Page 146 of 1226
Clutch Disc
INSPECTION
Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)
+Check clutch disc for backlash of spline and runout of facing.
Maximum backlash of spline (at outer edge of disc):
Model 240
1.0 mm (0.039 in)
Runout limit:
Model 240
0.7 mm (0.028 in)
Distance of runout check point (from hub center):
Model 240
115.0 mm (4.53 in)
+Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
INSTALLATION
+Apply recommended grease to contact surface of spline por-
tion.
Too much lubricant might cause clutch disc facing damage.
SCL778
SCL780
SCL779
CLUTCH DISC AND CLUTCH COVER
CL-13
Page 153 of 1226
Special Service Tools
FOR DIESEL ENGINE INJECTION PUMP
Tool number
Tool nameDescription
KV11229352
Measuring device
V1KV11229350
Holder
V2KV11229360
Nut
V3KV11229370
Pin
V4KV11254410
Dial gauge
NT570
Measuring plunger lift
KV11102900
Pulley puller
NT647
Removing injection pump sprocket
FOR DIESEL ENGINE INJECTION NOZZLE
Tool number
Tool nameDescription
KV11289004
Nozzle cleaning kit
V1KV11290012
Box
V2KV11290110
Brush
V3KV11290122
Nozzle oil sump scraper
V4KV11290140
Nozzle needle tip
V5KV11290150
Nozzle seat scraper
V6KV11290210
Nozzle holder
V7KV11290220
Nozzle hole cleaning
needle
NT296
PRECAUTIONS AND PREPARATION
EC-2
Page 172 of 1226
Description
In this system, blow-by gas is sucked into the air inlet pipe through
the control valve after oil separation by oil separator in the rocker
cover.
Inspection
BLOW-BY CONTROL VALVE
Check control valve for clogging and abnormalities.
VENTILATION HOSE
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEF456HA
SEC586B
Blow-by control valve
Rocker coverIntake
manifold
SEC692
CRANKCASE VENTILATION SYSTEM
EC-21
Page 174 of 1226

Inspection (No.2-4nozzles)
Thoroughly clean all disassembled parts with fresh kerosene or
solvent.
+If nozzle needle is damaged or fused, replace nozzle assem-
bly with a new one.
+If end of nozzle needle is seized or excessively discolored,
replace nozzle assembly.
+Check nozzle body and distance piece for proper contact. If
excessively worn or damaged, replace nozzle assembly or dis-
tance piece.
+Check distance piece and nozzle holder for proper contact. If
excessively worn or damaged, replace distance piece or nozzle
holder.
+Check nozzle spring for excessive wear or damage. If exces-
sively worn or damaged, replace it with a new spring.
Cleaning (No.2-4nozzles)
a. Do not touch the nozzle mating surface with your ®ngers.
b. To wash the nozzles, use a wooden stick and brass brush
with clean diesel fuel.
1. Remove any carbon from exterior of nozzle body (except wrap-
ping angle portion) by using Tool.
2. Clean oil sump of nozzle body using Tool.
3. Clean nozzle seat by using Tool.
This job should be performed with extra precautions, since
efficiency of nozzle depends greatly on a good nozzle seat.
SEF830
SEF831
SEF832
INJECTION NOZZLE
EC-23
Page 199 of 1226

Symptom Matrix Chart
SYSTEM
Ð Basic engine
control systemSYMPTOM
Reference page
Feature of symptom, Check pointHARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator lamp illuminates.
Can be detected by CONSULT?
Fuel cutNO START (with ®rst ®ring)
NO START (without ®rst ®ring)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATING
BLACK SMOKE
WHITE SMOKEWarranty symptom
codeAA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Injection
timingAdvancedjj
++j+jj+jEC-47
Retardedjj
++j+jj+jEC-47
Electric injection pump
mainframe
++++jjjjj+jjj++jj+j jjjÐ*1
Injection nozzlejjjjjjj
+jj j++ +EC-22 *2
Glow systemjj
++ + +EC-151
Engine body
jj
++jjj+jj j++jjj+EM sec-
tion*3
EGR system
++ +EC-156
Air cleaner and ducts
++ +jMA sec-
tion*4
+; High Possibility Item
j; Low Possibility Item
*1: Insufficient or excess amount. Governor malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
TROUBLE DIAGNOSIS Ð General Description
EC-48
Page 200 of 1226

