Toyota 1C Operating instructions

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 
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 
 
  
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

IN-2 INTRODUCTION - How to Use This Manual
oaPump
DrivePulley
(@
Re~elva...;e---- ----
Spring __ ___ ___ _ ____.
HOW TO USE THIS MANUAL
To assist in finding your way through this manual, the Section
Title and major heading are given at the top of every page.
An INDEX is provided on the 1st page of each section to guide
you to the item to be repaired.
At the beginning of each section, PRECAUT IONS are given
that pertain to aff repair operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING tables are included for each system to
help you diagnose the system problem and find the cause. The
repair for each possible cause is referenced in the remedy col-
umn to quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit
together. ·
Example:
0-Ring
Drive Rotor
Driven Rotor
a
@-Gasket
RehefValv<fPlug
......
INTRODUCTION - How to Use This Manual IN-3
Illustration:
what to do and where
The procedures are presented in a step-by-step format :-
• The illustration shows what to do and where to do it
• The task heading tells what to do.
• The detailed text tells how to perform the task and gives
other information such as specifications and warnings.
Example:
.___.--Task heading: what to do
IN STAL L FLYW HEEL _.--
Using SST and a press, press out the bushing.
SST 09222-64010 (09222-02020, 09222-02040)
I I
Set part No. Components part NO.
Tighte n the bolls to the specified torque in two or three passes
and in the sequence shown. \
Torque: 900 kg -cm (65 ft -lb, 88 N·ml
\ Detail text:
Specification how to do it
This format provides the experienced technician with in FAST
TRACK to the information needed. He can read the task head-
ings and only refer to the detailed text when he needs it. Impor-
tant specifica tions and warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. However. when they
are required you are given the page to go to .
SPECIFICATIONS
Specifications are presented in bold type throughout the text in
the applicable step . You never have to leave the procedure to
look up your specs. All specifications are also found in Appen-
dix A. Specifications . for quick reference .
WARNINGS . CAUTIONS. NOTES :
• WARNINGS are presented in bold type, and indicate there is
a possibility of injury to you or other people .
• CAUTIONS are also presented In bold type, and indicate
there is a possibility of damage to the components being
repaired.
• NOTES ar·e separated from the text but do not appear in
bold . They provide additional information to more efficiently
help you perform the repair.

IN-2 INTRODUCTION - How to Use This Manual
oaPump
DrivePulley
(@
Re~elva...;e---- ----
Spring __ ___ ___ _ ____.
HOW TO USE THIS MANUAL
To assist in finding your way through this manual, the Section
Title and major heading are given at the top of every page.
An INDEX is provided on the 1st page of each section to guide
you to the item to be repaired.
At the beginning of each section, PRECAUT IONS are given
that pertain to aff repair operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING tables are included for each system to
help you diagnose the system problem and find the cause. The
repair for each possible cause is referenced in the remedy col-
umn to quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit
together. ·
Example:
0-Ring
Drive Rotor
Driven Rotor
a
@-Gasket
RehefValv<fPlug
......
INTRODUCTION - How to Use This Manual IN-3
Illustration:
what to do and where
The procedures are presented in a step-by-step format :-
• The illustration shows what to do and where to do it
• The task heading tells what to do.
• The detailed text tells how to perform the task and gives
other information such as specifications and warnings.
Example:
.___.--Task heading: what to do
IN STAL L FLYW HEEL _.--
Using SST and a press, press out the bushing.
SST 09222-64010 (09222-02020, 09222-02040)
I I
Set part No. Components part NO.
Tighte n the bolls to the specified torque in two or three passes
and in the sequence shown. \
Torque: 900 kg -cm (65 ft -lb, 88 N·ml
\ Detail text:
Specification how to do it
This format provides the experienced technician with in FAST
TRACK to the information needed. He can read the task head-
ings and only refer to the detailed text when he needs it. Impor-
tant specifica ti ons and warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. However. when they
are required you are given the page to go to .
SPECIFICATIONS
Specifications are presented in bold type throughout the text in
the applicable step . You never have to leave the procedure to
look up your specs. All specifications are also found in Appen-
dix A. Specifications . for quick reference .
WARNINGS . CAUTIONS. NOTES :
• WARNINGS are presented in bold type, and indicate there is
a possibility of injury to you or other people .
• CAUTIONS are also presented In bold type, and indicate
there is a possibility of damage to the components being
repaired.
• NOTES ar·e separated from the text but do not appear in
bold . They provide additional information to more efficiently
help you perform the repair.

IN-4 INTROD UCTION - Identification Information, General Repair Instructions
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left side of the
cylinder block.
GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and floor covers to keep the vehicle clean
and prevent damage.
2. During disassembly, keep parts in order to facilitate
reassembly.
3. Observe the following :
(al Before performing electrical work, disconnect the
negative cable from the battery terminal.
(b) If it is necessary to disconnect the battery for inspec•
tion or repair, always disconnect the cable from the
negative (-1 terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight up
without twisting or prying it
(d) Clean the battery terminal posts and cable terminals
with a shop rag . Do not scrape them with a file or
other abrasive object
(e) Install the cable terminal to the battery po st with the
nut loose, and tighten the nut af t er installation . Do
not use a hammer to tap the terminal onto the post
(f) Be sure lhe cover for the positive (+) terminal is pro-
perly in place.
4 . Check hose and wiring connectors to make sure that they
are secure and correct .
5. Always replace cotte r pins gaskets and 0-rings with new
ones.
6. When necessary, use sealer on gaskets to prevent leaks.
7. Carefully observe all specifications for bolt tightening tor-
ques. Always use a torque wrench .
8. Use ot special service tools (SST! may be required ,
depending on the nature of the repair. Be sure to use SST
where specified and follow the proper work procedure . A
list of SST can be found at the back of this manual.
9 . When replacing fuses, be sure the new fuse ls the correct
amperage. 00 NOT exceed the fuse amp rating or use one
of a lower rating .
10 . Care must be taken when jacking up and suppo rt ing the
vehicle. Be sure to lift and support the vehicle at the
proper locations .
(al If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(bl After the vehicle is jacked up, be sure to support it on
stands . It is extremely dangerous to do any work on
the vehicle raised 011Jack alone, ,iven for a small job
that can be r,n,shou quickly
INTRODUCT ION - General Repair Instructions IN-6
11. Observe the following precautions to avoid damage to the
parts:
(a) To disconnect vacuum hoses, pull on the end, not the
middle of the hose.
(b) To pull apart electrical connectors, pull on the con-
nector itself. not the wires.
(cl Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on a hard floor,
they should be replaced and not reused.
(d) When steam cleaning an engine. protect the air filter
and injection pump fr om water .
(e) Never use an impact wrench to remove or install ther-
mo switches or thermo sensors.
(f) When check ing continuity at the wire connector,
insert the tester probe carefully to prevent term inals
from bendinp.
(gl When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step-down
adapter instead. Once the hose has been stretched, it
may leak. ·
12. After removing and reinstalling the injection pump and fuel
hoses, clean off the fuel on engine components. In par-
ticular, be sure to check the radiator hose and by-pass
hose, because deterioration occurs easily if they come into
contact with fue l.

