ENGINE TUNE-UP

SECTION ET
CONTENTS
GASOLINE DIESEL
SERVICE DATA AND SPECIFICATIONS (SDS) ............2 SERVICE DATA AND SPECIFICATIONS (SDS) ..........19
Inspection and Adjustment ..........................................2 General Specifications...............................................19
Tightening Torque ........................................................2 Inspection and Adjustment ........................................20
TROUBLE DIAGNOSES AND CORRECTIONS.............3 Tightening Torque ......................................................20
ENGINE TUNE-UP...........................................................9 TROUBLE DIAGNOSES AND CORRECTIONS...........21
Ignition and Fuel System.............................................9 ENGINE TUNE-UP.........................................................34
Governor System.......................................................16 Injection and Fuel System .........................................34
SPECIAL SERVICE TOOL ............................................18 SPECIAL SERVICE TOOLS..........................................36

BASIC MECHANICAL SYSTEM ...................................37

 SERVICE DATA AND SPECIFICATIONS (SDS) GASOLINE

Inspection and Adjustment

Engine model H20-II H25
Intake
Valve clearance (Hot) mm (in) 0.38 (0.0150)
Exhaust
Fan belt deflection mm (in) 11 - 13 (0.43 - 0.51)
Applied pushing force N (kg, lb) 98 (10, 22)
Engine oil capacity  (Imp qt)
With oil filter 3.8 (3-3/8)
Without oil filter 3.5 (3-1/8)
Engine compression pressure
kPa (bar, kg/cm2, psi)/rpm
Standard 1,226 (12.26, 12.5, 178)/300 1,275 (12.75, 13.0, 185)/300
Minimum 1,030 (10.30, 10.5, 149)/300 1,079 (10.79, 11.0, 156)/300
Spark plug
Type BP4ES, BPR4ES
Gap mm (in) 0.8 - 0.9 (0.031 - 0.035)
Distributor
Air gap mm (in) 0.35 - 0.45 (0.0138 - 0.0177)
High tension cable resistance Ω Less than 30,000
Ignition timing idle speed 4°/700
BTDC degree/rpm 12°/700 (LPG) 8°/750 (LPG)
Max. engine speed under no load rpm 3,100 - 3,300 2,800 - 3,000
Max. engine speed under load rpm 2,600 - 3,000 2,300 - 2,600

Tightening Torque
Unit: N⋅m (kg-m, ft-lb)
Cylinder head bolt 74 - 83 (7.5 - 8.5, 55 - 61)
Manifold nut 16 - 18 (1.6 - 1.9, 12 - 13)
Oil pan drain plug 20 - 39 (2.0 - 4.0, 15 - 28)
Spark plug 18 - 23 (1.8 - 2.4, 13 - 17)

ET-2
 TROUBLE DIAGNOSES AND CORRECTIONS GASOLINE

Condition Probable cause Corrective action

CANNOT CRANK Improper grade oil. Replace with proper grade oil.
ENGINE OR SLOW Discharged battery. Charge battery.
CRANKING
Faulty battery. Replace.
Loose fan belt. Adjust.
Trouble in charge system. Inspect.
Wiring connection trouble in starting circuit. Correct.
Faulty starter switch. Repair or replace.
Faulty starter motor. Repair or replace.
(Troubleshooting procedure on starting circuit)
Switch on the starting motor with light “ON”.
When light goes off or dims considerably:
a. Check battery.
b. Check connection and cable.
c. Check starter motor.
When light stays bright:
a. Check wiring connection between battery and
starter motor.
b. Check starter switch.
c. Check starter motor.
ENGINE WILL CRANK In this case, the following trouble causes may
NORMALLY BUT WILL exist, but in many cases ignition system or fuel
NOT START system is in trouble.
Ignition system trouble (Troubleshooting procedure)
Fuel system trouble Check spark plug first by following procedure.
Valve mechanism does not work properly Disconnect high tension cable from one spark
Low compression plug and hold it about 10 mm (0.39 in) from the
engine metal part and crank the engine.
If good spark occurs:
a. Check spark plug.
b. Check ignition timing.
c. Check fuel system.
d. Check cylinder compression.
If no spark occurs:
Check the current flow in primary circuit.
Very high current:
Inspect for shorted primary circuit.

ET-3
 TROUBLE DIAGNOSES AND CORRECTIONS GASOLINE

Condition Probable cause Corrective action

Ignition trouble Faulty condenser. Replace.
Leak at rotor cap and rotor. Clean or replace.
Faulty spark plug. Clean, adjust plug gap or replace.
Improper ignition timing. Adjust.
Faulty ignition coil. Replace.
Disconnection of high tension cable. Replace.
Loose connection or disconnection in primary cir- Repair or replace.
cuit.
Fuel system trouble Lack of fuel. Supply.
Dirty fuel strainer. Replace.
Dirty or clogged fuel pipe. Clean.
Fuel pump will not work properly. Repair or replace.
Carburetor choke will not work properly. Check and adjust.
Improper adjustment of float level. Correct.
Improper idling. Adjust.
Dirty or clogged carburetor. Disassemble and clean.
Clogged breather pipe of fuel tank. Repair and clean.
Low compression Incorrect spark plug tightening or damaged gas- Tighten to normal torque or replace gasket.
ket.
Improper grade engine oil or low viscosity. Replace with proper grade oil.
Incorrect valve clearance. Adjust.
Compression leak from valve seat. Remove cylinder head and lap valves.
Sticky valve stem. Correct or replace valve and cylinder head.
Weak or defective valve springs. Replace valve springs.
Compression leak at cylinder head gasket. Replace gasket.
Sticking or worn piston ring. Replace piston rings.
Worn piston ring or cylinder. Overhaul engine.
(Troubleshooting procedure)
Pour engine oil into plug hole, and then measure
cylinder compression.
If compression increases:
Trouble in cylinder or piston ring.
If compression does not change:
Compression leaks from valve, cylinder head or
head gasket.

