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Toyota 4Y User Manual

Toyota 4Y
209 pages
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TOYOTA Material Handling Company
A Division of TOYOTA INDUSTRIES CORPORATION
Printed in USA Pub. No. CE602-2
4Y ENGINE
4Y ENGINE
353908_01a_cov 3/24/05 19:57 Page 1

Table of Contents

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Toyota 4Y Specifications

General IconGeneral
Displacement2237 cc
Compression Ratio8.8:1
Fuel SystemCarburetor
Cooling SystemWater-cooled
Fuel TypeGasoline
Engine Type4-cylinder
Valve TrainOHV
Max Power97 hp

Summary

General Information

Specifications

Lists detailed specifications for the 4Y engine.

Engine Tune-Up

Ignition Plug Cleaning and Gap Inspection & Adjustment

Guide to cleaning, gapping, and adjusting ignition plugs.

Ignition Timing Inspection and Adjustment

Procedures for inspecting and adjusting ignition timing.

Idle Speed Inspection and Adjustment

How to inspect and adjust the engine's idle speed.

No-Load Maximum Governed Speed Inspection and Adjustment

Procedures for inspecting and adjusting no-load maximum governed speed.

Compression Pressure Inspection

Steps for performing a compression pressure test.

Engine Overhaul

Cylinder Head Removal

Step-by-step guide for removing the cylinder head.

Cylinder Head Disassembly

Steps for disassembling the cylinder head.

Cylinder Head Distortion Inspection

How to inspect cylinder head for distortion.

Valve Seat Correction

Steps for correcting valve seats.

Valve Spring Inspection

Inspecting valve spring squareness, free length, and tension.

Rocker Arm to Rocker Shaft Oil Clearance

Measuring oil clearance for rocker arm and shaft.

Timing Gear & Camshaft Removal

Steps for removing timing gear and camshaft components.

Timing Chain and Camshaft Components Inspection

Inspecting camshaft runout, height, journal, and timing gear.

Crankshaft Front Oil Seal; Replacement

Procedures for replacing front oil seal and bearings.

Piston and Connecting Rod Assembly

Steps for assembling pistons and connecting rods.

Cylinder Block Assembly

Procedures for assembling the cylinder block.

Crankshaft Installation

Installing the crankshaft assembly.

Fuel System

Carburetor Body Disassembly

Disassembling the carburetor body.

Assembly

Assembling carburetor components.

Carburetor Adjustment

Idle Adjusting Screw Adjustment

Adjusting the idle adjusting screw.

Throttle Valve Adjustment

Adjusting the throttle valve.

Fast Idle Inspection and Adjustment

Inspecting and adjusting fast idle cam.

Choke Valve Adjustment

Adjusting the choke valve.

Unloader Inspection and Adjustment

Inspecting and adjusting unloader.

Air Governor Adjustment

Adjustment Procedure of Each Part

Procedures for adjusting air governor parts.

Air Governor Standard

Standards for air governor adjustments.

Cooling System

Coolant Inspection and Replacement

Inspecting and replacing engine coolant.

Coolant Replacement

Steps for draining and filling coolant.

Thermostat

Inspection and installation of the thermostat.

Lubrication System

Oil Pressure Inspection

Inspecting oil pressure.

Oil Filter

Components and replacement of the oil filter.

Engine Oil Filter Replacement

Procedures for replacing engine oil filter.

Engine Oil Filling

Filling engine with oil.

Drive and Driven Rotor Inspection

Inspecting oil pump rotor clearances.

Ignition System

Spark Plug Inspection and Adjustment

Inspecting and adjusting spark plugs.

Distributor Inspection

Inspecting distributor components.

Governor Shaft (or Spiral Gear) Replacement

Replacing governor shaft or spiral gear.

Air Gap Inspection

Inspecting air gap.

Starting System

Starting Motor

Components and removal/installation of the starting motor.

Armature Assy Removal

Removing armature assembly.

Armature Coil Grounding Test

Testing armature coil grounding.

Armature Coil Open-Circuit Test

Testing armature coil for open circuit.

Installation

Installing starting motor components.

Charging System

Disassembly

Disassembling alternator components.

Service Standards

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