Page 1513 of 3573
SERVICE INFORMATION 00 Ð 13
Checkpoint Possible cause Correction 4. SLAPPING NOISE
Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Rocker arm Damaged rocker arm Replace the rocker arm
Flywheel Loose flywheel bolts Retighten the flywheel bolts
Crankshaft and
thrust bearingsWorn or damaged crankshaft and/or
thrust bearingsReplace the crankshaft and/or the
thrust bearings
Crankshaft and
connecting rod
bearingsWorn or damaged crankshaft and/or
connecting rod bearingsReplace the crankshaft and/or the
connecting rod bearings
Connecting rod
bushing and piston
pinWorn or damaged connecting rod bushing
and piston pinReplace the connecting rod bushing
and/or the piston pin
Piston and cylinder
linerWorn or damaged piston and cylinder liner.
Foreign material in the cylinder.Replace the piston and the cylinder
liner.
Page 1514 of 3573
00 Ð 14 SERVICE INFORMATION
Condition Possible cause Correction
Engine overheating Low coolant level Replenish
Thermo unit faulty
Faulty thermostat
Faulty coolant unit
Clogged radiator
Faulty radiator cap
Low engine oil level or use of improper
engine oil
Damaged cylinder head gasket
Clogged exhaust system
Loose fan belt
Excessive fuel injected
Improper injection timing
Injection timing improper
Faulty thermostat
Faulty thermostatReplace
Replace
Repair or replace
Clean or replace
Replace
Replenish or change oil
Replenish
Replace
Clean exhaust system or replace
faulty parts
Adjust
Adjust
Adjust
Replace
Replace
Thermo unit faultyReplace Engine overcooling
Too long engine
warm-up time
Adjust
ENGINE COOLING TROUBLE
Page 1515 of 3573
SERVICE INFORMATION 00 Ð 15
ENGINE ELECTRICAL
Check if the battery is normal, then perform the following diagnosis.
STARTER DOES NOT RUN
CHECK BATTERY
CHARGING FAILURE OR LIFE
CHECK BATTERY
BATTERY IS NORMAL
CHECK TERMINAL CONNECTION
CONNECTION FAILURE
CLEAN BATTERY TERMINALS, AND RECONNECT
TERMINAL CONNECTION IS NORMAL
CHECK STARTER OR STARTER SWITCH
FAILURE
REPAIR OR REPLACE
TURN ON HEAD LAMP AND STARTER SWITCH
HEAD LAMP DOES NOT COME ON
OR IT IS EXTREMELY DARK
a) LACK OF BATTERY CHARGING
b) SHORT-CIRCUIT IN STARTER COIL
c) FAULTY STARTER PARTS
HEAD LAMP ILLUMINATES
a) DISCONNECTED STARTER CIRCUIT
b) DISCONNECTED STARTER COIL
c) FAULTY STARTER SWITCH
Page 1516 of 3573
00 Ð 16 SERVICE INFORMATION
FAULTY MESHING OR PINION AND RING GEAR
CHECK IF BATTERY VOLTAGE IS PRESENT AT
MAGNETIC SWITCH TERMINAL “S” WHEN
STARTER SWITCH IS TURNED TO “START (ST)”
YESNO
EXTREME WEAR OF
PINION AND RING
GEARSTARTER SLIDING
RESISTANCE IS
LARGE
REPAIR OR REPLACE
STARTER. REPLACE
RING GEARREPAIR OR REPLACE
STARTER
UNDER THIS CONDITION, CHECK IF VOLTAGE
OF CONNECTOR 3BW ON MAGNETIC SWITCH
OF RESTART RELAY IS NORMAL
DISCONNECTION OR
FAULTY CONNECTION
BETWEEN STARTER
SWITCH AND MAGNETIC
SWITCHCHECK IF VOLTAGE IS
PRESENT AT WIRING
CONNECTOR 3BW ON
STARTER SWITCH OF
RESTART RELAY
YESNO
REPAIR
YESNO
