINT: Always use a fully charged battery to obtain engine
revolution of 250 rpm or more.
(e) Repeat steps (a) through (d) for each cylinder.
NOTICE: This measurement must be done in as short
a time as possible.
Compression pressure:
IPZ and 1HZ
37.0 kg/cm2 (526 psi, 3,628 kPa) or more
1HD-T
35.0 kg/cm2 (498 psi, 3,432 kPa) or more
Minimum pressure:
IPZ and 1HZ
27.0 kg/cm2 (384 psi, 2,648 kPa) or more
1HD-T
25.0 kg/cm2 (356 psi, 2,452 kpa) or more
Difference between each cylinder:
5.0 kg/cm2 (71 psi, 490 kPa) or less
(f) If the cylinder compression in one or more cylinders is
low, pour a small amount of engine oil into the
cylinder through the glow plug hole and repeat steps
(a) through (d) for the cylinder with low compression.
• If adding oil helps the compression chances are that
the piston rings and/or cylinder bore are worn or
damaged.
• If pressure stays low, a valve may be sticking or
seating improperly, or there may be leakage past the
gasket.
5.
REINSTALL GLOW PLUGS
(See step 11 on page EM-81)
6.
RECONNECT INJECTION PUMP (FUEL CUT
SOLENOID) CONNECTOR
EM-32
ENGINE MECHANICAL - Timing Belt
TIMING BELT
HINT: If replacing the timing belt before the timing belt
warning light comes on, (light comes on after 100,000 km
of driving), be sure to reset the timing belt counter of the
speedometer to zero.
COMPONENTS
ENGINE MECHANICAL - Timing Belt
EM-33
REMOVAL OF TIMING BELT
(See page EM-32)
1.
REMOVE TIMING BELT COVER
Remove the three seal washer, bolts, four clips, timing
belt cover and gasket.
2.
SET NO.1 CYLINDER TO BDC
Turn the crankshaft pulley clockwise, set the No.1 and No.2
camshaft pulley grooves at each position (BDC mark).
HINT: By positioning the No.1 cylinder at BDC, interference between the valve and piston is avoided, even if the
camshaft rotates.
3.
REMOVE TIMING BELT
HINT: If re-using the timing belt, draw a direction arrow
on the timing belt (in direction of engine revolution), and
place matchmarks on the pulleys and timing belt.
(a) Using SST, remove the tension spring.
SST 09717-20010
EM-34
ENGINE MECHANICAL - Timing Belt
(c) Remove the timing belt.
4.
REMOVE TIMING BELT IDLER PULLEY
Using SST, remove the bolt, timing belt idler pulley and
plate.
SST 09923-00020
5.
REMOVE NO.2 CAMSHAFT TIMING PULLEY
(a) Place matchmarks on the camshaft timing pulley No.2
flange and No.2 camshaft timing pulley.
(b) Remove the four bolts, camshaft timing pulley No.2
flange, No.2 camshaft timing pulley and camshaft
timing pulley No.1 flange.
6.
REMOVE INTAKE PIPE
(IPZancMHZ)
(a) Disconnect the PCV hose.
(b) Remove the four bolts, intake pipe and gasket.
(c) (1HZ (Eourope))
Remove the intake pipe insulator.
(1HD-T)
(a) Disconnect the turbo vacuum hose.
(b) Loosen the air hose clamp bolt.
(c) Remove the three bolts, intake pipe and gasket.
ENGINE MECHANICAL
Timing Belt
EM-35
7.
REMOVE CYLINDER HEAD COVER
Remove the twelve bolts (1PZ) or fourteen bolts (1HZ
and 1HD-T), two nuts, cylinder head cover and gasket.
8.
REMOVE NO.1 CAMSHAFT TIMING PULLEY
(a) Hold the hexagonal wrench head portion of the camshaft with a wrench, and remove the No.1 camshaft
timing pulley bolt.
(b) Using SST, remove the No.1 camshaft timing pulley.
SST 09950-20017
(c) Remove the set key.
EM-36
ENGINE MECHANICAL - Timing Belt
INSPECTION OF TIMING BELT COMPONENTS
1.
INSPECT TIMING BELT
NOTICE:
• Do not bend, twist or turn the timing belt inside out.
• Do not allow the timing belt to come into contact
with oil, water or steam.
• Do not utilize timing belt tension when installing or
removing the mount bolt of the camshaft timing
pulley.
If there are any defects as shown in the illustration, check
the following points:
(a)
Premature parting
• Check for proper installation.
• Check the timing belt cover gasket for damage and,
check for proper installation.
(b)
If the belt teeth are cracked or damaged, check to see
if the camshaft is locked.
(c)
If there are cracks or noticeable wear on the belt face,
check to see if there are nicks on one side of the idler
pulley lock.
