Shop Manual

cover.
fm 1 ページ２００８年７月２日　水曜日　午後１２時３０分
TB45E-BE1
TB45E ENGINE
TB45E
GASOLINE ENGINE (ECU)
LIFT TRUCK MODEL SERIAL No.

FG40Z-10 M251-133001 and up
FG35-10 M253-133001 and up
FG40-10 M253-133001 and up
FG45-10 M253-133001 and up
FG50A-10 M253-133001 and up
2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan

TB45E-BE1
TB45E ENGINE
TB45E
GASOLINE ENGINE (ECU)
LIFT TRUCK MODEL SERIAL No.

FG40Z-10 M251-133001 and up
FG35-10 M253-133001 and up
FG40-10 M253-133001 and up
FG45-10 M253-133001 and up
FG50A-10 M253-133001 and up
2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan

CONTENTS
Page No.
ENGINE GENERAL
PRECAUTIONS FOR SAFETY AND QUALITY ..................................................................EG-2
Description .....................................................................................................................................................EG-2
Safe Work ......................................................................................................................................................EG-2
Correct Work ..................................................................................................................................................EG-3
Precautions for Radio Equipment Installation ................................................................................................EG-3
HOW TO READ THIS MANUAL ..........................................................................................EG-4

Outline ............................................................................................................................................................EG-4
Definition of Terms .........................................................................................................................................EG-4
Definition of Units ...........................................................................................................................................EG-4
Description .....................................................................................................................................................EG-5
Component Parts Location ............................................................................................................................EG-5
TROUBLE DIAGNOSIS .......................................................................................................EG-7

ECM Trouble Diagnosis .................................................................................................................................EG-7
ECM Abbreviations List ................................................................................................................................EG-10
ECM GENERAL SERVICE INFORMATION ......................................................................EG-11

Connector Terminal Inspection ....................................................................................................................EG-11
Inspection for Electrical System ...................................................................................................................EG-12
Control Unit and Electronic Component .......................................................................................................EG-13
SST ..............................................................................................................................................................EG-14
PRECAUTIONS FOR WORK ............................................................................................EG-15

Precautions for Draining Coolant .................................................................................................................EG-15
Precautions for Separating Fuel Piping .......................................................................................................EG-15
Precautions for Removal and Disassembly .................................................................................................EG-15
Precautions for Checking, Repairing, and Replacing Parts .........................................................................EG-15
Precautions for Assembling and Installing Parts ..........................................................................................EG-15
Precautions for Using Power Tools ..............................................................................................................EG-16
Precautions for Applying Gasket Sealent ....................................................................................................EG-16
Parts Which Need to be Tightened by Angle Tightening Method ................................................................EG-17
PREPARATION .................................................................................................................EG-18
Special Service Tools ..................................................................................................................................EG-18
Service Parts ................................................................................................................................................EG-20
SERVICE DATA .................................................................................................................EG-21

Periodical Inspection ....................................................................................................................................EG-21
Standard, Repair Limit .................................................................................................................................EG-23
Tightening Torque ........................................................................................................................................EG-24
ENGINE MECHANICAL
INTAKE MANIFOLD ............................................................................................................EM-2
Component Parts Location ........................................................................................................................... EM-2
Removal and Installation of Intake Manifold ................................................................................................. EM-3
Removal and Installation of Air Horn Bolt ..................................................................................................... EM-3
Inspection ...................................................................................................................................................... EM-3
EXHAUST MANIFOLD ........................................................................................................EM-4

Component Parts Location ........................................................................................................................... EM-4
Removal and Installation ............................................................................................................................... EM-4
1
OIL PAN AND OIL STRAINER ........................................................................................... EM-6
Component Parts Location ............................................................................................................................EM-6
Removal and Installation ...............................................................................................................................EM-6
ROCKER COVER ............................................................................................................... EM-8

Preparation ....................................................................................................................................................EM-8
Removal ........................................................................................................................................................EM-8
Installation .....................................................................................................................................................EM-8
ROCKER ARM AND ROCKER SHAFT ASSEMBLY ......................................................... EM-9

Preparation ....................................................................................................................................................EM-9
Removal ........................................................................................................................................................EM-9
Installation ...................................................................................................................................................EM-10
Disassembly and Assembly .........................................................................................................................EM-10
Inspection ....................................................................................................................................................EM-10
CYLINDER HEAD ............................................................................................................. EM-12

Component Parts Location ..........................................................................................................................EM-12
Preparation ..................................................................................................................................................EM-12
Cylinder Head Auxiliary Bolt ........................................................................................................................EM-13
Cylinder Head Bolt .......................................................................................................................................EM-13
Cylinder Head Bolt Washer .........................................................................................................................EM-14
Cylinder Head Gasket .................................................................................................................................EM-14
Cylinder Head Assembly .............................................................................................................................EM-15
TIMING CHAIN .................................................................................................................. EM-20

Removal ......................................................................................................................................................EM-20
Installation ...................................................................................................................................................EM-23
CYLINDER BLOCK ........................................................................................................... EM-27

Disassembly ................................................................................................................................................EM-27
Selective-Fit Service Parts ..........................................................................................................................EM-31
Inspection After Disassembly ......................................................................................................................EM-31
Assembly .....................................................................................................................................................EM-44
ENGINE LUBRICATION
OIL PUMP ............................................................................................................................ LU-2
Component Parts Location .............................................................................................................................LU-2
Disassembly and Assembly ............................................................................................................................LU-2
Inspection .......................................................................................................................................................LU-3
ENGINE COOLING SYSTEM

CHANGING ENGINE COOLANT ......................................................................................... LU-2
Draining Engine Coolant .................................................................................................................................LU-2
Refilling Engine Coolant .................................................................................................................................LU-2
WATER PUMP ..................................................................................................................... LU-3

Component Parts Location .............................................................................................................................LU-3
Removal and Installation ................................................................................................................................LU-3
Water Pump Inspection ..................................................................................................................................LU-3
2
THERMOSTAT ..................................................................................................................... LU-4
Component Parts Location ............................................................................................................................ LU-4
Removal and Installation ................................................................................................................................ LU-4
ENGINE CONTROL
PRECAUTIONS ................................................................................................................... EC-3
General Precautions for Service Operations .................................................................................................EC-3
On Board Diagnostic (OBD) System of Engine .............................................................................................EC-4
Precaution ......................................................................................................................................................EC-4
Special Service Tools ....................................................................................................................................EC-7
ENGINE CONTROL SYSTEM ............................................................................................. EC-8

Description .....................................................................................................................................................EC-8
System Diagram ............................................................................................................................................EC-9
Sensors and Actuators Control Items .......................................................................................................... EC-12
TROUBLE DIAGNOSIS ..................................................................................................... EC-13

Trouble Diagnosis Procedure ...................................................................................................................... EC-13
Diagnosis Chart by Symptom ...................................................................................................................... EC-17
Locations of components ............................................................................................................................. EC-28
Circult Diagram ............................................................................................................................................ EC-32
ECM Terminal Layout .................................................................................................................................. EC-33
ECM Input/Output Signal Specifications ...................................................................................................... EC-36
SST ..............................................................................................................................................................EC-42
Self-diagnosis Function (without SST) ......................................................................................................... EC-46
Service Tool .................................................................................................................................................EC-48
Method of indicating failure code with troubleshooting tool ......................................................................... EC-49
Example of indication of failure code ...........................................................................................................EC-50
Method of indicating failure code with meter panel ...................................................................................... EC-50
SST Reference Value in Data Monitor ........................................................................................................EC-51
Fail-Safe Function ........................................................................................................................................ EC-52
Circuit Diagram ............................................................................................................................................ EC-53
CRANKSHAFT POSITION SENSOR 1° (POS) ................................................................. EC-54

CRANK ANGLE SENSOR 120° (REF) SIGNAL SYSTEM ............................................... EC-55

Component Parts Inspection ........................................................................................................................EC-55
MASS AIR FLOW SENSOR SYSTEM .............................................................................. EC-56

SST Data Monitor Display ............................................................................................................................EC-56
Component Parts Inspection ........................................................................................................................EC-56
HEATED OXYGEN SENSOR SYSTEM ............................................................................ EC-57

VEHICLE SPEED SENSOR SYSTEM ............................................................................... EC-58

3
THROTTLE POSITION SENSOR SYSTEM ......................................................................EC-59
SST Data Monitor Display ........................................................................................................................... EC-59
Component Parts Inspection ....................................................................................................................... EC-59
ACCELERATOR PEDAL POSITION SENSOR SYSTEM .................................................EC-60

Circuit Diagram ........................................................................................................................................... EC-60
INTAKE AIR TEMPERATURE SENSOR SYSTEM ...........................................................EC-61

IGNITION SYSTEM ............................................................................................................EC-62

FUEL INJECTOR SYSTEM (GASOLINE) .........................................................................EC-63

THROTTLE CONTROL MOTOR SYSTEM ........................................................................EC-64

HEATED OXYGEN SENSOR HEATER SYSTEM .............................................................EC-65

LPG INJECTOR SYSTEM .................................................................................................EC-66

Inspection .................................................................................................................................................... EC-66
LPG ASSISTANCE INJECTOR SYSTEM .........................................................................EC-67

LPG FUEL PRESSURE SENSOR SYSTEM .....................................................................EC-68

FUEL CUT FUNCTION ......................................................................................................EC-69

Inspection Procedure ................................................................................................................................... EC-69
INTERCEPTION VALVE SYSTEM ....................................................................................EC-70

4
FUEL CHANGING SWITCH SYSTEM ............................................................................... EC-71
BLOW-BY GAS REDUCING DEVICE ............................................................................... EC-72

System Chart ............................................................................................................................................... EC-72
Removal and Installation of Blow-by Control Valve .....................................................................................EC-72
Inspection of Blow-by Control Valve ............................................................................................................ EC-72
ECM COPMONENTS ......................................................................................................... EC-73

ECM ............................................................................................................................................................. EC-73
Crankshaft Position Sensor (Integrated Into the Distributor) ....................................................................... EC-73
Mass Air Flow Sensor .................................................................................................................................. EC-73
Engine Coolant Temperature Sensor .......................................................................................................... EC-73
Heated Oxygen Sensor (With Heated Oxygen Sensor Heater) ................................................................... EC-74
Throttle Position Sensor (Electric Throttle Control Actuator Assembly) .......................................................EC-74
LPG Injector Holder ..................................................................................................................................... EC-75
SERVICE DATA AND SPECIFICATIONS (SDS) .............................................................. EC-76

Standard, Repair Limit .................................................................................................................................EC-76
ENGINE FUEL SYSTEM

FUEL SYSTEM .....................................................................................................................FL-2
Description ......................................................................................................................................................FL-2
Gasoline Specification ....................................................................................................................................FL-2
LPG Specification ...........................................................................................................................................FL-3
Specification for Combined Gasoline and LPG ...............................................................................................FL-3
FUEL INJECTOR (GASOLINE AND COMBINED USE) ......................................................FL-4

Preparation .....................................................................................................................................................FL-4
Fuel Hose ........................................................................................................................................................FL-4
Fuel Tube and Fuel Injector ............................................................................................................................FL-4
Inspection ........................................................................................................................................................FL-6
LPG PARTS ..........................................................................................................................FL-7

LPG Device (Specifications for LPG and Gasoline/LPG) ...............................................................................FL-7
Injector Holder .................................................................................................................................................FL-9
Vaporizer .......................................................................................................................................................FL-12
ENGINE ELECTRICAL SYSTEM

STARTING SYSTEM ........................................................................................................... EL-2
Component Parts Location ............................................................................................................................ EL-2
Starter Motor .................................................................................................................................................. EL-2
STARTING MOTOR EXPRODED ........................................................................................ EL-3

MAINTENANCE OF STARTER ........................................................................................... EL-4
Starter Motor .................................................................................................................................................. EL-4
Armature Coil ................................................................................................................................................. EL-4
Data related to brush commutators ................................................................................................................ EL-4
CHARGING SYSTEM .......................................................................................................... EL-5

Component Parts Location ............................................................................................................................ EL-5
5
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR ............. EL-6
Component Parts Location .............................................................................................................................EL-6
Disassembly ...................................................................................................................................................EL-7
Inspection .......................................................................................................................................................EL-9
HIGH-TENSION CABLE .................................................................................................... EL-13

Assembly ......................................................................................................................................................EL-13
ENGINE TUNE-UP
VALVE CLEARANCE .......................................................................................................... ET-2
Description ......................................................................................................................................................ET-2
Inspection .......................................................................................................................................................ET-2
Adjustment ......................................................................................................................................................ET-3
ENGINE DRIVE BELT .......................................................................................................... ET-4

Inspection .......................................................................................................................................................ET-4
Belt Tension Adjustment .................................................................................................................................ET-5
ENGINE OIL ......................................................................................................................... ET-6

Inspection .......................................................................................................................................................ET-6
Replacement ..................................................................................................................................................ET-7
Oil Filter Replacement ....................................................................................................................................ET-8
COMPRESSION PRESSURE ............................................................................................ ET-10

Inspection .....................................................................................................................................................ET-10
SPARK PLUG .................................................................................................................... ET-11

Removal and Installation ..............................................................................................................................ET-11
Inspection After Removal .............................................................................................................................ET-11
6
KOMATSU TB45 ENGINE GENERAL
SECTION EG
CONTENTS
PRECAUTIONS FOR SAFETY AND QUALITY ... EG-2 PRECAUTIONS FOR WORK ........................... EG-15
Description ..................................................... EG-2 Precautions for Draining Coolant ................. EG-15
Safe Work ...................................................... EG-2 Precautions for Separating Fuel Piping ....... EG-15
Correct Work .................................................. EG-3 Precautions for Removal and Disassembly . EG-15
Precautions for Radio Equipment Installation .. EG-3 Precautions for Checking, Repairing, and
HOW TO READ THIS MANUAL ........................ EG-4 Replacing Parts ........................................... EG-15
Outline ............................................................ EG-4 Precautions for Assembling and
Definition of Terms ......................................... EG-4 Installing Parts ............................................. EG-15
Definition of Units ........................................... EG-4 Precautions for Using Power Tools ............. EG-16
Description ..................................................... EG-5 Precautions for Applying Gasket Sealent .... EG-16
Component Parts Location ............................ EG-5 Parts Which Need to be Tightened by Angle
TROUBLE DIAGNOSIS ...................................... EG-7 Tightening Method ....................................... EG-17
ECM Trouble Diagnosis ................................. EG-7 PREPARATION ................................................ EG-18
ECM Abbreviations List ................................ EG-10 Special Service Tools .................................. EG-18
ECM GENERAL SERVICE INFORMATION .... EG-11 Service Parts ............................................... EG-20
Connector Terminal Inspection .................... EG-11 SERVICE DATA ............................................... EG-21
Inspection for Electrical System ................... EG-12 Periodical Inspection .................................... EG-21
Control Unit and Electronic Component ....... EG-13 Standard, Repair Limit ................................. EG-23
SST .............................................................. EG-14 Tightening Torque ........................................ EG-24
PRECAUTIONS FOR SAFETY AND QUALITY
Description
• Observe the following precautions for safe and proper maintenance.
• Only qualified and appointed persons shall inspect, repair, or
adjust the vehicle.
• Keep the workplace and tools clean.
Safe Work
• Do not run the engine in a place which has no exhaust ducts
and which is poorly ventilated.
• Ventilate the workplace well and do not place a combustible
thing there. Take extreme care when handling a combustible
thing or a hazardous material such as gasoline.
• Dispose of the replaced oil, parts washing oil, etc. according to
laws.
• When working on parts which become hot, rotary parts, or
sliding parts, take care not to burn or injure yourself.
• When working in a pit or a closed place, ventilate it to discharge
EGM0043
harmful materials in advance.
• Do not work on the vehicle jacked up. When working on it,
support it by the specified parts on wood blocks, etc.
• When lifting up the vehicle, support it by the specified parts and
apply a safety device.
• When removing a heavy part such as the engine, vehicle body,
etc. take care not to drop it by unbalancing it.
• Do not smoke while maintaining the vehicle.
• When maintaining the vehicle, take off rings and necklace to
prevent a short circuit in the electrical system.
EGM0044
• Before starting repair which does not need the battery power,
turn the key switch OFF and disconnect the negative (–)
terminal of the battery.
EGM0045
• Take care not to touch the hot metal parts just after stopping the
engine. While the engine is still hot, do not remove the radiator
cap or another part of the coolant system.
• Use the specified proper common tools or special tools for safe
and efficient repair.
EGM0046
EG-2
Correct Work
• Grasp the contents of each trouble, and then troubleshoot and
work efficiently.
• When removing and disassembling parts, check their normal
assembly condition in advance. Make match marks on places
which do not affect the function, if necessary.
• If an oil seal, gasket, packing, O-ring, lock washer, cotter pin,
self-lock nut, etc. are removed, replace them according to the
directions in their sections (Parts which must not be reused).
• When a tapered roller bearing or a needle roller bearing needs
to be replaced, replace its inner race and outer race as a set.
• Arrange the removed parts in order so that they will not be
mixed up.
• Before checking or assembling the disassembled parts, clean
them.
• When replacing a part, install a NISSAN genuine part.
• Use the specified oil, grease, sealant, etc.
• Before removing a pressurized pipe, hose, etc., release the
pressure.
• After repairing the fuel, oil, coolant, exhaust, or vacuum system,
check it for leakage securely.
Precautions for Radio Equipment Installation

Check the following when installing a commercial/ham radio or
mobile phone. If mounting position is not chosen carefully, the unit
may interfere with the electronic control system.
• Separate the antenna as far from the ECM as possible.
• Route an antenna feeder line at least 20 cm (7.87 in) apart from
the control unit harness.
• Adjust an antenna and feeder line to eliminate radio wave
interference.
EG-3
HOW TO READ THIS MANUAL
Outline
This chapter explains how to read the procedures of "removal,
disassembly, assembly, inspection, and adjustment" and "trouble-
shooting".
Definition of Terms
CAUTION:
• An item or a work procedure, neglect of which can cause a
death or a serious injury if neglected.
• An item or a work procedure to be observed especially
among those, neglect of which can cause an injury, an
accident, or a damage of the vehicle or component parts.
Reference : Supplementary explanation for the ease of work.