FAULTY CONNECTION
OF STARTER SWITCH DISCONNECTION OR
FAULTY CONNECTION
BETWEEN STARTER
SWITCH AND BATTERY
REPLACE STARTER
SWITCH
REPAIR
OR
Page 1517 of 3573
SERVICE INFORMATION 00 Ð 17
MAGNETIC SWITCH DOES NOT OPERATE THOUGH
STARTER SWITCH IS TURNED TO “START (ST)”
CHECK IF VOLTAGE IS PRESENT AT MAGNETIC
SWITCH TERMINAL “S” WHEN STARTER SWITCH
IS TURNED TO “START (ST)”
YESNO
CHECK IF INDICATOR LAMP ON
METER COMES ON NORMALLY
CHECK CONTINUITY
STARTER SWITCH AND
MAGNETIC SWITCH
TERMINAL “S”DISCONNECTION OR
FAULTY CONNECTION
BETWEEN BATTERY
AND STARTER SWITCH
YESNO
CHECK GROUND CABLE
YESNO
PINION
SLIDING
PART DOES
NOT MOVEMAGNETIC SWITCH
OR COIL IS
DISCONNECTED
OR BURNED OUT
REPAIR
REPAIR OR REPLACE STARTER
REPAIR
CHECK STARTER
RELAYFAULTY CONNECTION
OR STARTER SWITCH
CHECK CLUTCH
START SWITCHREPLACE STARTER
SWITCH
OR
Page 1518 of 3573
00 Ð 18 SERVICE INFORMATION
PINION MESHES WITH RING GEAR BUT
ENGINE DOES NOT RUN
CHECK GROUND CABLE
YESNO
REPAIR OR REPLACE
GROUND CABLE
FAULTY CONNECTION
OF BRUSH AND
COMMUTATORBURNED-OUT
MAGNETIC
STARTER SWITCHDISCONNECTION
OR DAMAGE OF
FIELD COILDISCONNECTION
OR DAMAGE OF
ARMATURE COILSLIP OF
PINION
CLUTCH
REPAIR OR REPLACE STARTER
Page 1519 of 3573
SERVICE INFORMATION 00 Ð 19
STARTER DOES NOT STOP THOUGH STARTER
SWITCH IS RETURNED TO “ON”
YESNO
REPLACE STARTER SWITCHMAGNETIC SWITCH CONTACTS
ARE FUSED AND NOT MOVED, OR
A RETURN SPRING IS BROKEN OR
DETERIORATED
DISCONNECTED STARTER SWITCH WIRING CONNECTOR, AND CHECK STARTER SWITCH OPERATION.
THERE MUST BE NO CONTINUITY EXCEPT ABOVE LINES
KEY
POSITIONBATTERY
B1
LOCK
OFF
ACC
ON
START
IGNITION
IG1BATTERY
B2ACCESSORIES
ACCIGNITION
IG2STARTER
ST
REPLACE MAGNETIC SWITCH
Page 1520 of 3573

00 Ð 20 SERVICE INFORMATION
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Engine type
Camshaft type
Cylinder line-type
Number of cylinders
Bore x stroke
Total piston displacement
Compression ratio
Engine weight (dry)
Engine idling speed (Reference)
Compression pressure
Firing order
Injection timing
VALVE SYSTEM
Intake valves
Exhaust valve
Valve clearance at
Oil filter
Oil capacity (Original factory fill or rebuilt engine)
Oil capacity (Service change)
with filter change
without filter change
Oil cooler
Inter cooler
Turbocharger
Control method
Lubrication method
Cooling method
(mm)
(cc)
(to 1)
N (kg/lb)
RPM
open at:
close at:
open at:
close at:
cold
intake:
exhaust:mm (in)Diesel, four cycle water cooled inline
Overhead valve
Dry type
4
95.4 x 107
3,059
20.0
2353 (240/529)(4JG2-NA)
2597 (265/584)(4JG2-T)
750 (4JG2-NA)
720 (4JG2-T)
2940 (30/426)-200
1–3–4–2
1¡A.T.D.C (4JG2-NA)
T.D.C. (4JG2-T)
B.T.D.C. 24¡
A.B.D.C. 55¡
B.B.D.C. 54¡
A.T.D.C. 26¡
0.40 (0.016)
0.40 (0.016)
Full flow and bypass combined type
7.1 liters (6.3 US quarts)
6.0 liters (6.3 US quarts)
5.0 liters (5.3 US quarts)
Water cooled type
Air cooled type
Wastegate control
Pressurized control
Coolant cooled kpa (kg/cm /psi)-rpm
2