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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HOW TO USE THIS MANUAL
EXPLANATIONMETHOD
1. Operating procedure
(1) Operating procedures are described using either pattern A or pattern B.
Pattern A: Each step of the operation is explainedwith its own illustration.
Pattern
B: The entire operation is indicated by step numbersin one illustration,followed by cautions, notes,
and "Point Operations".
Example of pattern B
Tightening torque unit -+ T = Nm(kgfcm) [ft.lbfl
The numbers may partially be
omitted in the illustration.
In the case where a part for
which the tightening torque is
specified is not shown in the
illustration, the name of the
part will be listed inside the
illustrationframe.
DisassemblymReassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
PointOperations Explanationof operation
pointwith illustration Operations that have a following explanation
[Point 11
Inspection:
Measurethe backlash.
Standard: 0.05 mm (0.0020 in.)
Reassembly
3
4
[Point 21
No.
1
2
[Point I]
Idlegear No.1
Oil pump
ASSY
Reassemblv: Installthe rotor in the ~ositionshown in the illustration.
DisassemblyItem
Crank pulley
WI set bolt
Timing gear cover
[Point 21
Inspection
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2. How to read component figures
3.
Matters omitted from this manual
(1) This manual omits descriptions of the following jobs, but
perform them in actual operation:
(1) The component figures use the illustration in the parts
(Example)
Parts catalog
f
FIG number
catalog for the vehicle model. Please refer to the catalog
to check the
art name.
(a) Cleaning and washing of removed parts as required
3201
(b) Visual inspection (partiallydescribed)
TERMINOLOGY
Warning:
ltems that may lead to an injury to either the operator or another person, and items and operation points
which, ifnot followed, may lead to an injury or accident.
Caution:
ltemsthat must not be performedbecausedoing sowill result indamage tothe vehicle or it's components,
and itemsinthe operationto which specialattentionshould be paid.
Note:
Supplementalexplanationsfor performingthe operation easily.
Standard: Value showing the allowablerangeininspection or adjustment.
Limit: The maximumor minimumvalue allowed ininspection or adjustment.
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ABBREVIATIONS
Referencesymbol
iH
-H
Originalword
Right Hand
Left Hand
Meaning
Right handside
Left hand side
Front Front
Rear Rear
This refersto the part size used by the makerat the time of assembly
beingthe standard size.
STD Standard
For partsthat do not engagewell anymore due to wear from long use,
or repeateddisassembly, by replacingthe partthat is engaged by a
part of slightly largerdimensions, it's correspondingpartcan be
reused.These partsthat have larger dimensions than STD, and are
referredto as 01s.
As with the OIS parts,by replacingthe engagingpartwith one that has
a smaller hole, it's corresponding part can be reused. These partsthat
have smaller dimensions than STD, and are referredto as UIS.
Over Size
UIS Under Size
After Top DeadCenter
Before Top DeadCenter
ATDC
BTDC After the top deadcenter point of the piston in the cylinder.
Beforethe top dead center point of the piston in the cylinder.
Refersto the intake system.
Refersto the exhaust system.
IN
EX
SST
Intake
Exhaust
Special ServiceTool Special service tool
Torque Tightening torque
ASSY
SUBIASSY
Assembly A partthat consists of two or more single parts or sub-assembledparts
that have been assembled together into an intergratedwhole.
Sub Assembly A part inwhich two or more partsarejoined together by welding,
casting,rivetingetc.
WI
LWR
The following items are attached.
(Example:WIwasher
... With a washer attached)
Lower Lower
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OPERATING TIPS
POINTS FOR WHICH SPECIAL CARE MUST BE TAKEN
1. Always set the engine on an engine stand for carrying out assembly and disassembly of an engine. Never
operate on a workbenchor on the floor as this is dangerous.
2. When handlingand moving the cylinder head ASSY or the cylinder block, always wear gloves and do not use
your bare hands.
GENERAL INSTRUCTIONS
1. Forsafe operation
(1) Wear the correct safety gear (cap, safety goggles, gloves, safety shoes).
(2) To prevent burns,do nottouch the radiator, muffleror exhaust pipedirectly after stopping the engine.
(3) Do not put your clothing or tools near to the rotating partwhen the engine is turning.
(4) When the engine is not on, always havethe engine switch OFF, and removethe starter key.
2. Preparationfor disassembly
(1) Preparegeneral tools, SSTs, measuringinstruments,lubricantand parts that cannot be reused.
(2) Whendisassemblinga complex part,put imprintsand matchmarksin placesthat will not effect the function
of the part in order to facilitate easy reassembly.
3. Preventionof entry of foreign bodies
Foreign bodiessuch as dust, sand and metal pieces insidethe engine cause faults to occur.
(1) Thoroughly remove sand and mud etc. sticking to the engine exterior.
(2) Protectdisassembledparts from dust with a plasticcover or similar.
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4. Prevention of damage to parts
Damageto contact surfaces or rotating partscan cause oil leakage or burning
(1) To disassemble contact surfaces of parts, do not use a screw driver or such, but tap them lightly with a
plastic hammer to separate them.
(2) When clamping parts in a vice, do not clamp them directly in the vice, but betweenaluminum plates.
5. Washing parts
(1) Before reassemblingeach part,wash thoroughly,dry by blowing them with air and apply the specified oil.
(2) Partsthat may not be washed in alkaline chemicals.
Aluminum parts, rubber parts (O-rings etc.)
(3) Partsthat may not bewashed in treated oil (kerosene, non-residue solvent etc.).
Rubber parts (O-rings etc.)
6.
Removaland installationof fuel system parts
(1) Work area for removaland installationof fuel system parts
(a) Work in a well-ventilated area where there are no sparks from surrounding welding equipment,
grinders, drills, electric motors, or stoves.