ET-4
 TROUBLE DIAGNOSES AND CORRECTIONS GASOLINE

Condition Probable cause Corrective action

IMPROPER ENGINE
IDLING
Fuel system trouble Clogged or damaged carburetor jets. Clean or replace.
Incorrect idle adjustment. Adjust.
Clogged air cleaner. Replace element.
Damaged manifold gaskets or carburetor insulator. Replace gasket or insulator.
Improper float level adjustment. Adjust.
Low compression Previously mentioned.
Others Incorrect valve clearance. Adjust.
Extremely low revolution. Adjust.
ENGINE POWER NOT UP
TO NORMAL
Low compression Previously mentioned.
Ignition system trouble Incorrect ignition timing. Adjust.
Faulty spark plugs. Clean, adjust or replace plugs.
Fuel system trouble Malfunction of choke system. Adjust.
Clogged fuel pipe. Clean.
Dirty or clogged fuel strainer. Replace.
Fuel pump will not work properly. Repair or replace.
Clogged carburetor jets and/or needle valve. Disassemble and clean.
Throttle valve does not open fully. Readjust.
Fuel pump out of adjustment. Readjust.
Air intake system trouble Clogged air cleaner. Replace element.
Air inhaling from manifold gasket or carburetor Replace gasket.
gasket.
Overheating Insufficient coolant. Replenish.
Loose fan belt. Adjust fan belt.
Worn or loose fan belt. Replace.
Faulty thermostat. Replace.
Faulty water pump. Replace.
Clogged or leaky radiator. Flush, repair or replace.

ET-5
 TROUBLE DIAGNOSES AND CORRECTIONS GASOLINE

Condition Probable cause Corrective action

Faulty radiator filler cap. Replace.
Air in cooling system. Retighten each part of cooling system.
Improper engine oil grade. Replace with proper grade oil.
Incorrect ignition timing. Adjust.
Faulty carburetor (lean mixture). Overhaul carburetor.
Overcooling Damaged thermostat. Replace.
Others Improper octane fuel. Replace with specified octane fuel.
Improper tire pressure. Inflate to specified pressure.
Dragging brake. Adjust.
Clutch slipping. Adjust.
NOISY ENGINE
Knocking Overloaded engine. Use right gear in driving.
Carbon knocking. Disassemble cylinder head and remove carbon.
Timing knocking. Adjust ignition timing.
Fuel knocking. Use specified octane fuel.
Preignition (misusing of spark plug). Use specified spark plug.
Mechanical knocking
Crankshaft bearing This strong dull noise increases when engine is This is caused by worn or damaged bearings, or
knocking. accelerated. To locate the place, cause a misfire unevenly worn crankshaft. Renew bearings and
on each cylinder. If the noise stops by the adjust or change crankshaft.
misfire, this cylinder generates the noise. Check lubrication system.
Connecting rod bearing This is a little higher-pitched noise than the Same as the case of crankshaft bearings.
knocking. crankshaft knocking, and also increases when
engine is accelerated. Cause a misfire on each
cylinder and if the noise diminishes almost
completely, this crankshaft bearing generates the
noise.
Piston and cylinder noise. When you hear an overlapping metallic noise This may cause an abnormal wearing of cylinder
which increases its magnitude with the revolution and lower compression which in turn will cause a
of engine and which decreases as engine is lower out-put power and excessive consumption
warmed up, this noise is caused by piston and of oil.
cylinder. To locate the place, cause a misfire on
each cylinder. Overhaul engine.
Piston pin noise. This noise is heard at each highest and lowest This may cause a wear on piston pin, or piston
dead end of piston. To locate the place, cause a pin hole.
misfire on each cylinder. Renew piston and piston pin assembly.
Water pump noise. This noise may be caused by worn or damaged Replace water pump with a new one.
bearings, or by the uneven surface of sliding
parts.

ET-6
 TROUBLE DIAGNOSES AND CORRECTIONS GASOLINE

Condition Probable cause Corrective action

Others An improper adjustment of valve clearance. Adjust.
Noise of timing chain. Replace chain and tensioner sprocket.
An excessive end-play on crankshaft. Disassemble engine and renew main bearing.
Note:This noise will be heard when clutch is
disengaged.
Wear on clutch pilot bushing. Renew bush and adjust drive shaft.
Note:This noise will be heard when clutch is
disengaged.
ABNORMAL COMBUS-
TION
(back fire, after fire run-on
etc.)
Improper ignition timing Improper ignition timing. Adjust ignition timing.
Improper heat range of spark plugs. Use specified spark plugs.
Fuel system trouble Damaged carburetor or manifold gasket. Replace them with new parts.
(back fire, after fire).
Faulty carburetor jet. Disassemble carburetor and check it.
Improper function of the float. Adjust the level, and check needle valve.
Uneven idling. (Run on) Adjust.
Defective cylinder head, Improper adjusted valve clearance. Adjust.
etc. Excess carbon in combustion chamber. Remove head and get rid of carbon.
Damaged valve spring (back fire, after fire). Replace it with a new one.
EXCESSIVE OIL CON-
SUMPTION
Oil leakage Loose oil drain plug. Tighten it.
Loose or damaged oil pan gasket. Renew gasket or tighten it.
Loose or damaged chain cover gasket. Renew gasket or tighten it.
Damaged oil seal in front and rear of crankshaft. Renew oil seal.
Loose or damaged locker cover gasket. Renew gasket or tighten it (but not too much).
Improper tightening of oil filter. Renew gasket and tighten it with the proper
torque.
Loose or damaged oil pressure switch. Renew oil pressure switch or tighten it.
Excessive oil consump- Cylinder and piston wear. Overhaul cylinder and renew piston.
tion
Improper location of piston ring gap or reversely Remount piston rings.
assembled piston ring.
Damage piston rings. Renew rings.
Repair or renew piston and cylinder.