Standard value : Permissible deviation of a value at inspection or
adjustment.
Limit value : The maximum or minimum which a value must not
exceed at inspection or adjustment.
Definition of Units
In this manual, tightening torque, pressure, etc. are indicated by the
"SI unit" (International unit) first, then by the "metric unit) in { }.
Example) Tightening torque: 59 - 78 Nm {6.0 - 8.0 kgf•m}
SI unit {Metric unit}
CONVERSION OF MAJOR UNITS
Quantity SI unit Conventional unit Coefficient of conversion into SI
Acceleration m/s2 G 9.80665
Torque and moment Nm kgf•m 9.80665

Force N kgf 9.80665
Pressure MPa kgf/cm 2 0.09809665
kPa mmHg 0.133322

Power/Power efficiency kW PS 0.735499
W kcal/h 1.16279
Volume cm 3 cc 1
Spring constant N/mm kgf/mm 9.80665

Fuel consumption g/kW•h(*1) g/PS•h 1.3596
*1. Conventional unit may be used in SI.
EG-4
Description
CAUTION : At the beginning of each section, the precautions
exclusive to the section are described.
Preparation: At the beginning of each section and during the trouble
diagnosis items, the SSTs, gauges, and other tools to
be prepared before operation are described. Some
commercial service tools, assumed to be available in
any workshop, are omitted.
Description : To perform correct operations, operational procedures,
notes, SSTs, and other service information are
described.
CAUTION : Descriptions of visual inspections and cleaning of
removed parts are generally omitted. Please
remember that actual operations require these
processes.
Component Parts Location

The "Component Parts Location" diagram (refer to the figure)
includes information for removal, installation, disassembly, and
assembly (tightening torque, grease points, non-reusable parts) as
well as other information important for repair work.
EGM0097
EG-5
Component Parts Location (Cont'd)

COMPONENT SYMBOLS
EG-6
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
ECM Trouble Diagnosis

CAUTION:
• The following trouble diagnosis procedures are designed
to identify the trouble causes efficiently. When performing
diagnoses, carefully observe the following instructions.
• Before starting a trouble diagnosis, carefully read and
understand the contents in "Basic Inspection", "Diagnosis
Chart by Symptom" and "Trouble Diagnosis Flowchart".
• After the repair work, always verify that the trouble is
eliminated.
• For the locations of the parts and harness connectors,
refer to "Component Parts Location" in the relevant
section.
• To perform a simple inspection, utilize the circuit diagrams.
To inspect the circuit for continuity in details including the
sub-harnesses, identify the relevant connectors and
harness layouts referring to the "Wiring Diagrams".
• Before inspecting a circuit for continuity, always turn the
ignition switch to OFF.
• Before measuring voltage at a connector, always measure
the battery voltage.
• After finishing diagnoses or inspections, always ensure
that all removed harness connectors are reconnected
correctly.
EG-7
TROUBLE DIAGNOSIS
ECM Trouble Diagnosis (Cont'd)

SYMBOLS
EG-8
TROUBLE DIAGNOSIS
ECM Trouble Diagnosis (Cont'd)

SYMBOLS FOR HARNESS CONNECTOR
FEMALE CONNECTOR
• When a harness connector is viewed from A (terminal side), the
outer frame of the connector symbol is indicated with a single
line. In addition, the direction indicator shows "TS" (Terminal
Side) in description type font.
EGM0050
• When a harness connector is viewed from B (harness side), the

outer frame of the connector symbol is indicated with double
lines. In addition, the direction indicator shows "HS" (Harness
Side) in description type font.
• Terminal assignments of a connector viewed from A and B are
mirror images, indicating just as they are seen.
EGM0051
MALE CONNECTOR
The illustration method is the same as that for a female connector,
the black guide box, however, indicates a male connector (the white
guide box a female connector).
EGM0052
SINGLE UNIT (CONTROL UNIT)

A single control unit is viewed only from A, and the illustration is as
shown in the figure.
EGM0053
EG-9
TROUBLE DIAGNOSIS
ECM Abbreviations List

Abbreviations Description Abbreviations Description
A/C Air conditioner INT Intake

A/T Automatic transmission LH Left
ALT Alternator LED Light emitting diode
ASSY Assembly LLC Long-life coolant
BAT Battery M/T Manual transmission
C/P Crankshaft pulley OHV Overhead valve
C/U Control unit OS Oversize
Cyl Cylinder P/S Power steering
ENG Engine PTO Power take-off
EXH Exhaust RH Right
F/L Fusible link RR Rear
FR Front TAS Throttle adjust screw
I/P Idler pulley Tr Transistor
IGN Ignition US Undersize
EG-10
ECM GENERAL SERVICE INFORMATION
Connector Terminal Inspection

CONNECTOR INSPECTION PROCEDURE
In circuit inspection, inappropriate connector probing will cause
connector damages and/or poor connection. The probes provided
with the circuit tester may be too large to probe connector terminals
without damaging them. Always use alligator clips and "T" pins
according to following the procedure.
INSPECTION FROM HARNESS SIDE

For a standard connector without any waterproofing, use "T" pins
from the harness side.
CAUTION:
• For a connector with a rear cover, such as ECM
connectors, remove the rear cover before the inspection.
• For a waterproof connector, do not probe the terminals
from the harness side. Doing so may damage the seal.
EGM0054
INSPECTION FROM TERMINAL SIDE

1. Female terminal
• Female connector terminals have a small notch difference
inside. Insert a "T" pin along the step to inspect.
CAUTION:
Do not insert any objects to a female connector terminal other
than the corresponding male connector terminal.
EGM0055
• In case of a female connector terminal without any notches,

remove the retainer before probing.
EGM0056
EG-11
Connector Terminal Inspection (Cont'd)

2. Male terminal
For a male connector terminal, apply a "T" pin to the surface of the
terminal.
CAUTION:
Do not bend terminals.
EGM0057
Inspection for Electrical System

DESCRIPTION
• If the malfunction can be traced directly to the electrical system,
first check for items such as burned-out fuses and fusible links,
broken wires or loose connectors, pulled-out terminals, and
improper connections.
• If a fuse or a fusible link is blown out, determine the possible
cause and restore it. Always replace it with a new fuse or fusible
link of the specified capacity.
• When removing a connector, do not apply excessive force to the
main body by grasping and twisting.
• Do not pull a connector off by tugging on the harness.
• For a lock-type connector, disengage its lock first, then
disconnect the connector by holding the main body of the
connector.
EGM0058
• Before connecting a connector, check terminals for bends or

breakage. Connect it securely.
• For a lock-type connector, press it until its lock is securely
engaged.
• When installing parts, prevent harnesses from being snagged
or overextended.
EGM0059
EG-12
Control Unit and Electronic Component

PRECAUTIONS
• Never reverse polarity of battery terminals.
• Install only parts specified for each model.
• Before replacing a control unit, check input and output signals
to/from the control unit, and component functions.
• When disconnecting a connector, do not twist or apply
excessive force.
• For a bolt-type connector, loosen the bolt first, then hold the
main body of the connector to disconnect.
• Before connecting a connector, check terminals for bends or
breakage. Connect it securely. For a bolt-type connector, screw
in the bolt until the colored lug is flush with the surface to be
sure it is securely connected.
• Do not drop, hit, or subject control units to impact.
• Be sure to protect control units from condensation caused by a
sudden shift in temperature, or from raindrops or splashes. If
any water drops adhere to the unit, dry it well prior to
installation.
• Be sure to protect control unit connectors from oil.
• Avoid cleaning control units with benzine.
• Do not open a top or bottom cover on a control unit.
EGM0062
• When using a circuit tester, ensure the appropriate distance

between test probes. A longer distance is recommended,
because if the distance is too short, it may cause contact of the
test probes, resulting in a short circuit. A short circuit allows
battery voltage to be applied directly to the control unit, resulting
in damage to its internal power transistors.
• Use the specified check adapter to check input and output
signals to/from control units.
EGM0063
EG-13
SST
DESCRIPTION
SST is a small, lightweight handheld tester. When connected to the
vehicle-side data link connector, it communicates with control units
installed on the vehicle and performs a variety of diagnostic tests.
FUNCTION AND APPLIED SYSTEM
Items Function
WORK SUPPORT Sends command to control unit to set status suitable for inspection and service.
FUNCTION SYSTEM Checks each system as ECM basic inspection.
SELF-DIAG RESULTS Receives self-diagnostic results from control unit and indicates DTCs and number of occurrences.
SELF-DIAG RESULTS DTCs (Diagnostic Trouble Codes) recorded in control unit's memory are displayed.
[MEMORY]
DATA MONITOR Receives input/output signals from control unit and indicates and stores them to facilitate locating cause of
malfunctions.
DATA MONITOR [SPEC]
Active test Sends command to control unit to change output signals and check operation of output system.
DTC RECORD DISPLAY Indicates self-diagnostic results stored in ECM prior to the most recent "ERASE MEMORY".
Control unit part No. Displays control unit part number.
Control unit identification No. Displays control unit identification number.
Diagnostic systems Engine
WORK SUPPORT {
SELF-DIAG RESULTS {
SELF-DIAG RESULTS [MEMORY]
DATA MONITOR {
DATA MONITOR [SPEC] {
Active test {
DTC RECORD DISPLAY
Control unit part No. {
Control unit identification No.
EG-14
PRECAUTIONS FOR WORK
Precautions for Draining Coolant

Drain the coolant after its temperature lowers sufficiently.
Precautions for Separating Fuel Piping

• Work in a place where there is nothing to start a fire.
• Release the fuel pressure in advance.
• After separating the fuel piping, plug it to prevent the fuel from
flowing out.
Precautions for Removal and Disassembly

• If specified, use correct special tools and pay attention. Do not
apply an excessive force.
• Take extreme care not to lower the accuracy of the mating
faces, sliding faces, etc.
• If necessary, cover the openings with tapes, etc. to prevent
foreign matter from entering the engine.
• Make marks on the removed parts and arrange them for secure
troubleshooting and assembly.
• As a rule, loosen the bolts and nuts from outside in the diagonal
direction. If the loosening order is specified, observe it.
Precautions for Checking, Repairing, and

Replacing Parts
Before repairing or replacing parts, check them sufficiently according
to the check procedure. Check the new parts similarly and replace
them if necessary.
Precautions for Assembling and Installing

Parts
• When tightening the bolts and nuts, be sure to use torque
wrenches.
• As a rule, tighten the bolts and nuts from inside to outside in the
diagonal direction in 2 – 3 times. If the tightening order is
specified, observe it.
• Replace the gaskets, packings, oil seal, and O-rings with new
ones.
• Clean each part and dry it by blowing compressed air against it.
In particular, take care that the oil passages and coolant
passages will not be clogged.
• Take care not to damage the sliding surfaces and mating faces,
and remove all dirt, lint, etc. from them. Apply sufficient oil to the
sliding surface before assembling.
• If the coolant is drained, bleed air from the coolant system.
• After repairing, run the engine at high speed and check for
leakage of the coolant, fuel, oil, grease, and exhaust gas.
EG-15
Precautions for Using Power Tools

Use power tools such as an air runner for disassembly only. Do not
use them for assembly.
Precautions for Applying Gasket Sealent

SEPARATION OF PARTS COATED WITH GASKET
SEALANT
• After removing the mounting bolts and mounting nuts, cut and
remove the gasket sealant with seal cutter A (special tool
KV101-11100) according tothe following procedure.
[1] Drive in the seal cutter in the direction of the arrow.
[2] Slide the seal cutter in the direction of the arrow.
[3] Slide the seal cutter in the direction of the arrow.
CAUTION:
• Take care not to damage the mating faces.
• If it is difficult to use the seal cutter, remove the gasket
sealant by hitting it lightly with a plastic hammer.
EGM0066
CAUTION:
If it is obliged to use a flat-head screwdriver, take extreme care
not to damage the mating faces.
PROCEDURE FOR APPLYING GASKET SEALANT

1. Remove the old gasket sealant sticking to the mating faces with
scraper B.
• Remove all the gasket sealant from the grooves, mounting
bolts, and bolt holes, too.
2. Wipe the mating faces with isoparaffin, etc. to remove water, oil,
grease, and foreign matter.
3. Install the genuine gasket sealant to tube presser C (common
tool).
EGM0067
4. Apply the gasket sealant to the specified parts and dimensions

without breaking it.
• Apply the gasket sealant to the grooves, too, if specified so.
• As a rule, apply the gasket sealant to the inside of the bolt
holes. The outside of the bolt holes may need to be coated
with the gasket sealant, however. Accordingly, refer to
themanual without fail.
• Install the parts within 5 minutes after applying the gasket
sealant.
• Wipe off the projected gasket sealant immediately.
EGM0068
• Do not retighten the bolts after installing the parts.
• After installing the parts, wait at least 30 minutes before
supplying engine oil or coolant.
CAUTION:
If a direction is given in the manual, ob-serve it.
EG-16
Parts Which Need to be Tightened by Angle

Tightening Method
• Use angle wrenches (special tools) to tighten the following
parts.
• Cylinder head bolt
Check that the cylinder head, cylinder block mounting face, and
cylinder head gasket are free from oil and dirt, and then coat the
threads and stem of the cylinder head bolt and tighten it.
EG-17
PREPARATION
PREPARATION
Special Service Tools

Special Service Tools (Cont'd)
Description Application Remarks
Seal cutter Removing parts attached with

KV1011 11100 liquid gasket
EGM0069
Ring gear stopper Removing and installing

KVl101 056S0 crankshaft pulley
1 Adapter
KV101 05630
2 Stopper plate
KV101 05610
EGM0070
Oil seal drift Installing front oil seal

KV101 04900
EGM0071
Angle wrench Checking tightening angle

KV101 12100
Already established
EGM0072
1. Valve spring compressor Removing and installing valve

KV101 09210 collet
2. Adapter
KV101 11200
EGM0073
Valve oil seal puller Removing valve oil seal

KV101 07901
EGM0074
Valve oil seal drift Installing valve oil seal

KV101 13000
EGM0075
EG-18
PREPARATION

Engine stand assembly Overhauling engine

ST0501 S000
EGM0076
Engine attachment
KV101 06500
EGM0077
Engine sub-attachment
KV111 04800 Already established
EGM0078
Camshaft bushing tool set Removing and installing camshaft

KV111 045S0 bushing
1. Bar
KV111 04510
2. Guide plate
KV111 04520
3. Adapter
KV111 04530
4. Drift
ST1524 3000
EGM0079
Pulley puller Removing crankshaft pulley. Already established

KV111 03000
EGM0080
Oil filter wrench Removing oil filter Already established

KV101 15801
EGM0081
EGI fuel pressure indicator For measuring fuel pressure

ST1959 0000 gauge
EGM0082
EG-19
PREPARATION

Heated oxygen sensor wrench Removing and installing heated

KV101 13700 oxygen sensor
EGM0083
Maintenance tool For system inspection and

1. DIAGNOSIS KIT diagnosis
SKVEE GY010
2. SOFT WARE
SKVEE GY100
Check adapter V For control unit input/output signal
EG1755 0000 inspection
(for SMJ 150-pin connector)
EGM0084
Harness adapter
EG1755 0200
(150-pin to 121-pin conversion adapter)
EGM0085
For molding coil Checking engine speed

Adapter harness
EG101 17500
EGM0086
Service Parts
Piston oversize
0.5 mm (0.020 in) OS [0.5 mm (0.020 in) oversize]
1.0 mm (0.039 in) OS [1.0 mm (0.039 in) oversize]
Main bearing undersize
Unit: mm (in)
Size Thickness
STD 2.000 (0.0787)

US 0.25 (0.0098) 2.125 (0.0837)
US 0.50 (0.0197) 2.250 (0.0886)
US 0.75 (0.0295) 2.375 (0.0935)
US 1.00 (0.0394) 2.500 (0.0984)
EG-20
SERVICE DATA
SERVICE DATA
Periodical Inspection
To maintain the initial performance of the NISSAN FORKLIFT, make
sure to perform appropriate maintenance and service work.
PERFORM INSPECTION
Make sure to perform the periodical inspections at the appropriate
times, according to the month basis or the operating hour basis,
whichever comes first.
Refer to the following notes for values in ( ).
Engine system inspection (except LPG fuel systems)
Months of
1 2 3 4 5 6 7 8 9 10 11 12 ... 18
Applicab use
No. nspection items le control
Operation
system hours 2 4 6 8 10 12 14 16 18 20 22 24 ... 36
(x 100 hours)
1 Intake/exhaust valve clearance Electronic A A A A A ... A

Electronic controls controls
2 Engine drive belt tension Electronic I I I I I I I I I I I I ... I
controls
3 Engine oil Electronic (1) R R R R R R R R R R R R ... R
controls
4 Oil filter Electronic (1) R R R R R ... R
controls
5 Engine coolant Electronic R ...
controls
6 Air cleaner element Electronic C C C C C R C C C C C R ... R
controls
7 Ignition timing Electronic A A A A A A A A A A A A ... A
controls
8 Spark plug Electronic I I I I I I I I I I I I ... R
controls
9 Distributor Electronic C ...
controls
10 PCV valve Electronic (1) I I I I ... I
controls
11 PCV hose Electronic I I I I ... I
controls
EG-21
SERVICE DATA
Periodical Inspection (Cont'd)

No. Engine system inspection (LPG models)
1 Gas leakage from piping and piping Electronic (2) I I I I I I I I I I I I ... I

joints controls
2 Damage to piping and piping joints Electronic I I I I I I I I I I I I ... I
controls
3 Tar in vaporizer Electronic D D D D D D D D D D D D ... D
controls
4 Injection nozzle Electronic I I I I I ... I
controls
5 LPG filter Electronic C C C R ... C
controls
CAUTION:
• If the vehicle is being used in dusty and dirty environments, the maintenance work should be performed
more frequently.
• After replacing the LPG tank, apply soapsuds to the piping joints to check for any gas leakage.
Meanings of symbols: I = Inspection. Repair or replace if necessary.
R = Replacement
A = Adjustment
C = Cleaning
D = Draining
T = Tightening (Retightening)
EG-22
SERVICE DATA
Standard, Repair Limit

