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8FGCU20
Toyota 8FGCU20 User Manual
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ENGINE
SECTIONAL
VIEW
4Y-E Repair
Section 1.1.0
87
89
Table of Contents
Table of Contents
2
Exterior Views
3
Vehicle Model
5
Frame Number
6
How to Use this Manual
8
Explanation Method
8
Terminology
9
Abbreviations
9
Operational Tips
10
Hoisting the Vehicle
12
How to Start the Hour Meter
12
Attentive Points on Sas
13
Circuit Tester
14
Standard Bolt & Nut Tightening Torque
16
Bolt Strength Class Identification Method
16
Precoat Bolts
19
High Pressure Hose Fitting Tightening Torque
19
Wire Rope Suspension Angle List
20
Safe Load for each Wire Rope Suspension Angle
20
Components Weight
21
Recommended Lubricant Quantity & Types
22
Lubrication Chart
24
Periodic Maintenance
26
Inspection Method
26
Engine Exterior View
33
Engine Main Parameters
35
Engine Performance Curves
38
Engine Assy
41
Removal·installation
41
Air Bleeding of the Fuel System
44
Engine Inspection·adjustment
44
4Y Engine
48
1Dz-II Engine Vehicle
49
Air Cleaner
51
Specifications
51
Components
51
Air Cleaner Cleaning·inspection
53
Clogging Warning System Inspection (Opt)
54
Radiator
55
Components
55
Specifications
56
Coolant Capacity and Antifreeze Table
56
Coolant Inspection
56
Muffler & Exhaust Pipe
60
Components
60
Removal·installation
61
Battery
64
Components
64
Specifications
65
Inspection
66
V-Belt Tension Adjustment
67
Accelerator Pedal
68
Components
68
Inspection·adjustment
69
Ez Pedal (Opt)
71
Components
71
Disassembly·inspection·reassembly
72
Adjustment
74
Travel and Load Handling Control Device (Opt)
76
Components
76
Removal·installation
77
Throttle Opening Degree Adjustment
79
Troubleshooting
82
Specifications
85
Engine Exterior View
86
Engine Sectional View
88
How to Use this Manual
90
Explanation Method
90
Terminology
91
Abbreviations
92
Operating Tips
93
General Instructions
93
Electrical Parts Inspection
96
Bolt & Nut Tightening Torques
98
Method and Tightening Torque
98
Precoated Bolts
101
Si Units
101
HANDLING Flpg (LIQUID GASKETS)
102
Troubleshooting
105
Mechanical Trouble
105
Engine Does Not Crank Normally
106
Or Does Not Start at All
107
During Idling
108
Cannot Accelerate Smoothly
109
Insufficient Power Output
111
Engine Overheats
112
Excessive Fuel Consumption
113
Abnormal Combustion
114
Or Noisy Engine
116
Excessive Engine Oil Consumption
119
Sst to be Used
121
Engine Attachments
123
Cylinder Head
126
Components
126
Disassembly=Inspection=Reassembly
141
Timing Gear
141
Components
150
Cylinder Block
150
Engine Adjustment
161
V-Belt 1Nspection.adjustment
161
Idle-Up Speed
162
Load Maximum Speed Inspection and
163
Adjustment
163
Compression Inspection
163
Sst to be Used
167
Engine Attachments
169
Removal-Inspection~Installation
169
Cylinder Head
173
Components
173
Timing Gear
185
Components
185
Cylinder Block
197
Components
197
Engine Adjustment
208
V-Belt Inspection-Adjustment
208
Idle Speed Inspection
209
Load Maximum Speed Measurement
210
Compression Inspection
210
Sst to be Used
213
Fuel Pump
214
Components
214
Removal
215
Airtightness Inspection
215
Installation
216
Carburetor
217
Schematic Diagram
217
Components
218
On-Vehicle Inspection
219
Disassembly
220
Inspection
224
Reassembly
226
Carburetor Adjustment
228
Fast Idle Cam Adjustment
230
Air Governor
231
Components
231
Removallinstallation
232
Disassembly
232
Inspection
233
Reassembly
234
Adjustment
235
Sst to be Used
239
Throttle Body
240
Components
240
Injector
243
Removal-Inspection-Installation
244
Fuel Pressure Regulator
247
Fuel Pump
248
Components
248
Intake Temperature Sensor
252
Removal
252
Inspection
252
Installation
252
Ventilation Valve
255
Components
255
Removal
256
Inspection
256
Installation
256
Sst to be Used
265
Oil Pressure Inspection
266
ENGINE Oilmoil FILTER REPLACEMENT
267
OIL Pumpmstrainer
268
Components
268