ET-7
 TROUBLE DIAGNOSES AND CORRECTIONS GASOLINE

Condition Probable cause Corrective action

Worn piston ring groove and ring. Renew piston and piston ring.
Fatigue of valve oil seal lip. Replace seal lip with a new one.
Worn valve stem. Renew valve.
Others Inadequate quality of engine oil. Use the designated oil.
Engine overheat. Previously mentioned.
POOR FUEL ECONOMY
See the explanation of
the power decrease
Others Exceeding idling revolution. Adjust it to the designated rpm.
Faulty acceleration recovery. Adjust it.
Fuel leakage. Repair or tighten the connection of fuel pipes.
TROUBLE IN OTHER
FUNCTIONS
Decreased oil pressure Inadequate oil quality. Use the designated oil.
Overheat. Previously mentioned.
Faulty function of oil pump regulator valve. Disassemble oil pump and repair or renew it.
Function deterioration of oil pump. Repair or replace it with a new one.
Blocked oil filter. Renew it.
Increased clearance in various sliding parts. Disassemble and replace the worn parts with new
ones.
Blocked oil strainer. Clean it.
Troubles in oil gauge pressure switch. Replace it with a new one.
Excessive wear on the Oil pressure decreases. Previously mentioned.
sliding parts Faulty quality or contamination of oil. Exchange the oil with proper one and change ele-
ment.
Unsufficient air cleaner. Check element.
Overheat or overcool. Previously mentioned.
Improper fuel mixture. Check the fuel system.
Scuffing of sliding parts Decrease in oil pressure. Previously mentioned.
Insufficient clearances. Readjust to the designated clearances.
Overheat. Previously mentioned.
Improper fuel mixture. Check the fuel system.

ET-8
ENGINE TUNE-UP GASOLINE

Ignition and Fuel System

ETM0039

AIR CLEANER CHECK AND MAINTENANCE

1. Check the air cleaner, air duct, air horn, and blow-by hose for
any cracks or damage.
2. If they have any abnormalities, replace the parts with new ones.
NOTE:
For the inspection procedure of the air cleaner element, refer
to “Air cleaner element cleaning and replacement”.

AIR CLEANER ELEMENT CLEANING AND

REPLACEMENT
Check the condition of the air cleaner element for cleaning or
replacement.
1. Open the top panel.
2. Release the clamps of the air cleaner.
3. Remove the case cover assembly.
4. Remove the dust cover inside the case, and clean the inside.
5. Remove the wing nuts and remove the element.
6. Check the inside of the air cleaner case for damage or any
abnormalities, and clean the inside.
7. Check the condition of the element. Clean or replace if neces-
sary.
Element replacement interval (reference):
Standard
Every 6 months or 1,200 hours
Dusty roads
Once every month or 200 hours

ET-9
 ENGINE TUNE-UP GASOLINE
Ignition and Fuel System (Cont’d)
8. Follow the steps below carefully when cleaning
I When compressed air is used, keep the pressure at 500 kPa
(5.00 bar, 5.1 kg/cm2, 73 psi) or less.
I Blow the compressed air from the inside of the element to the
outside.
I After cleaning, check the soil status. If necessary, replace the
cleaner element with a new one.
9. Install in the reverse order of removal. Follow the steps below
carefully.
Element mounting wing nut:
: 1.5 - 1.6 N⋅m (0.15 - 0.17 kg-m, 13 - 14 in-lb)
ETM0041
10. Install the cover so the mark “TOP!” faces upward.
CLEANING OR REPLACING AIR CLEANING FILTER
Dry paper type
It is necessary to clean the element or replace it at the recom-
mended interval, and more frequent maintenance should be carried
out under dusty or other dirty operating conditions.

ETM0042

ADJUSTMENT

EFM0047

ET-10
 ENGINE TUNE-UP GASOLINE
Ignition and Fuel System (Cont’d)
P-I MONITOR
Specifications
I 5 solenoid frequencies are available for selection.
10 Hz, 15 Hz, 20 Hz, 30 Hz, or 40 Hz
I Data can be output to a pen recorder (P-I OUT terminal).
I The power supply is DC 8.5 to 17.0V.
Batteries with the voltage mentioned above are also accept-
able.

ETM0034

OPERATING PROCEDURE
CAUTION:
I Be sure to observe the operating procedure.
I When connecting or disconnecting terminals, be sure the
power switch is turned off and that the negative battery
cable is disconnected.
I Do not reverse the polarity of the positive and negative
terminals of the battery: connect them correctly.
I Keep oil and water away from the monitor.
I Keep the monitor away from direct sunlight, abnormal
temperatures, and high humidity.

Zero adjustment
1. Connect the positive and negative battery terminals at the
backside of P-I monitor to the battery.
2. Connect the negative terminal of SIGNAL to the negative bat-
tery terminal.
3. Connect the positive terminal of SIGNAL to the positive battery
terminal.
4. Turn on the POWER SW, and then adjust the pointer of the
meter to “0” using the ZERO knob.
5. Disconnect the positive and negative terminal of SIGNAL from
ETM0043 the battery.

ET-11
 ENGINE TUNE-UP GASOLINE
Ignition and Fuel System (Cont’d)
Gain adjustment
6. Connect the positive terminal of SIGNAL to the negative battery
terminal.
7. Connect the negative terminal of SIGNAL to positive battery
terminal.
8. Turn on the POWER SW, then adjust the pointer of the meter
to “10” using the GAIN knob.
9. Once adjusted, do not turn the ZERO and GAIN knob.
10. Disconnect the positive and negative terminal of SIGNAL from
the battery.
ETM0044

Idle speed and MAS (LPG) adjustment

ETM0045

1. Turn off the ignition switch, disconnect the battery negative

cable.
2. Disconnect the connector between carburetor (mixer) and
engine harness, and connect the intermediate adapter between
them.
3. Connect the terminals of intermediate adapter to the P-I moni-
tor. (Figure above)

ET-12
 ENGINE TUNE-UP GASOLINE
Ignition and Fuel System (Cont’d)
4. Follow the steps for the idle speed and MAS (LPG) adjustment.
CAUTION:
I Adjust the monitor value to the middle (50%) of the range.
I Check the ignition timing before adjustment:
Engine type Ignition timing (BTDC degree)/rpm
H20-II
4°/650 - 750
H25
H20-II (LPG) 12°/650 - 750
H25 (LPG) 8/750 - 800

FICD setting speed (For reference):

H20-II 1,000 - 1,200 rpm
H25 1,000 - 1,100 rpm

Warm up the engine.