IN-4 INTROD UCTION - Identification Information, General Repair Instructions
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left side of the
cylinder block.
GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and floor covers to keep the vehicle clean
and prevent damage.
2. During disassembly, keep parts in order to facilitate
reassembly.
3. Observe the following :
(al Before performing electrical work, disconnect the
negative cable from the battery terminal.
(b) If it is necessary to disconnect the battery for inspec•
tion or repair, always disconnect the cable from the
negative (-1 terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight up
without twisting or prying it
(d) Clean the battery terminal posts and cable terminals
with a shop rag . Do not scrape them with a file or
other abrasive object
(e) Install the cable terminal to the battery po st with the
nut loose, and tighten the nut af t er installation . Do
not use a hammer to tap the terminal onto the post
(f) Be sure lhe cover for the positive (+) terminal is pro-
perly in place.
4 . Check hose and wiring connectors to make sure that they
are secure and correct .
5. Always replace cotte r pins gaskets and 0-rings with new
ones.
6. When necessary, use sealer on gaskets to prevent leaks.
7. Carefully observe all specifications for bolt tightening tor-
ques. Always use a torque wrench .
8. Use ot special service tools (SST! may be required ,
depending on the nature of the repair. Be sure to use SST
where specified and follow the proper work procedure . A
list of SST can be found at the back of this manual.
9 . When replacing fuses, be sure the new fuse ls the correct
amperage. 00 NOT exceed the fuse amp rating or use one
of a lower rating .
10 . Care must be taken when jacking up and suppo rt ing the
vehicle. Be sure to lift and support the vehicle at the
proper locations .
(al If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(bl After the vehicle is jacked up, be sure to support it on
stands . It is extremely dangerous to do any work on
the vehicle raised 011Jack alone, ,iven for a small job
that can be r,n,shou quickly
INTRODUCT ION - General Repair Instructions IN-6
11. Observe the following precautions to avoid damage to the
parts:
(a) To disconnect vacuum hoses, pull on the end, not the
middle of the hose.
(b) To pull apart electrical connectors, pull on the con-
nector itself. not the wires.
(cl Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on a hard floor,
they should be replaced and not reused.
(d) When steam cleaning an engine. protect the air filter
and injection pump fr om water .
(e) Never use an impact wrench to remove or install ther-
mo switches or thermo sensors.
(f) When check ing continuity at the wire connector,
insert the tester probe carefully to prevent term inals
from bendinp.
(gl When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step-down
adapter instead. Once the hose has been stretched, it
may leak. ·
12. After removing and reinstalling the injection pump and fuel
hoses, clean off the fuel on engine components. In par-
ticular, be sure to check the radiator hose and by-pass
hose, because deterioration occurs easily if they come into
contact with fue l.

IN-6 INTRODUCTION - Abb reviations Used in This Manual
ABBREVIATIONS USED IN THIS MANUAL
A/C Air Conditioner
A/T Automatic Transmission
BDC Bottom Dead Center
BTDC Before Top Dead Center
EX Ellhaust
FF Front Engine Front Drive
FR Front Engine Rear Drive
HAC High Altitude Compensator
IN Intake
LH Left- hand
LHD Left- hand Drive
MP Multipu rpose
OPT Option
0/ S Oversize
PCV Positive Crankcase Ventilation
PS Power Steering
RH Right-hand
RHO Right- hand Drive
SST Special Service Tool
STD Standard
TDC Top Dead Center
U/ S Undersize
w / With
w/ o Without
ENGINE MECHANICAL
DIESEL ENGINE DIAGNOSIS .. . ....•..... . .....
DIESEL ELECTRICAL SYSTEM DIAGNOSIS ....•
TURBOCHARGER DIAGNO SIS .. . .... . .. . ..... .
TURBOCHARGER ELECTRICAL SYSTEM
DIAGNOSIS • . .••••••.•• . . .. •••••• . ••. . •• • • .
ENGINE TUNE - UP ••••.••••.• • •••.•••••• • •••••
COMPRESSION CHECK .................. .. .. .
TIMING BELT ••• . • . •.•.•••.•.•.••••••••• •• •••
TURBOCHARGER •••••••••• . •. .. •. . ••• . •••••••
CYLINDER HEAD ..... .. ......... . ........... .
CYLINDER BLOCK .• • . • •.••••.•.••..•••.••••. .
EM- 1
Page
EM -2
EM -10
EM -13
EM -15
EM -16
EM -25
EM -26
EM -38
EM-46
EM -70

IN-6 INTRODUCTION - Abb reviations Used in This Manual
ABBREVIATIONS USED IN THIS MANUAL
A/C Air Conditioner
A/T Automatic Transmission
BDC Bottom Dead Center
BTDC Before Top Dead Center
EX Ellhaust
FF Front Engine Front Drive
FR Front Engine Rear Drive
HAC High Altitude Compensator
IN Intake
LH Left- hand
LHD Left- hand Drive
MP Multipu rpose
OPT Option
0/ S Oversize
PCV Positive Crankcase Ventilation
PS Power Steering
RH Right-hand
RHO Right- hand Drive
SST Special Service Tool
STD Standard
TDC Top Dead Center
U/ S Undersize
w / With
w/ o Without
ENGINE MECHANICAL
DIESEL ENGINE DIAGNOSIS .. . ....•..... . .....
DIESEL ELECTRICAL SYSTEM DIAGNOSIS ....•
TURBOCHARGER DIAGNO SIS .. . .... . .. . ..... .
TURBOCHARGER ELECTRICAL SYSTEM
DIAGNOSIS • . .••••••.•• . . .. •••••• . ••. . •• • • .
ENGINE TUNE - UP ••••.••••.• • •••.•••••• • •••••
COMPRESSION CHECK .................. .. .. .
TIMING BELT ••• . • . •.•.•••.•.•.••••••••• •• •••
TURBOCHARGER •••••••••• . •. .. •. . ••• . •••••••
CYLINDER HEAD ..... .. ......... . ........... .
CYLINDER BLOCK .• • . • •.••••.•.••..•••.••••. .
EM- 1
Page
EM -2
EM -10
EM -13
EM -15
EM -16
EM -25
EM -26
EM -38
EM-46
EM -70

EM-2 ENGINEMECHANICAL-Diesel Engine Diagnosis
DIESEL ENGINE DIAGNOSIS
GENERAL
Diesel engine problems are usually caused by the engine or fuel system . The injection pump ls very rarely the
cause of fuel system problems.
Before beginning fuel system tests, first check that the engine compression, valve timing and other major
systems are within specification. ·
PRELIMINARY CHECKS
(8) Before performing fuel system checks, insure that the engine Is in good running condition . If necessary,
first check the compression, timing and major components or systems.
(bl Check the air filter and clean or rep lace it if necessary.
(cl Confirm that there is sufficient fuel in the tank.
(d) Check if the fuel is contaminated with gasoline or other foreign elements . Only good-quality diesel fuel
should be used.
le) Bleed air from th e sys tem by pumping the priming pump 30 - 40 ti~.
(f) Check for water in the fuel filter and fuel tank and drain as necessary .
(g) If the engine will not crank or if it cranks slowly, first troubleshoot the electrical system .
ENGINE MECHANICAL - Diesel Engine Diagnosis EM -3
DIAGNOSIS
PRECAUTION:
1. The basic troubleshooting procedures for the diesel engine itself (valve clearance, compressio11. bear-
ings, valves, pistons. etc.} are the same checks you would make for a gasoline eng ine.
2. The repair of the Injection poo,p requires considerableskiU and use of a special test bench.
1. LOOSEORCORRODED
BATTERYCABLES
2. DISCHARGEDBATTERY
ENGINE WILL NOT CRANK
(Chec k Procedure and Correction Method)
Check cables from battery to st~er and matte
necessary repairs.
Check a.ltemator output and the drive belt
Repair as necessary . (See page CH-4)
I3. INOPERATIVE START ER :1--- --........j Check for battery voltage at starter termina ls 30 and
50.
If Okay, see STARTING SYSTEM, page
(ST-11 or 12) for repair procedure .
ENGINE CRANKS SLOWLY-WILL NOT START
(Possi b le Cause)
1. LOOSE OR CORRODED
BATTERY CABLES
NOTE: Minimum cranking speed: 100 rpm Cold
150 rpm Hot
(Check Procedure and CorTectlon Method)
L..:2::..._: D:,:l::_SC=-:_H=A::.:R::G::E::D~B::A:..:TT.::..:..:E::R.:_Y:._J-----7 Refer to items 1 and 2 of ENGINEWILL NOT CRANK.
I 3. IMPROPERENGINEOIL 1 1------ Check engine oil.
If improper viscosity, drain and refill with oil of
viscosity recommended by manufacturer. (See page
LU-3)

