Engine Mechanical.pdf

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Inspection
of
Components
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Installation
of Timing
Belt.
Disassembly
of
Cylinder
Head.
.
Inspection,
Cleaning and Repair of Cylinder
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Assembly
of
Cylinder
Head
Replacement
HeadComponents
Camshaft
Seal
. . . . . . . . . . . . . . .
Installation
of Cylinder
Head.
Components
:
Disassembly of Cylinder Block.
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Disassembly
of Piston and Connecting
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Inspection
of Piston and Connecting
Rod
Rod
Assembly
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Replacement of Connecting Rod Bushing.
. . . .
Assembly
. . . . .
Replacement
of
Crankshaft
Oil
Seais.
Assembly of Piston and Connecting
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Installation
of Crankshaft,
Piston and
Rod
Assembly
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AssemblyofCylinderBlock
Connecting
Rod
Assembly
t
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MECHANICAL- DieselEngineDiagnosis
ENGINE
M-2
)IESEL ENGINE DIAGNOSIS
GENERAL
Diesel engine problems are usuallycausedby the engine or tuel system. The injection pump is very rarely
the causeof fuel systemproblems.
valve timing and other
Before beginning fuel system tests. first check that the engine compression.
major systems are within specification.
The following fuel system diagnosis proceduresare applicable to Toyota 1C. 1C-T. 2C. l. 2l and 2l- T
engines equipped with the distributor type injection pump.
!. ~;RELIMINARY CHECKS
Betore performing tuel system checks. check that the engine is in good running condition. It
necessary. first check the compression. timing and major components
(a)
or systems.
Check the air filter and clean or replace as needed.
(b)
Check that there is sufficient fuel in the tank.
(c)
Check if the fuel is contaminated with gasoline or other foreign elements. Only good-quality diesel
fuel should be used.
(d)
Bleed air from the system by pumping the priming pump 30 - 40 times.
(e)
Check for water in the fuel filter and fuel tank and drain as necessary.
(fl
If the engine will not crank or if it cranks slowly, first troubleshoot
~
the electrical system.
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ENGINE MECHANICAL - DieselEngineDiagnosis
EM-3
PRECAUTION
1
The basictroubleshootingproceduresfor the dieselengine(valveclearance.compression.bearings.
valves,pistons.etc.)are the samechecksyou would makefor a gasolineengine.
The repairof an injectionpump requiresconsiderableskill and useof a specialtest bench.
2
ENGINE WILL NOT CRANK
(Possible Cause)
(Check Procedure and Correction Method)
;.[)-~~c~~- BATTE-;;
ENGINE CRANKS SLOWL Y-WILL
NOT START
NOTE: Minimum cranking speed:
Cold
MIT 100 rpm
A/T
110 rpm
Hot
150 rpm
(Possible Cause)
(Check Procedure and Correction Method)
LOOSE OR CORRODED
BATTERY CA BLES
1.
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ENG IN E MECHANICAL - Diesel Engine Diagnosis
i-4
-:=;;
:=;;-~.
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ENGINE CRANKS NORMALLY SUT WILL NOT START
-
=- (Possible Cause)
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(Check
Procedure
and Correctlon
Method)
NO FUEL TO NOZZLE
loosen any one injection pipe union nut from its
nozzle holder.
Crank the engine for about 5 seconds while con-
firming that fuel is being discharged from the pipe
If fuel is coming out, begin diagnosis from item 4.
If not, begin from item 2.
With starter switch tumed ON, check for fuel cut
solenoid operation noise (clicking sound) while
repeatedly connecting and disconnecting fuel cut
solenoid.
If no noise, check if there are 12 volts to the
solenoid when the starter switch is ON.
If 12 volts are confirmed, fuel cut solenoid is faulty
and should be replaced. If not 12 volts. refer to
ELECTRICALDIAGNOSISand make necessary
repairs.
:.
NO FUEL CUT SOLENOlD
OPERATION
-..
NO FUEllNTO INJECTION
PUMP
}.
With the starter switch turned ON and the glow plug
indicator light illuminated, check that there are 6 volt
applied to the glow plug.
It not. reter to ELECTRICALDIAGNOSISand repair as
necessary.
Check glow plug for continuity.
If no continuity, a broken wire is indicated and the
glow plug should be replaced.
~
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