Toyota 1KD Engine Repair manual (General) PDF

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1KD_RM.book 1 ページ ２０１３年９月２７日　金曜日　午後１２時４７分 FOREWORD This repair manual explains the repair points of the 1KD model engine equipped on the Toyota Industrial Vehicles. Please use these manuals for providing quick, correct servicing of this engine. This manual deals with the above models as of October ...

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1KD_RM.book

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２０１３年９月２７日　金曜日　午後１２時４７分

FOREWORD This repair manual explains the repair points of the 1KD model engine equipped on the Toyota Industrial Vehicles. Please use these manuals for providing quick, correct servicing of this engine. This manual deals with the above models as of October 2013. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News.

1KD_RM.book

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1KD_RM.book

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SECTION INDEX NAME

SECTION

GENERAL

0

TROUBLESHOOTING

1

ENGINE OVERHAUL

2

FUEL SYSTEM

3

COOLING SYSTEM

4

STRTING SYSTEM

5

LUBRICATION SYSTEM

6

CHARGING SYSTEM

7

APPENDIX

8 9 10

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0-1

GENERAL

SPECIFICATIONS .......................................................... 0-2

1

ENGINE EXTERIOR VIEW .......................................... 0-3

0

ENGINE SECTIONAL VIEW ........................................ 0-4

1

HOW TO READ THIS MANUAL ................................. 0-6

2

EXPLANATION METHOD............................................... 0-6 TERMINOLOGY .............................................................. 0-7

3

ABBREVIATIONS ........................................................... 0-7

4

OPERATION PRECAUTIONS ..................................... 0-9

5

SPECIAL PRECAUTIONS .............................................. 0-9

6

GENERAL PRECAUTIONS ............................................ 0-9

7

INSPECTION OF ELECTRIC PARTS ........................... 0-11

8

SIMULATION OF DEFECT PHENOMENA ............ 0-16 STANDARD BOLT AND NUT TIGHTENING TORQUE ................................. 0-18 BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE..................................... 0-18

9 10 11 12

PRECOAT BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON THREADS) ....................... 0-21

13

SI UNITS......................................................................... 0-22

14

HANDLING THE FIPG (LIQUID GASKET) ............ 0-23

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0-2

SPECIFICATIONS Engine model

1KD

Type

Diesel

Cycle

4

Number of cylinder and arrangement

In-line 4 cylinders, vertical

Ignition order

1-3-4-2

Starting method

Pinion shift

Fuel supply system

Common rail

Combustion chamber type

Direct injection Direct acting DOHC4 valve Belt and gear drive

Valve mechanism Intake and exhaust system

Crossflow Electronically-controlled variable nozzle turbo

Turbo charging system Bore x stroke

mm (in.) cm3 (cu in)

Total displacement Compression ratio

96.0 x 113 (3.78 x 4.06) 2982 (181.97) 16.0

Compression pressure

MPa/rpm

Maximum output

kW (PS)/rpm

Maximum torque

N m/rpm

2.6/250 55 (75)/2200 300/1200 to 1500

No-load static maximum speed

rpm

2350, 2600

Idling speed

rpm

720 to 780

Compression ring

2

Oil ring

1

Number of piston rings Cylinder liner type

No liner Open

BTDC 3°

Close

ABDC 28°

Open

BBDC 48°

Close

ATDC 0°

Intake valve opening & closing timing

Exhaust valve opening & closing timing Ignition system

Compression ignition

Oil pump type

Cycloid gear

Oil filter type

Engine oil amount

Paper filter type

L

No filter change

6.6

Filter change

7.0

Total capacity

7.8

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0-3

ENGINE EXTERIOR VIEW

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0-4

ENGINE SECTIONAL VIEW

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0-5

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0-6

HOW TO READ THIS MANUAL EXPLANATION METHOD 1.

Operation procedure • The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with an illustration. Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summarized as "key point operations".

Example of description in pattern B

Disassembly, inspection and reassembly  Non-reusable parts T = N m

Parts to be replaced with new ones at disassembly/installation

2

Tightening torque unit

• Step numbers are sometimes partially omitted in illustrations. • When a part requiring tightening torque instruction is not indicated in the illustration, the part name is described in the illustration frame.

4



1

3 T = 274.59 to 370.69 (2800 to 3780) [202.58 to 273.48]

Disassembly and reassembly procedure The reassembly procedure is the reverse of the disassembly procedure. No.

Item

1

Crank pulley

2

Timing gear cover

3

Idle gear No.1

4

Oil pump assembly

Point operation

Disassembly

Inspection

Reassembly

[Point 1] [Point 2]

Explanation of operation point with illustration [Point 1] Inspection:Measure the backlash. Standard: 0.05 mm (0.0020 in.) Operation covered on the following page Disassembly:Install the rotor in the position shown in the illustration. Abbreviation used for point operations Removal Reassembly Installation Adjustment Disassembly Inspection

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0-7 2.