Disassemblyminspection.reassembly
271
Circuit Diagram
275
Spark Plugs
276
Inspection
276
Distributor
277
Components
277
On-Vehicle Inspection
278
Spark Plugs
289
Inspection
289
Distributor
290
Components
290
On-Vehicle Inspection
291
Removal
291
Installation
292
Igniter
293
General
293
Sst to be Used
297
Starter Motor
298
Components
298
Disassembly-Inspection-Reassembly
300
Starter Motor Assy Unit Inspection
305
How to Read this Manual
335
Explanation Method
335
Terminology
336
Abbreviations
336
Operation Precautions
338
Special Precautions
338
General Precautions
338
Inspection of Electric Parts
341
Bolt and Nut Tightening Torque
343
Bolt Strength Type Identification Method and Tightening Torque
343
Precoat Bolts
346
Agent Coating on Threads)
346
Si Units
346
HANDLING the Flpg (LIQUID GASKET)
347
Engine Does Not Crank Normally
350
Engine Does Not Start Easily or Does Not Start at All
351
Engine Malfunctions or Stops While Idling
352
Cannot Accelerate Smoothly
352
Insufficient Output
353
Engine Overheating
353
High Fuel Consumption
354
Frequent Diesel Knocking
355
Large Amount of Exhaust Smoke While Driving
355
Unusual Engine Sounds and Noises
356
High Engine Oil Consumption
359
Used Ssts
361
Engine Accessories
363
Removal. Inspection and Installation
363
Cylinder Head
368
Components
368
Disassembly. Inspection and Reassembly
370
Timing Gear Components
379
Disassembly. Inspection and Reassembly
381
Cylinder Block Components
392
Disassembly. Inspection and Reassembly
394
Cylinder Block Bore Dimensions
406
Engine Tune-Up
407
Belt Tension Inspection and Adjustment
407
Valve Clearance Inspection and Adjustment
408
Idling Speed Inspection and Adjustment
408
Maximum Engine Speed Inspection and Adjustment
409
Injection Timing Inspection and
409
Compression Inspection
411
Used Ssts
413
Fuel Filter
415
Removal and Installation
415
Disassembly, Inspection and Reassembly
417
Injection Nozzle
419
Removal and Installation
420
Injection Pump
424
Specifications
424
Removal and Installation
426
Disassembly
427
Inspection
433
Reassembly
437
Airtightness Test
449
Adjustment
450
Used Ssts
471
Oil Pressure Inspection
472
Engine Oil and Oil Filter Replacement
472
Oil Strainer
473
Oil Pump
474
Used Ssts
479
Preheating System
480
Electric Circuit Diagram
480
Inspection of Glow Plug
481
Inspection of Preheating Timer
481
Inspection of Water Temperature Sensor
482
Starter Motor
483
Removal, Inspection and Installation
484
Disassembly. Inspection and Reassembly
485
Starter Assembly Individual Inspection
491
Appendix
505
Sst List
505
Service Standards
509
Engine Overhaul
509
Fuel System
515
Cooling System
519
Lubrication System
519
Starting System
520
Type of Lpg Devices
525
Engine Performance Curves
526
Engine Specifications
529
Principal Differences from Gasoline Vehicle
530
General Rules of Servicing Work
531
Bolt & Nut Tightening Torques
532
Bolt Strength Class Identification Method and Tightening Torque
532
Precoated Bolts (Bolts with Seal Lock Agent Coating on Threads)
535
Periodic Maintenance
536
Inspection Method
536
Periodic Replacement Parts
536
Outline of Lpg Device
539
Fuel Filter for Lpg
540
Solenoid Valve
540
Adapter
541
Specifications
541
Regulators System Components
548
Before Troubleshooting
571
Connector Handling
571
Wire Harness and Connector Inspection Procedure
571
Before Beginning Troubleshooting
573
Diagnosis (Self Diagnosis Function)
574
General
574
How to Interpret the Flow-Charts
575
Analyzer
576
Analyzer Menu Screen List
577
About Trouble Shooting by Error Codes
578
Troubleshooting by Symptoms
581
Other manuals for Toyota 8FGCU20
Repair Manual
222 pages
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Toyota 8FGCU20 Specifications
General
Model
8FGCU20
Load Capacity
4, 000 lbs
Transmission
Automatic
Engine Type
Internal Combustion
Fuel Type
LPG
Tire Type
Pneumatic
Mast Type
3-Stage
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