Fuel in use Gasoline specification Lead-free regular gasoline with an octane value of 91 or more
LPG specification 20-100P
Engine weight (without water, with oil) kg (lb) Approx. GAS, LPG:301’, DUAL:302’
Firing order 1-5-3-6-2-4
Compression pressure Standard 1,187 (11.87, 12.1, 172)/200
kPa (bar, kgf/cm2, psi)/rpm Repair limit 892 (8.92, 9.1, 129)/200
Difference limit among cylinders 98 (0.98, 1.0, 14)/200
Distortion limit mm (in) Intake manifold 0.2 (0.008)
0.3 (0.012)
Exhaust manifold
Cylinder head 0.2 (0.008)
Cylinder block 0.1 (0.004)
Engine oil amount l (Imp qt) When replacing oil only Approx. 8.3 (7-1/4)
(SL class)
When replacing oil and filter Approx. 8.6 (6-5/8)
Spark plug Manufacturer/type/gap mm (in) NGK/BPR4ES-D/0.8 - 0.9 (0.031 - 0.035)
Resistance on high-tension cable (kΩ) #1: Approx. 2.7 #2: Approx. 2.8 #3: Approx. 4
#4: Approx. 5 #5: Approx. 5.2 #6: Approx. 6.1
Ignition advance device Electronically controlled ignition advance
Onboard idle speed (rpm) 750 ± 50
Onboard idling pace speed (When feedback control is stopped) (rpm) 750
Density of CO at idle speed/Density of HC at idle speed (%/ppm) 0.1 or less/50 or less
Ignition timing (When feedback control is stopped) (BTDC°/rpm) 10 ± 2/750
Valve clearance mm (in) INT/EXH Hot 0.35 (0.0138)/0.35 (0.0138)
Thermostat opening valve temperature (Start - Full open) °C (°F) 82 - 95 (180 - 203)
Engine drive belt deflection New belt After adjustment Limit
[Measured by pressing Alternator belt/Fan belt 10 - 12 13 - 15
16 (0.63)
with 98 N (10 kg, 22 lb)] mm (in) (0.39 - 0.47) (0.51 - 0.59)
EGM0098
EG-23
SERVICE DATA
Tightening Torque
STANDARD BOLT TIGHTENING TORQUE
<Hexagon head> <No lubrication> Unit: N•m (kg-m, ft-lb)
N•m (kg-m, in-lb)*
4T 7T 9T
Normal size Pitch
d P Non-flanged Non-flanged
Flanged bolt Non-flanged bolt Flanged bolt Flanged bolt
bolt bolt
M3 0.5 0.6 0.7 1.1 1.3 1.6 1.9

(0.06, 5)* (0.07, 6)* (0.11, 10)* (0.13, 11)* (0.16, 14)* (0.19, 16)*
M3.5 0.6 1.0 1.2 1.7 2.1 2.5 2.8
(0.10, 9)* (0.12, 10)* (0.17, 15)* (0.21, 18)* (0.25, 22)* (0.29, 25)*
M4 0.7 1.5 1.7 2.5 2.9 3.5 4.2
(0.15, 13)* (0.17, 15)* (0.25, 22)* (0.30, 26)* (0.36, 31)* (0.43, 37)*
M5 0.8 2.9 3.5 5.0 5.9 7.2 8.5
(0.30, 26)* (0.36, 31)* (0.51, 44)* (0.6, 52)* (0.73, 63)* (0.87, 76)*
M6 1.0 5.0 6.0 8.4 10 11.8 14.7
(0.51, 44)* (0.61, 53)* (0.86, 75)* (1.0, 87)* (1.2, 8.7) (1.5, 10.8)
M8 1.25 12.7 14.7 20.6 24.5 29.4 35.3
(1.3, 9.4) (1.5, 10.8) (2.1, 15) (2.5, 18) (3.0, 22) (3.6, 26)
1.0 13.7 15.7 21.6 26.5 31.4 37.3
(1.4, 10) (1.6, 12) (2.2, 16) (2.7, 20) (3.2, 23) (3.8, 27)
M10 1.5 24.5 29.4 41.2 49 58.8 69.6
(2.5, 18) (3.0, 22) (4.2, 30) (5, 36) (6.0, 43) (7.1, 51)
1.25 25.5 30.4 43.1 51 61.8 73.6
(2.6, 19) (3.1, 22) (4.4, 32) (5.2, 38) (6.3, 46) (7.5, 54)
M12 1.75 42.2 51 70.6 84.3 98.1 118
(4.3, 31) (5.2, 38) (7.2, 52) (8.6, 62) (10, 72) (12, 87)
1.25 46.1 55.9 77.5 92.2 108 137
(4.7, 34) (5.7, 41) (7.9, 57) (9.4, 68) (11, 80) (14, 101)
M14 1.5 73.6 87.3 127 147 177 206
(7.5, 54) (8.9, 64) (13, 94) (15, 108) (18, 130) (21, 152)
M16 1.5 108 137 186 226 265 324
(11, 80) (14, 101) (19, 137) (23, 166) (27, 195) (33, 239)
M18 1.5 167 196 275 324 392 471
(17, 123) (20, 145) (28, 203) (33, 239) (40, 289) (48, 34)
M20 1.5 226 275 382 451 549 657
(23, 166) (28, 203) (39, 282) (46, 333) (56, 405) (67, 485)
M22 1.5 304 363 510 608 736 883
(31, 224) (37, 268) (52, 376) (62, 448) (75, 542) (90, 651)
CAUTION:
• Except special parts.
• The bolt applicable to the list has the following number embossed on the head.
Model Number
4T ... 4 or none
7T ... 7
9T ... 9
CAUTION FOR USE OF POWER TOOLS

Do not use any power tools (e.g. air ratchet, impact wrench) to
tighten the bolts and nuts. Use these tools only for loosening the
bolts and nuts. However, do not use power tools in any event and for
any purposes on the parts subject to heat (catalyst, muffler, and
other exhaust parts) and the tapping screws. These parts may also
be damaged when loosened with a power tool.
EG-24
SERVICE DATA
Tightening Torque (Cont'd)

MAIN TIGHTENING TORQUE
* : Parts with tightening sequence
1) - :Tighten separately in several turns.
Unit :N•m (kg-m, ft-lb)
N•m (kg-m, in-lb)*
Parts name or location Tightening torque
Adjusting screw Lock nut 16 - 22 (1.6 - 2.2, 12 - 16)

AlternatorAdjusting bar side 17.5 - 23.7 (1.8 - 2.4, 13 - 17)
Bracket side 50.0 - 67.6 (5.1 - 6.9, 37 - 50)
Oil pan drain plug 54 - 59 (5.5 - 6.0, 40 - 43)
Spark plug 20 - 29 (2.04 - 2.96, 14 - 22)
* Intake manifold 15.7 - 18.6 (1.6 - 1.9, 12 - 14)
* Air horn 20.6 - 26.5 (2.1 - 2.7, 16 - 27)
Exhaust manifold cover 6.37 - 7.45 (0.65 - 0.76, 56 - 66)*
* Exhaust manifold 27 - 31 (2.8 - 3.2, 20 - 23)
Exhaust manifold connector 59 - 78 (6.0 - 8.0, 43 - 58)
* Oil pan [M6] 6.3 - 8.3 (0.64 - 0.85, 56 - 74)*
[M8] 15.7 - 20.6 (1.6 - 2.1, 12 - 15)
Oil strainer 16 - 19 (1.6 - 1.9, 12 - 14)
* Rocker cover 1.0 - 2.9 (0.1 - 0.3, 9 - 26)*
Rocker shaft bracket 15.6 - 21.6 (1.6 - 2.2, 12 - 16)
* Cylinder head bolt 1) 29.4 (3, 22)
2) 61.7 (6.3, 46)
3) 0 (0, 0)
4) 29.4 (3, 22)
5) 69° - 74° (Angle tightening)
Cylinder head additional bolt 6.4 - 7.5 (0.65 - 0.76, 56 - 66)*
Crankshaft pulley 181 - 191 (18.5 - 19.5, 134 - 141)
* Front cover 15.7 - 20.6 (1.6 - 2.1, 12 - 15)
Camshaft sprocket 132.3 - 142.1 (13.5 - 14.5, 98 - 105)
Chain tensioner 5.6 - 8.4 (0.57 - 0.86, 49.5 - 74.7)
Distributor 9.35 - 11 (0.95 - 1.1, 82 - 95)*
Camshaft locating plate 5.6 - 8.4 (0.57 - 0.86, 49.5 - 74.7)
* Flywheel 146 - 167 (15 - 17, 108 - 123)
* Main bearing cap 162 - 172 (16.5 - 17.5, 119 - 127)
Connecting rod nut 1) 38 - 40 (3.9 - 4.1, 28 - 30)
2) 40° - 45° (Angle tightening)
Engine coolant drain plug 34 - 44 (3.5 - 4.5, 25 - 33)
Water pump 15.7 - 18.6 (1.6 - 1.9, 12 - 14)
Engine coolant temperature sensor 20 - 29 (2.0 - 3.0, 14 - 22)
PCV valve 20 - 29 (2.0 - 3.0, 14 - 22)
* Fuel tube 1) 9.3 - 20.6 (0.9 - 2.1, 78 - 182)*
2) 20.6 - 26.5 (2.1 - 2.7, 15 - 20)
Starter motor 41.2 - 52 (4.2 - 5.3, 30 - 38)
Heated oxygen sensor 1 40 - 60 (4.1 - 6.1, 30 - 44)
EG-25
KOMATSU TB45 ENGINE MECHANICAL
SECTION EM
CONTENTS
INTAKE MANIFOLD ........................................... EM-2 CYLINDER HEAD ............................................ EM-12
Component Parts Location ............................ EM-2 Component Parts Location .......................... EM-12
Removal and Installation of Intake Manifold .. EM-3 Preparation .................................................. EM-12
Removal and Installation of Air Horn Bolt ...... EM-3 Cylinder Head Auxiliary Bolt ........................ EM-13
Inspection ....................................................... EM-3 Cylinder Head Bolt ....................................... EM-13
EXHAUST MANIFOLD ....................................... EM-4 Cylinder Head Bolt Washer ......................... EM-14
Component Parts Location ............................ EM-4 Cylinder Head Gasket .................................. EM-14
Removal and Installation ................................ EM-4 Cylinder Head Assembly ............................. EM-15
OIL PAN AND OIL STRAINER .......................... EM-6 TIMING CHAIN ................................................. EM-20
Removal and Installation ................................ EM-6 Removal ....................................................... EM-20
ROCKER COVER ............................................... EM-8 CYLINDER BLOCK .......................................... EM-27
Preparation .................................................... EM-8 Disassembly ................................................ EM-27
Removal ......................................................... EM-8 Selective-Fit Service Parts ........................... EM-31
Installation ...................................................... EM-8 Inspection After Disassembly ...................... EM-31
ROCKER ARM AND ROCKER SHAFT Assembly ..................................................... EM-44
ASSEMBLY ........................................................ EM-9
Component Parts Location ............................ EM-9
Preparation .................................................... EM-9
Removal ......................................................... EM-9
Installation .................................................... EM-10
Disassembly and Assembly ......................... EM-10
Inspection ..................................................... EM-10
INTAKE MANIFOLD
INTAKE MANIFOLD
Screw
Bolt (4)
1.0 - 2.0 (0.1 - 0.2, 9 - 17)
22 - 37
(2.2 - 3.8, 16 - 27)
: Liquid gasket
: Not reusable
: N•m (kg-m, ft-lb)

Mass air flow sensor
: N•m (kg-m, in-lb)
Air horn
LPG injector holder
(LPG and combined use)
Air horn spacer

(Gasoline)
Gasket
Plug
(Gasoline)
Electric throttle
control actuator Water
connector
(LPG)
Gasket (3)
Plug
Water
connector
Plug Nut (3)

(Gasoline) 15.7 - 18.6
(1.6 - 1.9, 12 - 13)
Water bypass
connector Bolt (9)
15.7 - 18.6
(1.6 - 1.9, 12 - 13)
Water hose
Water Water hose
connector
(LPG)
Water inlet Thermostat
housing
Gasket (3)
EMM0723
EM-2
INTAKE MANIFOLD
Removal and Installation of Intake Manifold

PREPARATION
• Drain engine coolant
• Oil level gauge
• Wiring, disconnecting lines, moving
Removal and Installation of Air Horn Bolt

REMOVAL
Loosen bolts.
INSTALLATION
Tighten bolts evenly in two steps.
: 1st: 9 - 10 N•m (0.9 - 1.1 kg-m, 6.5 - 7.9 ft-lb)
2nd: 22 - 37 N•m (2.2 - 3.8 kg-m, 16 - 27 ft-lb)
EMM0724
Inspection
CHECK INTAKE MANIFOLD DISTORTION.
Check distortion of mounting surface in 6 directions using
straightedge and feeler gauge.
Limit: 0.2 mm (0.008 in)
MASS AIR FLOW SENSOR

Refer to "Mass air flow sensor system" in EC section.
LPG INJECTOR HOLDER (LPG AND COMBINED USE)

Refer to "LPG injector system" and "LPG assistance injector
system" in EC section.
ELECTRIC THROTTLE CONTROL

Refer to "Throttle position sensor system" and "Throttle control
motor system" in EC section.
EM-3
EXHAUST MANIFOLD
EXHAUST MANIFOLD
EMM0725
Removal and Installation

PREPARATION
• Disassemble exhaust front tube
• Exhaust manifold cover and exhaust connector cover
• O2 sensor
REMOVAL AND INSTALLATION OF EXHAUST

MANIFOLD
1. Removal
• Loosen nuts in the reverse of the order shown in the figure.
• Loosen O2 sensor (usage with care)
2. Installation
• Install yoke with flat side facing exhaust manifold. (Refer to
"Component Parts Location".)
• Tighten nuts in the numerical order shown in the figure.
EMM0397
EM-4
EXHAUST MANIFOLD
Exhaust manifold cover

REMOVAL OF O2 SENSOR
• Separate the harness connector of O2 sensor from the intake
manifold at its rear part. Detach all intermediate fixed points of
the harness.
• Remove the exhaust manifold cover.
• Detach the O2 sensor with an O2 sensor removing/installing
wrench (special tool).
INSPECTION
O2 sensor EMM0398
1. Exhaust manifold distortion
• Check distortion of mounting surface in 4 directions using
straightedge and feeler gauge.
Limit: 0.3 mm (0.012 in)
CAUTION:
If value is over limit, change new exhaust manifold.
EM-5
OIL PAN AND OIL STRAINER
EMM0552

PREPARATION
Drain engine oil.
REMOVAL OF OIL PAN

• Loosen bolts in the reverse of the order shown in the figure.
• Use a seal cutter (SST).
EMM0400
EM-6
Removal and Installation (Cont'd)

INSTALLATION OF OIL PAN
• Apply a continuous bead of Three Bond 1207C (KP51000150)
to the positions shown in the figure.
• Tighten bolts in the numerical order shown in the figure.
INSTALLATION OF OIL PAN DRAIN PLUG WASHER

Install it with bending side facing oil pan. (Refer to "Component Parts
Location".)
EMM0531
EM-7
ROCKER COVER
ROCKER COVER
EMM0532
Preparation
• Move high-tension core
Removal
Loosen screws in the reverse of the order shown in the figure.
Installation
• Make sure that gasket is not missing from rocker cover
mounting groove.
• Tighten screws in the numerical order shown in the figure.
CAUTION:
Tightening torque of the first screw may decrease after
tightening all screws. Retighten all screws.
EMM0403
EM-8
ROCKER ARM AND ROCKER SHAFT ASSEMBLY
EMM0533
CAUTION:
Apply new engine oil to the parts marked in the figure before
installation.
Preparation
• Rocker cover
• Adjusting valve clearance (after installation)
Removal
• Loosen lock nut, and then fully loosen valve clearance adjusting
screw.
• Loosen bolts evenly in several setps from outside to center.
• Carry each bracket with mounting bolts.
CAUTION:
Hold No. 8 bracket (end) only so as not to drop it when carrying.
EMM0405
EM-9
Installation
Tighten bolts evenly in several steps from center to outer side in this
order.
CAUTION:
• Make sure that valve clearance adjusting screw is securely
inserted to push rod head.
• Perform installation with valve clearance adjusting screw
fully loosened so as not to be affected by valve spring
tension.
• Adjust valve clearance after installation.
Refer to "Inspection and adjustment of valve clearance" in
EMM0406
ET section.
PUSH ROD
Rotate push rod after inserting, and then make sure that push rod tip
is securely inserted into valve lifter sphere surface.
EMM0407
Disassembly and Assembly

• Remove each part individually and avoid mixing.
• Install them to the original position.
SPRING WASHER
Install with each convex surface facing flat washer side. (Refer to
"Component Parts Location".)
ROCKER ARM
Assemble rocker shaft with bolt hole side facing engine front side
and oil hole facing downward. (Refer to "Component Parts
Location".)
Inspection
ROCKER SHAFT BEND
• Hold both ends of rocker shaft with V-blocks, and then set dial
indicator on the center.
• Rotate the rocker shaft in one direction by hand and read
indication on the dial indicator.
• Half of the reading is the rocker shaft bend.
Standard:
0.15 mm (0.0059 in) or less
Limit:
0.3 mm (0.012 in)
ECM0408
EM-10
Inspection (Cont'd)
ROCKER ARM OIL CLEARANCE
1. Rocker shaft outer diameter
• Measure outer diameter around rocker arm mounting using a
micrometer.
Standard:
19.988 - 20.000 mm (0.7869 - 0.7874 in) dia.
EMM0409
2. Rocker arm inner diameter

• Measure rocker arm shaft hole inner diameter using an inside
micrometer.
Standard:
20.020 - 20.038 mm (0.7882 - 0.7889 in) dia.
EMM0410
3. How to calculate rocker arm oil clearance

• (Clearance)
= (Rocker arm inner diameter) - (Rocker shaft outer diameter)
Standard:
0.020 - 0.050 mm (0.0008 - 0.0020 in)
Limit:
0.15 mm (0.0059 in)
• Replace rocker arm and/or rocker shaft if outside the repair
limit. Refer to standards for the outer diameter and inner
diameter.
PUSH ROD BEND

• Hold both ends of push rod with V-blocks, and then set dial
indicator on the center.
• Rotate push rod in one direction by hand and read indication on
the dial indicator.
• Half of the reading is the push rod bend.
Limit:
0.2 mm (0.008 in)
EMM0411
EM-11
CYLINDER HEAD
CYLINDER HEAD
EMM0550
CAUTION:
installation.
Preparation
• Drain engine coolant
• Exhaust manifold
• Intake manifold
• High tension core
• Rocker cover
• Rocker arm and rocker shaft assembly
• Push rod
• Alternator adjusting bar
EM-12
CYLINDER HEAD
Cylinder Head Auxiliary Bolt

REMOVAL
Remove before loosening cylinder head bolt.
INSTALLATION
Install after tightening cylinder head bolt.
EMM0413
Cylinder Head Bolt

REMOVAL
Loosen bolts in the reverse of the order shown in the figure.
INSTALLATION
• Lubricate threads and seat surface of each cylinder head bolt
with new engine oil.
• Tighten bolts in the numerical order shown in the figure with the
following steps.
CAUTION:
In step 3), loosen all bolts in the reverse of the order shown in
the figure.
1) Tighten to 29.4 N•m (3.0 kg-m, 22 ft-lb)
2) Tighten to 61.8 N•m (6.3 kg-m, 46 ft-lb).
3) Fully loosen to 0 N•m (0 kg-m, 0 in-lb).
4) Tighten to 29.4 N•m (3.0 kg-m, 22 ft-lb).
5) Tighten to 69° to 74°
EMM0414
Check tightening angle with an angle wrench (SST) or a protractor.