EM-2 ENGINEMECHANICAL-Diesel Engine Diagnosis
DIESEL ENGINE DIAGNOSIS
GENERAL
Diesel engine problems are usually caused by the engine or fuel system . The injection pump ls very rarely the
cause of fuel system problems.
Before beginning fuel system tests, first check that the engine compression, valve timing and other major
systems are within specification. ·
PRELIMINARY CHECKS
(8) Before performing fuel system checks, insure that the engine Is in good running condition . If necessary,
first check the compression, timing and major components or systems.
(bl Check the air filter and clean or rep lace it if necessary.
(cl Confirm that there is sufficient fuel in the tank.
(d) Check if the fuel is contaminated with gasoline or other foreign elements . Only good-quality diesel fuel
should be used.
le) Bleed air from th e sys tem by pumping the priming pump 30 - 40 ti~.
(f) Check for water in the fuel filter and fuel tank and drain as necessary .
(g) If the engine will not crank or if it cranks slowly, first troubleshoot the electrical system .
ENGINE MECHANICAL - Diesel Engine Diagnosis EM -3
DIAGNOSIS
PRECAUTION:
1. The basic troubleshooting procedures for the diesel engine itself (valve clearance, compressio11. bear-
ings, valves, pistons. etc.} are the same checks you would make for a gasoline eng ine.
2. The repair of the Injection poo,p requires considerableskiU and use of a special test bench.
1. LOOSEORCORRODED
BATTERYCABLES
2. DISCHARGEDBATTERY
ENGINE WILL NOT CRANK
(Chec k Procedure and Correction Method)
Check cables from battery to st~er and matte
necessary repairs.
Check a.ltemator output and the drive belt
Repair as necessary . (See page CH-4)
I3. INOPERATIVE START ER :1--- --........j Check for battery voltage at starter termina ls 30 and
50.
If Okay, see STARTING SYSTEM, page
(ST-11 or 12) for repair procedure .
ENGINE CRANKS SLOWLY-WILL NOT START
(Possi b le Cause)
1. LOOSE OR CORRODED
BATTERY CABLES
NOTE: Minimum cranking speed: 100 rpm Cold
150 rpm Hot
(Check Procedure and CorTectlon Method)
L..:2::..._: D:,:l::_SC=-:_H=A::.:R::G::E::D~B::A:..:TT.::..:..:E::R.:_Y:._J-----7 Refer to items 1 and 2 of ENGINEWILL NOT CRANK.
I 3. IMPROPERENGINEOIL 1 1------ Check engine oil.
If improper viscosity, drain and refill with oil of
viscosity recommended by manufacturer. (See page
LU-3)

EM-4 ENGINE MECHANICAL - Diesel Engine D
iagnosis
ENGINE CRANKS NORMALLY BUT WIL L NOT START ,
(Possible Cause)
1. NO FUEL TO NOZZLE HOLDER
2. NO FUEL CUT SOLENO ID
OPERATION
3. NO FUEL INTO INJECT ION
PUMP
4. INOPERATIVE PRE-HEATING
OPERATION
5. FAULTY GLOW PLUG
OPERATION
6. FUEL LEAKAGE FROM
INJECTION PIPE
{Check Proc edura and Correction M ethod)
jection pipe union nut from it s
loosen any one in
nozzle holder .
Crank the engine f
ing that fuel is be
or about 5 seconds while conf1m1-
ing discharged from the pipe.
ut, begin diagnosis from item 4 .
If fuel is coming o
If not begin from item 2.
h turned ON, chec k for fuel cut
With starter switc
solenoid operation
repeatedly conn ec
so lenoid .
noise (clic king sound) while
ting and disconnecting fuel cut
If no noise, check
solenoid when the
if there is battery voltag e to the
starte r swi tc h is ON.
Is confirme d , fuel cu t solenoid is
If battery voltage
faulty and should
ELECTRICAL DIA
be replaced. If no voltage, refer to
repairs.
GNOSIS and make necessary
oses to fu el filter and feed clean
Disconnect in let h
fuel from separat
e containe r directly into pump.
ilher the fue l filler or line between
If engine starts, e
fuel tank and rilte
accord ingly .
r is clogged and should be repaired
s not start (no fuel intake), check
If engine still doe
fuel line between filt er and pump.
s faulty and should be replaced.
If normal . pump i
NOTE: W hen f
keep conta in er a
eeding fuel direct ly into pump,
t s ame level as vehic le fuel tank.
ch ON and the glow plug indicator
With starter swit
lamp illuminated,
to the glo w plugs
check that th ere is voltage applied
CTRICAL DIAGNOSIS and repair as
If not. refer to ELE
necessary.
continuity (See page ST-61.
Check glow plug
If no continuity. a
plug should be re
broken wire Is indicated and glow
placed .
unions or cracks .
Check for loose
If leaking, tighten
replace pipe (sl.
to specified torque or. if necessary,
-
1 7.
I 1 8.
1 9.
,,
I
'
11,
12 .
1 3.
ENGINE MECHANICAL -Diesel Engine Diagnosis EM -5
I
IMPROPER INJECTION Tum crankshaft pulley clockwise to where either
TIMING J No.1 or No . 4 piston is at TDC and, after releasing
co ld start advance system (CM), check plunger
stroke with SST. (See page EM-20)
SST 09276-64010
Plun ge r stroke: CV 0 .67 - 0.73 mm
10 .0264 - 0 .0287 in.I
Others O.77 - 0.83 mm
(0.0303 - 0 .0327 In.I
If not within specification, inject ion pump is
imp roperly adjusted.
NOTE : If cranks haft pulley is off more than 1 0°.
i t could ind icate a Jump ed tim ing belt.
IMPROPER COLD START I Measure timer piston stroke and fast idle lever )
ADVANCE A ND FA ST IDLE I opening angle with injection pump tester when
cold sta rt advance Is operated.
Check nozzle with nozzle tester . (See page FU-6)
FAULTY NOZZLE OR I
NOZZLE HOLDER I Opening pressure: 135 -155 kg/cm•
(1,920 -2.205 psi)
(13,239 -15 ,200 kPa)
If not within specification, nozzle adjustment
is improper and pressure should be readjusted .
If pressure cannot be adjusted to speci fi cation,
replace nozzle holder assembly. (See page FU-8)
ROUGH IDLE WITH WARM ENGINE
(Possib le Cause) (Check Procedure and Correction M ethod)
IMPROPER ADJUSTMENT OF I With accelerator pedal released, check that adjust ing
ACCELERATOR CABLE I lever is in contact with idle screw. Also check if
accelerato r cable is catc hing on somet hing .
If necessary, adjust so lever is in contac t with screw.
or make other required repairs .
Check the idle speed as specified below. (See page
IDLE SPEED TOO LOW I EM-23)
J
Idl e spee d : 750 - 850 rpm
If not, adjust with idle adjus ting screw.
NOTE : If le ss than spec ifi e d, idling would
normally be rough.
FUEL LEAKAGE I Check for leaks at the pump connectiol)s. pump
J distributive head bolts. nozzle holder and
delivery valve.
Tighten any loose connec tion s to specified
torque or replace parts as necessary.