Stop the engine.

Set the P-I monitor.

Idle setting LPG specifications

ETM0036
H
H Go to q
A.
Gasoline specifications

Adjust using the adjust screw of the carburetor.

Throttle adjust screw (TAS): Rotation adjustment
Slow adjust screw (SAS): Fuel adjustment

Setting value
Idle speed: 650 - 750 rpm (H20-II, H25)
Monitor value: Set at 40 to 60% of the P-I monitor.

ET-13
 ENGINE TUNE-UP GASOLINE
Ignition and Fuel System (Cont’d)

q
A

Main range setting

F
(When tilt-relief: When loaded)
H
LPG specifications

ETM0037 Adjust using the screw mentioned below.

Main adjust screw (MAS): Flow adjustment

H
Setting value
Monitor value: Set at 40 to 60% of the P-I
monitor.

Idle setting

ETM0047 H
Adjust using the adjust screw of mixer and
vaporizer.
Mixer-side: Air adjust screw (AAS): Rotation
adjustment
Vaporizer-side: Slow adjust screw (SAS): Fuel
adjustment

H
Setting value
Idle speed: 650 - 750 rpm (H20-II)
750 - 800 rpm (H25)
Monitor value: Set to 40 to 60% of P-I monitor.

H
After setting the idle range, recheck the main
range. If necessary, reset the main range.

ET-14
 ENGINE TUNE-UP GASOLINE
Ignition and Fuel System (Cont’d)
BIMETAL ADJUSTMENT
1. The ambient temperature of the operation limit has been fac-
tory-set to −15°C (5°F).
2. Change the bimetal setting if too much black smoke is emitted,
and the idle speed is unstable due to excess operation of the
auto choke.
When lowering the effect of the bimetal (ambient temperature is
high):
I Loosen the three securing vises, then turn the bimetal case
clockwise (to the LEAN-side). Set to the position where the
EFM0057 engine starts easily, and keeps the engine speed at 1,200 to
1,400 rpm after the engine starts.
When increasing the effect of the bimetal (to start the engine eas-
ily at cold temperatures):
I Turn the bimetal case counterclockwise (to the RICH-side).
NOTE:
I The engine should be cool for the bimetal adjustment.
I Disconnect the wiring of the auto choke during adjust-
ment.

EFM0058

CAM MOVEMENT TIME ADJUSTMENT

1. When the ambient temperature is 25°C (77°F), and the cam
has been set to move from step 1 to step 2 within 45±15 sec-
onds after being energized.
NOTE:
Adjust when cool.
2. When changing the amount of required for the cam to drop to
the step for the idle speed, turn the cam movement time adjust-
ing screw.

EFM0059

ET-15
 ENGINE TUNE-UP GASOLINE
Ignition and Fuel System (Cont’d)
FAST IDLE OPENING ADJUSTMENT
NOTE:
Readjustment will not be required because the adjustment has
been factory-set to the optimum position. If the engine speed
is substantially changed by bimetal adjustment and so on,
follow the steps below to readjust.
1. Adjust the engine speed using the throttle valve adjusting screw
when warming-up the engine.
2. This adjustment determines the initial engine speed, when the
engine is cool and the auto choke is operating. Therefore, it is
recommended adjustments be conducted when the engine is
considerably cool (in the morning).
3. Before adjustment, check that the idle speed is normal when
the engine is warmed up.
4. Depress the accelerator pedal once and disconnect the wiring
of the auto choke when adjusting. Start the engine and make
adjustment quickly. Turn off the engine and connect the wiring.
5. After the auto choke is released (after the warming-up), the
engine speed cannot be changed by turning the screw.
Tighten the screw to open the throttle valve and increase engine
speed. When lowering the engine speed, loosen the screw and
adjust to the engine speed mentioned below.
EFM0060
Appropriate engine speed:
1,000 - 1,200 rpm

Governor System
Governor is adjusted at factory and requires no further adjust-
ment.
ADJUSTING MAXIMUM ENGINE SPEED UNDER
NO-LOAD
1. Shift Forward/Reverse control lever into neutral.
2. Run engine and set carburetor throttle valve at fully-open posi-
tion. Check engine speed.
Maximum engine speed:
H20-II
3,100 - 3,300 rpm
H25
2,800 - 3,000 rpm

ET-16
 ENGINE TUNE-UP GASOLINE
Governor System (Cont’d)
3. If engine speed is not within the specified range, adjust it by
turning governor adjusting handle.
Engine speed:
Increases when turning clockwise
Decreases when turning counterclockwise

ETM0033

ADJUSTING MAXIMUM ENGINE SPEED UNDER LOAD

1. Shift F-R control lever into neutral.
2. Run engine with mast assembly tilted fully backward with
hydraulic control lever.
3. With carburetor throttle valve at fully open position, check
engine rpm.
Maximum engine speed under load:
H20-II
2,600 - 3,000 rpm
H25
2,300 - 2,600 rpm
4. If the engine speed is not within the specified range, adjust it
by turning governor adjusting screw.
Also adjust maximum engine speed under no-load.