Do not simply estimate tightening angle.
• Tighten 64 - 74 N•m (6.5 - 7.5 kgf-m, 47 - 54 ft-lb) in step 5) if
checking tightening angle is difficult.
• Apply anticorrosive or engine oil after installation onto eitire
head surfaces of cylinder head bolts (3, 5, 11, 13, 19, 21 in the
figure) that expose rocker cover exterior.
EMM0415
EM-13
CYLINDER HEAD
Cylinder Head Bolt Washer

INSTALLATION
• Washer installing direction is not specified if cylinder head bolt
angle-tightens in step 5).
• Install it in the direction shown in the figure if it does not angle-
tighten in step 5).
EMM0416
Cylinder Head Gasket

INSTALLATION
After applying Three Bond 1207C (KP51000150) to the position
shown in the figure, install cylinder head gasket.
EMM0417
EM-14
CYLINDER HEAD
Cylinder Head Assembly

COMPONENT PARTS LOCATION
EMM0535
CAUTION:
installation.
DISASSEMBLY
1. Compress the valve spring with a valve spring compressor
(SST), and remove the valve collet with a magnetic driver.
2. Remove valve spring retainer.
3. Remove valve spring.
4. Push the valve stem toward the combustion chamber side and
remove valve.
• Check valve guide clearance before removal.
• Check the location, and store individually.
EMM0419
EM-15
CYLINDER HEAD
Cylinder Head Assembly (Cont'd)

5. Remove valve oil seal using a valve oil seal puller (SST) when
removing.
6. Remove valve spring seats.
7. Refer to (EM section), "Valve seat contact inspection" when
removing valve seat.
8. Blow compressed air around spark plug and use a spark plug
wrench (commercial service tool) when removing spark plug.
EMM0420
INSPECTION
1. Cylinder head distortion
• Remove oil, scale, gasket, sealant, and carbon deposits from
surface of cylinder head using a scraper.
CAUTION:
• Do not allow gasket fragments to enter oil or engine
coolant passages.
• Check flatness of cylinder head lower surface. Measure
distortion in 6 directions shown in the figure, at several
points in each direction.
Limit: 0.2 mm (0.008 in)
EMM0421
2. Bulb Dimensions
• Measure dimensions at the points shown in the figure using a
micrometer.
Standard Unit: mm (in)
Intake Exhaust
a :118.15 (4.65) 118.8 (4.677)
b :3.1 - 3.5 (0.122 - 0.138) 3.1 - 3.5 (0.122 - 0.138)
c :1.15 - 1.45 (0.0453 - 0.0571) 1.35 - 1.65 (0.0531 - 0.0650)
D (diameter) :46.95 - 47.25 (1.848 - 1.860) 37.95 - 38.25 (1.4941 - 1.5059)
d (diameter) :7.965 - 7.980 (0.3136 - 0.3142) 7.945 - 7.960 (0.3128 - 0.3134)
α (degree) :45°15' - 45°45' 45°15' - 45°45'
EMM0422
EMM0423
• Valve face is corrected using valve surface grinder.
EM-16
CYLINDER HEAD

• Stem edge surface is corrected using oilstone.
• Keep corrections to a minimum due to surface reduction.
Replace if outside the repair limit.
EMM0424
CORRECTION REPAIR LIMIT

Face correction length:
Intake valve:
0.5 mm (0.020 in) or less
Exhaust valve:
0.5 mm (0.020 in) or less
Stem edge surface correction length:
Intake valve:
0.2 mm (0.008 in)
Exhaust valve:
EMM0425 0.2 mm (0.008 in)
3. Valve guide clearance

• Check before removing the valve guide.
• Make sure the valve stem diameter is within the standard.
Refer to "Valve direction inspection (previous page)".
• Push the valve out toward the combustion chamber. Measure
runout while pushing the stem edge surface toward the dial
indicator.
• 1/2 of the dial indicator reading is the valve guide clearance.
Standard:
Intake:
0.020 - 0.053 mm (0.0008 - 0.0021 in)
EMM0426
Exhaust:
0.040 - 0.073 mm (0.0016 - 0.0029 in)
Repair limit:
Intake:
0.1 mm (0.004 in)
Exhaust:
0.1 mm (0.004 in)
• Replace cylinder head if it exceeds the limit.
4. Valve seat contact

• This inspection must be done after ensuring that the dimensions
of the valve guide and the valve are within the standard.This
inspection must be done after ensuring that the dimensions of
the valve guide and the valve are within the standard.
• Check valve contact by applying DICATOL PL-1 to valve seat
contact surface.
• Make sure that contact surfaces are connected all around.
• Reseat the valve and check again if seating condition is not
correct. Replace cylinder head if seating condition cannot be
corrected by reseating.
EMM0427
EM-17
CYLINDER HEAD

5. Valve spring squareness
• Set the valve spring against a square. Rotate the spring and
record the maximum gap between spring upper end and the
square.
Limit:
1.9 mm (0.075 in) (Inner)
2.1 mm (0.083 in) (Outer)
EMM0428
6. Free length and compression load of valve spring

• Check with a valve spring tester.
Standard mm (in)
Inner Outer
Free length mm (in):
42.72 (1.6819) 48.02 (1.8905)
Length at installation mm (in):
35.0 (1.378) 40.0 (1.57)
Load at installation N (kg, lb):
105 - 115 219 - 240
(10.7 - 11.7, 23.6 - 25.8) (22.3 - 24.4, 49.2 - 53.8)
EMM0429
Valve opening length mm (in):
24.7 (0.972) 29.7 (1.169)
Valve opening load N (kg, lb):
292 - 319 584 - 638
(29.8 - 32.5, 65.7 - 71.7) (59.6 - 65.1, 131.4 - 143.5)
Identification paint:
Green Green
ASSEMBLY
1. Install valve spring seats.
• Install valve spring seat (outer) with rounded side facing
upward.
2. Install valve oil seals.
• Install valve oil seal to the dimensions specified in the figure
using a valve oil seal drift (SST).
EMM0430
EM-18
CYLINDER HEAD

3. Install valves.
• Apply engine oil to valve stem.
4. Install valve springs.
• Face the narrower pitch side of valve spring (with identification
paint mark) toward cylinder head.
5. Install valve spring retainers.
6. Compress the valve spring with a valve spring compressor
(SST), and install the valve collet with a magnetic driver.
• Tap valve stem tip with a plastic hammer to ensure a proper fit
after installing valve collet.
EMM0431
7. Install water connector (gasoline) or plug (LPG or combined
use).
• Apply Three Bond 1386B or equivalent to the threads, and then
connect the connector.
8. Install spark plug if it is removed.
EMM0432
EM-19
TIMING CHAIN
TIMING CHAIN
EMM0726
CAUTION:
Apply new engine oil to the parts marked in the figure prior to
installation.
Removal
1. Remove the following parts. (Refer to the appropriate section
for each preparation.)
• Engine drive belt
• Water pump pulley
• Oil pan
• Rocker cover
• Rocker arm
• Rocker shaft assembly
• Push rod
• Cylinder head
EM-20
TIMING CHAIN
Removal (Cont'd)
2. Make sure that No. 1 cylinder is at TDC on its compression
stroke with the following procedure:
1) Rotate the crankshaft pulley clockwise (as viewed from the
front) and align orange notch with the timing indicator
(protrusion) on the front cover.
2) Make sure that distributor rotor is facing the direction (front side)
as shown in the figure.
• Turn crankshaft pulley 360 degrees in the direction shown
in the figure if the rotor is facing rear side.
3. Remove distributor.
4. Remove crankshaft pulley with the following procedure.
1) Remove starter motor.
2) Secure crankshaft by installing a ring gear stopper (SST) to
starter mounting hole.
• Use approximately 10 mm spacer between plate and
stopper.
3) Loosen crankshaft pulley bolts, and then remove crankshaft
pulley washer.
4) Screw crankshaft bolt by hand until it stops, and then rotate it 2
or 3 turns back.
5) Position a pulley puller (SST) to crankshaft pulley with M8 bolts
(2).
6) Set puller bolt to a pulley puller, and then tighten it until it
contacts with crankshaft pulley bolt.
7) Tighten M8 bolts (2) temporarily installed.
8) Tighten puller bolt approximately 2 turns after feeling that
EMM0437
sticking of crankshaft pulley is released.
9) Remove the pulley puller, place it to front surface of crankshaft
pulley, and tap it with a hammer. Release sticking of cone
bushing.
10) Remove cone bushing using long-nose pliers.
11) Remove crankshaft pulley.
12) Remove key for cone bushing.
5. Remove front cover bolt in the reverse of the order on EM
section, and then remove front cover using a seal cutter (SST).
CAUTION:
Be careful not to damage mounting surface.
6. Remove key for cone bushing.

7. Remove oil pump drive spacer.
8. Remove crankshaft sprocket.
9. Remove key for crankshaft sprocket.
10. Lift and remove front seal on front cover using a screwdriver if it
needs to be replaced.
11. Remove O-ring of crankshaft pulley washer.
CAUTION:
Do not reuse O-ring.
EM-21
TIMING CHAIN
Removal (Cont'd)
12. Remove camshaft sprocket bolt.
• Insert a screwdriver wrapped in a shop cloth to the hole on
camshaft sprocket, secure camshaft sprocket by attaching the
tip of screwdriver to camshaft locating plate bolt, and then
loosen the bolt.
EMM0439
13. Remove chain tensioner and chain guide.

CAUTION:
Hold the sleeve with a finger to prevent it from popping out
when removing.
14. Remove distributor drive gear.

15. Remove camshaft sprocket and crankshaft sprocket together
with timing chain.
EMM0438
EM-22
TIMING CHAIN
Installation
NOTE:
Installing condition and matching mark location of each part are
1. Install the key for crankshaft sprocket after making sure that
crankshaft key groove and camshaft key point straight up.
EMM0440
2. Install camshaft sprocket and crankshaft sprocket aligning with

matching mark on timing chain.
• Insert each sprocket to the shaft in turn and in several steps.
EMM0441
• Move camshaft into cylinder block when inserting camshaft

sprocket. Hold camshaft by temporarily tightening bolts, tap it
using a plastic hammer, and then fully insert camshaft sprocket.
NOTE:
Key for distributor drive gear to camshaft.
3. Instal distributor drive gear is not visible if camshaft sproket

insertion is insufficient.
• Install so that indication stamp mark side is facing camshaft
sprocket side. (Refer to "Component Parts Location".)
EMM0442
EM-23
TIMING CHAIN
Installation (Cont'd)
4. Install camshaft sprocket bolt.
• Install washer with flat side facing camshaft sprocket side.
(Refer to "Component Parts Location".)
• Secure camshaft sprocket in the same procedure as removal,
and tighten bolts.
5. Install chain guide and chain tensioner.

• Install chain tensioner sleeve with the arrow on sliding portion
facing chain rotating direction (up).
6. Install oil pump drive spacer to crankshaft.
7. Install key for cone bushing.
EMM0443
8. Install front oil seal to front cover when replacing front oil seal.
• Install with the arrow facing outside.
• Press oil seal in until it is flush with the end surface of front
cover using an oil seal drift (SST) or 78 mm (3.07 in) dia. drift.
CAUTION:
Make sure that the circumference of oil seal is not damaged
and there is no burr.
EMM0444
9. Install front cover.

• Remove oil, scale, and sealant completely from flange surface
and water hole.
CAUTION:
Do not apply to inlet/outlet side groove of oil pump inlet/outlet.
(2 at mark)
NOTE:
EMM0445 Grooves at mark prevent liquid gasket from spreading into oil
pump inlet/outlet when installing.
• Install O-rings (2).

CAUTION:
• Be careful to prevent O-ring from dropping and dislocating
when installing front cover to cylinder block.
• Do not reuse O-ring.
EM-24
TIMING CHAIN
• Refer to the figure for location and tightening order of bolts.
A: M8 X Length under head: 35 mm (1.38 in) (4)
B: M8 X Length under head: 65mm (2.56 in) (8)
C: M8 X Length under head: 80mm (3.15 in) (1)
EMM0551
10. Insert a crankshaft pulley guide (SST) to crankshaft, and then

install crankshaft pulley.
CAUTION:
Front oil seal may be damaged if crankshaft pulley is installed
directly. Always use crankshaft pulley guide.
11. Install cone bushing.

12. Apply engine oil to O-ring, and then install O-ring to the O-ring
groove on crankshaft pulley washer. (Refer to "Component
Parts Location".)
CAUTION:
Do not reuse O-ring.
13. Install crankshaft pulley washer, and then tighten crankshaft

pulley bolt using a ring gear stopper (SST) following the
procedures above.
EMM0447
EM-25
TIMING CHAIN
14. Install distributor.
• Check TDC on compression stroke with matching mark on
crankshaft pulley.
• Insert distributor shaft to front cover aligning distributor shaft
matching mark (circle stamp mark) with unit side matching mark
(short stamp line).
NOTE:
Matching mark on shaft is aligned with unit side matching mark (long
stamp line) by engagement of helical gear after inserting.
EMM0448
15. Reinstall removed parts in the reverse order of removal.
EM-26
CYLINDER BLOCK
CYLINDER BLOCK
EMM0538
CAUTION:
installation.
Disassembly
1. Remove engine assembly from the vehicle.
2. Keep the position using a hoist so as not to tilt engine.
3. Remove engine mount bracket.
4. Install engine assembly to engine stand (SST) with the following
procedure:
EM-27
CYLINDER BLOCK
Disassembly (Cont'd)
1) Install engine sub-attachment (SST, A shown in the figure) to
engine mount bracket mounting hole on exhaust manifold side.
2) Install engine attachment (SST, B shown in the figure) to engine
sub-attachment.
EMM0546
3) Hoist engine and mount it on engine stand (SST, C shown in the

figure).
• It is possible to set engine attachment and sub-attachment
to engine stand, and then install hoisting engine later.
5. Drain engine oil from oil pan drain plug.
6. Drain engine coolant from cylinder block drain plug.
(Refer to "Coolant Replacement" in CO section.)
7. Remove the following parts.
• Auxiliary brackets
• Exhaust manifold
• Thermostat housing
• Water pipe
• Intake manifold
• Distributor
• Rocker cover
• Rocker shaft assembly
• Cylinder assembly
• Oil pan
• Oil strainer
• Timing chain
• Oil filter and oil filter bracket
EMM0453
8. Remove flywheel.
• Secure crankshaft using a stopper plate (SST), and then
remove bolts.
CAUTION:
• Place a shop cloth on flywheel surface to prevent damage.
• Loosen bolts diagonally and remove them.
9. Remove flywheel housing.

10. Remove rear oil seal and retainer assembly.
EMM0454 NOTE:
Oil seal is integrated with retainer.
EM-28
CYLINDER BLOCK
11. Remove valve lifter.
• Pull out from block upper surface with a finger and remove it.
• Remove camshaft with valve lifter in non-contact condition if
removal is difficult, and then remove valve lifter after tapping
from crankshaft side hole.
• Check the location, and store individually.
EMM0455
12. Remove camshaft.

• Pull camshaft straight out so as not to damage bushing.
EMM0456
13. Remove piston and connecting rod assembly.

1) Set crankshaft at removal piston assembly to BDC on
compression stroke.
2) Remove connecting rod cap and push piston and connecting
rod assembly out toward cylinder head side with handle of a
hammer.
• Before loosening connecting rod nuts, check connecting
rod side clearance. (Refer to EM section, "Inspection of
connecting rod side clearance".)
EMM0457
3) Remove connecting rod bearing.

CAUTION:
Check installation position of each part. Arrange removed
valves to prevent mixing them up.
14. Remove piston ring using piston ring expander (commercial

service tool).
CAUTION:
• Be careful not to damage piston.
• Do not expand piston rings excessively. It can damage
piston rings
• Check piston ring side clearance before removing piston
ring. (Refer to EM section, "Inspection of piston ring side
clearance".)
EMM0458
EM-29
CYLINDER BLOCK
15. Remove connecting rod from piston.
1) Remove snap ring using snap ring pliers.
EMM0459
2) Heat piston to between 60 and 70°C (140 and 158°F) using a

drier.
EMM0460
3) Push out piston pin from piston using a round bar with outer
diameter of approximately 20 mm (0.79 in).
CAUTION:
Do not remove connecting rod bolt from connecting rod.
EMM0523
16. Remove main bearing caps.

