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Toyota 4Y 2006 User Manual

Toyota 4Y 2006
259 pages
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This repair manual explains the repair points of the 4Y model engine equipped on the
Toyota Forklift Trucks.
Please make good use of this manual for your technical service.
This repair manual contains the latest information available as of August
2006.
For
any changes thereafter, Toyota reserves the right to make such changes in
specifications and descriptions without incurring any obligation and without previous
notice.
TOYOTA Material Handling Company
A
Division
of
TOYOTA
INDXTRIES
CORPORATION
ProCarManuals.com

Table of Contents

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Toyota 4Y 2006 Specifications

General IconGeneral
Engine code4Y
Cylinders4
Valves per Cylinder2
Compression Ratio8.8:1
Fuel typePetrol
Displacement2237 cc
Fuel SystemCarburetor

Summary

FOREWORD

GENERAL

SPECIFICATIONS

Technical specifications for the 4Y engine models (4Y-M and 4Y-E).

ENGINE EXTERIOR VIEW

Illustrations showing the external view of the 4Y-M and 4Y-E engines.

ENGINE SECTIONAL VIEW

Cross-sectional illustration of the engine, showing internal components.

HOW TO USE THIS MANUAL

Explanation of the manual's structure, illustration methods, and terminology.

TERMINOLOGY

Definitions of Warning, Caution, Note, Standard, and Limit.

ABBREVIATIONS

List of abbreviations used in the manual with their meanings.

OPERATING TIPS

Precautions and general instructions for engine handling and maintenance.

BOLT & NUT TIGHTENING TORQUES

Table and method for identifying bolt strength class and standard tightening torques.

SI UNITS

Explanation of SI units and conversion rates between conventional and SI units.

TROUBLESHOOTING

ENGINE DOES NOT CRANK NORMALLY

Identifies causes and inspection points for when the starter motor does not respond.

ENGINE DOES NOT START EASILY, OR DOES NOT START AT ALL

Lists potential causes and checks for ignition, fuel, and compression systems.

ENGINE IS ROUGH, OR STOPS, DURING IDLING

Details inspection points for rough idling or engine stalling during idle operation.

CANNOT ACCELERATE SMOOTHLY (INCLUDING HESITATION)

Outlines checks for fuel, ignition, and compression related to smooth acceleration.

INSUFFICIENT POWER OUTPUT (INCLUDING HUNTING)

Covers inspection of ignition, fuel, and drivetrain for power output issues.

ENGINE OVERHEATS

Identifies causes in ignition, compression, and cooling systems for engine overheating.

EXCESSIVE FUEL CONSUMPTION

Provides questions and inspection areas for diagnosing high fuel consumption.

ABNORMAL COMBUSTION

Classifies abnormal combustion noises like knocking, run-on, after-fire, and backfire.

ABNORMAL ENGINE NOISE, OR NOISY ENGINE

Breaks down engine noises by cause, such as clutch operation or idling.

EXCESSIVE ENGINE OIL CONSUMPTION

Explains oil loss phenomena via piston rings, valve guides, or PCV system.

ENGINE OVERHAUL (4Y-M)

SST TO BE USED

Lists and illustrates Special Service Tools (SSTs) required for engine overhaul.

ENGINE ATTACHMENTS

Details the removal, inspection, and installation of engine external components.

CYLINDER HEAD

Components and disassembly/reassembly procedures for the cylinder head.

TIMING GEAR

Components and disassembly/reassembly procedures for the timing gear system.

CYLINDER BLOCK

Components and disassembly/reassembly procedures for the cylinder block.

ENGINE ADJUSTMENT

Procedures for adjusting V-belt, idle speed, and ignition timing.

ENGINE OVERHAUL (4Y-E)

SST TO BE USED

Lists and illustrates Special Service Tools (SSTs) required for engine overhaul.

ENGINE ATTACHMENTS

Details the removal, inspection, and installation of engine external components.

CYLINDER HEAD

Components and disassembly/reassembly procedures for the cylinder head.

TIMING GEAR

Components and disassembly/reassembly procedures for the timing gear system.

CYLINDER BLOCK

Components and disassembly/reassembly procedures for the cylinder block.

ENGINE ADJUSTMENT

Procedures for adjusting V-belt, idle speed, and ignition timing.

FUEL SYSTEM (4Y-M)

SST TO BE USED

Lists and illustrates Special Service Tools (SSTs) for fuel system maintenance.

FUEL PUMP

Components, removal, inspection, and installation of the fuel pump.

CARBURETOR

Schematic diagram, components, inspection, and adjustment of the carburetor.

AIR GOVERNOR

Components, removal, inspection, reassembly, and adjustment of the air governor.

FUEL SYSTEM (4Y-E)

SST TO BE USED

Lists and illustrates Special Service Tools (SSTs) for fuel system maintenance.

THROTTLE BODY

Components and removal/inspection/installation of the throttle body assembly.

INJECTOR

Components, removal, inspection, and installation of fuel injectors.

FUEL PRESSURE REGULATOR

Inspection procedure for the fuel pressure regulator.

FUEL PUMP

Components, removal, inspection, and installation of the fuel pump.

INTAKE TEMPERATURE SENSOR

Removal, inspection, and installation of the intake air temperature sensor.

PCV DEVICE

VENTILATION VALVE

Components, removal, inspection, and installation of the ventilation valve.

COOLING SYSTEM

WATER PUMP

Components, removal, inspection, and disassembly/reassembly of the water pump.

WATER TEMPERATURE SENSOR

Removal, inspection, and installation of the water temperature sensor.

LUBRICATION SYSTEM

SST TO BE USED

Lists and illustrates Special Service Tools (SSTs) for lubrication system maintenance.

OIL PRESSURE INSPECTION

Procedure for inspecting engine oil condition and measuring oil pressure.

ENGINE OIL-OIL FILTER REPLACEMENT

Steps for draining engine oil and replacing the oil filter.

OIL PUMP-STRAINER

Components, removal, inspection, and reassembly of the oil pump and strainer.

IGNITION SYSTEM (4Y-M)

CIRCUIT DIAGRAM

Electrical circuit diagram of the 4Y-M ignition system.

SPARK PLUGS

Inspection of spark plugs, including cleaning and gap measurement.

DISTRIBUTOR

Components, on-vehicle inspection, and removal/installation of the distributor.

IGNITION SYSTEM (4Y-E)

SPARK PLUGS

Inspection of spark plugs, including cleaning and gap measurement.

DISTRIBUTOR

Components related to the distributor system.

IGNITER

General information and caution regarding igniter inspection.

STARTING SYSTEM

SST TO BE USED

Lists and illustrates Special Service Tools (SSTs) for starter motor maintenance.

STARTER MOTOR

Components, removal, inspection, and disassembly/reassembly of the starter motor.

CHARGING SYSTEM

SST TO BE USED

Lists and illustrates Special Service Tools (SSTs) for alternator maintenance.

ON-VEHICLE INSPECTION

Procedures for checking battery, V-belt, fuse, wiring, and performing a no-load test.

ALTERNATOR

Electrical circuit diagram and components of the alternator.

APPENDIX

SST LIST

A detailed list of Special Service Tools (SSTs) cross-referenced by section.

SERVICE STANDARDS

Technical specifications and limits for engine body components.

TIGHTENING TORQUE FOR EACH PART

Table listing tightening torques for various engine components.

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