(d)
If there is wear or damage on only one side of the belt,
check the alignment of the each pulley.
ENGINE MECHANICAL
Timing Belt
EM-37
(e) If there is noticeable wear on the belt teeth, check
timing belt cover for damage and check for correct
gasket installation. Check for foreign material on the
pulley teeth.
If necessary, replace the timing belt.
2.
INSPECT IDLER PULLEY
(a) Check the turning smoothness of the idler pulley.
If necessary, replace the idler pulley.
(b) Check that the idler pulley and the pulley bolt slide
smoothly.
If necessary, replace the idler pulley.
3.
INSPECT TENSION SPRING
(a) Measure the free length of the tension spring.
Free length: 72.7 mm (2.862 in.)
If the free length is not as specified, replace the tension
spring.
(b) Measure the tension of the tension spring at the
specified installed length.
Installed tension:
2 3 - 2 8 kg (50.7-61.7 Ib, 2 2 5 - 2 7 5 Nm)
at 90.1 mm (3.547 in.)
If the installed tension is not as specified, replace the
tension spring.
EM-38
ENGINE MECHANICAL - Timing Belt
INSTALLATION OF TIMING BELT
(See page EM-32)
1.
INSTALL NO.1 CAMSHAFT TIMING PULLEY
(a)
Install the set key to the key groove of the camshaft.
(b)
Align the pulley set key with the key groove of the
No.1 camshaft timing pulley, slide the No.1 camshaft timing pulley.
(c)
Temporarily install the No.1 timing pulley bolt.
(d)
Hold the hexagonal wrench head portion of the camshaft with a wrench, and tighten the No.1 camshaft
timing bolt.
Torque:
2.
1,000 kg-cm (72 ft-lb, 98 Nm)
INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b)
Apply seal packing to the cylinder head as shown in
the illustration.
Seal packing:
3.
Part No.08826-00080 or equivalent
(c)
Install the gasket to the cylinder head cover.
(d)
Install the cylinder head cover with the twelve bolts
(1PZ) or fourteen bolts (1 HZ and 1HD-T) and two
nuts.
INSTALL INTAKE PIPE
(1PZand1HZ)
(a)
(1HZ (Eourope))
Place the intake pipe insulator on the cylinder head
cover.
(b)
Install a new gasket and intake pipe with the four
bolts.
(c)
Connect the PCV hose.
(1HD-T)
(a)
Install a new gasket and intake pipe with the three
bolts.
(b) Connect the air hose and tighten the hose clamp.
(c)
Connect the turbo vacuum hose.
ENGINE MECHANICAL - Timing Belt
4.
EM -39
INSTALL N0.2 CAMSHAFT TIMING PULLEY
(a) Align the knock pin of the injection pump drive gear
with the knock pin hole of the camshaft timing pulley
No.1 flange and cutout portion of the No.2 camshaft
timing pulley.
(b) Align the matchmarks of the No.2 camshaft timing
pulley and camshaft timing pulley No.2 flange, and
install and tighten the four bolts.
Torque: 315 kg-cm (23 ft-lb, 31 N-m)
5.
INSTALL TIMING BELT IDLER PULLEY
Using SST, install the plate and timing belt idler pulley with
the bolt.
SST 09923-00020
Torque: 270 kg-cm (20 ft-lb, 26 N m)
6.
SET NO.1 CYLINDER TO BDC
Set the timing pulleys at each position.
NOTICE: When turning the crankshaft, the valve
heads will hit against the piston top. So do not turn it
more than necessary.
7.
INSTALL TIMING BELT
NOTICE: The engine should be cold.
HINT: If re-using the timing belt, align the points marked
during removal, and install the timing belt with the arrow
pointing in the direction of engine revolution.
EM-40
ENGINE MECHANICAL - Timing Belt
(a) Remove any oil or water on each pulley, and keep
them clean.
(b) Install the timing belt in following order:
(1) No.2 camshaft timing pulley
(2) No.1 camshaft timing pulley
(3) Timing belt idler pulley
(c) Using SST, install the tension spring.
SST 09718-20010
(d) Install and torque the spring bolt of the timing belt
idler.
Torque: 270 kg-cm (20 ft-lb, 26 Nm)
8.
CHECK VALVE TIMING
Turn the crankshaft pulley clockwise and check that each
pulley align with the timing marks (TDC mark) as shown in
the illustration.
If the marks do not align, remove the timing belt and
reinstall it.
ENGINE MECHANICAL - Timing Belt
9.
EM-41
INSTALL TIMING BELT COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the camshaft oil seal retainer
and timing gear cover as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
(c) Install the gasket to the timing belt cover.
(d) Install the timing belt cover with the three seal washers, three bolts and four clips.