1) Loosen bolts in the reverse of the order shown in the figure.
EMM0462
EM-30
CYLINDER BLOCK
2) Remove main bearing cap while shaking it left/right using main
bearing bolts.
17. Remove crankshaft.
18. Remove main bearing from main bearing cap and cylinder
block.
CAUTION:
• Check installation position of each part. Arrange removed
parts to prevent mixing them up.
• Before loosening main bearing cap bolts, check crankshaft
side clearance.
EMM0463
(Refer to EM section, "Inspection of crankshaft side
clearance".)
Selective-Fit Service Parts

SELECTION METHOD
Position Selective-fit service parts Item to be selected Selection method
Cylinder block to piston Piston and piston pin assembly Piston grade Piston grade = Cylinder bore grade (Bore
NOTE: Piston and piston pin are a (Piston outer diameter) inner diameter)
matched set. They make up one
part as an assembly.
• Identification grade stamped on each part shows the dimension

measured when it was new as a grade. It is not applicable when
it has been reused.
• When part is used or corrected, measure its dimension and
decide appropriate grade by referring to Selective-fit Service
Parts Table in this section.
• Refer to the direction specified in the text for details of
measurement method for each part, reusable standard, and
selection method for selective-fit service parts.
Inspection After Disassembly

CRANKSHAFT SIDE CLEARANCE
• Move crankshaft to front or rear and measure clearance
between thrust bearing (journal 6) and crank arm using a dial
indicator or a feeler gauge.
Standard:
0.05 - 0.17 mm (0.0020 - 0.0067 in)
Repair limit:
0.30 mm (0.0118 in)
• Replace main bearing (integrated with thrust bearing) of journal
6, and then measure clearance again if outside the repair limit.
EMM0464 • Replace crankshaft if it still exceeds the limit.
EM-31
CYLINDER BLOCK
Inspection After Disassembly (Cont'd)

CONNECTING ROD SIDE CLEARANCE
• Measure connecting rod-to-crank arm side clearance using a
feeler gauge.
Standard:
0.20 - 0.3 mm (0.0079 - 0.0118 in)
Repair limit:
0.40 mm (0.0157 in)
• Replace connecting rod, and then measure clearance again if
outside the repair limit.
• Replace crankshaft if it still exceeds the limit.
EMM0465
PISTON-TO-PISTON PIN CLEARANCE

1. Piston pin hole diameter
• Measure inner diameter of piston pin hole using an inside
micrometer
Standard:
22.993 - 23.005 mm (0.9052 - 0.9057 in) dia.
EMM0466
2. Piston pin outer diameter

• Measure piston pin outer diameter using a micrometer.
Standard:
22.989 - 23.001 mm (0.9051 - 0.9055 in) dia.
3. How to calculate piston-to-piston pin clearance
• (Piston pin clearance)
= (Piston pin hole diameter) - (Piston pin outer diameter)
Standard clearance at room temperature [20°C (68°F)]:
-0.002 to 0.010 mm (0 to 0.0004 in)
• Replace piston and piston pin assembly if clearance exceeds
EMM0467
the standard.
PISTON RING SIDE CLEARANCE

• Measure piston ring-to-piston ring groove clearance using a
feeler gauge.
Standard:
Top ring 0.040 - 0.073 mm (0.0016 - 0.0029 in)
Second ring 0.030 - 0.063 mm (0.0012 - 0.0025 in)
Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Repair limit:
Top ring 0.1 mm (0.004 in)
Second ring 0.1 mm (0.004 in)
EMM0468 Oil ring -
• Replace piston and/or piston ring assembly if outside the repair
limit.
EM-32
CYLINDER BLOCK

PISTON RING END GAP
• Make sure cylinder bore inner diameter is within the standard.
(Refer to EM section, "Piston and Cylinder Bore Clearance".)
• Press-fit piston rings in cylinder halfway using a piston, and
measure end gap.
Standard:
Top ring 0.30 - 0.45 mm (0.012 - 0.018 in)
Second ring 0.30 - 0.45 mm (0.012 - 0.018 in)
Oil ring 0.20 - 0.60 mm (0.008 - 0.024 in)
Repair limit:
EMM0469 Top ring 1.5 mm (0.059 in)
Second ring 1.5 mm (0.059 in)
Oil ring -
CONNECTING ROD BEND AND TORSION

Check connecting rod bend and torsion using a connecting rod
alignment tool.
Bend limit:
0.15 mm (0.0059 in) [per 100 mm (3.9370 in)]
Torsion limit:
0.30 mm (0.0118 in) [per 100 mm (3.9370 in)]
EMM0470
CONNECTING ROD LARGE END DIAMETER

• Install connecting rod cap without connecting rod bearing.
Tighten connecting rod nuts to the specified torque.
• Measure connecting rod large end diameter using an inside
micrometer.
Standard:
59.987 - 60.000 mm (2.3617 - 2.3622 in) dia.
EMM0471
CONNECTING ROD BUSHING OIL CLEARANCE (AT

SMALL END)
1. Connecting rod small end inner diameter
• Measure inner diameter of connecting rod small end using an
inside micrometer.
Standard:
23.000 - 23.012 mm (0.9055 - 0.9060 in) dia.
EMM0472
EM-33
CYLINDER BLOCK

2. Piston pin outer diameter
• Measure piston pin outer diameter using a micrometer.
Standard:
22.989 - 23.001 mm (0.9051 - 0.9055 in) dia.
EMM0473
3. How to calculate connecting rod bushing oil clearance

• (Connecting rod small end oil clearance)
= (Connecting rod small end inner diameter) - (Piston pin outer
diameter)
Standard:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
• Refer to standards for each part if clearance was not within the
standard. Replace connecting rod and/or piston and piston pin
assembly.
• Refer to EM section, "Piston Selective-fit Service Parts" if
reusing connecting rod and replacing piston and piston
assembly with new one. Select piston fitted to the bore grade of
cylinder block.
NOTE:
Piston and piston pin are a matched set. They make up one part as
an assembly.
EMM0474
CYLINDER BLOCK UPPER SURFACE DISTORTION

Completely remove old gasket on cylinder block surface using a
scraper. Also remove oil, water stains, and carbon deposits.
CAUTION:
• Do not allow gasket fragments to enter oil or engine
coolant passages.
• Check flatness of cylinder block upper surface. Measure
distortion in 4 directions shown in the figure, at several
points in each direction.
Repair limit:
0.1 mm (0.004 in)
EMM0475
EM-34
CYLINDER BLOCK

PISTON-TO-CYLINDER BORE CLEARANCE
1. Cylinder bore diameter
• Measure cylinder bore at 2 points (A and B) in 2 directions (X
and Y) using a bore gauge.
Cylinder bore inner diameter standard:
99.500 - 99.550 mm (3.9173 - 3.9193 in) dia.
Wear limit:
0.2 mm (0.008 in)
Out-of-round limit
(difference between measurements X and Y):
EMM0476 0.015 mm (0.0006 in)
Taper limit (difference between measurements A and B):
0.01 mm (0.0004 in)
• Hone or bore cylinder if outside the repair limit or cylinder inner
wall is found with damage and seizure.
• 0.5 (0.020) OS [0.5 mm (0.020 in) oversize] and 1.0 (0.039) OS
[1.0 mm (0.039 in) oversize] pistons are available for service.
Be sure to use the same oversize piston rings with piston
cylinder clearance size piston when using oversize piston.
EMM0477
2. Piston outer diameter

• Measure piston skirt outer diameter using a micrometer.
Measuring point:
20 mm (0.79 in) up from piston bottom
Standard:
99.460 - 99.510 mm (3.9157 - 3.9177 in) dia.
HOW TO CALCULATE PISTON-TO-CYLINDER BORE CLEARANCE

• (Clearance) =
(Cylinder bore inner diameter) - (Piston skirt outer diameter)
EMM0478 Standard clearance at room temperature [20°C (68°F)]:
0.030 - 0.050 mm (0.0012 - 0.0020 in)
• Replace piston and piston pin assembly if clearance is outside
the standard.
3. Piston selective-fit service parts
• When using new cylinder block
1) Check cylinder bore grade number (1 to 5) stamped on cylinder
block upper surface and select piston from selective-fit service
parts table.
NOTE:
Piston and piston pin are a matched set. They make up one part as
an assembly.
EMM0479
EM-35
CYLINDER BLOCK

• When reusing cylinder block
1) Measure cylinder bore inner diameter.
2) Find grade number of the measured cylinder bore in "Cylinder
Bore Inner Diameter Selective-fit Service Parts Table", and
select piston (grades 1 to 5) from selective-fit service parts
table.
Selective-fit service parts table Unit: mm (in)
Grade
number 1 2 3 4 5
EMM0480
(stamping)
99.510 99.520 99.530 99.540 99.550
Cylinder bore (3.9117) (3.9181) (3.9185) (3.9189) (3.9193)
inner
diameter 99.500 99.510 99.520 99.530 99.540
(3.9173) (3.9177) (3.9181) (3.9185) (3.9189)
99.470 99.480 99.490 99.500 99.510
Piston outer (3.9161) (3.9165) (3.9169) (3.9173) (3.9177)
diameter 99.460 99.470 99.480 99.490 99.500
(3.9157) (3.9161) (3.9165) (3.9169) (3.9173)
CRANKSHAFT JOURNAL DIAMETER

Measure the journal outer diameter using a micrometer.
Standard:
70.907 - 70.920 mm (2.7916 - 2.7921 in) dia.
CRANKSHAFT PIN DIAMETER

Measure the pin outer diameter using a micrometer.
Standard:
56.913 - 56.926 mm (2.2407 - 2.2412 in) dia.
EMM0481
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

• Measure each journal and pin at 4 positions shown in the figure
using a micrometer.
• Out-of-round is indicated by the difference between dimensions
A and B measured at points 1 and 2.
• Taper is indicated by difference between dimensions 1 and 2
measured in directions A and B.
Repair limit:
0.06 mm (0.0024 in) dia.
(both out-of-round and taper)
EMM0482
CRANKSHAFT BEND
• Set a pair of V-blocks on a level surface and support journals 1
and 7 of crankshaft.
• Set a dial indicator vertically onto journal 4.
• Rotate crankshaft and read indication on the indicator.
• Half of the reading is the bend.
Repair limit:
0.2 mm (0.008 in)
EMM0483
EM-36
CYLINDER BLOCK

CONNECTING ROD BEARING OIL CLEARANCE
1. Measuring method
• Install connecting rod bearing to connecting rod and connecting
rod cap. Tighten connecting rod nuts to the specified torque.
Measure connecting rod inner diameter using an inside
micrometer.
(Oil clearance)
= (Connecting rod bearing inner diameter)
- (Crankshaft pin outer diameter)
Standard:
EMM0484 0.027 - 0.061 mm (0.0011 - 0.0024 in)
Repair limit:
0.09 mm (0.0035 in)
• Replace connecting rod bearing and/or crankshaft according to
judgement from values measured at previous steps 11 and 15-
1) if connecting rod bearing oil clearance is outside the repair
limit.
2. Using plastigage
• Completely clean off oil and dust on crankshaft pins and bearing
surfaces.
• Cut a piece of plastigage slightly shorter than bearing width, and
place it in axial direction avoiding oil hole.
• Install connecting rod bearing to connecting rod cap. Tighten
connecting rod nuts to the specified torque.
CAUTION:
Do not rotate crankshaft while plastigage is in place.
EMM0485
• Remove connecting rod cap and bearing. Measure width of the
plastigage using scale printed on its bag.
CAUTION:
Follow the method outlined in "By measuring" if clearance is
standard and repair limit, and if clearance exceeds repair limit,
but remeasure if clearance is less than standard.
MAIN BEARING OIL CLEARANCE

1. Measuring method
• Install main bearing to cylinder block and bearing cap. Tighten
bearing cap bolts to the specified torque and measure main
bearing inner diameter.
(Oil clearance)
= (Main bearing inner diameter) - (Crankshaft journal outer
diameter)
Standard:
0.030 - 0.087 mm (0.0012- 0.0034 in)
Repair limit:
EMM0486
0.09 mm (0.0035 in)
• Replace undersized bearing upper and lower as a set if
standard size main bearing oil clearance is outside the
standard.
(Refer to EM section, "Using Undersized Bearing".)
EM-37
CYLINDER BLOCK

2. Using plastigage
• Completely clean off oil and dust on crankshaft journal and
bearing surfaces.
• Cut a piece of plastigage slightly shorter than bearing width, and
place it in axial direction avoiding oil hole.
• Tighten main bearing to the specified torque.
CAUTION:
Do not rotate crankshaft while plastigage is in place.
• Remove bearing cap and bearing. Measure width of the

EMM0487
plastigage using scale printed on its bag.
CAUTION:
Follow the method outlined in "By measuring" if clearance is
standard and repair limit, and if clearance exceeds repair limit,
but remeasure if clearance is less than standard.
3. Using undersized bearing

• Use undersized bearing if standard size main bearing oil
clearance is outside the standard.
• When using undersize bearing, install it, measure bearing inner
diameter, and grind journal to obtain specified oil clearance.
Main bearing undersize table Unit: mm (in)
Size Thickness
STD 2.000 (0.0787)
US0.25 (0.0098) 2.125 (0.0837)
US0.50 (0.0197) 2.250 (0.0886)
US0.75 (0.0295) 2.375 (0.0935)
US1.00 (0.0394) 2.500 (0.0984)
EMM0547
NOTE:
Each tolerance is +0.008 to +0.012 (+0.0003 to +0.0005).
CAUTION:
Be careful not to damage fillet-roll area when grinding
crankshaft journal in order to use undersize bearing.
MAIN BEARING CRUSH HEIGHT

Tighten bearing cap to the specified torque with main bearing
installed. Remove bearing cap and make sure that the main bearing
edges protrude (There must be crush height.).
EMM0489
EM-38
CYLINDER BLOCK

VALVE LIFTER OIL CLEARANCE
• Check sliding surfaces with camshaft and lifter bore for uneven
wear and damage.
• Replace valve lifter if necessary.
1. Valve lifter outer diameter
• Measure the valve lifter outer diameter using a micrometer. (A in
the figure)
Standard:
24.960 - 24.970 mm (0.9827 - 0.9844 in) dia.
2. Valve lifter bore inner diameter
• Measure valve lifter bore inner diameter using a bore gauge. (B
in the figure)
Standard:
25.000 - 25.033 mm (0.9843 - 0.9844 in) dia.
EMM0490
3. How to calculate valve lifter oil clearance
• (Clearance) = (Valve lifter bore inner diameter) - (Valve lifter
outer diameter)
Standard:
0.030 - 0.073 mm (0.0012 - 0.0029 in)
Repair limit:
0.1 mm (0.004 in)
• Refer to standards for each part and replace valve lifter and/or
cylinder block if clearance exceeds the repair limit.
VISUAL INSPECTION OF CAMSHAFT

• Check camshaft nose or journal for damage and uneven wear.
• Replace camshaft as necessary.
CHECKING FOR CAMSHAFT BEND

• Set a pair of V-blocks on a level surface and support journals (1
and 7) of camshaft.
• Set a dial indicator vertically onto center of journal 4.
• Rotate the camshaft in one direction by hand and read
indication on the dial indicator. (Half of the reading is the bend.)
Repair limit:
0.03 mm (0.0012 in)
EMM0491
CAM NOSE HEIGHT

Measure with a micrometer.
Standard (intake side):
42.126 - 42.376 mm (1.6585 - 1.6683 in)
Standard (exhaust side):
42.126 - 42.376 mm (1.6585 - 1.6683 in)
EMM0492
EM-39
CYLINDER BLOCK

CAMSHAFT OIL CLEARANCE
1. Camshaft journal outer diameter
• Measure with a micrometer.
Standard:
Journal 1 50.721 - 50.740 mm (1.9969 - 1.9976 in)
Journal 2 50.521 - 50.540 mm (1.9890 - 1.9898 in)
Journal 3 50.321 - 50.340 mm (1.9811 - 1.9819 in)
Journal 4 50.121 - 50.140 mm (1.9733 - 1.9740 in)
Journal 5 49.921 - 49.940 mm (1.9654 - 1.9661 in)
Journal 6 49.721 - 49.740 mm (1.9575 - 1.9583 in)
EMM0493 Journal 7 49.521 - 49.540 mm (1.9496 - 1.9504 in)
2. Camshaft bushing inner diameter

• Measure using a bore gauge.
Standard:
Journal 1 50.76 - 50.83 mm (1.9984 - 2.0012 in)
Journal 2 50.56 - 50.63 mm (1.9905 - 1.9933 in)
Journal 3 50.36 - 50.43 mm (1.9827 - 1.9854 in)
Journal 4 50.16 - 50.23 mm (1.9748 - 1.9776 in)
Journal 5 49.96 - 50.03 mm (1.9669 - 1.9697 in)
Journal 6 49.76 - 49.83 mm (1.9591 - 1.9618 in)
Journal 7 49.56 - 49.63 mm (1.9512 - 1.9539 in)
EMM0494
3. How to calculate camshaft oil clearance
• Oil clearance = Camshaft bushing inner diameter - Camshaft
journal outer diameter
Standard:
0.020 - 0.109 mm (0.0008 - 0.0043 in)
Repair limit:
0.15 mm (0.0059 in)
• Refer to the standards if clearance exceeds the repair limit.
Replace camshaft and/or camshaft bushing.
REPLACEMENT OF CAMSHAFT BUSHING

1. Remove welch plug.
EMM0495
EM-40
CYLINDER BLOCK

2. Pull out camshaft bushings from cylinder block using a bar
(SST).
EMM0496
3. Install camshaft bushings (journals 7 to 2).

• Install journals 7 to 2 in the order from cylinder block front side
holes.
• Install camshaft bushings with cutout facing frontward and
upward. (It is same as journal 1.)
EMM0497
• Align camshaft bushing notches with knock pin of a bar (SST)

when installing.
EMM0498
• Secure journals 4 to 2 wrapped in tape so as not to dislocate

bushings.
EMM0499
EM-41
CYLINDER BLOCK

• Insert bar with bushings into cylinder block, and then install a
guide plate (SST).
• Tighten bolts with "TB" mark stamped on guide plate facing up.
• Press-fit until bar matching mark (stamp line) is in the same
position as guide plate edge surface A.
EMM0500
EMM0501
• Slide bar matching mark (stamp line) in order depending on

journal position.
EM-42
CYLINDER BLOCK
EMM0502
• Make sure that oil holes in each journal and cylinder block oil
holes are aligned after installing each journal.
4. Install camshaft bushing (journal 1).
• Align journal oil hole with cylinder block oil hole.
• Press-fit until journal front end is 0.5 mm (0.020 in) inside from
cylinder block front end surface using a drift (SST).
• Make sure that journal oil hole and cylinder block oil hole are
aligned after installing journal.
EMM0503
EMM0504
EM-43
CYLINDER BLOCK

5. Check camshaft bushing inner diameter and make sure that it is
within the standard.
EMM0505
6. Install welch plug.

• Apply liquid gasket (Three Bond TB1303) to welch plug.
• Press-fit using a drift (commercial service tool).
EMM0506
CAMSHAFT END PLAY

• Install locating plate and camshaft gear to camshaft, and tighten
bolt to the specified torque.
• Measure clearance between locating plate and camshaft front
end surface using a feeler gauge.
Standard:
0.08 - 0.28 mm (0.0031 - 0.0110 in)
Repair limit:
0.5 mm (0.020 in)
• Replace locating plate and measure again if outside the repair
EMM0507 limit.
• Replace camshaft if it still exceeds the limit.
Assembly
1. Thoroughly clean engine coolant and oil passages in cylinder
block, as well as inside of crank case and cylinder bores using
compressed air.
EM-44
CYLINDER BLOCK
Assembly (Cont'd)
2. Install main bearing.
1) Clean bearing mounting surfaces on cylinder block and main
bearing cap to remove any foreign material, dust, and oil.
2) Install main bearing in the correct direction.
• Install main bearing half with oil groove and oil hole to
cylinder block, and the half without oil groove and oil hole to
main bearing cap.
• Install integrated thrust bearing to journal 6.
• Apply engine oil to bearing surface (inside) and thrust
outside when installing bearing. Do not apply engine oil to
reverse side of bearing, but thoroughly clean it.
• Install by aligning main bearing detent with the notch.
• Make sure the oil holes in cylinder block and main bearing
are aligned.
3. Install crankshaft to cylinder block.
• Make sure that it turns smoothly by hand.
EMM0508
4. Install main bearing caps.

• Install it by aligning main bearing identification number with
journal position.
• Install so that upper identification number faces the front of
engine.
• Tap with a plastic hammer and install it.
EMM0509
5. Tighten main bearing cap bolts.