3.

How to read components figures (Example) The components figure uses the illustration in the parts catalog for the vehicle model. Please see the catalog for checking the part name. Parts catalog FIG number Matters omitted from this manual This manual omits descriptions of the following jobs, but perform them in actual operation:

3201

(1) Cleaning and washing of removed parts as required (2) Visual inspection (partially described)

TERMINOLOGY WARNING: Important information and operation procedures, failure to observe which may cause accidents. Caution: Important information and operation procedures, failure to observe which may cause accidents. Note: Important information, failure to observe which may cause accidents, or information on operation procedures that requires special attention. Standard: The permissible range in inspection or adjustment Limit: The maximum or minimum value of the criterion in inspection or adjustment

ABBREVIATIONS Abbreviation

Original term

Meaning

ABDC

After Bottom Dead Center

After the bottom dead center position of the piston in the cylinder.

ASSY

Assembly

An assembly is composed of two or more individual parts or subassembly parts that are put together.

ATDC

After Top Dead Center

After the top dead center position of the piston in the cylinder.

BBDC

Before Bottom Dead Center

Before the bottom dead center position of the piston in the cylinder.

BTDC

Before Top Dead Center

Before the top dead center position of the piston in the cylinder.

DTC

Diagnostic Trouble Code

Diagnostic trouble code

ECD

Electronically Controlled Diesel Electronically controlled diesel

ECU

Electronic Control Unit

Electronic control unit

EDU

Electronic Driver Unit

Electronic driver unit

EGR

Exhaust Gas Recirculation

Exhaust gas recirculation system

EX

Exhaust

Indicates the exhaust system.

FB

Feed Back

Feed back

FCM

Fuel Control Module

Fuel control module

FIPG

Formed In Place Gasket

Formed in place gasket

FR

Front

Front side

IG

Ignition

Ignition

IN

Intake

Indicates the intake system.

LH

Left Hand

Left side

LWR

Lower

Lower side

M/T

Manual Transmission

Indicates a manual transmission.

O/S

Over Size

For items that have worn over a long time, or where the fitting has loosened due to repeated removal and reassembly, by replacing the one side (fitting side) with an item that has a larger size, the other side can be reused. Sizes larger than this standard are indicated with O/S.

RH

Right Hand

Right side

RR

Rear

Rear side

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0-8 Abbreviation

Original term

Meaning

SST

Special Service Tool

Indicates special tools.

STD

Standard

Indicates that the standard size is the size of the parts that were used for assembly at the manufacturer.

SUB/ASSY

Sub Assembly

Two or more individual parts that are welded, cast or caulked together.

T=

Torque

Tightening torque

T/C

Torque Converter

Indicates an automatic transmission.

TDC

Top Dead Center

Top dead center

U/S

Under Size

In the same way as O/S, by replacing the one side (fitted side) with an item that has a smaller hole, the other side can be reused. Sizes smaller than this standard are indicated with U/S.

W/

With/

The item following is attached. (Example: w/washer = with a washer)

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0-9

OPERATION PRECAUTIONS SPECIAL PRECAUTIONS 1.

Disassembly and reassembly operations for the engine assembly must be carried out while the engine is set on the engine stand. Never perform the operations on a work bench or the floor, since doing so is very dangerous.

2.

Always wear gloves when holding or moving the cylinder head assembly or cylinder block: never use bare hands.

GENERAL PRECAUTIONS 1.

For safe operation (1) Correctly wear protection tools (cap, safety glasses, gloves, safety shoes, etc.). (2) Do not touch the radiator, muffler, exhaust pipe and other engine related parts immediately after stopping the engine to prevent scalding. (3) Do not bring clothes, tools and others close to rotating parts during engine operation. (4) Always turn the ignition switch OFF and remove the ignition key unless engine operation is necessary.

2.

Preparation for disassembly (1) Prepare general tools, SST, measuring tools, greases, and non-reusable parts. (2) When disassembling a complicated assembly, put punch or matching marks at places not affecting the function to facilitate reassembly operations.

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0-10 3.

Keeping out foreign matter If foreign matter such as dust, sand or metal pieces enter the engine, it could cause a malfunction. (1) Fully clean off any sand or mud from the outside of the engine. (2) Use plastic covers to protect the disassembled parts from dust.

4.

Prevention of part damage If there is damage to rotating parts or the connection surface of parts, it could cause oil leaks or seizures. (1) Do not use a screwdriver when disassembling the connection surface of parts. Disassemble by striking the parts gently with a plastic hammer. (2) When securing parts in a vise, do not secure the parts directly. Use aluminum plates between the parts and the vise.

5.