SYSTEM
Ð ECCS systemMalfunction
SYMPTOM
Reference
page Feature of symptom
Check point
HARD/NO START/
RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE) Malfunction indicator lamp illuminates.
Can be detected by CONSULT?
Fuel cut
NO START (with ®rst ®ring) NO START (without ®rst ®ring)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGBLACK SMOKE WHITE SMOKE
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM AP HAECCS
Camshaft position sensor (PUMP) cir-
cuitopen, shortjj
EC-69Tachometer malfunction
noisejjjj jj
Mass air ¯ow sensor circuitopen, ground shortjjj j
EC-74
shortjjj
Engine coolant temperature sensor
circuitopen, shortjjj jjj jjEC-79Compensation according to
engine coolant temperature does
not function.
Vehicle speed sensor circuit open, shortjjEC-83
Control sleeve position sensor circuit open, shortjjjjjjEC-87
Adjustment resistor circuit open, shortj j jjjj j jEC-92
Electric governor circuitopen, ground shortj jjjjjj
EC-96
shortjj
Injection timing control valve circuitopen, shortjjj
EC-101Injection timing cannot be con-
trolled.
ground shortjj
Accelerator switch (FC) circuitopen, shortjjj
EC-106
ground shortjj
Charge air temperature sensor circuit open, shortjEC-122
Needle lift sensor circuit open, shortjjjEC-126
Fuel cut solenoid valve circuitopen, ground shortj jjjj
EC-130
shortjjjEngine runs on after turning igni-
tion switch OFF.
Fuel temperature sensor circuit open, shortjj jj jj j jj jEC-135Compensation for amount of fuel
injected according to fuel tem-
perature does not function.
Accelerator position sensor circuit open, shortjjj jjEC-139
Crankshaft position sensor (TDC) cir-
cuitopen, shortjj jj
EC-144
noisejjjjj
TROUBLE DIAGNOSIS Ð General Description
Symptom Matrix Chart (Cont'd)
EC-49
Page 201 of 1226

SYSTEM
Ð ECCS systemMalfunction
SYMPTOM
Reference page Feature of symptom
Check point
HARD/NO START/
RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE) Malfunction indicator lamp illuminates.
Can be detected by CONSULT?
Fuel cut
NO START (with ®rst ®ring) NO START (without ®rst ®ring)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGBLACK SMOKE WHITE SMOKE
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM AP HAECCS
Start signal circuit open, shortjjEC-163 Start control does not function.
Neutral position switch circuitopen, shortjjj
EC-170
ground shortjj
Accelerator position switch (Idle) cir-
cuitopen, ground shortjj j
EC-165
shortjjj jjAccelerator position sensor NG
signal is output.
Accelerator position switch (Full) cir-
cuitopen, shortjjj jjEC-165
Ignition switch circuitopenj jjj
EC-63
shortEngine does not stop.
Power supply for ECM circuitopenjjj
EC-63
shortjj
Throttle control solenoid valve circuitopen, short
EC-156Does not operate.
ground shortjj jDoes not stop operating.
EGRC-solenoid valve A, B circuitopen, short
EC-156
ground shortjDoes not stop operating.
Glow relay circuitopenjjjjj
EC-151Glow lamp does not turn on.
shortGlow lamp does not turn off.
ECCS relay (Self-shutoff) circuitopenjjjj
EC-63
shortjjGround short makes engine
unable to stop.
ECM, Connector circuit open, shortjjjjjjjjjjjjj jjjjjjjjjjjjEC-111
Air conditioner relay circuitopen
EC-187Air conditioner does not operate.
shortAir conditioner does not stop
operating.
Air conditioner switch circuitopen, ground short
EC-187Air conditioner does not stop
operating.
shortAir conditioner does not work.
TROUBLE DIAGNOSIS Ð General Description
Symptom Matrix Chart (Cont'd)
EC-50
Page 220 of 1226

Camshaft Position Sensor (CMPS) (PUMP)
The camshaft position sensor (PUMP) is located on the electronic
fuel injection pump.
The sensor consists of a permanent magnet, core and coil.
When engine is running, gap between sensor and drive shaft rotat-
ing plate will periodically change. Permeability near the sensor also
changes.
Due to the permeability change, the magnetic ¯ux near the core is
changed. Therefore, the voltage signal generated in the coil is
changed.
The ECM receives the voltage signal (6 pulses/2 engine revolu-
tions).
These signals are used for tachometer indication.
CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Speci®cation data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
CKPSzRPM (REF)+Tachometer: Connect
+Run engine and compare tachometer indication with the CONSULT
value.Almost the same speed as the
CONSULT value.
CKPSzRPM-PUMP
ECM TERMINALS AND REFERENCE VALUE
Remarks: Speci®cation data are reference values and are measured between each terminal andV43(ECCS
ground) with a voltmeter.
TER-
MINAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC Voltage and Pulse
Signal)
28
33BCamshaft position sensor
(PUMP) groundEngine is running.
(Warm-up condition)
Idle speedApproximately 0V
41
45WCamshaft position sensor
(PUMP)Engine is running.
(Warm-up condition)
Idle speedApproximately 0V
SEF722V
Engine is running.(Warm-up condition)
Engine speed is 2,000 rpm.Approximately 0V
SEF723V
SEF674V
TROUBLE DIAGNOSIS FOR ``CAM POS SEN (PUMP)'' (DTC 11)
EC-69