• Lubricate threads and seat surface of bolt with new engine oil.
• Tighten bolts evenly in several steps in the order shown in the
figure.
• Rotate crankshaft by hand and make sure it turns smoothly after
tightening.
6. Install piston to connecting rod.
1) Install snap ring in snap ring installation groove on rear side of
piston using snap ring pliers.
• Make sure snap ring is securely seated in the groove.
EMM0510
EM-45
CYLINDER BLOCK
Assembly (Cont'd)
2) Install piston to connecting rod.
• Heat piston [to between 60 and 70°C (140 and 178°F)]
using a dryer so that piston pin can be easily inserted by
hand. Insert piston pin in piston and connecting rod from
front side of piston.
• Assemble so that front mark on position head, oil hole in
connecting rod, and cylinder No. stamped on connecting
rod are positioned as shown in the figure.
3) Install snap ring onto piston front side.
• Make sure that the connecting rod swings freely after
EMM0511
completing work.
7. Install piston rings with piston ring expander (commercial
service tool).
CAUTION:
Be careful not to damage piston.
• Install top and second rings with stamp marks on end gaps
facing up.
EMM0512
• Install oil ring with ring end gap as shown in the figure.
EMM0513
• Position end gaps of each piston ring as shown in the figure.
EMM0514
EM-46
CYLINDER BLOCK
Assembly (Cont'd)
8. Install connecting rod bearing to connecting rod and connecting
rod cap.
• Apply engine oil to bearing surface (inside) when installing
connecting rod bearing. Do not apply engine oil to reverse side
of bearing, but thoroughly clean it.
• Install connecting rod bearing by aligning the projection with
detent notch on connecting rod.
EMM0515
9. Install piston and connecting rod assembly to crankshaft.

• Set crankshaft pin at the installation position to BDC on
compression stroke.
• Apply engine oil to cylinder bore, piston, and crankshaft pin
sufficiently.
• Install connecting rod to cylinder position corresponding to
cylinder stamped on it.
• Install piston so that front mark on piston head faces toward
crankshaft pulley mounting side using a piston ring compressor
(commercial service tool).
EMM0516
CAUTION:
Be careful not to damage crankshaft pin with connecting rod
large end by contact.
10. Install connecting rod cap.
• Be sure that cylinder on connecting rod and connecting rod cap
match.
11. Tighten connecting rod nut.
• Angle-tighten as described below.
1) Apply new engine oil to threads and seat surfaces of connecting
rod.
2) Tighten to 38 - 40 N•m (3.9 - 4.1 kg-m, 28 - 30 ft-lb).
3) Tighten 40 to 45° using an angle wrench (SST) or a protractor.
CAUTION:
EMM0517
Do not just estimate tightening angle.
NOTE:
Tighten to 67 to 71 N•m (6.8 to 7.2 kg-m, 49 to 52 ft-lb) if checking
tightening angle is difficult.
4) Rotate crankshaft and make sure it turns smoothly after all
cylinders are tightened.
12. Install camshaft.
• Apply engine oil to camshaft machining surface.
• Install camshaft straightly so as not to damage bushing.
13. Install locating plate.
• Install locating plate with its mark (concave mark) facing up.
14. Install valve lifter.
• Apply engine oil to valve lifter.
• Install them in their original positions.
EMM0518
EM-47
CYLINDER BLOCK
Assembly (Cont'd)
15. Install rear oil seal and retainer assembly.
EMM0519
16. Install flywheel housing.

17. Install flywheel.
• Secure crankshaft using a ring gear stopper (SST).
• Tighten bolts evenly in several steps in the order shown in the
figure.
18. Assemble other parts in reverse order of disassembly.
EMM0520
EM-48
KOMATSU TB45 ENGINE LUBRICATION
SECTION LU
CONTENTS
OIL PUMP ............................................................LU-2 Disassembly and Assembly ............................ LU-2
Component Parts Location ............................ LU-2 Inspection ....................................................... LU-3
OIL PUMP
OIL PUMP
LUM0008
CAUTION:
installation.
Disassembly and Assembly

PREPARATION
Front cover (Refer to "TIMING CHAIN" in EM section.)
NOTE:
Oil pump is integrated in front cover.
LU-2
OIL PUMP
Inspection
OIL PUMP COMPONENTS INSPECTION
• Measure each clearance using a feeler gauge.
Outer rotor to housing clearance (1 in the figure)
Standard:
0.114 - 0.260 mm (0.0045 - 0.0102 in)
Outer rotor to inner rotor tip clearance (2 in the figure)
Standard:
0.180 mm (0.0071 in) or less
LUM0009
• Measure each clearance using a feeler gauge and straightedge.

Inner rotor to housing side clearance (3 in the figure)
Standard:
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Outer rotor to housing side clearance (4 in the figure)
Standard:
0.030 - 0.190 mm (0.0012 - 0.0075 in)
LUM0004
LU-3
KOMATSU TB45 ENGINE COOLING SYSTEM
SECTION CO
CONTENTS
CHANGING ENGINE COOLANT ....................... CO-2 Removal and Installation ............................... CO-3
Draining Engine Coolant ............................... CO-2 Water Pump Inspection ................................. CO-3
Refilling Engine Coolant ................................. CO-2 THERMOSTAT ................................................... CO-4
WATER PUMP ................................................... CO-3 Component Parts Location ........................... CO-4
Component Parts Location ........................... CO-3 Removal and Installation ............................... CO-4
CHANGING ENGINE COOLANT
CHANGING ENGINE COOLANT
Draining Engine Coolant

WARNING:
Do not drain coolant when engine is still hot. It may cause
burns.
Remove exhaust manifold side drain plug of cylinder block and drain
the coolant in cylinder block.
Refilling Engine Coolant

• Refer to the following for the coolant level and LLC density.
Engine coolant level [including the reservoir tank (MAX level) volume]
Unit: l (US qt, Imp qt)
Engine type TB45E

COM0011 Without rear heater Approx. 11.2 (11-7/8, 9-7/8)
LLC density (%):

30 (Standard)
50 (Cold area)
• Install cylinder block drain plug.
• Apply sealant (Three Bond 1215B or equivalent) to the threads
of cylinder block drain plug.
: 34 - 44 N•m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
• Make sure that each clamp and drain plug is securely tightened.
CO-2
WATER PUMP
WATER PUMP
COM0017

PREPARATION
WARNING:
Do not drain coolant when engine is still hot. It may cause
burns.
Engine drive belts

CAUTION:
Handle water pump vane so that it does not contact with other
parts.
Water Pump Inspection

• Check water pump body and vanes for severe corrosion and
dirt.
• Make sure that water pump shaft turns smoothly without
roughness.
CO-3
THERMOSTAT
THERMOSTAT
COM0016

WARNING:
Do not touch thermostat or container and hot water until they
get cold. They may cause burns.
INSTALLATION OF THERMOSTAT
• Install thermostat with jiggle valve facing upward.
• Make sure that thermostat flange is securely inserted to seal
ring.
COM0014
CO-4
THERMOSTAT
Removal and Installation (Cont'd)

THERMOSTAT INSPECTION
WARNING:
Do not touch thermostat or container and hot water until they
get cold. They may cause burns.
• Put a thread through thermostat valve and submerge it in a

water-filled container, then heat it up while stirring the water.
• Read the water temperature when thermostat drops. This is the
valve opening temperature.
Valve opening temperature standard:
COM0015
82 ± 2°C (180 ± 3.6°F) (Standard and cold area)
Maximum valve lift standard:
10 mm or more/95°C (0.39 in or more/203°F)
(Standard and cold area)
CO-5
KOMATSU TB45 ENGINE CONTROL
SECTION EC
CONTENTS
PRECAUTIONS .................................................. EC-3 CRANK ANGLE SENSOR 120° (REF)
General Precautions for Service Operations .... EC-3 SIGNAL SYSTEM ..............................................EC-55
On Board Diagnostic (OBD) ECM Input/Output Signal Specifications .......EC-55
System of Engine ........................................... EC-4 Circuit Diagram .............................................EC-55
Precaution ...................................................... EC-4 Component Parts Inspection ........................EC-55
Special Service Tools .................................... EC-7 MASS AIR FLOW SENSOR SYSTEM ..............EC-56
ENGINE CONTROL SYSTEM ............................ EC-8 SST Data Monitor Display ............................EC-56
Description ..................................................... EC-8 ECM Input/Output Signal Specifications .......EC-56
System Diagram ............................................ EC-9 Circuit Diagram .............................................EC-56
Sensors and Actuators Control Items .......... EC-12 Component Parts Inspection ........................EC-56
TROUBLE DIAGNOSIS .................................... EC-13 HEATED OXYGEN SENSOR SYSTEM ............EC-57
Trouble Diagnosis Procedure ...................... EC-13 SST Data Monitor Display ............................EC-57
Diagnosis Chart by Symptom ...................... EC-17 ECM Input/Output Signal Specifications .......EC-57
Locations of components ............................. EC-28 Circuit Diagram .............................................EC-57
Circult Diagram ............................................ EC-32 VEHICLE SPEED SENSOR SYSTEM ..............EC-58
ECM Terminal Layout .................................. EC-33 SST Data Monitor Display ............................EC-58
ECM Input/Output Signal Specifications ...... EC-36 ECM Input/Output Signal Specifications .......EC-58
SST .............................................................. EC-42 Circuit Diagram .............................................EC-58
Self-diagnosis Function (without SST) ......... EC-46 THROTTLE POSITION SENSOR SYSTEM ......EC-59
Service Tool ................................................. EC-48 SST Data Monitor Display ............................EC-59
Method of indicating failure code ECM Input/Output Signal Specifications .......EC-59
with troubleshooting tool .............................. EC-49 Circuit Diagram .............................................EC-59
Example of indication of failure code ........... EC-50 Component Parts Inspection ........................EC-59
Method of indicating failure code with ACCELERATOR PEDAL POSITION
meter panel .................................................. EC-50 SENSOR SYSTEM ............................................EC-60
SST Reference Value in Data Monitor ......... EC-51 SST Data Monitor Display ............................EC-60
Fail-Safe Function ........................................ EC-52 ECM Input/Output Signal Specifications .......EC-60
ECM Input/Output Signal Specifications ...... EC-53 Circuit Diagram .............................................EC-60
Circuit Diagram ............................................ EC-53 INTAKE AIR TEMPERATURE
CRANKSHAFT POSITION SENSOR 1° (POS) .. EC-54 SENSOR SYSTEM ............................................EC-61
ECM Input/Output Signal Specifications ...... EC-54 SST Data Monitor Display ............................EC-61
Circuit Diagram ............................................ EC-54 ECM Input/Output Signal Specifications .......EC-61
Circuit Diagram .............................................EC-61
Component Parts Inspection ........................EC-61
IGNITION SYSTEM ...........................................EC-62 FUEL CUT FUNCTION ..................................... EC-69
SST Data Monitor Display ............................EC-62 Inspection Procedure .................................... EC-69
ECM Input/Output Signal Specifications .......EC-62 INTERCEPTION VALVE SYSTEM ................... EC-70
Circuit Diagram .............................................EC-62 SST Data Monitor Display ............................ EC-70
Component Parts Inspection ........................EC-62 ECM Input/Output Signal Specifications ....... EC-70
FUEL INJECTOR SYSTEM (GASOLINE) ........EC-63 Circuit Diagram ............................................. EC-70
SST Data Monitor Display ............................EC-63 FUEL CHANGING SWITCH SYSTEM .............. EC-71
ECM Input/Output Signal Specifications .......EC-63 SST Data Monitor Display ............................ EC-71
Circuit Diagram .............................................EC-63 ECM Input/Output Signal Specifications ....... EC-71
Component Parts Inspection ........................EC-63 Circuit Diagram ............................................. EC-71
THROTTLE CONTROL MOTOR SYSTEM .......EC-64 BLOW-BY GAS REDUCING DEVICE .............. EC-72
ECM Input/Output Signal Specifications .......EC-64 System Chart ................................................ EC-72
Circuit Diagram .............................................EC-64 Removal and Installation of
Component Parts Inspection ........................EC-64 Blow-by Control Valve .................................. EC-72
HEATED OXYGEN SENSOR Inspection of Blow-by Control Valve ............. EC-72
HEATER SYSTEM ............................................EC-65 ECM COPMONENTS ........................................ EC-73
SST Data Monitor Display ............................EC-65 ECM .............................................................. EC-73
ECM Input/Output Signal Specifications .......EC-65 Crankshaft Position Sensor
Circuit Diagram .............................................EC-65 (Integrated Into the Distributor) ..................... EC-73
Component Parts Inspection ........................EC-65 Mass Air Flow Sensor ................................... EC-73
LPG INJECTOR SYSTEM ................................EC-66 Engine Coolant Temperature Sensor ........... EC-73
ECM Input/Output Signal Specifications .......EC-66 Heated Oxygen Sensor
Inspection .....................................................EC-66 (With Heated Oxygen Sensor Heater) .......... EC-74
LPG ASSISTANCE INJECTOR SYSTEM ........EC-67 Throttle Position Sensor (Electric Throttle
ECM Input/Output Signal Specifications .......EC-67 Control Actuator Assembly) .......................... EC-74
Circuit Diagram .............................................EC-67 LPG Injector Holder ...................................... EC-75
Component Parts Inspection ........................EC-67 SERVICE DATA AND SPECIFICATIONS
LPG FUEL PRESSURE SENSOR SYSTEM ....EC-68 (SDS) ................................................................. EC-76
ECM Input/Output Signal Specifications .......EC-68 Standard, Repair Limit .................................. EC-76
Circuit Diagram .............................................EC-68
PRECAUTIONS
PRECAUTIONS
General Precautions for Service Operations

• Even when ignition switch is OFF, battery voltage may damage
the control unit. Turn ignition switch OFF and disconnect battery
ground cable before removing and installing control unit
harness.
ECM0215
• Be careful not to damage connector terminals when connecting

and disconnecting. Check the terminals for bend or breakage
before connecting.
• Check the input/output signal of terminal before replacing
control unit. Confirm that it operates normally.
Refer to EC section, "ECM Input/Output Signal Specifications".
ECM0216
• Ensure the appropriate distance between test probes when

using a circuit tester. A longer distance is recommended,
because if the distance is too short, it may cause contact of test
probes, resulting in a short circuit. A short circuit allows battery
voltage to be applied directly to the control unit, resulting in
damage to its internal power transistors.
EGM0063
EC-3
PRECAUTIONS
On Board Diagnostic (OBD) System of

Engine
The ECM has an on board diagnostic system. It will light up the
malfunction indicator lamp (MIL) to warn the driver of a malfunction
causing emission deterioration.
CAUTION:
• Be sure to turn the ignition switch OFF and disconnect the
negative battery cable before any repair or inspection work.
The open/short circuit of related switches, sensors,
solenoid valves, etc. will cause the MIL to light up.
• Be sure to connect and lock the connectors securely after
work. A loose (unlocked) connector will cause the MIL to
light up due to the open circuit. (Be sure the connector is
free from water, grease, dirt, bent terminals, etc.)
• Certain systems and components, especially those related
to OBD, may use a new style slide-locking type harness
connector.
• Be sure to route and secure the harnesses properly after
work. The interference of the harness with a bracket, etc.
may cause the MIL to light up due to the short circuit.
• Be sure to connect rubber tubes properly after work. A
misconnected or disconnected rubber tube may cause the
MIL to light up due to the malfunction of fuel injection
system, etc.
• Be sure to erase the unnecessary malfunction information
(repairs completed) from the ECM before returning the
vehicle to the customer.
Precaution
• Always use a 12 volt battery as power source.
• Do not attempt to disconnect battery cables while engine is
running.
• Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect battery
ground cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
• Before removing parts, turn ignition switch OFF and then
disconnect battery ground cable.
SEF0289H
• Do not disassemble ECM.

• If a battery cable is disconnected, the memory will return to
the ECM value. The ECM will now start to self-control at its
initial value. Engine operation can vary slightly when the
terminal is disconnected. However, this is not an indication
of a malfunction. Do not replace parts because of a slight
variation.
• If the battery is disconnected, the following emission-
related diagnostic information will be lost within 24 hours.
– Diagnostic trouble codes
– 1st trip diagnostic trouble codes
EC-4
PRECAUTIONS
Precaution (Cont’d)
• When connecting ECM harness connector, fasten it
securely with levers as far as they will go as shown in the
figure.
• When connecting or disconnecting pin connectors into or

from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
• Securely connect ECM harness connectors. A poor
connection can cause an extremely high (surge) voltage to
develop in coil and condenser, thus resulting in damage to
ICs.
• Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control
system malfunctions due to receiving external noise,
degraded operation of ICs, etc.
• Keep engine control system parts and harness dry.
• Before replacing ECM, perform ECM Terminals and
Reference Value inspection and make sure ECM functions
properly.
• Handle mass air flow sensor carefully to avoid damage.
• Do not disassemble mass air flow sensor.
• Do not clean mass air flow sensor with any type of
detergent.
• Do not disassemble electric throttle control actuator.
• Even a slight leak in the air intake system can cause
serious incidents.
MEF040D • Do not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
• After performing each TROUBLE DIAGNOSIS, perform DTC
Confirmation Procedure or Overall Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Overall Function
Check should be a good result if the repair is completed.
EC-5
PRECAUTIONS
Precaution (Cont’d)
• When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact. Accidental contact
of probes will cause a short circuit and damage the ECM
power transistor.
• Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the
ECM's transistor. Use a ground other than ECM terminals,
such as the ground.
SEF348N
• Do not operate fuel pump when there is no fuel in lines.

• Tighten fuel hose clamps to the specified torque.
• Do not depress accelerator pedal when starting.