EM-42
ENGINE MECHANICAL - Timing Gears
TIMING GEARS
COMPONENTS
ENGINE MECHANICAL - Timing Gears
EM-43
REMOVAL OF TIMING GEARS
(See page EM-42)
1.
REMOVE DRIVE BELT, FAN AND WATER PUMP PULLEY
(See step 2 on page CO-7)
2.
REMOVE TIMING BELT AND PULLEYS
(See page EM-32)
3.
REMOVE CAMSHAFT OIL SEAL RETAINER
(See step 14 on page EM-59)
4.
REMOVE OIL PIPE
5.
6.
(a)
Remove the two union bolts and four gaskets.
(b)
Remove the bolt and oil pipe.
REMOVE VACUUM PUMP
(a)
Remove the two nuts and vacuum pump.
(b)
Remove the O-ring.
(IHZandiHD-T)
REMOVE NO.2 CRANKSHAFT PULLEY
Remove the six bolts and No.2 crankshaft pulley.
7.
REMOVE NO.1 CRANKSHAFT PULLEY
(a)
Using SST, remove the pulley bolt and plate.
SST 0921 3-58011 and 09330-00021
EM-44
ENGINE MECHANICAL - Timing Gears
(b) Using SST, remove the No.1 crankshaft pulley.
SST 09213-60017 (09213-00020, 09213-00030,
09213-00060) and 09950-20017
(c) Remove the O-ring from the No.1 crankshaft pulley.
8.
REMOVE TIMING GEAR COVER
(a) Remove the fourteen bolts.
(b) Pry out the timing gear cover.
9.
CHECK THRUST CLEARANCE OF IDLER GEAR
Using a thickness gauge, measure the thrust clearance.
Standard thrust clearance:
0.05-0.15 mm
(0.0020-0.059 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust plate. If necessary, replace the idler gear and/or idler
gear shaft.
10. REMOVE PUMP DRIVE SHAFT GEAR
Using SST, remove the pump drive shaft gear.
SST 09213-36020 and 09950-20017
ENGINE MECHANICAL - Timing Gears
EM-45
11. REMOVE IDLER GEAR
Remove the two bolts, thrust plate, idler gear and idler gear
shaft.
12. REMOVE INJECTION PUMP DRIVE GEAR
(a) Using SST, remove the injection pump drive gear set
nut.
SST 09330-00021
(b) Remove the O-ring.
(c) Using SST, remove the injection pump drive gear.
SST 09213-60017 (09213-00020, 09213-00030,
09213-00060) and 09950-20017
NOTICE:
• Tighten the two bolts of SST more than 8 mm (0.31
in.)
• Set the SST so that it is balanced.
13. REMOVE CRANKSHAFT TIMING GEAR
Using SST, remove the crankshaft timing gear.
SST 09213-36020 and 09950-20017
EM-46
ENGINE MECHANICAL
Timing Gears
INSPECTION OF TIMING GEARS
1.
INSPECT IDLER GEAR
(a) Using a cylinder gauge, measure the inside diameter
of the idler gear.
Idler gear inside diameter: 45.000-45.025 mm
(1.7717-1.7726 in.)
(b) Using a micrometer, measure the diameter of the idler
gear shaft.
Idler gear shaft diameter: 44.950-44.975 mm
(1.7697-1.7707 in.)
(c) Subtract the idler gear shaft diameter measurement
from the idler gear inside diameter measurement.
Standard oil clearance:
0.025-0.075 mm
(0.0010-0.0030 in.)
Maximum oil clearance: 0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the gear
and shaft.
2.
INSPECT INJECTION PUMP DRIVE GEAR BEARING
Check that bearing is not rough or worn.
3.
IF NECESSARY, REPLACE INJECTION PUMP DRIVE
GEAR BEARING
A.
Remove bearing
Using SST, remove the bearing.
SST 09950-20017
ENGINE MECHANICAL - Timing Gears
EM-47
B.
Install bearing
Using SST and a press, press in a new bearing.
SST 09214-76011
4.
CHECK BACKLASH OF TIMING GEARS
Using a dial indicator, measure the backlash.
Standard gear backlash: 0.05-0.15 mm
(0.0020-0.0060 in.)
Maximum gear backlash: 0.30 mm (0.0118 in.)
If the gear backlash is greater than maximum, replace the
gears as a set.
EM-48
ENGINE MECHANICAL - Timing Gears
REPLACEMENT OF CRANKSHAFT FRONT OIL
SEAL
HINT: There are two methods (A and B) to replace the oil
seal as follows:
REPLACE CRANKSHAFT FRONT OIL SEAL
A.
If timing gear cover is removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the timing gear cover edge.
SST 09223-78010
(c) Apply MP grease to the oil seal lip.
B.
If timing gear cover is installed to the cylinder block:
(a) Using SST, remove the oil seal.
