Engine(1).pdf

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ENGINE

Page

Page

0

ENGINE EXTERIOR VIEW ............. 1-2

ENGINE MAIN PARAMETERS ....... 1-5

ENGINE PERFORMANCE

CURVES........................................ 1-7

ENGINE ASSY .............................. 1-10

REMOVAL·INSTALLATION .............. 1-10

AIR BLEEDING OF THE FUEL

SYSTEM...................................... 1-13

ENGINE

INSPECTION·ADJUSTMENT ..... 1-14

4Y ENGINE .................................... 1-14

1DZ-III·3Z ENGINE .......................... 1-15

AIR CLEANER .............................. 1-17

SPECIFICATIONS ........................... 1-17

COMPONENTS .............................. 1-17

AIR CLEANER

CLEANING·INSPECTION ............... 1-18

CLOGGING WARNING SYSTEM

INSPECTION (OPT) ...................... 1-19

RADIATOR .................................... 1-20

COMPONENTS .............................. 1-20

SPECIFICATIONS ........................... 1-24

COOLANT CAPACITY AND

ANTIFREEZE TABLE .................... 1-24

COOLANT INSPECTION .................. 1-24

MUFFLER & EXHAUST PIPE....... 1-26

COMPONENTS .............................. 1-26

REMOVAL·INSTALLATION .............. 1-29

MAINTENANCE OF CATALYTIC

MUFFLERS .................................. 1-29

BATTERY ...................................... 1-30

COMPONENTS .............................. 1-30

SPECIFICATIONS ........................... 1-31

INSPECTION .................................. 1-32

FAN BELT TENSION

ADJUSTMENT ............................ 1-33

ACCELERATOR PEDAL .............. 1-35

COMPONENTS .............................. 1-35

INSPECTION·ADJUSTMENT ............ 1-36

D2 PEDAL (OPT) .......................... 1-38

COMPONENTS ............................... 1-38

DISASSEMBLY·INSPECTION·

REASSEMBLY ............................. 1-39

ADJUSTMENT ................................ 1-41

TRAVEL AND LOAD HANDLING

CONTROL DEVICE(OPT)........... 1-43

COMPONENTS ............................... 1-43

REMOVAL·INSTALLATION ............... 1-44

THROTTLE OPENING DEGREE

ADJUSTMENT .............................. 1-46

TROUBLESHOOTING ..................... 1-47

DPF-II SYSTEM (OPT) .................. 1-49

COMPONENTS ............................... 1-49

CONNECTOR DIAGRAM ................. 1-53

DPF MUFFLER

REMOVAL·INSTALLATION ............ 1-55

DPF MUFFLER DISASSEMBLY·

INSPECTION·REASSEMBLY .......... 1-56

CONTROLLER

REMOVAL·INSTALLATION ............ 1-58

BLOWER

REMOVAL·INSTALLATION ............ 1-59

DPF VALVE

REMOVAL·INSTALLATION ............ 1-60

DPF VALVE DISASSEMBLY·

INSPECTION·REASSEMBLY .......... 1-61

INDIVIDUAL INSPECTION OF

FUNCTIONAL PARTS ................... 1-62

CONTROLLER ERROR CODE

CLEARING METHOD .................... 1-66

DPF FILTER MEMORY

CLEARING METHOD .................... 1-66

REGENERATION METHOD .............. 1-66

DISPLAY OF PAST

ERROR CODES ............................ 1-67

CLEARING OF PAST

ERROR CODES ............................ 1-68

TROUBLESHOOTING ..................... 1-69

ENGINE CONTROLLER ASSY .... 1-94

ENGINE ECU (4Y) OR ASC

CONTROLLOER (1DZ-lll·3Z:OPT)

REMOVAL·INSTALLATION ............ 1-94

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1-2

ENGINE EXTERIOR VIEW

4Y Engine

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1-3

1DZ-III Engine

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1-4

3Z Engine

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1-5

ENGINE MAIN PARAMETERS

Gasoline Engine

Vehicle model

0

1·2·K2 ton series

3·J3.5 ton series

Item

Engine model

4Y

←

1

Engine type

Gasoline·4 cycle

←

In-line 4 cylinder, longitudinally

mounted

2

Number and arrangement of cylinders

←

Combustion chamber type

Wedge

←

3

OHV · chain drive

Valve mechanism

←

91.0 × 86.0

(3.583 × 3.386)

4

Bore x stroke

mm (in)

←

cm 3 (in 3 )

Total displacement

2237 (136.51)

←

5

Compression ratio

8.8

←

Maximum power

Gasoline exclusive

38 (51)/2570

44 (59)/2570

6

kW (PS)/rpm

LPG convertible/Gasoline

38 (51)/2570

43 (58)/2570

LPG convertible/LPG

38 (51)/2570

42 (57)/2570

7

LPG exclusive

38 (51)/2570

42 (57)/2570

8

Maximum torque

Gasoline exclusive

160 (16.3)/2100

165 (16.8)/2570

N · m (kgf · m)/rpm LPG convertible/Gasoline

160 (16.3)/2100

162 (16.5) 2570

9

LPG convertible/LPG

160 (16.3)/2100

160 (16.3) 2200

LPG exclusive

160 (16.3)/2100

160 (16.3) 2200

10

BSFC*

Gasoline exclusive

298 (219)/2000

310 (228)/1600

g/kW · h (g/PS · h)/rpm

LPG convertible/Gasoline

298 (219)/2000

310 (228)/1600

11

LPG convertible/LPG

233 (171)/2000

←

LPG exclusive

233 (171)/2000

←

12

Service weight

kg (lb)

135 (298)

←

No-load maximum speed

rpm

2570

←

13

*: BSFC:Brake Specific Fuel Consumption

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