• Immediately after starting, do not rev up engine
unnecessarily.
• Do not rev up engine just prior to shutdown.
SEF709Y
EC-6
PRECAUTIONS
Special Service Tools

Description Application
EGI fuel pressure indicator For measuring fuel pressure gauge

ST19590000
ECM0013
Heated oxygen sensor wrench Removing and installing heated oxygen sensor
KV10113700
ECM0014
SST For system inspection and diagnosis
Check adapter V For control unit input/output signal inspection

EG1755000 (for SMJ 150-pin connector)
ECM0016
Harness adapter
EG17550200
(150-pin to 121-pin conversion adapter)
ECM0017
Adapter harness for molded coil Speed inspection (TB45E)

EG10117500
ZZA1165D
EC-7
ENGINE CONTROL SYSTEM
Description
• Adopts Electronic Concentrated Engine Control System
(ECCS). Fuel injection control, ignition timing control, idle speed
control, and electronically controlled governor control etc. are all
performed by a single control unit.
• Adopts electric throttle control actuator system to control
electronically controlled governor.
Item Description
Electric throttle control • Adopts electronic throttle control actuator with integrated throttle control motor to adjust throttle valve opening
optimally according to driving conditions or to improve safety and operability by electronically controlled governor.
Fuel injection control • With SOFIS control, amounts of injected fuel are optimized to improve exhaust performance and response.
• Using feedback control through learning of air-fuel ratio compensation, the system corrects the ratio during
transitional conditions, such as sudden sharp changes in the ratio, in order to improve drivability.
Ignition timing control • Controls ignition timing depending on driving conditions on basis of the ignition timing map stored in the ECM.
• Performs knock control, in which ignition timing is retarded or advanced according to the presence of knocking, so
that optimum ignition timing is selected according to operating conditions and fuel in use.
Idle speed control • Adopts electronic throttle control actuator that continuously regulates intake air amount required for idling.
Governor speed control • Performs maximum regulation of engine speed for oil pressure pump protection by engine speed signal.
Maximum speed • Performs maximum speed regulation by vehicle speed sensor signal. Also, performs variable control of maximum
regulation control speed by changeover switch as an option.
Idling area torque up • Performs torque up control in idling area by engine speed signal in order to also enable cargo work at idling.
control
Overheat prevention • Reduces engine heat generation by reducing maximum engine speed and regulating maximum throttle opening
control when engine coolant temperature reaches approximately 110°C (230°F).
• Prevents resulting in engine breakage by overheat by performing fuel cut at 1,000 rpm or more when engine
coolant temperature reaches approximately 135°C (275°F).
Fuel pump control • Turns fuel pump relay ON/OFF depending on engine speed signal.
(gasoline)
LPG interception valve • Turns interception valve relay ON/OFF depending on engine speed signal and fuel pressure sensor signal.
control
Fail-safe function • Ensures vehicle's safe operation and enables vehicle to be driven in an emergency when any of the major system
components (mass air flow sensor, engine coolant temperature sensor, etc.) have malfunctioned.
Diagnostic system • Adopts self-diagnosis system for easier trouble diagnosis.
EC-8
Battery voltage
Electric load switch signal
EGI relay control output
Ignition key switch signal
KLINE
Accelerator pedal position sensor signal (2 systems)
A/C relay control output
Monitor lamp output
A/C SW signal
Vehicle speed sensor signal
Vehicle speed selector switch (resistor) Neutral switch signal
O2 sensor heater control output Brake switch signal
O2 sensor signal Fuel control changing switch signal (2)
Throttle position sensor signal (2 systems) E.C.M Fuel pump relay output
Electric throttle control actuator control output Engine coolant temperature sensor signal
Cylinder discrimination signal
Crank angle sensor signal
Ignition signal output
Fuel injection (gasoline) control output (6)
Air flow meter signal
Intake air temperature
sensor signal
Air flow meter

(Slot-in)
Gasoline
injector (6)
DIST
EC-9
GASOLINE
W/coil optical crank

Air cleaner
Electric throttle control actuator angle sensor
(Throttle position sensor 2 systems)
System Diagram
Engine coolant
temperature
sensor
O2 sensor
Fuel pump relay
Fuel pump
(gasoline)
Fuel tank (gasoline)

Muffler Catalyzer
ECM0511
Battery voltage
KLINE
Monitor lamp output
A/C SW signal
Throttle position sensor signal (2 systems) E.C.M
LPG interception valve control output Cylinder discrimination signal
LPG PTC heater relay control output Crank angle sensor signal
Fuel injection (LPG) control output (2) Ignition signal output
Assistance fuel injector Air flow meter signal
control output Intake air temperature
Fuel pressure sensor signal sensor signal
Air flow meter

(Slot-in)
Fuel pressure sensor

LPG
Assistance fuel injector
2 pieces are used

LPG injector DIST
EC-10
Air cleaner
angle sensor
Electric throttle Engine coolant

control actuator temperature
(Throttle position sensor
Vaporizer sensor 2 systems)
O2 sensor
System Diagram (Cont'd)
PTC heater relay Interception valve LPG gas tank
Relay
Muffler Catalyzer
ECM0512
Battery voltage
KLINE
Monitor lamp output
A/C SW signal
Throttle position sensor signal (2 systems) E.C.M Fuel pump relay output
LPG interception valve control output Cylinder discrimination signal
LPG PTC heater relay control output Crank angle sensor signal
Fuel injection (LPG) control output (2) Ignition signal output
Assistance fuel injector Fuel injection (gasoline) control output (6)
control output Air flow meter signal
Fuel pressure sensor signal Intake air temperature
sensor signal
Air flow meter

(Slot-in)

DUAL
Assistance fuel injector

Gasoline
2 pieces are used injector (6)
LPG injector DIST
EC-11
Air cleaner
angle sensor
Electric throttle Engine coolant

control actuator temperature
(Throttle position sensor
Vaporizer sensor 2 systems)
O2 sensor
Fuel pump relay

System Diagram (Cont'd)
PTC heater relay Interception valve LPG gas tank
Relay
Fuel pump
(gasoline)
Fuel tank (gasoline)

Muffler Catalyzer
ECM0513
Sensors and Actuators Control Items

Main sensors and actuators related to the ECM are listed below.
Gasoline std std std std std std std std Combined std std
Fuel
LPG std std std – std std std std Combined std std
Control Item Fuel injection control
Fuel changing (Gasoline and LPG)
Fail-safe
Ignition timing control
Maximum engine speed control
Maximum vehicle speed control

Idle speed control
Fuel pump control
Self-diagnosis
A/F feedback control
Fuel cut-off control

Fuel injection control
⊕ : Significant impact to control

♦ : Impact to control
Crankshaft position sensor (POS, REF) ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦
Mass air flow sensor ⊕ ⊕ ♦ ⊕ ♦ ♦
Intake air temperature sensor ♦ ♦
Engine coolant temperature sensor ♦ ⊕ ♦ ♦ ♦ ♦ ♦
Heated oxygen sensor ⊕ ♦ ♦
Vehicle speed sensor ♦ ♦ ♦ ♦ ⊕ ♦
Throttle position sensor ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
Sensors
Accelerator pedal position sensor ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

Ignition switch IGN ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
PNP switch ♦ ♦ ♦ ♦ ♦
Stop lamp switch ♦
Headlamp (electrical load) switch ♦
Battery voltage ♦ ♦ ♦ ♦ ♦
LPG fuel pressure sensor ♦ ⊕ ♦
Fuel changing switch ⊕ ⊕ ⊕ ⊕ ⊕
Gasoline injector ⊕ ⊕ ⊕
Ignition system Power transistor ⊕ ♦
Ignition coil ⊕
Throttle control motor relay ⊕ ♦
Throttle control motor ⊕ ♦ ♦
Gasoline fuel pump relay ⊕ ⊕
Actuators
Gasoline fuel pump ⊕ ♦

Ignition relay ⊕
ECM relay ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
LPG injector ⊕ ⊕ ⊕ ♦
LPG assistance injector ⊕ ⊕ ⊕ ♦
LPG interception valve relay ⊕ ⊕ ♦
LPG interception valve ⊕ ♦
EC-12
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
Trouble Diagnosis Procedure

1) The most important thing when carrying out trouble diagnosis is
to fully understand the vehicle's system (control details and
mechanical system).
ECCS engine controls actuators such as injectors and ignition
coils, based on information provided by lots of sensors. The
actuators make the engine (mechanical system) rotate. The
sensors also transmit ever-changing information to C/U. It is
necessary to understand this cycle.
ECM0233
2) Before starting inspection, it is important to clarify about what

phenomenon of the vehicle the customer complains.
For this purpose, it is necessary to reproduce the malfunction
and to totally understand its details.
It is also required to deliberately interview the customer and to
ride the vehicle with the customer to verify the actual machine
where necessary.
CAUTION:
Customers are not professionals. It can be dangerous to easily
interpreting their explanations assuming that "the customer may
ECM0234
mean this" or "the customer may refer to this phenomenon."
3) In order to repair a malfunction without fail, it is essential to

verify the nature of the malfunction.
For a malfunction that is hard to be reproduced, it is important to
reproduce the malfunction based on inquiry results and similar
cases in the past instead of conducting inspection in an
impromptu manner. In the case of defective contact which
causes most of malfunctions which are hard to be reproduced,
one of the effective means of reproducing the malfunction is to
shake the harness and connectors by hand. If predictive repairs
are carried out without verifying the phenomenon, judgment of
ECM0235 the result of repair, i.e., whether the malfunction is really fixed,
cannot be made.
4) Another important thing is to identify whether the malfunction is
caused by the ECCS control signal system or mechanical
system (main body of the engine, auxiliary parts). It is important
to identify the system causing the malfunction by using a
service tool or inspecting I/O signals of the ECCS C/U.
When inspecting I/O signals of the ECCS C/U, carry out the
inspection procedure with a check adapter (special tool)
connected to the C/U in order to prevent a wrong diagnosis of
defective contact or other problems.
Special tool:
Check adapter V (EG1755 0000)
(For SMJ150 pole connector)
Harness adapter (EG1755 0200)
(Adapter for converting 150 pole to 121 pole)
EC-13
TROUBLE DIAGNOSIS
5) To judge whether the I/O signals of the ECCS C/U are normal,
use the reference values (yardstick) of the I/O data stated in this
manual. If it is hard to make judgment, one of effective means
will be comparison of the data on the vehicle under trouble
diagnosis with data obtained by measuring another vehicle of
the same model under the same conditions. In that sense, a
shortcut to correct trouble diagnosis is personally accumulating
lots pieces of data on the vehicle under the normal state.
ECM0236
1. Trouble diagnosis flowchart

Phenomena of malfunction vary widely. There may therefore be no
absolute way of trouble diagnosis for all malfunctions. In addition,
whether a cause is determined largely depends on techniques and
experiences of the maintenance personnel in charge.
However, the trouble diagnosis procedure itself can be carried out in
a comparatively common manner regardless of the type of
phenomena of malfunction. Conduct trouble diagnosis following the
flowchart shown below.
ECM0237
EC-14
TROUBLE DIAGNOSIS
2. Interview sheet
1) General
• To confirm a phenomenon of malfunction, it is necessary to
obtain information about what phenomenon of the vehicle the
customer complains through an interview with the customer.
• Important information on a phenomenon of malfunction includes
what phenomenon occurs under what conditions and that no
such a phenomenon occurs under what conditions.
• To ensure that complete information can be obtained with no
missing piece, it is recommended to use the interview sheet.
ECM0238
EC-15
TROUBLE DIAGNOSIS
3. Flowchart for narrowing down information on the cause of

problems
ECM0393
EC-16
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom

TB45 Engine Trouble Phenomena and Sensor
System
The quick reference table shown below organizes trouble phenomena
which can occur when a malfunction occurs in the sensor system.
Im- Im-
Check that symptoms are in fail-safe condition.

Check that symptoms are detected with self-diagnosis.
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
High idle rpm

Low idle rpm
Poor fuel
Fast idle is not effective
During surge and constant speed drive

When engine is cold
Backfire
Inconsistent idle when engine is cold.
Inconsistent idle when warming up
Poor power output
Poor acceleration
After-burn
Overheat
Engine rpm does not increase smoothly.
During surge and acceleration
Knocking
At Idle
Driving
During deceleration
During a heavy load
No initial combustion
Initial combustion
When engine is warming up

Description/notable characteristics of
the symptom
Actuator malfunction
O : Highly possible
O : Possible
Crank angle sensor (POS, OPEN • The REF signal wire or POS signal
PHASE) wire, whichever has a break, the
vehicle cannot be started.
O O O O O O
• The sensor signals are not output
both to the fuel system nor ignition
system.
Instanta- • The phenomena which may occur

neous vary depending on the time of
interrup- instantaneous interruption and the
tion operating conditions. In general,
O O O O O O O O O O O O O
however, a light physical impact is
caused or knocking of the engine
occurs during travel, or an engine
stall might occur during idling.
Air flow meter Signal OPEN • The fail-safe device is actuated to

O O O O O O O O O O O O O O
allow operation at 800 rpm or less.
Output is • The air-fuel ratio becomes rich. In

excessive some cases, black smoke may also
O O O O O O O O O O O O O O O O be produced. The trouble may be
caused by the defective contact of
the ground.
Output is • The air-fuel ratio becomes lean.

inadequate O O O O O O O O O O O O O O O O O O The trouble may be caused by
soiled hot wire or sucked air.
Ground OPEN • The air-fuel ratio becomes

O O O O O O
excessively rich.
Electric OPEN
• The fail-safe device is actuated to
power O O O O O O O O O O O O
allow operation at 800 rpm or less.
supply
Intake air temperature OPEN/

O O
sensor SHORT
Coolant temperature sensor OPEN/ • The fail-safe device is actuated to

SHORT make the engine warning lamp light
up. In addition, the engine is
O O O O O O O O O O O O O O O brought into OVERHEAT STEP #1.
Normal operation is possible. A
malfunction is likely to occur during
the engine cool-down or warm-up.
Resistance • The sensor judges that the water

is excessive temperature is low. A malfunction is
O O O O O O O O O O O O O O O O
likely to occur during the engine
warm-up.
Resis- • The sensor judges that the water

tance is temperature is high. A malfunction
O O O O O O O O O O O O O O O O O O O O
inadequate is likely to occur during the engine
cool-down.
O2 sensor OPEN/ • The air-fuel ratio becomes the

O O O O O O O O O
SHORT basic value.
EC-17
TROUBLE DIAGNOSIS
TB45 Engine Trouble Phenomena and Sensor

System (Cont’d)
Im- Im-

possi- possi-
ble to ble to
start start

Poor power output

Initial combustion
Poor acceleration
When engine is cold

Knocking
Overheat
Backfire
After-burn
Driving
During deceleration
During a heavy load
High idle rpm

Low idle rpm
At Idle
Poor fuel
the symptom
O : Highly possible
O : Possible
Vehicle speed sensor OPEN/ • The fail-cut time is shortened or the

O O O O O
SHORT fail-cut does not work.
Throttle position sensor OPEN/ • Idle will be base rpm. No addition

O O O O O O O O O O O O O O O
SHORT for acceleration.
Output • Possible interruption by

fluctuation unnecessary fuel injection. Poor
O O O O O O O O O O O
ground or control unit connection
may be the cause.
Poor • Idling is judged as OFF during idle.

adjustment Turning ignition switch repeatedly to
O
ON and OFF will set the system to
normal.
Accelerator pedal position OPEN/

O O O O O O O O O
sensor SHORT
Output
O O O O O O O O
fluctuation
Ignition switch (IGN) OPEN • Impossible to start without outputs

O O O O O
for fuel and ignition systems.
Neutral switch OPEN • Neutral switch is judged as OFF,

O O O O O O O and the target cold engine speed in
N/P position is lowered.
SHORT • Neutral switch is judged as ON, and

fast idle is effective for cold engine
in positions other than N/P position,
making the creep larger.
Stop lamp switch OPEN/

SHORT
Headlamp (electrical load) OPEN/

O O O O
switch SHORT
Power supply for control unit OPEN • Impossible to start without outputs
O O O O O O
for fuel and ignition systems.
Sensor ground (coolant OPEN/

• The same as the open circuit in the
temperature sensor, throttle SHORT O O O O O O O O O O O O O O O O
applicable sensor.
position sensor)
Control unit and connector Poor • A slightly raised connector often

connection, results in poor connection. Entry of
water entry water causes engine stall and
O O O O O O O O O O O O O O O O O O O O O O O afterwards it is momentarily
impossible to restart engine. In
some cases, restarting is possible
after a short wait.
LPG fuel pressure sensor SHORT • Impossible to start with LPG

O O O O O O interception valve off when the
sensor is shorted.
Fuel changing switch OPEN O • Fuel changing cannot be done.
LPG fuel pressure sensor OPEN O O O O O O O • LPG interception valve off.
EC-18
TROUBLE DIAGNOSIS
TB45 Engine Trouble Phenomena and Actuator

System
which can occur when a malfunction occurs in the actuator system.
Im- Im-

possi- possi-
ble to ble to
start start

Initial combustion

Low idle rpm
Poor acceleration
Backfire
Knocking
After-burn
At Idle
Driving
During deceleration
During a heavy load
When engine is cold
High idle rpm
Poor fuel
Poor power output
Overheat
the symptom
O : Highly possible
O : Possible
Gasoline injector Power OPEN O O O O O O O O O O O O O O • Cylinder wire of which has a

circuit disconnection does not inject fuel.
Instanta- The O2 sensor output becomes
neous O O O O lean.
interruption • If wires of all cylinders have a
disconnection, the engine cannot
be started.
Coil OPEN O O O O O O O O O O O O O O
Instanta-
neous O O O O
interruption
Drive OPEN O O O O O O O O O O O O O O O
circuit
(C/U Instanta-
unit) neous O
interruption
SHORT • Cylinder wire of which is short-circuited

continues to inject, resulting in exces-
O O O O O O O O O O O O O O O sively-rich air-fuel ratio or accidental fire.
• If wires of all cylinders have a disconnec-
tion, the engine cannot be started.
Nozzle Biting of • Cylinder which bites a foreign

hole foreign O O O O O O O O O O O O O O material continues to inject.
materials
Clogging • The compensation factor for the air-

O O O O O O O O O O O O O O O O fuel ratio increases, though depending
on how the nozzle hole is clogged.
Ground- OPEN O O O O
ing cir-
cuit (C/U Instanta-
unit) neous O O O O O O O O
interruption
Ignition signal circuit OPEN O O O O O O O In the case of disconnection:

• The engine stalls instantaneously
Instanta- while it is in rotation and does not
neous O O O O O O O O O O O O O O O re-start.
interruption • The engine injects fuel while it is
being cranked. As a result, the
spark plug does not make a spark
Ignition coil Power OPEN O O O O O O O normally.
circuit
Instanta- In the case of instantaneous interruption:
neous O O O O O O O O O O O O O O O • In general, a light physical impact is
interruption caused or knocking of the engine
occurs during travel, though
Coil OPEN O O O O O O O depending on the length of time of
instantaneous interruption and the
operating conditions. If the length of
Instanta-
the instantaneous interruption
neous O O O O O O O O O O O O O O O
increases, an engine stall can
interruption
occur.
Ground- OPEN O O O O O O O
ing cir-
cuit Instanta-
neous O O O O O O O O O O O O O O O
interruption
ECCS & IGN relay circuit OPEN O O O O O O
EC-19
TROUBLE DIAGNOSIS
TB45 Engine Trouble Phenomena and Actuator

System (Cont’d)
Im- Im-

possi- possi-
ble to ble to
start start


High idle rpm
Initial combustion
Low idle rpm
Backfire

Knocking
After-burn
At Idle
Driving
During deceleration
During a heavy load
When engine is cold
Poor acceleration
Poor fuel
Poor power output
Overheat
the symptom
O : Highly possible
O : Possible
Throttle control motor circuit OPEN/

O O O O O O
SHORT
Throttle control motor relay OPEN • The same troubles as those occur
circuit when the power cable of the throttle
O O O O O O O O O O O O O
motor and throttle sensor has a
disconnection can occur.
O2 sensor heater circuit OPEN
OPEN O O O O • Impossible to start.