ET-17
 SPECIAL SERVICE TOOL GASOLINE

Tool number
Description
Tool name
EG11140000
Ignition coil adapter harness

NT782

ET-18
 SERVICE DATA AND SPECIFICATIONS (SDS) DIESEL

General Specifications
Engine model TD27
Engine general specifications
Classification Diesel
Cycle 4
No. of cylinders and arrangement 4, in-line
Valve arrangement OHV
Bore x stroke mm (in) 96 x 92 (3.78 x 3.62)
Displacement cm3 (cu in) 2,663 (162.50)
Compression ratio 24.6
Number of piston rings
Compression 2
Oil 1
Number of main bearings 5
Valve clearance (Hot) mm (in)
Intake 0.35 (0.014)
Exhaust 0.35 (0.014)
Engine idle speed rpm 700
Ignition timing at idle speed BTDC degree/rpm 5°/700
Engine oil capacity  (Imp qt)
With oil filter 6.2 (5-1/2)
Without oil filter 5.5 (4-7/8)
Lubrication system
Oil pump type Gear pump
Oil filter type Paper element (Cartridge)
Cooling system
Water pump type Centrifugal
Thermostat operating temperature °C (°F) 82 (180)
Engine fuel system
Air cleaner
Filter type Paper element (Dry)
Alternator
LR150-430S
Alternator model
LR150-221 for D01
Capacity V-A 12-50
Starter motor
Model S13-327
Capacity kW 2.0
Injection system
Firing order 1-3-4-2
Combustion chamber configuration Swirl chamber

ET-19
 SERVICE DATA AND SPECIFICATIONS (SDS) DIESEL

Inspection and Adjustment

BASIC MECHANICAL SYSTEM INJECTION AND FUEL SYSTEM
Valve clearance (Hot) mm (in) Injection timing B.T.D.C./rpm 5°/700
Intake & Exhaust 0.35 (0.014) Idling rpm 700
Fan belt deflection Max. engine speed under no-load
2,600 - 2,700
mm (in)/98 N (10 kg, 22 lb) rpm
Used 11 - 13 (0.43 - 0.51) Initial injection pressure 9,807
New 9 - 11 (0.35 - 0.43) kPa (bar, kg/cm2, psi) (98.1, 100, 1,422)
Engine oil capacity (Without oil filter)
5.5 (4-7/8)
 (Imp qt) TIGHTENING TORQUE
Water capacity  (Imp gal) 10.8 (2-3/8)
Radiator cap relief pressure N⋅m kg-m ft-lb
88 (0.88, 0.9, 13)
kPa (bar, kg/cm2, psi) Cylinder head bolt*
Cooling system leaking testing pres- 1st step 39 - 44 4.0 - 4.5 29 - 33
147 (1.47, 1.5, 21)
sure kPa (bar, kg/cm2, psi) 2nd step 54 - 59 5.5 - 6.0 40 - 43
Compression pressure Intake manifold 13 - 19 1.3 - 1.9 9 - 14
kPa (bar, kg/cm2, psi)/rpm Exhaust manifold 25 - 29 2.5 - 3.0 18 - 22
2,942 Oil drain plug 49 - 59 5.0 - 6.0 36 - 43
Standard
(29.4, 30, 427)/200
2,452 *: Then turn further 80° - 100°.
Minimum
(24.5, 25, 356)/200
Difference between cylinders 294 (2.9, 3, 43)/200

Tightening Torque
N⋅m kg-m ft-lb
Cylinder head bolt*
1st step 40 - 44 4.0 - 4.5 29 - 32
2nd step 54 - 58 5.5 - 6.0 40 - 43
Intake manifold 13 - 18 1.3 - 1.9 10 - 13
Exhaust manifold 25 - 29 2.5 - 3.0 18 - 21
Oil drain plug 49 - 58 5.0 - 6.0 37 - 43
*: Then turn further 80° - 100°.

ET-20
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

Engine fails or is hard to start.

H
Are battery electrolyte and fuel levels OK? NG
Eq
A and q
B
OK
H
ELECTRICAL SYSTEM

H
Does starter motor rotate? NG Repair or replace.
E
Check points.
I Connections
I Ignition switch
I Starting circuit
I Starter motor

OK

H
Check glow system. NG Repair or replace.
E
OK
H
ETM0001 q
C

ETM0002

ET-21
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

q
A

H
FUEL SYSTEM

q
C

H H
Check fuel cut solenoid valve. NG Replace.
E
Check points.
I Circuit
I Function
ETM0003
OK

H OK
Crank engine to make sure fuel reaches Eq
D

injection nozzle.

NG

H
Is fuel delivered to injection pump? NG Repair or replace.
E
Check points.
I Fuel line twisted or clogged
I Fuel filter clogged
ETM0004
OK q
E

H H
Check injection timing (plunger lift). NG Adjust.
E
(Refer to EF section.)

OK
H
Does delivery valve stick? No Replace.
E
Yes
H
Overhaul injection pump.
ETM0005 Disassembling and assembling injection
pump should be done only in service
shops authorized by the pump manufac-
turer.

ET-22
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

q
B

H
MECHANICAL SYSTEM

q
D

H H
Crank engine and check compression NG Repair or replace.
E
pressure. (Refer to EM section.)
Check points.
I Valve lip seal worn
ETM0006 I Piston or piston ring worn
I Valve stem or valve seat worn
I Cylinder gasket damaged

OK

H
Check injection nozzle. NG Adjust, repair or replace.
E
Check points.
I Fuel injection pattern
I Clogging
I Sticking
I Injection pressure
ETM0007
OK

H
Check that timing gear is set properly. NG Adjust.
E
OK
H
Check valve clearance. NG Adjust.
E
OK
H
q
E

ET-23
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

UNSTABLE IDLING SPEED

Eq
A

H
FUEL SYSTEM

H
Check idle speed. NG Adjust.
E
OK
H
ETM0008 NG
Check fuel line. Repair, retighten or
E
Check points. replace.
I Fuel line twisted clogged
I Fuel filter clogged
I Leaks or loose

OK

H
Purge air and drain water. (Refer to EF
section.)