EM-4 ENGINE MECHANICAL - Diesel Engine D
iagnosis
ENGINE CRANKS NORMALLY BUT WIL L NOT START ,
(Possible Cause)
1. NO FUEL TO NOZZLE HOLDER
2. NO FUEL CUT SOLENO ID
OPERATION
3. NO FUEL INTO INJECT ION
PUMP
4. INOPERATIVE PRE-HEATING
OPERATION
5. FAULTY GLOW PLUG
OPERATION
6. FUEL LEAKAGE FROM
INJECTION PIPE
{Check Proc edura and Correction M ethod)
jection pipe union nut from it s
loosen any one in
nozzle holder .
Crank the engine f
ing that fuel is be
or about 5 seconds while conf1m1-
ing discharged from the pipe.
ut, begin diagnosis from item 4 .
If fuel is coming o
If not begin from item 2.
h turned ON, chec k for fuel cut
With starter switc
solenoid operation
repeatedly conn ec
so lenoid .
noise (clic king sound) while
ting and disconnecting fuel cut
If no noise, check
solenoid when the
if there is battery voltag e to the
starte r swi tc h is ON.
Is confirme d , fuel cu t solenoid is
If battery voltage
faulty and should
ELECTRICAL DIA
be replaced. If no voltage, refer to
repairs.
GNOSIS and make necessary
oses to fu el filter and feed clean
Disconnect in let h
fuel from separat
e containe r directly into pump.
ilher the fue l filler or line between
If engine starts, e
fuel tank and rilte
accord ingly .
r is clogged and should be repaired
s not start (no fuel intake), check
If engine still doe
fuel line between filt er and pump.
s faulty and should be replaced.
If normal . pump i
NOTE: W hen f
keep conta in er a
eeding fuel direct ly into pump,
t s ame level as vehic le fuel tank.
ch ON and the glow plug indicator
With starter swit
lamp illuminated,
to the glo w plugs
check that th ere is voltage applied
CTRICAL DIAGNOSIS and repair as
If not. refer to ELE
necessary.
continuity (See page ST-61.
Check glow plug
If no continuity. a
plug should be re
broken wire Is indicated and glow
placed .
unions or cracks .
Check for loose
If leaking, tighten
replace pipe (sl.
to specified torque or. if necessary,
-
1 7.
I 1 8.
1 9.
,,
I
'
11,
12 .
1 3.
ENGINE MECHANICAL -Diesel Engine Diagnosis EM -5
I
IMPROPER INJECTION Tum crankshaft pulley clockwise to where either
TIMING J No.1 or No . 4 piston is at TDC and, after releasing
co ld start advance system (CM), check plunger
stroke with SST. (See page EM-20)
SST 09276-64010
Plun ge r stroke: CV 0 .67 - 0.73 mm
10 .0264 - 0 .0287 in.I
Others O.77 - 0.83 mm
(0.0303 - 0 .0327 In.I
If not within specification, inject ion pump is
imp roperly adjusted.
NOTE : If cranks haft pulley is off more than 1 0°.
i t could ind icate a Jump ed tim ing belt.
IMPROPER COLD START I Measure timer piston stroke and fast idle lever )
ADVANCE A ND FA ST IDLE I opening angle with injection pump tester when
cold sta rt advance Is operated.
Check nozzle with nozzle tester . (See page FU-6)
FAULTY NOZZLE OR I
NOZZLE HOLDER I Opening pressure: 135 -155 kg/cm•
(1,920 -2.205 psi)
(13,239 -15 ,200 kPa)
If not within specification, nozzle adjustment
is improper and pressure should be readjusted .
If pressure cannot be adjusted to speci fi cation,
replace nozzle holder assembly. (See page FU-8)
ROUGH IDLE WITH WARM ENGINE
(Possib le Cause) (Check Procedure and Correction M ethod)
IMPROPER ADJUSTMENT OF I With accelerator pedal released, check that adjust ing
ACCELERATOR CABLE I lever is in contact with idle screw. Also check if
accelerato r cable is catc hing on somet h ing .
If necessary, adjust so lever is in contac t with screw.
or make other required repairs .
Check the idle speed as specified below. (See page
IDLE SPEED TOO LOW I EM-23)
J
Idl e spee d : 750 - 850 rpm
If not, adjust with idle adjus ting screw.
NOTE : If le ss than spec ifi e d, idling would
normally be rough.
FUEL LEAKAGE I Check for leaks at the pump connectiol)s. pump
J distributive head bolts. nozzle holder and
delivery valve.
Tighten any loose connec tion s to specified
torque or replace parts as necessary.

EM-6 ENGINE MECHANICAL - Diesel Engine Diagnosis
4. IMPROPERINJECTION
TIMING
5. IMPROPEROPERATIONOF
NOZZLEORDELIVERYVALVE
Refer to item 7 of ENGINECRANKS NORMALLY
BUT Will NOT START, above.
With engine idling, loosen th e injection pipe to .
each cylinder in order. and check if the idle speed
changes .
If no change, a faulty cylind er is indicated.
Check according to following procedure .
• Faulty Nozzle or Nozzle Holder
Check nozzle with nozzle tester . (See page FU- 6)
Opening presure: 135 -155 kg/cm' -
11,92 0 -2 ,2 05 psi)
(13,239 -15,200 kPal
If pressure is not within specification . l'\OZZle
is faulty and -injection -pressure shou ld be
readjusted . (See page FU-8)
• Faulty Delivery Valve
If injection pressure is within specification , delivery
valve is defectiv e and should be replaced.
ENGINE SUDDENLY STOPS
(Poaible Cause)
1. ENGINEWILLNOTRE-START
2. ROUGH IDLE
3. MALFUNCTION OF FUEL-CUT
SOLENOID
4 . NO FUEL INTO INJECTION
PUMP
(Check Procedure and Correction M ethod)
Check to see if engine re-starts according to
prescribed procedure.
If not refer to ENGINE CRANKS NORMALLY BUT
WIL L NOT START. above, and repair as necessary.
If idle is not stable, refer to ROUGH IDLE WITH
WARM ENGINE and repair accordingly .
Refer to ENGINECRANKS NORMALLY BUT Will
NOT START. above. and chec k accord ingly.
NOTE : No operation noise from the fuel cut
solenoid may be due to loose electrical
connect ions, so check connectors before
Pf'OCHdlng with further repair s.
Ref!lf . to item 3 of ENGINECRANKS NORMALLY
BUT WILL NOT START, above.
ENGINE MECHANICAL - Diesel Engine Diagnosis EM-7
LACK OF POWER
NOTE:
1. First confirm that the air c leaner Is no t clogge d or t he engine ove rhe ating . . .
2. Not eppllceble If the cuetomer desires an output p0wer higher than specifi ed for tha t vehicle .
For eocureoy, edJuet with • chassis dynamo.
........c.u.,
IMPIIOPIII ACCILERATOR
GAIi.i ADJUITMENT
(Check Procedure end Correction Method)
11--- --i With accelerator fully depressed, check that
I adjusting lever Is in contact with maximum speed set
screw . (See page EM-23)
If not adjust accordingly .
I
:a. INSUFFICIENT I Start engine. depre ss accelerator pedal to floor end
MAXIMUM SPEED ,1-- -----i check that maximun speed is as speci fi ed below .
'---""""'"""';;.;.;.;.=.c.:_.c..---- - --~ (See page EM- 23)
, INTIRCHANGEDOVERFLOW
ICM W (OUT) AND INLET (NO
MAIIKIFITTING
M aximum speed : CV 5,100 -5,200 rpm
Others 5 ,300 - 5,400 rpm
If not. adjust with maximum speed adjusting screw .
NOTE : Overflow screw Is marked " OUT" end
t----l has an Inner jet. Although both fitting s ere same
size. they must not be Interchanged.
1-- -- --l Refer to item 3 of ROUGH IDLE WITH WARM
PUILLIAKAGE
'-------- --- -__J ENGINE.
II , CLOGGEDFUEL FILTER ' 1 1-----< Disconnect inlet hose to fuel filter and feed clean
'----------- -- ---' 1 fuel directly into the pump .
If engine cond ition improves , fu el filter 'is clogged
and should be replaced. (See page FU-2)
NOTE : When fee ding fuel direct ly Into pump,
keep container at same leve l ea vehicle fuel
tank.
If no increase in engine conditi o n after replacing
fuel fitter, check priming pump or perform other
necessaryrepairs.
I. INJICfflONTIMING1---- -i Refer to item 7 of ENGINECRANKS NORMALLY
7. PAUL TY NOZZLIOIi NOzal
HOLDER
BUT Will NOT START.
1------l Refer to item 9 of ENGINECRANKS NORMALLY
BUT WILL NOT START.