Washing the parts (1) Wash the parts thoroughly before reassembly, dry with compressed air, and coat with the specified oil. (2) Parts that must not be washed with alkaline solutions: Aluminum parts, rubber parts (O-rings, etc.) (3) Parts that must not be washed with cleaning oil (kerosene, white gasoline, etc.): Rubber parts (O-rings, etc.)

6.

Removal and reassembly of fuel system parts (1) Work area for removing and reassembling fuel system parts (a) Perform the work in an area with good ventilation where there is no machinery that cause sparks, such as welders, grinders, drills, electric motors or stoves. (b) Do not work in or around a work pit where there is a danger of ignited fuel flowing in. (2) Removal and reassembly of fuel system parts (a) Prepare a fire extinguisher before starting to work. (b) To prevent static electricity, attach a ground wire to areas such as the fuel changer, vehicle and fuel tank, and pour water over the parts, but not so much that it will cause you to slip. (c) Do not use electric equipment such as power pumps and working lamps, because they could cause sparks or high temperatures. (d) Do not use tools such as iron hammers, because they could cause sparks during work. (e) Dispose of cloths that are saturated with fuel separately.

7.

Reassembly position and direction (1) Reassemble the parts in the position and direction they were in before disassembly. (2) Install correct parts according to the correct procedure and observing the determined standards (tightening torques, adjustment values, etc.). (Reassemble at the median of the ranges for tightening torques and adjustment values.) (3) Always use genuine parts for replacement of existing parts. (4) Always use new oil seals, O-rings, gaskets, cotter pins, etc. (5) Coat the seal packing on the gaskets depending on where they will be used, coat the specified oil or the grease on the specified places on the sliding parts, and coat the MP grease on the oil seal lips before reassembly.

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0-11 8.

9.

Tightening by extension tool attached torque wrench

L1

L2

L1

L2

(1) For the case a torque wrench is used after extending the total length by combining with SST or another tool, the actual tightening torque becomes excessive when the reading on the torque wrench is at the specified torque. (2) This manual shows the specified torque only. To use a SST or extension tool, calculate the reading of torque wrench using the following formula. (3) Formula: T' = T x L2 / (L1 + L2) T'

Reading of torque wrench [N m]

T

Specified tightening torque [N m]

L1

SST or tool length [in]

L2

Torque wrench length [in]

Handling the hose clamps (1) Before removing the hose, check the insertion depth of the hose and the clamp positions to make sure that reassembly is performed correctly. (2) Replace deformed or dented clamps with new ones. (3) When reusing the hose, install by aligning the clamps to the clamp marks on the hose. (4) With plate spring clamps, after installation apply pressure in the direction it is to be tightened.

10. Adjustment and checking work Adjust to the service standard values by using gauges and testers. 11. Disposal of waste fluid, etc. When draining waste fluid from the vehicle, receive it in a container. If oil, fuel, coolant, oil filters, batteries or other harmful substances are directly discharged or scrapped without permission, it will either adversely affect human health or destroy the environment. Always sort waste fluids etc. and treat them properly by requesting disposal by specialized companies. Further, always recover or wipe up any waste fluid that is spilt. 12. Protection of function 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 the controller connectors or incomplete connection may damage the elements inside the controllers.

INSPECTION OF ELECTRIC PARTS 1.

Always disconnect the battery plug before performing electric part inspections or maintenance.

2.

Electric parts resistance measurement condition Unless otherwise specified, the resistance of electric parts should be measured at an ambient temperature of 20 °C. The resistance value is out of the specified range when measured at a high ambient temperature immediately after using a truck, therefore measure the resistance after the engine is cooled sufficiently.

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0-12 3.

Handling the connectors

(2) Release the lock

(1) Push to the fitted side

(1) To disconnect a connector with lock, push the connector to the fitted side to ease the tab of the lock and then release the lock. (2) Hold the connector, not the harness, to disconnect the connector. (3) Before connecting the connector, check it for deformation, damage or looseness of the terminal. (4) Insert the connector with lock securely until it clicks. (5) To inspect the connector using a tester, it should be performed at the back (harness side) using a mini test lead. Caution: • Since the waterproof connector cannot be inspected at the back, a sub harness needs to be connected. • Do not damage the terminal by carelessly moving a tester probe after inserting it.

4.

Connector inspection Looseness of swaged area

Core breakage Terminal deformation Pull lightly

Male terminal for inspection

(1) With the connector connected, hold the connector housing and check for insertion and locking conditions. (Fitting condition) (2) With the connector disconnected, pull the wire harness lightly. (Check for terminal disconnection, condition of swaged area and core breakage) Caution: Always use a gold plated male terminal to test a gold plated female terminal. (3) Visually check the connector for a presence of rust, metal chip or water, and bend of the t...