OK
ETM0019 q
B

H H
Check injection timing (plunger lift). (Refer NG Adjust.
E
to EF section.)

OK
H
Does delivery valve stick? No Replace.
E
Yes
H
Overhaul injection pump.
Disassembling and assembling injection
ETM0009 pump should be done only in service
shops authorized by the pump manufac-
turer.

ET-24
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

q
A

H
MECHANICAL SYSTEM

H
Crank engine and check compression NG Repair or replace.
E
pressure.
(Refer to EM section.)
Check points.
I Valve lip seal worn
ETM0006 I Piston or piston ring worn
I Valve stem or valve seat worn
I Cylinder gasket damaged

OK

H
Check injection nozzle. NG Adjust, repair or replace.
E
Check points.
I Fuel injection pattern
I Clogging
I Sticking

ETM0007 OK

H
Check that timing gear is set properly. NG Adjust.
E
OK
H
Check valve clearance. NG Adjust.
E
OK
H
Check engine mounting. NG Replace or retighten.
E
Check points.
I Cracked
I Loose

OK
H
q
B

ET-25
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

EXCESSIVE WHITE or BLACK SMOKE

Eq
A

H
FUEL SYSTEM

q
B

H H
Check fuel line. NG Repair, retighten or
E
Check points. replace.
I Fuel line twisted or clogged
ETM0019 I Fuel filter clogged
I Leaks or loose

OK

H
Purge air and drain water.
(Refer to EF section.)

OK
q
C

H H
Check injection timing. NG Adjust.
E
ETM0009
OK
H
Does delivery valve stick? No Replace.
E
Yes
H
Overhaul injection pump.
Disassembling and assembling injection
pump should be done only in service
shops authorized by the pump manufac-
turer.

ET-26
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

q
A

H
MECHANICAL SYSTEM

H
Black smoke or white smoke? (White smoke)

(Black smoke)
H
Is air cleaner element clogged? No
Eq
B
ETM0006 Yes
H
Replace.

H
Is oil or similar material in or on tail pipe? No
Eq
B
Yes
H
Crank engine and check compression NG Repair or replace.
E
pressure. (Refer to EM section.)
Check points.
I Cylinder head gasket damaged
ETM0007 I Piston or piston ring worn
I Valve stem or valve seat worn
I Valve lip seal worn

OK

H
Check injection nozzle. NG Adjust, repair or replace.
E
Check points.
I Nozzle worn.
I Spring worn.
I Injection pressure.

OK

H
Check that timing gear is set properly. NG Adjust.
E
OK
H
Check valve clearance. NG Adjust.
E
OK
H
q
C

ET-27
 TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

NOISY ENGINE

ENGINE FROM CYLINDER AT INJECTION FROM ENGINE

KNOCKING HEAD PUMP SIDE OF ITSELF (CYLINDER
ENGINE BLOCK)

H H
Check engine warm- Check cylinder head
up. bolt. H
Check points.
OK NG OK NG H I Piston worn
H
H Check injection I Connecting rod
Warm-
Retighten. pump. bent or worn
up.
Refer to EF section. I Crankshaft bent or
H H worn
Check injection tim- Check for gas leak- I Loose bolts
ing. age.

OK NG OK NG
H
H Replace
Adjust. head
gasket.
H
Check compression H
pressure. Check valve clear-
I Check piston and ance.
piston ring for
OK NG
wear.
I Check valve seat
and valve stem for H
wear. Adjust.
OK NG
H
Repair H
or END
replace.
H
Check injection
nozzle.
I Fuel injection pat-
tern
I Clogging nozzle
I Damage gasket
I Injection pressure

OK NG
H
Clean or
replace.
H
Check injection
pump.
Refer to EF section.

ET-28
 TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

OIL LEAKAGE

OIL PUMP ENGINE COMPONENT

Check mating areas of oil pump and cylinder block. E Check rocker cover.

OK NG OK NG
H
H
Retighten or
Retighten or
replace gasket.
replace.
H
H
Check mating areas of cylinder block and cylinder
Check regulator valve.
head.
OK NG
OK NG
H
H
Replace gas-
Retighten or
ket.
replace.
H
H
Check areas around blind plug at cylinder block’s oil
Check oil pump body for cracks or damage.
gallery.
OK NG
OK NG
H
H Replace blind
Replace. plug.
H H
Check areas around oil seal. Check oil cooler mounting area.

OK NG OK NG
H H
Replace oil Retighten or
seal. replace O-ring.
H
Check mating areas of oil pan and cylinder block.

OK NG
H
Retighten or
replace gasket.
H
Check oil pan drain plug.

OK NG
H
Retighten or
replace gasket.
H
Check areas around rear plate.

OK NG
H
Replace oil
seal.
H
Check oil leaks around transmission.

OK NG
H
H
Replace oil
END
seal.

ET-29
 TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

WATER LEAKAGE

ENGINE COMPO-
RADIATOR WATER PIPE OIL COOLER
NENT

Check mating areas of

Check water pipe for Check oil cooler for
Check drain cock. E E E cylinder block and
cracks. cracks.
head.
OK NG
OK NG OK NG
OK NG
H H
H H
Replace Retighten or
Repair or Repair or
packing or replace gas-
replace. replace.
retighten. ket.
H H H
H
Check water pipe Check oil cooler hoses Check areas around
Check radiator for
hoses for cracks and for cracks and loose blind plug at cylinder
cracks.
loose joints. joints. block’s water gallery.
OK NG
NG OK NG OK OK NG
H H
H H
Repair or Replace blind
Retighten or replace. Retighten or replace.
replace. plug.
H
H
Check radiator hoses
Check water pumps.
for cracks.
OK NG
NG OK
H
H Retighten or
Retighten or replace. replace gas-
ket.
H
END

HIGH OIL CONSUMPTION

Crank engine and check compression pressure.