EM-6 ENGINE MECHANICAL - Diesel Engine Diagnosis
4. IMPROPERINJECTION
TIMING
5. IMPROPEROPERATIONOF
NOZZLEORDELIVERYVALVE
Refer to item 7 of ENGINECRANKS NORMALLY
BUT Will NOT START, above.
With engine idling, loosen th e injection pipe to .
each cylinder in order. and check if the idle speed
changes .
If no change, a faulty cylind er is indicated.
Check according to following procedure .
• Faulty Nozzle or Nozzle Holder
Check nozzle with nozzle tester . (See page FU- 6)
Opening presure: 135 -155 kg/cm' -
11,92 0 -2 ,2 05 psi)
(13,239 -15,200 kPal
If pressure is not within specification . l'\OZZle
is faulty and -injection -pressure shou ld be
readjusted . (See page FU-8)
• Faulty Delivery Valve
If injection pressure is within specification , delivery
valve is defectiv e and should be replaced.
ENGINE SUDDENLY STOPS
(Poaible Cause)
1. ENGINEWILLNOTRE-START
2. ROUGH IDLE
3. MALFUNCTION OF FUEL-CUT
SOLENOID
4 . NO FUEL INTO INJECTION
PUMP
(Check Procedure and Correction M ethod)
Check to see if engine re-starts according to
prescribed procedure.
If not refer to ENGINE CRANKS NORMALLY BUT
WIL L NOT START. above, and repair as necessary.
If idle is not stable, refer to ROUGH IDLE WITH
WARM ENGINE and repair accordingly .
Refer to ENGINECRANKS NORMALLY BUT Will
NOT START. above. and chec k accord ingly.
NOTE : No operation noise from the fuel cut
solenoid may be due to loose electrical
connect ions, so check connectors before
Pf'OCHdlng with further repair s.
Ref!lf . to item 3 of ENGINECRANKS NORMALLY
BUT WILL NOT START, above.
ENGINE MECHANICAL - Diesel Engine Diagnosis EM-7
LACK OF POWER
NOTE:
1. First confirm that the air c leaner Is no t clogge d or t he engine ove rhe ating . . .
2. Not eppllceble If the cuetomer desires an output p0wer higher than specifi ed for tha t vehicle .
For eocureoy, edJuet with • chassis dynamo.
........c.u.,
IMPIIOPIII ACCILERATOR
GAIi.i ADJUITMENT
(Check Procedure end Correction Method)
11--- --i With accelerator fully depressed, check that
I adjusting lever Is in contact with maximum speed set
screw . (See page EM-23)
If not adjust accordingly .
I
:a. INSUFFICIENT I Start engine. depre ss accelerator pedal to floor end
MAXIMUM SPEED ,1-- -----i check that maximun speed is as speci fi ed below .
'---""""'"""';;.;.;.;.=.c.:_.c..---- - --~ (See page EM- 23)
, INTIRCHANGEDOVERFLOW
ICM W (OUT) AND INLET (NO
MAIIKIFITTING
M aximum speed : CV 5,100 -5,200 rpm
Others 5 ,300 - 5,400 rpm
If not. adjust with maximum speed adjusting screw .
NOTE : Overflow screw Is marked " OUT" end
t----l has an Inner jet. Although both fitting s ere same
size. they must not be Interchanged.
1-- -- --l Refer to item 3 of ROUGH IDLE WITH WARM
PUILLIAKAGE
'-------- --- -__J ENGINE.
II , CLOGGEDFUEL FILTER ' 1 1-----< Disconnect inlet hose to fuel filter and feed clean
'----------- -- ---' 1 fuel directly into the pump .
If engine cond ition improves , fu el filter 'is clogged
and should be replaced. (See page FU-2)
NOTE : When fee ding fuel direct ly Into pump,
keep container at same leve l ea vehicle fuel
tank.
If no increase in engine conditi o n after replacing
fuel fitter, check priming pump or perform other
necessaryrepairs.
I. INJICfflONTIMING1---- -i Refer to item 7 of ENGINECRANKS NORMALLY
7. PAUL TY NOZZLIOIi NOzal
HOLDER
BUT Will NOT START.
1------l Refer to item 9 of ENGINECRANKS NORMALLY
BUT WILL NOT START.