SST 09308-10010 and 09950-20017
(b) Apply MP grease to a new oil seal lip.
(c) Using SST and a hammer, tap in the oil seal until its
surface is flush with the timing gear cover edge.
SST 09223-78010
ENGINE MECHANICAL
Timing Gears
EM-49
REPLACEMENT OF INJECTION PUMP DRIVE
GEAR OIL SEAL
HINT: There are two methods (A and B) to replace the oil
seal as follows:
REPLACE INJECTION PUMP DRIVE GEAR OIL SEAL
A.
If timing gear cover is removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the timing gear cover edge.
SST 09214-76011
(c) Apply MP grease to the oil seal lip.
B.
If timing gear cover is installed to the cylinder block:
(a) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the injection
pump drive gear. Tape the screwdriver tip.
(b) Apply MP grease to the oil seal lip.
(c) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the timing gear cover edge.
SST 09214-76011
EM-50
ENGINE MECHANICAL - Timing Gears
INSTALLATION OF TIMING GEARS
(See page EM-42)
1.
INSTALL CRANKSHAFT TIMING GEAR
(a) Put the timing crankshaft timing gear with the timing
mark facing frontward.
(b) Align the timing gear set key with the key groove of
the timing gear.
(c) Using SST and a hammer, tap in the timing gear.
SST 09223-00010
2.
INSTALL INJECTION PUMP DRIVE GEAR
(a) Install the set key to the groove of the injection pump
drive shaft.
(b) Align the set key with the key groove of the injection
pump drive gear and install the drive gear.
(c) Install a new O-ring to the drive gear.
(d) Install the injection pump drive gear set nut.
(e) Using SST, torque the nut.
SST 09330-00021
Torque: 1,000 kg-cm (72 ft-lb, 98 N-m)
3.
INSTALL IDLER GEAR
(a) Install the idler gear shaft.
(b) Align the idler gear timing marks "0" and " 1 " with the
crankshaft timing gear mark "0" and injection pump
drive gear timing mark " 1 " respectively, and mesh the
gears.
ENGINE MECHANICAL - Timing Gears
EM-51
(c) Align the thrust plate set bolt holes.
(d) Install the thrust plate with the two bolts. Torque the
bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N m)
4.
INSTALL PUMP DRIVE SHAFT GEAR
(a) Align the pump drive shaft gear set key with the key
groove of the drive shaft gear.
(b) Using SST and a hammer, tap in the pump drive shaft
gear.
SST 09223-00010
5.
INSTALL TIMING GEAR COVER
(a) Remove any old packing (FIPG) material and be
careful not to drop any oil on the contact surfaces of
the timing gear cover and cylinder block.
• Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
• Thoroughly clean all components to remove all the
loose material.
• Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the timing gear cover as shown
in the illustration.
Seal packing: Part No.08826-00080 or equivalent
• Install a nozzle that has been cut to a 2 - 3 mm
(0.08-0.12 in.) opening.
• Parts must be assembled within 5 minutes of application. Otherwise the material must be removed
and reapplied.
• Immediately remove nozzle from the tube and reinstall cap.
EM-52
ENGINE MECHANICAL - Timing Gears
(c) Install the timing gear cover with the fourteen bolts.
Torque: 200 kg-cm (14 ft-lb, 20 N m)
6.
INSTALL NO.1 CRANKSHAFT PULLEY
(a) Install a new O-ring in the No.1 crankshaft pulley
groove.
(b) Align the pulley set key with the key groove of the
pulley.
(c) Using SST and a hammer, tap in the pulley.
SST 09214-60010
(d) Using SST, install and torque the plate and bolt.
Torque: 5,000 kg-cm (362 ft-lb, 490 N m)
7.
(1HZand1HD-T)
INSTALL NO.2 CRANKSHAFT PULLEY
Install the No.2 crankshaft pulley with the six bolts.
Torque: 250 kg-cm (18 ft-lb, 25 N-m)
ENGINE MECHANICAL - Timing Gears
8.
EM-53
INSTALL VACUUM PUMP
(a) Install a new O-ring to the vacuum pump.
(b) Install the vacuum pump with the two nuts.
Torque: 400 kg-cm (29 ft-lb, 39 N m )
9.
INSTALL OIL PIPE
Install the oil pipe with the bolt, two union bolts and four
new gaskets.
Torque: Bolt
200 kg-cm (14 ft-lb, 20 Nm)
Union bolt 185 kg-cm (13 ft-lb, 18 Nm)
10. INSTALL CAMSHAFT OIL SEAL RETAINER
(See step 6 on page EM-79)
11. INSTALL PULLEYS AND TIMING BELT
(See page EM -38)
12. INSTALL WATER PUMP PULLEY, FAN AND DRIVE
BELT
(See step 5 on page CO-9)