(Refer to EM section.)
Check points.
Oil leakage. I Cylinder gasket damaged
Refer to OIL LEAKAGE. I Piston or piston ring worn
I Valve stem or valve seat worn
I Valve lip seal worn

OK NG
H
Repair or
replace.
H
END

ET-30
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

OVERHEATING

Check amount of coolant.

OK NG
H
Replenish.
H
Check cooling system for leakage.
I Check hose connection.
I Check radiator cap.
I Check radiator fins for breakage.
I Check cylinder head gasket for leakage.
I Check water pump for leakage.
I Check cylinder block for cracks.

OK NG
H
Adjust or replace.
H
Check fan belt tension.

OK NG
H
Adjust.
H
Is cooling system clogging?

No Yes
H
Clean.
H
Is thermostat sticking?

No Yes
H
Replace.
H
Check water pump.
I Check body assembly and vane for rust formation or corrosion.
I Check end play or roughness of bearing in operation.

OK NG
H
Replace water pump assembly.
H
END

ET-31
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

INSUFFICIENT OUTPUT
Eq
A

H
FUEL SYSTEM

H
Check that fuel quality is normal. NG Replace.
E
OK
H
Does control lever contact maximum NG Adjust or repair.
ETM0005 E
speed adjusting screw?
Check points.
I Accelerator pedal stroke
I Accelerator wire elongated
I Accelerator linkage stuck

OK
H
Check fuel line. NG Repair, retighten or
E
Check points. replace.
I Fuel line twisted or clogged
I Fuel filter clogged
ETM0006 I Leaks or loose

OK

H
Purge air and drain water.
(Refer to EF section.)

OK
q
B

H H
Check injection timing. (plunger lift) NG Adjust.
E
(Refer to EF section.)

OK
H
Does delivery valve stick? No Replace.
E
Yes
H
Overhaul injection pump.
Disassembling and assembling injection
pump should be done only in service
shops authorized by the pump manufac-
turer.

ET-32
TROUBLE DIAGNOSES AND CORRECTIONS DIESEL

q
A

H
MECHANICAL SYSTEM

H
Check air cleaner element for clogs. NG Replace.
E
OK
H
Crank engine and check compression NG Repair or replace.
E
pressure. (Refer to EM section.)
ETM0009
Check points.
I Valve lip seal worn
I Piston or piston ring worn
I Valve stem or valve seal worn
I Cylinder gasket damaged

OK

H
Check injection nozzle. NG Adjust, repair or replace.
E
Check points.
I Fuel injection pattern
I Clogging
ETM0007
I Sticking
I Injection pressure

OK

H
Check that timing gear is set properly. NG Adjust.
E
OK
H
Check valve clearance. NG Adjust.
E
OK
H
q
B

ET-33
 ENGINE TUNE-UP DIESEL

Injection and Fuel System

CHECKING IDLE SPEED
1. Make sure that injection timing is correct.
2. Make sure that injection nozzle is in good condition.
3. Make sure that the following parts are in good condition.
I Air cleaner (clogging)
I Engine oil and coolant levels
I Valve clearances
4. Set F-R lever in neutral position. Engine parking brake and lock
both front and rear wheels with wheel chocks.
5. Start engine and warm it up until coolant temperature indicator
points to middle of gauge.

6. Attach tachometer’s pick-up to No. 1 fuel injection tube.

In order to take accurate reading of engine rpm, remove
clamps that secures No. 1 fuel injection tube.

ETM0013

7. Adjust engine to specified idle speed with idle speed adjusting

screw.
Idle speed:
700 rpm

ETM0014

NO-LOAD MAXIMUM ENGINE SPEED

General inspection
I Shift the gear to the neutral position.
I Check that the maximum speed setting bolt is sealed.
I From idling, depress the accelerator pedal fully and check that
the accelerator control lever hits against the maximum speed
setting screw. Then, check the engine speed at that time.
Inspection
I When the injection pump is replaced or overhauled, check the
no-load maximum engine speed. If it is out of the specified
range, adjust it.
ET-34
 ENGINE TUNE-UP DIESEL
Injection and Fuel System (Cont’d)
I After the engine is warmed up, shift the gear to the neutral
position. Open the throttle valve fully, then measure the no-load
maximum engine speed.
No-load maximum engine speed
2,600 - 2,700 rpm

I Remove the seal of the maximum speed setting screw, then

loosen the lock nut. Adjust the engine speed to the specified
value by rotating the maximum speed setting screw.

ETM0015

LOAD MAXIMUM ENGINE SPEED

General inspection
I Basically, when the no-load maximum engine speed is within
the specified range, it is considered to be good. Generally,
check only that the maximum speed setting screw is surely
sealed.
Inspection
I Check and adjust the no-load maximum engine speed before-
hand.
I After the engine is warmed up, shift to the neutral position.
Adjust the hydraulic control lever to the maximum tilt (rear-
most) position. Then, check the load maximum engine speed
(relief valve operated).
Load maximum engine speed
2,400 - 2,500 rpm

ET-35
 SPECIAL SERVICE TOOLS DIESEL

Tool number
Description
Tool name
ED19600000
Compression gauge set

NT783

KV11254410
Dial gauge

NT784

KV11229042
“K” & “KF” measuring
device

NT785

ET-36
BASIC MECHANICAL SYSTEM

CHECKING AND ADJUSTING FAN BELTS

WARNING:
I Be sure the engine is not running.
I Keep hands clean.
1. Visually inspect for cracks, fraying, wear or oiliness.
The belts should not touch the bottom of the pulley groove.
2. Check belt tension by pushing midway between pulleys.
Drive belt deflection:
H20-II, H25
11 - 13 mm (0.43 - 0.51 in)
ETM0046 TD27 (Used)
11 - 13 mm (0.43 - 0.51 in)
TD27 (New)
9 - 11 mm (0.35 - 0.43 in)
Pushing force:
98 N (10 kg, 22 lb)

LCM0020

CHECKING ENGINE COMPRESSION PRESSURE

(GASOLINE)
1. Warm up engine sufficiently, then stop engine.
2. Remove all spark plugs.