EM -8 ENGINE MECHANICAL - Diesel Engine Diagnosis
EXCESSIVE EXHAUST SMOKE
NOTE:
1. Confirm that the air cleaner I• not clogged.
2. Confirm l(Yith the c ustomer whethe r or not oil consumption has be en excessiv e.
1Possible Cause) (Check Proced~e and Correction Method)
j 1. · IMPROPER INJECTI ON TIMING 1 1-----l Refer to item 7 of ENGINECRANKS NORMALLY
BUT WILL NOT START.
I2. CLOGGED FUEL Fil TER I
13. FAULTY NOZZLE OR NOZZLE 11-- - --l
HOLDER I
NOTE : Bla ck smok e indicates advance d ti ming
while white smoke~••• retsded timing.
Adjustmenu 1hould be made accordingly.
Refer to item 5 of LACK OF POWER.
NOTE : At h igh ..,aed 12.000 - 3,000 rpm), a
clogged filter tendl to make the exhault
smoke white .
Refer to item 9 of ENGINECRANKS NORMALLY
BUT Will NOT START.
NOTE : Excessive exhaust smoke is ofte n
caused by nozzle pressure being too low .
EXCESSIVE FUEL CONSUMPTION
NOTE : Confirm whether clutch sli pping . brak es grabbing, tires wrong size or air filter clogged.
(Possible Cause) (Check Procedure and Correction Method)
1. FUEL LEAKAGE ,____ __. Refer to item 3 of ROUGH IDLE WITH WAAM
~- -- - ----------' ENGINE.
j 2. IDLE SPEED TOO HIGH
I3. MAXIMUMSPEEDTOO HIGH I,__ _ _ _,
After sufficiently warming up engine, check that
idle speed ls as specified below. (See page EM-23)
Idle speed: 750 - 850 rpm
If not, adjust with idle adjusting screw.
Start engine, depress accelerator pedal to floor
and check that maximum speed is as specified
below. (See page EM-23)
Maximum speed: CV 5, 100 - 5,200 rpm
Others 5,300 - 5,400 rpm
If not. adjust with maximum speed adjus ting screw
4 . IMPROPERINJECTIO N TIMING 1-- ---1 Refer to item 7 of ENGINECRANKSNORMALLY
BUT WILL NOT START .
5. FAULTY NOZZLE OR NOZZLE
HOLDER
Refer to item 9 of ENGINECRANKS NORMALLY
BUT Will NOT START
ENGINEMECHANICAL - EngiM Diagnosis EM-t
ENGINE NOISE WHEN WARM
(Clanking Noise with Exces sive Vibration)
IPONlblec.-) (Check Procedure and Correction Method)
COOLANTTIMPIIIATUMTOO I Check coolant temperature with coolant
LOW 11-----1 temperature gauge.
3. PAULTY NOZZLE OR NOZZLE
HOlO£R
If not suffic iently warm. thermostat It faulty and
should be replaced .
1-----t Refer to item 9 of ENGINECRANKS NORMAll Y
BUT Will NOT START.
ENGINE WILL NOT RETURN TO IDLE
...... c-.,
f IINDINCIACCILIRATORCABLE
(Check Procedure and Correction Method)
•1-------1 Operate adjusting lever on top of injection pump
1 and check if engine retwns to idle. (Seepage EM-23)
If so. accelerator cable is binding or impropertv
adjusted and should be repaired accordingly.
If engine does not return to idle. injection pump is
faulty and should be replaced.
ENGINE WILL NOT SHUT OFF WITH KEY
....... C.U..I (Check Procedure and Correction M ethod)
Disconnect connector on top of fuel cut solenoid and
,____ check if engine sto·ps..
.., __________ _, If so, starter switch is faulty and should be repaired
as necessary or replaced.
If engine does not stop, eithef" fuel cut solenoid is
faulty or there is interference by foreign particles.
Repair as necessary.

EM -8 ENGINE MECHANICAL - Diesel Engine Diagnosis
EXCESSIVE EXHAUST SMOKE
NOTE:
1. Confirm that the air cleaner I• not clogged.
2. Confirm l(Yith the c ustomer whethe r or not oil consumption has be en excessiv e.
1Possible Cause) (Check Proced~e and Correction Method)
j 1. · IMPROPER INJECTI ON TIMING 1 1-----l Refer to item 7 of ENGINECRANKS NORMALLY
BUT WILL NOT START.
I2. CLOGGED FUEL Fil TER I
13. FAULTY NOZZLE OR NOZZLE 11-- - --l
HOLDER I
NOTE : Bla ck smok e indicates advance d ti ming
while white smoke~••• retsded timing.
Adjustmenu 1hould be made accordingly.
Refer to item 5 of LACK OF POWER.
NOTE : At h igh ..,aed 12.000 - 3,000 rpm), a
clogged filter tendl to make the exhault
smoke white .
Refer to item 9 of ENGINECRANKS NORMALLY
BUT Will NOT START.
NOTE : Excessive exhaust smoke is ofte n
caused by nozzle pressure being too low .
EXCESSIVE FUEL CONSUMPTION
NOTE : Confirm whether clutch sli pping . brak es grabbing, tires wrong size or air filter clogged.
(Possible Cause) (Check Procedure and Correction Method)
1. FUEL LEAKAGE ,____ __. Refer to item 3 of ROUGH IDLE WITH WAAM
~- -- - ----------' ENGINE.
j 2. IDLE SPEED TOO HIGH
I3. MAXIMUMSPEEDTOO HIGH I,__ _ _ _,
After sufficiently warming up engine, check that
idle speed ls as specified below. (See page EM-23)
Idle speed: 750 - 850 rpm
If not, adjust with idle adjusting screw.
Start engine, depress accelerator pedal to floor
and check that maximum speed is as specified
below. (See page EM-23)
Maximum speed: CV 5, 100 - 5,200 rpm
Others 5,300 - 5,400 rpm
If not. adjust with maximum speed adjus ting screw
4 . IMPROPERINJECTIO N TIMING 1-- ---1 Refer to item 7 of ENGINECRANKSNORMALLY
BUT WILL NOT START .
5. FAULTY NOZZLE OR NOZZLE
HOLDER
Refer to item 9 of ENGINECRANKS NORMALLY
BUT Will NOT START
ENGINEMECHANICAL - EngiM Diagnosis EM-t
ENGINE NOISE WHEN WARM
(Clanking Noise with Exces sive Vibration)
IPONlblec.-) (Check Procedure and Correction Method)
COOLANTTIMPIIIATUMTOO I Check coolant temperature with coolant
LOW 11-----1 temperature gauge.
3. PAULTY NOZZLE OR NOZZLE
HOlO£R
If not suffic iently warm. thermostat It faulty and
should be replaced .
1-----t Refer to item 9 of ENGINECRANKS NORMAll Y
BUT Will NOT START.
ENGINE WILL NOT RETURN TO IDLE
...... c-.,
f IINDINCIACCILIRATORCABLE
(Check Procedure and Correction Method)
•1-------1 Operate adjusting lever on top of injection pump
1 and check if engine retwns to idle. (Seepage EM-23)
If so. accelerator cable is binding or impropertv
adjusted and should be repaired accordingly.
If engine does not return to idle. injection pump is
faulty and should be replaced.
ENGINE WILL NOT SHUT OFF WITH KEY
....... C.U..I (Check Procedure and Correction M ethod)
Disconnect connector on top of fuel cut solenoid and
,____ check if engine sto·ps..
.., __________ _, If so, starter switch is faulty and should be repaired
as necessary or replaced.
If engine does not stop, eithef" fuel cut solenoid is
faulty or there is interference by foreign particles.
Repair as necessary.