(b) Do notwork in or near a pit that could fill up with the vapor from evaporated fuel.
(2) Removaland installation of fuel system parts
(a) Prepare a fire extinguisher before beginningwork.
(b) To prevent staticelectricity,attach an earthwire to the fuel changer,vehicle, fuel tank and so forth, and
spread as muchwater on the floor as can be spread without causing slipping.
(c) Do not use electric pumps or working lights as these may give off sparks or become hot.
(d) Do not use a steel hammer as there is a possibility of a spark being generated during use.
(e) Dispose of fuel-soaked waste cloths separately.
7. Positionand orientationwhen reassembling
(1) Reassembleeach partwith the same position and orientation from before it was disassembled.
(2) Reassemble the correct parts in the correct order, keeping to the specified standards (tightening torque,
adjustment values etc.). (Reassemble using the middle value within the range for tightening torque and
adjustment values).
(3) Always use genuine parts for replacements.
(4) Always use new partsfor oil seals, O-rings, gaskets,cotter-pins and so forth.
(5) Before reassembling, apply seal packing for gaskets depending on their place of application, apply the
specified oil or grease to the specified placesfor sliding parts, and apply MP grease to the lip section of oil
seals.
8. Handlinghose clamps
(1) Beforeremoving a hose, check the insertion depth of the hose, and the position of the hose clamp so that
you can definately return them to their original positions.
(2) Replacedeformed or fatigued clampswith new parts.
(3) When reusing the hose, align the new clamp over the mark left on the hose by the previousclamp.
(4) Adapt leaf spring clamps by applying force in the direction of tightening after attachingthem.
9. Adjustment and checking operations
Use a gauge or tester to adjust to the specified service standard.
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10. Disposal of waste fluids
When draining waste fluid from the vehicle, always drain it into an appropriate container.
Careless discharge of oil,fuel, coolant, oilfilter, batteryor other harmfulsubstances may adversely affect human
health and the environment. Always collect and sort them well, and ask specialized companies for appropriate
disposal.
Also, be sure to collect or wipe up spilledwaste fluids.
11. Protection of functional parts
Before connecting the battery terminal after vehicle inspection or maintenance, thoroughly check each
connector for any connection failure or imperfect connection.
Failure to connect, or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers.
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ELECTRICAL PARTS INSPECTION
1. Always disconnect the battery plug before inspectingor servicing electrical parts.
2. Pay sufficient attentionwhen handling electronic parts.
(1) Never subject electronic parts, such as computers and
relays, to impact.
(2) Never expose electronic parts to high temperature or
humidity.
(3) Do not touch connector terminals, as they may be
deformed or damaged due to static electricity.
3. Use a circuit tester that matches the object and purpose of measurement.
Analog type: This type isconvenient for observing movement during operation and the operating condition.The
measuredvalue should be used only for reference or roughjudgement.
Digitaltype: A fairly accurate reading is possible. However, it may be difficultto observevariation or movement.
(1) Difference between results of measurementwith analog and digital types
The results of measurements using the analog type and the digital type may be different.
Use the circuit tester according to its instruction manual.
Differences betweenthe polarities of the analog type and the digital type are described below.
Forward Reverse
I Forward Reverse
(a) Analog circuit tester
Exampleof measurement result
Tester range:
kR range
Forwarddirection: Continuity 11 kR
Reversedirection: No continuity a,
(b) Digitalcircuit tester
Exampleof measurement result
Tester range:
2 MR range
Forwarddirection: Continuity 2 MR
Reversedirection: No continuity 1
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(2) Differences in results of measurementwith circuit testers
Forward voltage (v I
The circuit tester power supply voltage depends on the
tester type:
1.5 V, 3.0 V and 6.0 V.
The resistanceof a semiconductorsuch as a diode varies
with the circuit tester power supply voltage.
Diode characteristics are shown in the figure to the left.
The resistance values of the same diode measured with
two types of circuit testers having different power supply
voltages are different.
This manual describes the results of measurement with
an analog circuit tester with a power supply voltage of 3.0
v.
(3) Differences in results of measurement by measurementrange.
3
Variable resistor
0
G
Resistor
i,ay
Voltage: 1.5V
lo
"6
Red
3
Black
In the analog type circuit tester, changing the
measurement range switches over the internal circuit to
vary the circuit resistance. Even when the same diode is
measured, the measurement result varies according to
the measurement range.
Always use the range described in the repair manual for
measurement.
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BOLT & NUT TIGHTENING TORQUES
Standard Bolt & NutTightening 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.
1. 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.
2. Judge the tightening torque for the hexagonflange bolt based on the threading diameter.
3. The nut tightening torque can be judged from its corresponding bolt type by using procedure 1.
BOLT STRENGTH CLASS IDENTIFICATION METHODAND
TIGHTENING TORQUE
Identification by Actual Part
Hexagon head bolt
(standardbearing
surface)
Welded bolt
Stud bolt
Shape and Strength class
@
Number in reliefor hallmark on head
0
No mark
8
Boltwith two raised lines on head
0
Boltwith three raised lines on head
8
Boltwith four raised lines on head
No mark
About
2 mm (0.08 in.) groove@)on onelboth edge(@
Strengthclass
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Identificationby Part No.
TY pe I Part NO
Shape
Nominal
diameter
I
Hexagon bolt
Nominal length
_I
91611-40625
Nomtnal length (mm)
Nominaldiameter (mm)
Strengthclass
92132-40614
Nommallength (rnm)
Nominaldiameter (mm)
Strengthclass
Nominal
diameter
Stud bolt
Tightening Torque Table
Nominal diameter
mm Pitch
mm
Strengthclass Standard tighteningtorque
N.m kgfcm ft.lbf
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