Toyota 4Y 2006 User manual

This repairmanualexplainsthe repairpointsof the4Y modelengine equippedon the
Toyota Forklift Trucks.
Pleasemake good use of this manualfor your technical service.
This repair manual contains the latest information available as of August
2006. For
any changes thereafter, Toyota reserves the right to make such changes in
specifications and descriptionswithout incurring any obligation andwithout previous
notice.
TOYOTA MaterialHandlingCompany
A Division of TOYOTA INDXTRIES CORPORATION
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SECTION INDEX
1 NAME 1 SECTION
I
GENERAL0 0
TROUBLESHOOTING
ENGINE OVERHAUL (4Y-M)
ENGINE OVERHAUL (4Y-E)
FUEL SYSTEM (4Y-M)
FUEL SYSTEM (4Y-E)
PCV DEVICE
COOLING
SS
LUBRICATIONSYSTEM
IGNITION SYSTEM (4Y-M)
IGNITION SYSTEM (4Y-E)
STARTING SYSTEM
CHARGING SYSTEM
APPENDIX
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GENERAL
SPECIFICATIONS ............................................ 0-2
................................. ENGINE EXTERIORVIEW 0-3
.............................. ENGINE SECTIONALVIEW 0-5
........................... HOW TO USE THIS MANUAL 0-7
EXPLANATION METHOD .......................................... 0-7
TERMINOLOGY .......................................................... 0-8
ABBREVIATIONS ....................................................... 0-9
........................................... OPERATINGTIPS 0-10
POINTS FOR WHICH SPECIAL CARE
MUST BE TAKEN
.................................................. 0-10
GENERAL INSTRUCTIONS ..................................... 0-10
........................ ELECTRICAL PARTS INSPECTION 0-13
.......... BOLT & NUT TIGHTENING TORQUES 0-15
BOLT STRENGTH CLASS IDENTIFICATION
................ METHODAND TIGHTENINGTORQUE 0-15
PRECOATED BOLTS (BOLTS WITH SEAL
....
LOCKAGENT COATING ON THREADS) 0-18
SI UNITS
........................................................... 0-18
............
HANDLING FlPG (LIQUID GASKETS) 0-19
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SPECIFICATIONS
Engine model*
1 Type I Gasoline I t
Number and arrangement of cylinders
Cycle
lnline4 cylinder,
longitudinally mounted
I Ignition order
4
t
I Combustion chambertype
I I
Wedge type
Start up method
I Valve mechanism
1 OHV chain drive I
Self starting type t
I Total displacement cc (cu-in)
I
I I
t
Borex stroke mm (in.)
Compression ratio
Compression pressure kPa (kgf/cm2)[psi]/rpm
91.0
x 86.0 (3.58 x 3.39)
I
Minimum fuel consumption when fully loaded g1PS.h (rpm)
I
Engine dimensions (length x width x height)
8.8
1226 (12.5) [I7811250
Referto repair manualfor
each vehicle model
No-load maximumspeed
rpm
Idlespeed
rpm
t
t
1 Weight kg (Ib) /
Referto repair manual for
each vehicle model
Referto repair manual for
each vehicle model
mm (in.)
t
t
709x525~733
(27.9
x 20.7 x 28.9)
Numberof piston rings
-
Valve clearance
709x 513x 733
(27.9
x 20.2 x 28.9)
Intakevalve open/close interval
Exhaustvalve openlclose interval
Compression rings
Oil ring
Open
Close
Open
Close
mm (in.)
*: Inthis manualthe enginewith mechanicalfuel injectionfitted is referredto as 4Y-M, while the one with electronic
fuel injectionfitted is referredto as
4Y-E.
2
1
Blow-by gas reductortype
t
t
BTDC 12"
ABDC 40"
BBDC 54"
ATDC 6"
Intake
.
Exhaust
t
t
t
t
Closed type
0 (Automatic adjusting type)
0 (Automatic adjustingtype)
t
t
t
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ENGINE EXTERIOR VIEW
4Y-M
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4Y-E (OPT)
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ENGINE SECTIONAL VIEW
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