EM - 10 ENG IN E MEC HA NI CAL - Diesel Electrical System Diagnosis
DIESEL ELECTRICAL SYSTEM DIAGNOSIS
ENGINE DOES NOT START COLD
NOTE: 1. Battery voltage at leut 12 vo lts - stai-ter switch OFF.
2. Engi ne cran k s norma ll y . •
3. Fusib le link okay.
4 . For voltage martced with an asterisk. che ck Just as starter is turned ON because
vo l tage changes with elapse of time .
1. Sup er Glow· Sys te m
YES Check if Indicator light llghts up Wl\h starter
switch ON
Coolant temp. at 20'C IH ' FI : 2 - 4 ,eca .
Starter swi tch OFF. I
°Check for battery voltage to
terminal 2 of pr.. heating
tinMt with starter switch ON.
INo Voltage
"Check that there is 02 -1.0V
between terminals3 and 9.
If faulty. repair glow plug current
sensor.
Fuse ()I(
I Check indicator
light bulb.
Bulb OK
I
NO
Check fuse ISeePllll4I
ST-21
Fuse Blown
Check for short
circuit and repair
if necessary.
Bulb No Good
I AeplKe bulb.
II okay. timer is faulty and should
be replaced.
Chedt for battery voltage 10 terminal 7 of
pre-heat,ng lllnef connec tor Ionwire "-rness Sldel.
II okay. pr&-heabng timer Is faulty and should be
replaced.
Voltage
·check if voltage to tonninal 2 of pre-
heating timer is terminated after engine
is started.
YES
::.tart the engine and check if there is
voltege at terminal 4 of pre-heating
timer
If faulty. repair chargin g system as
I necessary.
Starter switch OFF.
,....____ _,
1
,......_ _ _ _, :.:~timeris faulty and should be
CONTINUED ON PAGE EM-11
Pre- heating Timer
Ex . CM
123105 4 1
For CM
_r~
9 753 I
ENGINE MECHANICAL -Diesel Electrical System Diagnosis .EM-11
CONTINUED FROM PAGE EM- 10
•pi.c;e tlM* ... ,1th e t ON .....
cheek If -""" IICw.IO lelminlll
I of tlll!llf .. In llf1'Jl!ldlNI<•
With I O(lito1t tt1n,111t•t1•• No Voltage
Pre-hea ting Duration I•Ouite
Different Than That Above
·• g,.i, o,, 1•1;18GI /I
,,., ... roo1,pl91l<>nOI pre-
h .. lM,O.theck tor voltage
at l• rmlnal 8 ogaln
when starter swi tch is
~• t ST
....... tw itch Off
......
I
tt••• tWll<ll at ON
No Voltege
rimerls faulty
and should be
replaced.
rimerIs faulty and
sho uld be replaced.
-
l..cli fol' 11<1ltoge10 glow
1141111
,...
,_ ~ond1 i. tw .
Tl,..n
1111)1)
It« . volt• should
.iiou, 1/2 .
OK
IIMW""Ill"~(UII INIUlty I
l,™HMMMV I:rn11l,~ty
Oluw
nby ...l a........ ,...,t.,
..... • huukl ...
...
I
Disconnect water tempeAture sensor
(left rear of engine) and check If
pre-heating dlntion is about 70 or 130
seconds or. if connector is
grounded. there is no continuity .
If okay, water temperature sensor
is faulty and should be replaced.
If not. timer is faulty and should
be replaced
No V oltage at An
·chec k tor battery voltilge at positive side of glow plug
current sensor (Resister sldel.
If okay, replace sensor.
II no voltage. No. 1 glow plug relay is faulty and
should be replaced.
!For component Inspection, SH page ST-2J
No 1/2 Voltage
Thereafter
·checkfor balle,y voltage to plus side of resistor
(Intake mani f old side).
If okay, replace resistor .
II no No. 2 gloW plug relay Is faulty
1nd should be replaced.

EM - 10 ENG IN E MEC HA NI CAL - Diesel Electrical System Diagnosis
DIESEL ELECTRICAL SYSTEM DIAGNOSIS
ENGINE DOES NOT START COLD
NOTE: 1. Battery voltage at leut 12 vo lts - stai-ter switch OFF.
2. Engi ne cran k s norma ll y . •
3. Fusib le link okay.
4 . For voltage martced with an asterisk. che ck Just as starter is turned ON because
vo l tage changes with elapse of time .
1. Sup er Glow· Sys te m
YES Check if Indicator light llghts up Wl\h starter
switch ON
Coolant temp. at 20'C IH ' FI : 2 - 4 ,eca .
Starter swi tch OFF. I
°Check for battery voltage to
terminal 2 of pr.. heating
tinMt with starter switch ON.
INo Voltage
"Check that there is 02 -1.0V
between terminals3 and 9.
If faulty. repair glow plug current
sensor.
Fuse ()I(
I Check indicator
light bulb.
Bulb OK
I
NO
Check fuse ISeePllll4I
ST-21
Fuse Blown
Check for short
circuit and repair
if necessary.
Bulb No Good
I AeplKe bulb.
II okay. timer is faulty and should
be replaced.
Chedt for battery voltage 10 terminal 7 of
pre-heat,ng lllnef connec tor Ionwire "-rness Sldel.
II okay. pr&-heabng timer Is faulty and should be
replaced.
Voltage
·check if voltage to tonninal 2 of pre-
heating timer is terminated after engine
is started.
YES
::.tart the engine and check if there is
voltege at terminal 4 of pre-heating
timer
If faulty. repair chargin g system as
I necessary.
Starter switch OFF.
,....____ _,
1
,......_ _ _ _, :.:~timeris faulty and should be
CONTINUED ON PAGE EM-11
Pre- heating Timer
Ex . CM
123105 4 1
For CM
_r~
9 753 I
ENGINE MECHANICAL -Diesel Electrical System Diagnosis .EM-11
CONTINUED FROM PAGE EM- 10
•pi.c;e tlM* ... ,1th e t ON .....
cheek If -""" IICw.IO lelminlll
I of tlll!llf .. In llf1'Jl!ldlNI<•
With I O(lito1t tt1n,111t•t1•• No Voltage
Pre-hea ting Duration I•Ouite
Different Than That Above
·• g,.i, o,, 1•1;18GI /I
,,., ... roo1,pl91l<>nOI pre-
h .. lM,O.theck tor voltage
at l• rmlnal 8 ogaln
when starter swi tch is
~• t ST
....... tw itch Off
......
I
tt••• tWll<ll at ON
No Voltege
rimerls faulty
and should be
replaced.
rimerIs faulty and
sho uld be replaced.
-
l..cli fol' 11<1ltoge10 glow
1141111
,...
,_ ~ond1 i. tw .
Tl,..n
1111)1)
It« . volt• should
.iiou, 1/2 .
OK
IIMW""Ill"~(UII INIUlty I
l,™HMMMV I:rn11l,~ty
Oluw
nby ...l a........ ,...,t.,
..... • huukl ...
...
I
Disconnect water tempeAture sensor
(left rear of engine) and check If
pre-heating dlntion is about 70 or 130
seconds or. if connector is
grounded. there is no continuity .
If okay, water temperature sensor
is faulty and should be replaced.
If not. timer is faulty and should
be replaced
No V oltage at An
·chec k tor battery voltilge at positive side of glow plug
current sensor (Resister sldel.
If okay, replace sensor.
II no voltage. No. 1 glow plug relay is faulty and
should be replaced.
!For component Inspection, SH page ST-2J
No 1/2 Voltage
Thereafter
·checkfor balle,y voltage to plus side of resistor
(Intake mani f old side).
If okay, replace resistor .
II no No. 2 gloW plug relay Is faulty
1nd should be replaced.