3. Properly attach a compression tester to spark plug hole in cyl-

inder being tested.

ETM0031

ET-37
BASIC MECHANICAL SYSTEM

4. Set carburetor throttle valve at fully-open position.

5. Crank engine and read gauge indication.
I Run engine at about 350 rpm.
I Engine compression measurement should be made as quickly
as possible.
Compression pressure:
Standard
H20-II
1,226 kPa (12.26 bar, 12.5 kg/cm2, 178 psi)/300
rpm
H25
1,275 kPa (12.75 bar, 13.0 kg/cm2, 185 psi)/300
rpm
Minimum
H20-II
1,030 kPa (10.30 bar, 10.5 kg/cm2, 149 psi)/300
rpm
H25
1,079 kPa (10.79 bar, 11.0 kg/cm2, 156 psi)/300
rpm
6. Cylinder compression in cylinders should not be less than 80%
of the highest reading.
If cylinder compression in one or more cylinders is low, pour a
small quantity of engine oil into cylinders through the spark plug
holes and retest compression.
I If adding oil helps the compression pressure, piston rings may
be worn or damaged.
I If pressure stays low, valve may be sticking or seating improp-
erly.
I If cylinder compression in any two adjacent cylinders is low, and
if adding oil does not help the compression, there is leakage
pass on the gasket surface.
Oil and water in combustion chambers can result from this problem.

CHECKING ENGINE COMPRESSION PRESSURE

(DIESEL)
1. Warm up engine.
2. Remove glow plate or injection nozzle.

ETM0010

3. Fit compression gauge adapter to cylinder head. Make sure

bleeder screw of gauge is closed.
Compression gauge adapter:
For glow plug hole
: 15 - 19 N⋅m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
For injection hole
: 54 - 63 N⋅m (5.5 - 6.5 kg-m, 40 - 47 ft-lb)

ETM0011

ET-38
BASIC MECHANICAL SYSTEM

ETM0012

4. Disconnect fuel cut solenoid wire and crank engine, then read
gauge indication.
I Engine compression measurement should be made as quickly
as possible.
Compression pressure:
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Standard 2,942 (29.4, 30, 427)
Minimum 2,452 (24.5, 25, 356)
Differential limit between cylinders 294 (2.9, 3, 43)

5. If cylinder compression in one or more cylinders is low, pour a

small quantity of engine oil into cylinders through the nozzle
holes and retest compression.
I If adding oil helps the compression pressure, piston rings may
be worn or damaged.
I If compression pressure stays low, valve may be sticking or
seating improperly.
I If compression pressure in any two adjacent cylinders is low,
and if adding oil does not help the compression, there is leak-
age pass on the gasket surface.
Oil and water in combustion chambers can result from this
problem.

ET-39
APPLIED MODEL: D01/D02 series
APPLIED AREA: Europe

ENGINE TUNEUP
Simple Idle Setting Method using Analog Circuit Tester

1. After warming up the engine sufficiently, turn off the ignition switch. Then ground terminal 1 of
the carburetor (LPG mixer). (Create the intermediate harness shown on page 2.)
2. After starting the engine, use an analog circuit tester to measure voltage of terminal 5 on the
connector. (Measure using the full - approximately 12V - range of the tester.)
3. Turn the key off, then restore the harness to its original condition. The measured voltage
should be in the range of 9.5 to 10V.
If it is out of this range, adjust it using the SAS (slow adjust screw). If the vehicle is an LPG
vehicle, use the tilt relief to also adjust MAS (main adjust screw).

The information in this bulletin should not be interpreted as the basis for claims unless so designated. Whenever you order
spare parts, refer to the Spare Parts Bulletin, not to this Technical Bulletin.

Printed in Japan Issue date: August 22, 2000 (I ) Publication No. TB00E-D12SE0

Page 1 of 4
 ENGINE TUNE-UP GASOLINE

Ignition and Fuel System

1. Turn off the ignition switch, disconnect the battery negative cable.
2. Disconnect the connector between carburetor (mixer) and engine harness, and connect
the intermediate harness between them.
3. Connect the terminals of harness to the circuit tester. (Figure above)

The information in this bulletin should not be interpreted as the basis for claims unless so designated. Whenever you order
spare parts, refer to the Spare Parts Bulletin, not to this Technical Bulletin.

Printed in Japan Issue date: August 22, 2000 (I ) Publication No. TB00E-D12SE0

Page 2 of 4
 ENGINE TUNE-UP GASOLINE

Ignition and Fuel System (Cont'd)

4. Follow the steps for the idle speed and MAS (LPG) adjustment.
CAUTION:
o Adjust the monitor value to the middle (50%) of the range.
o Check the ignition timing before adjustment:

Engine type Ignition timing (BTDC degree)/rpm

H20-11
4°/650 - 750
H25
H2O-II (LPG) 12°/650 - 750
H25 (LPG) 8/750- 800

FICD setting speed (For reference):

H20-11 1,000 - 1,200 rpm
H25 1,000 - 1,100 rpm

The information in this bulletin should not be interpreted as the basis for claims unless so designated. Whenever you order
spare parts, refer to the Spare Parts Bulletin, not to this Technical Bulletin.

Printed in Japan Issue date: August 22, 2000 (I ) Publication No. TB00E-D12SE0

Page 3 of 4
 ENGINE TUNE-UP GASOLINE

Ignition and Fuel System (Cont'd)

The information in this bulletin should not be interpreted as the basis for claims unless so designated. Whenever you order
spare parts, refer to the Spare Parts Bulletin, not to this Technical Bulletin.

Printed in Japan Issue date: August 22, 2000 (I ) Publication No. TB00E-D12SE0

Page 4 of 4