EM - 12 ENGINE MECHANICAL -Diesel Electrical -System Diagnosis
2. Fuel Cut Solenoid
With starter switch ON, check for fuel
cut solenoid operationnoise lcrockingsound)
while repeatedlyconnecting and .
<f,sconoectingfuel cut solenoid.
Noise No Noise
I Fuelcut solenoidokay. I ri Check fuse (Seepage }
ST-21.
FuseOK FuseBlown
Apply battery voltage Check for short
I12 voltsl di-ectly to circuit and repair
solenoidand check as necessary.
for noise.
Noise No Noise
Checkwire harness I Replacefuel cut I
from fuse (See
page ST-2 to fuel solenoid .
cut solenoid. ,
ENGINE MECHANICAL -Turbocharger Diagnosis EM-13
TURBOCHARGER DIAGNOSIS
INS~FFICIENT ACCELERATION, LACK OF POWER OR
EXCESSIVE FUEL CONSUMPTION
NOTE : Before ~oubleshooting the turbocharger, first check the valve clearance,
injectio ~ timing, etc.
(Possible Cau~l (Check Procedure and Correction Method)
1
1. INSUFFICIENT iU RBOCHARGING l-rrcheck turbocharging pressure (See page EM-39).
1.__.:..P.:..R=E=S.:.S=U.:..R=E_.......,-- ----- ---' If not within the standard shown below,
2. RESTRICTED 1NfAKE AIR SYSTEM
3. LEAK IN INTAKE AIR SYSTEM
4 . RESTRICTED E;,(HAUST SYSTEM
5. LEAK IN EXHAilS T SYS TEM
begin diagnosis from item 2.
Standard pressure : 0.54 - 0.68 kg/e ms
(7 .7 - 9.7 ps i, 53 - 67 kPal
Check intake air system. and repai r or
replace par1s as necessary. (See page EM-39)
Check intake air system. and repair or
replace par1Sas necessary. (See page EM-39)
Check exhaust system. and repair or replace
par1s as necessary. (See page EM-39)
Check exhaust system, and repair or replace
parts as necessary. (See page EM- 39)
I6. RELIEF VALVE ~EAKING I- Check for excessive oil oozing around outside
L_ __ _ __ ..:...:..~ - ----- ----' of relief valve.
If not. relief valve okay . If excessive oozing, check
performance of relief valve and replace if necessary.
'-
J 7. ERRATIC TURBOCHARGER OPERATION Check rota1ion of impeller wheel. If It does no1 turn
or turns with heavy drag, replace the turbocharger
assembly .
Check axial play of bearing shalt If not within limits.
replace the turbocharger assembly .
Standard clearance: 0 . 13 mm (0.005 1 in.I or less

EM - 12 ENGINE MECHANICAL -Diesel Electrical -System Diagnosis
2. Fuel Cut Solenoid
With starter switch ON, check for fuel
cut solenoid operationnoise lcrockingsound)
while repeatedlyconnecting and .
<f,sconoectingfuel cut solenoid.
Noise No Noise
I Fuelcut solenoidokay. I ri Check fuse (Seepage }
ST-21.
FuseOK FuseBlown
Apply battery voltage Check for short
I12 voltsl di-ectly to circuit and repair
solenoidand check as necessary.
for noise.
Noise No Noise
Checkwire harness I Replacefuel cut I
from fuse (See
page ST-2 to fuel solenoid .
cut solenoid. ,
ENGINE MECHANICAL -Turbocharger Diagnosis EM-13
TURBOCHARGER DIAGNOSIS
INS~FFICIENT ACCELERATION, LACK OF POWER OR
EXCESSIVE FUEL CONSUMPTION
NOTE : Before ~oubleshooting the turbocharger, first check the valve clearance,
injectio ~ timing, etc.
(Possible Cau~l (Check Procedure and Correction Method)
1
1. INSUFFICIENT iU RBOCHARGING l-rrcheck turbocharging pressure (See page EM-39).
1.__.:..P.:..R=E=S.:.S=U.:..R=E_.......,-- ----- ---' If not within the standard shown below,
2. RESTRICTED 1NfAKE AIR SYSTEM
3. LEAK IN INTAKE AIR SYSTEM
4 . RESTRICTED E;,(HAUST SYSTEM
5. LEAK IN EXHAilS T SYS TEM
begin diagnosis from item 2.
Standard pressure : 0.54 - 0.68 kg/e ms
(7 .7 - 9.7 ps i, 53 - 67 kPal
Check intake air system. and repai r or
replace par1s as necessary. (See page EM-39)
Check intake air system. and repair or
replace par1Sas necessary. (See page EM-39)
Check exhaust system. and repair or replace
par1s as necessary. (See page EM-39)
Check exhaust system, and repair or replace
parts as necessary. (See page EM- 39)
I6. RELIEF VALVE ~EAKING I- Check for excessive oil oozing around outside
L_ __ _ __ ..:...:..~ - ----- ----' of relief valve.
If not. relief valve okay . If excessive oozing, check
performance of relief valve and replace if necessary.
'-
J 7. ERRATIC TURBOCHARGER OPERATION Check rota1ion of impeller wheel. If It does no1 turn
or turns with heavy drag, replace the turbocharger
assembly .
Check axial play of bearing shalt If not within limits.
replace the turbocharger assembly .
Standard clearance: 0 . 13 mm (0.005 1 in.I or less

EM -14 ENGINE MECHANICAL - Turbocharger Diagnosis
ABNORMAL NOISE
(Possible ·eause)
1. TURBO INSULATOR RESONNANCE
2. EXHAUST PIPE LEAKING OR
VIBRATING
3. ERRATIC TURBOCHARGER OPERATION
(Check Procedu re and Correction Method)
Check for loose, improperly installed or deformed
insulator mount bolts, and repair or repliice
as necessary.
Check for deformed exhaust pipe, loose mo unt bolts
or damaged gasket, and repair or replace as neces-
sary.
Refer to item 7 of INSUFFICIENTACCELERATION,
LACK OF POWER OR EXCESSIVEFUEL
CONSUMPTION.
EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST
(Possi ble Cause)
FAULTY TURBOCHARGER SEAL
(Check Procedure and Correctio n Method )
Check for oil leakage in exhaust system
• Remove the turbine elbow from the turbocharger
and check for excessive carbon deposits on the
turbine wheel. Excessive carbon deposits would
indicate a faulty turbocharger.
Check for oil leakage in intake air syster,1.
• Check for axial play in impeller wheel, and replace
the turbocharger if necessary.
(See page EM-43) .
CAUTION: There is some oil mist from the
PCV in the blowby gas so care must t,e taken
not to diagnosis th is as an o il leakage from
the turbocharger.
ENGINE MECHANICAL - Turbocharger Electrical System Diagnosis E.M- 15
TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS
Troubleshooting of Turbocharger Indicator Light and Warning Light Operation
Do both green indic ator light and amber NO
warning lig ht light when ignition switch
is turned to ON?
YES
Are indicator and warning lights out during
engine idle?
Bot h lights stay on
Check GAUGE fuse
OK
Check CHG and
IGN fuse
OK
Is disc arge warning
light out?
YES
Faulty combination
meter
Is discharge warning NO Faulty charging
systemlight out?
Green light stays on
Check for open circuit in wire harness between
low pressure sw itc h and combination meter .
Amber light comes on
Check for open circuit in wire harness between high pressure switch
and combination meter and check for ground connection of switch.
YES
Does green indica tor light come on when
0.14 kg/ cm ! (2.0 psi, 14 kPal pressure is
applied to both pressure switches 7
NO
Check fo r short circuit in wire harness between low
pressure switch and combination meter.
Amber light comes on
Does green indica tor light come on when 0 .73 kg/cm 1
(10.4 psi. 72 kPal pressure applied to both switches?
Blown Check for short
and repair as
necessary
Check fo r short
Blown and repair as
necessary
NO Faulty charging
system
OK Faulty low pressure
switc h
OK Faulty high pressure
switch
OK Faulty low pressure
switch
NO Faulty high pressure
swi tch
YES
Does amber indicator light come on when 0 .73 kg/c m•
(10.4 psi. 72 kPa) pressure applied to both switches?
YES .Faulty combination
meter
YES
NO
Check for short circuit in wire harness between high
pressure switch and combination meter.
Turbocharger indicator and warn ing light
operation okay.
Faulty high pressure
switch