• Fuel pump relay circuit
• Fuel pump circuit Instanta- • There is a possibility of an engine
• Ignition relay circuit neous O O O O O knocking or surge.
interruption
Fuel pump Fixing

O O O O
Pressure regulator
LPG injector Hi side OPEN O O O O O O O • LPG interception valve off when

circuit self-diagnosis is NG
SHORT O O O O O O O
Coil OPEN O O O O O O O
Lo side OPEN O O O O O O O
circuit
SHORT O O O O O O O
LPG assistance injector OPEN O O O O O O O O
Control
unit side O O O O O O
SHORT
LPG interception valve relay OPEN O O O O O
Control
unit side
SHORT
LPG interception valve OPEN O O O O O
Engine warning lamp OPEN O O
Improper TAS learning OPEN O O O O O O
EC-20
TROUBLE DIAGNOSIS
TB45 Engine Trouble Phenomena and the Engine's

Main Unit System and Mechanical Parts
As long as three combustion factors, i.e., compressive pressure, air-fuel
mixture and ignition source, are normal, any combustion malfunction of
engine should not occur.
The air-fuel mixture and ignition source (ignition timing) are controlled
by the ECCS C/U. However, a combustion malfunction can occur
when the main body system has a malfunction (fault).
which can occur when a malfunction occurs in the engine's main unit
system. We hope the table could give you clues when conducting
trouble diagnosis. (The table given below is a versatile one and may
contain some irrelevant items.)
Im- Im-
possi- possi-
ble to ble to
start start
High idle rpm
Low idle rpm
Poor fuel
Poor power output
During deceleration
When engine is cold

Poor acceleration
Initial combustion
Knocking
Backfire
After-burn
During a heavy load

Overheat
At Idle
Driving
Description/notable characteristics of the
symptom
O : Highly possible
O : Possible
U : Rarely possible
Air-fuel mixture
Air is sucked from the oil level • Air-fuel ratio becomes lean.
O U O O U U U
gauge section • Compensation value for the air-fuel ratio
increases.
Air is sucked from the oil filler cap • Negative suction pressure of the intake
O U O O U U U manifold increases.
section
* Inspect with a negative suction pressure
Air is sucked from the blow-by hose gauge.
O U O U O O O O O U U O O O U * Common to air suction from the suction
(PCV downstream)
system in general.
Air is sucked from the intake
O U O U O O O O O U U O O O U
manifold and gasket sections
PCV remains open • Abnormal noise (peep, etc.) may be

O O U O O O O O
produced.
Fuel strainer is clogged O U O U O O O O O O O U O O • In general, malfunctions are likely to occur

at a high speed or under a high load, though
depending on how the strainer or element is
Air cleaner element is clogged O O O O O O clogged.
Gasoline pressure regulator is • Various phenomena occur due to explosion

U O O O O O O O O O O O O O O
defective pressure.
Gasoline property is defective • Various phenomena occur depending on the

U O O O O O O O O O O U O O O O U
gasoline property.
LPG fuel is not suited (in cold • Start-up performance in the cold season
season, propane ratio) differs depending on the propane ratio.
O O O O O O O O O O U O O O O
• LPG with a specified propane ratio should
be used.
LPG vaporizer pressure regulator • When the vaporizer pressure is inadequate,

is defective an output shortage occurs under a high
speed or high load.
• When the vaporizer pressure is excessively
high, the relief valve is actuated to cause an
engine stall due to a rich air-fuel ratio.
LPG vaporizer hot-water circuit is • In general, an engine stall or re-start error is

clogged O O O O O O O O O O O O likely to occur during warm-up operation,
though depending on the fuel temperature.
LPG interception valve section filter • In general, malfunctions are likely to occur
is clogged O U O U O O O O O O O U O O at a high speed or under a high load, though
depending on how the filter is clogged.
Valve deposit • Malfunction is likely to occur under a high

O O O U O O O O O O O O O O O U speed or high load (suction quantity
decreases).
EC-21
TROUBLE DIAGNOSIS

Main Unit System and Mechanical Parts (Cont’d)
Im- Im-
possi- possi-
ble to ble to
start start

When engine is cold
Poor power output

Initial combustion
Poor acceleration

Knocking
Backfire
After-burn
Driving
During deceleration
Overheat
During a heavy load
High idle rpm

Low idle rpm
At Idle
Poor fuel
Description/notable characteristics of the
symptom
O : Highly possible
O : Possible
U : Rarely possible
Sparks
High-pressure cords insertion error O O O O O O O O O O O O O O O • Is the ignition sequence correct?
Defective adjustment of ignition

O O O O O O O O O O O O O U O O O ----
timing
Spark plug is defective • Is the gap adequate? Does the plug have
O O O O O O O O O U U U
stains (by smoke, etc.)?
Leakage from the high-pressure • Phenomena which may occur vary

U O O O O O O O O O O O O O O O
cord depending on the degree of leakage.
Leakage from the distributor cap U O O O O O O O O O O O O O O O ----
Loose connection or disconnection

----
of the primary wire
Compressed
pressure
Defective contact of the valve • Phenomena which may occur vary

U O O O O O O O O O O O O O O O depending on the state of contact and the
number of cylinders.
Piston ring has worn out • Phenomena which may occur vary
U O O O O O O O O O O O O O O depending on the degree of wear and the
number of cylinders.
Others
Catalyst/exhaust system is clogged • In many cases of an engine stall, the engine

can be re-started after a period of time.
The basic number of revolutions of • Power steering load or material-handling

the idle is inadequate U U U U O O O O load may cause an engine stall during
deceleration or idling.
Brake piston is fixed O O O O • Tire wheel becomes hot.
Belt tension is excessively high

O O O O O ----
(excessively tensed)
A/T load is high • A/T oil quantity is inadequate or the oil

specifications are not suited (the overload
U U O U O
phenomenon occurs in particular in cold
season).
HYD PUMP load is high (PS, • Hydraulic pressure relief valve is defective
material handling) or the oil specifications are not suited (the
U U U O O U
overload phenomenon occurs in particular
in cold season).
Foreign materials (contaminants) • The phenomenon is likely to occur when the

inside the fuel tank fuel quantity has decreased.
Fan has broken, or water pump is • Abnormal noise is usually produced.

O
defective
Radiator or capacitor is clogged O ----
In addition to the above-stated items, the following should be inspected:

• Whether the harness tension is adequate
• Whether the connectors are securely connected
• Whether the ground wire has loosened
• Whether the battery connection has loosened or has corroded
• Whether water and oil are normal
• Whether the fan belt etc. has loosened
EC-22
TROUBLE DIAGNOSIS

Main Unit System And Mechanical Parts
As long as three combustion factors, i.e., compressive pressure, air-fuel
mixture and ignition source, are normal, any combustion malfunction of
engine should not occur.
The air-fuel mixture and ignition source (ignition timing) are controlled
by the ECCS C/U. However, a combustion malfunction can occur
when the main body system has a malfunction (fault).
The quick reference table shown below organizes trouble phenomena,
including those not related to combustion, which can occur when a
malfunction occurs in the engine's main-unit and components of
auxiliaries. We hope the table could give you clues when conducting
trouble diagnosis. The table given below is a versatile one and may
contain some irrelevant items.
Im- Im-
possi- possi-
ble to ble to
start start
Hydraulic-pressure warning lamp lights up

Initial combustion

When engine is cold
Poor power output

Poor acceleration
Knocking
Backfire
After-burn
Driving
During deceleration
Overheat
At Idle
During a heavy load
Overcooling
Excessive oil consumption
Abnormal mechanical noise

High idle rpm
Low idle rpm
Poor fuel
Description/notable
characteristics of the symptom
O : Highly possible
O : Possible
U : Rarely possible
Air-fuel mixture
Air is sucked from the oil level • Air-fuel ratio becomes

O U O O U U U
gauge section lean.
• Compensation value for
Air is sucked from the oil filler cap the air-fuel ratio increases.
O U O O U U U • Negative suction pressure
section
of the intake manifold
increases.
Air is sucked from the blow-by hose
O U O U O O O O O U U O O O U * Inspect with a negative
(PCV downstream)
suction pressure gauge
* Common to air suction
Air is sucked from the intake from the suction system
O U O U O O O O O U U O O O U
manifold and gasket sections in general
PCV remains open • Abnormal noise (peep,

O O U O O O O O
etc.) may be produced.
• In general, malfunctions
Fuel strainer is clogged O U O U O O O O O O O U O O are likely to occur at a high
speed or under a high
load, though depending on
Air cleaner element is clogged how the strainer or
O O O O O O
element is clogged.
Gasoline pressure regulator is • Various phenomena occur

defective due to explosion pressure
Gasoline property is defective • Various phenomena occur

U O O O O O O O O O O U O O O O U depending on the gasoline
property.
LPG fuel is not suited (in cold • Start-up performance in

season, propane ratio) the cold season differs
depending on the propane
O O O O O O O O O O U O O O O ratio.
• LPG with a specified
propane ratio should be
used.
LPG vaporizer pressure regulator • When the vaporizer

is defective pressure is inadequate, an
output shortage occurs
under a high speed or high
load.
U O O O O O O O O O O O O O O • When the vaporizer
pressure is excessively
high, the relief valve is
actuated to cause an
engine stall due to a rich
air-fuel ratio.
EC-23
TROUBLE DIAGNOSIS

Im- Im-
possi- possi-
ble to ble to
start start


Initial combustion

When engine is cold
Poor power output

Poor acceleration
Knocking
Backfire
After-burn
Overheat
Driving
During deceleration
During a heavy load
Overcooling

High idle rpm
Low idle rpm
At Idle

Poor fuel
Description/notable
O : Highly possible
O : Possible
U : Rarely possible
Air-fuel mixture
LPG vaporizer hot-water circuit is • In general, an engine stall

clogged or re-start error is likely to
occur during warm-up
O O O O O O O O O O O O
operation, though
depending on the fuel
temperature.
LPG interception valve section filter • In general, malfunctions

is clogged are likely to occur at a high
O U O U O O O O O O O U O O speed or under a high
load, though depending on
how the filter is clogged.
Valve deposit • Malfunction is likely to

occur under a high speed
O O O U O O O O O O O O O O O U
or high load (suction
quantity decreases).
Sparks
High-pressure cords insertion error • Is the ignition sequence

O O O O O O O O O O O O O O O
correct?
Defective adjustment of ignition

O O O O O O O O O O O O O U O O O ----
timing
Spark plug is defective • Is the gap adequate? Does

O O O O O O O O O U U U the plug have stains (by
smoke, etc.)?
Leakage from the high-pressure • Phenomena which may

cord U O O O O O O O O O O O O O O O occur vary depending on
the degree of leakage.
Leakage from the distributor cap U O O O O O O O O O O O O O O O ----
Loose connection or disconnection

----
of the primary wire
Compressed pressure
Defective contact of the valve • Various phenomena occur

U O O O O O O O O O O O O O O O depending on the state of
malfunction and the
number of malfunctioning
Piston ring wear, fixing, fouling U O O O O O O O O O O O O O O O cylinders.
Gasket blow-off • Various phenomena occur

depending on the state of
malfunction and the
U O O O O O O O O O O O O O O O number of malfunctioning
cylinders. Head bolt
tightening torque should
be carefully checked.
Valve spring breakage or • Various phenomena occur

deterioration depending on the state of
U O O O O O O O O O O O O O O malfunction and the
cylinders.
Valve stem fixing, knock-up • Various phenomena occur

depending on the state of
U O O O O O O O O O O O O O O malfunction and the
cylinders.
Leakage of compressed air from • Gasket and its tightened

O
the spark plug section state should be checked.
EC-24
TROUBLE DIAGNOSIS

Im- Im-
possi- possi-
ble to ble to
start start

Overheat
Overcooling

Initial combustion
When engine is cold
Low idle rpm

Poor power output

Poor acceleration

High idle rpm
During deceleration
During a heavy load
Knocking
Backfire
At Idle
Driving

After-burn
Poor fuel

Description/notable
O : Highly possible
O : Possible
U : Rarely possible
Others
The basic number of revolutions of • Power steering load or

the idle is inadequate material-handling load may
U U U U O O O O
cause an engine stall during
deceleration or idling.
Cylinder block crack or water

O
leakage
Main movement system
Excessive play in the crank

O
shaft end
Excessive clearance in the • Oil leakage from around

crank and connecting rod O O the crank shaft front/rear
bearing
Crank shaft front/rear oil • Oil leakage from around

O
seal breakage the crank shaft front/rear
Excessive clearance • Whitish exhaust gas.

between piston and cylinder O O Piston or cylinder has worn
out.
Main movement system
Excessive clearance in the

O
piston pin
Improper assembly of the • Whitish exhaust gas.

piston ring Misalignment of abutment
O
joint or upside-down
assembly
Excessive clearance in the • Whitish exhaust gas.

piston ring O Piston ring groove or
piston ring has worn out.
Torque converter pilot

O
bushing wear
Cylinder head cracks:

Head components
O
Water leakage
Carbon deposit in the

O
combustion chamber
Valve stem or guide wear O • Whitish exhaust gas
Valve oil seal's rip section

O
deterioration
Valve operating system
Excessive clearance or • Excessive clearance:

clogging in the valve Chattering during idling
O O O O O O • Clearance clogging:
Oil leakage from engine
during idling
Oil leakage from the rocker • Gasket has loosened or

O
cover gasket has broken.
EC-25
TROUBLE DIAGNOSIS

Im- Im-
possi- possi-
ble to ble to
start start


Poor power output
Poor acceleration
Overheat
Initial combustion
When engine is cold
High idle rpm

Low idle rpm
Knocking
Backfire
During deceleration
During a heavy load
Overcooling

At Idle
Driving
After-burn
Poor fuel

Description/notable
O : Highly possible
O : Possible
U : Rarely possible
Others
Chain system
Timing chain sagging • Shoe in the chain

O tensioner has worn out.
• Chain guide dropout
Improper valve timing • Timing mark for the timing

chain components should
O O O O O O O O O O
be checked for
misalignment.
Oil leakage from the front • Gasket has loosened or

O
cover section has broken.
Improper engine oil • Oil quantity is inadequate.

Lubrication system
Oil grade is not

appropriate. Oil has
O O
deteriorated.
• Add recommended oil by
the specified quantity.
Oil pump failure • Rotor has worn out or has

broken.
O O • Defective operation of or
oil leakage from the
regulator
Oil leakage around the oil • Oil pan gasket has

pan loosened or has broken.
O
• Oil pan drain plug has
loosened.
Oil strainer clogging • Engine oil has

contaminated or has
O
entrained foreign
materials.
Oil leakage from oil filter • Gasket has loosened or

has broken.
O • Apply oil to the gasket
section when changing the
oil filter.
Oil filter clogging • Engine oil has

contaminated or has
O
entrained foreign
materials.
Hydraulic switch has

O O
loosened or failed
Fuel system
Foreign materials • The phenomenon is likely

(contaminants) inside the U O O O O O O O O O O O O O O to occur when the fuel
fuel tank quantity has decreased.
Fuel leakage from the fuel • Leakage of LPG should be

system O checked by applying
Snoop.
EC-26
TROUBLE DIAGNOSIS

Im- Im-
possi- possi-
ble to ble to
start start


High idle rpm
Backfire
Initial combustion
Low idle rpm

Poor acceleration
After-burn
At Idle
Driving
During deceleration
Overcooling
When engine is cold

Knocking
During a heavy load

Poor fuel
Poor power output
Overheat
Description/notable
O : Highly possible
O : Possible
U : Rarely possible
Cooling system
Others
Defective rotation of fan or • Slip or belt break due to

O
water pump loosened belt
Water pump failure • Bearing has worn out or

O O has broken. Water leakage
from the shaft seal
Thermostat failure O O
Water temperature gauge

O O
failure
Water leakage from water

O
temperature sensor
Radiator components • Radiator cap pressure has

malfunction decreased. Water leakage
from the radiator cap
O
• Clogging in or water
leakage from the radiator
or capacitor
Cooling water contamination

O
or inadequate quantity
Water leakage from the

O
cooling system piping
Excessive tension of the belt for

O O O O O
auxiliaries (excessively tensed)
Catalyst/exhaust system is clogged • In many cases of an

engine stall, the engine
can be re-started after a
period of time.
Brake piston is fixed O O O O • Tire wheel becomes hot.
A/T load is high • A/T oil quantity is

inadequate or the oil
specifications are not
U U O U O
suited (the overload
phenomenon occurs in
particular in cold season).
HYD PUMP load is high • Hydraulic pressure relief

(PS, material handling) valve is defective or the oil
specifications are not
U U U O O U
suited (the overload
phenomenon occurs in
particular in cold season).
In addition to the above-stated items, the following should be inspected:

• Whether the harness tension is adequate
• Whether the ground wire has loosened
• Whether the connectors are securely connected
• Whether the battery connection has loosened or has corroded
• Whether the belt for auxiliaries has loosened
• Whether water and oil are normal
EC-27
TROUBLE DIAGNOSIS
Locations of components
Applicable specification
Major components Type Location
Combination
Gasoline LPG
use
Actuators
Gasoline injector High-resistance type Intake manifold O O
LPG injector Air injection type Built in the injector holder

O O
(upper side of the intake manifold)
Fuel pump Electric turbine type Built in the fuel tank O O
Pressure regulator Diaphragm type O O
Throttle control motor Direct-current electric motor type (DC motor) Built in the electronic control throttle O O O
Ignition coil Mold type (with a built-in power transistor) Built in the distributor O O O
Power transistor 1-channel type O O O

Sensors
Crank angle sensor Photoelectric type Built in the distributor O O O
Air flow meter Hot-wire type Air horn O O O
Accelerator pedal position sensor 1, 2 Variable-resistor type Built in the accelerator work unit
O O O
(accelerator pedal assembly.)
Throttle position sensor 1, 2 Built in the electronic control throttle O O O
Engine coolant temperature sensor Thermistor type Thermostat housing section O O O
Intake air temperature sensor Integral with the air flow meter O O O
O2 sensor Zirconia type (with a heater) Exhaust manifold O O O
Vehicle speed sensor Electromagnetic power-generation type (On the vehicle side) O O O
ECCS control unit 121-pole digital-control type O O O
ECCS relay Compact multi-purpose relay (2M type) O O O
EC-28
TROUBLE DIAGNOSIS
Locations of components (Cont’d)

Applicable specification Reference
Parts locations of which are indicated Location
Combination
Gasoline LPG Actuator Sensor Other
use
Gasoline injector Intake manifold O O O
LPG injector Built in the injector holder

O O O
(upper side of the intake manifold)
Throttle control motor Built in the electronic control throttle O O O O
Throttle position sensor 1, 2 Built in the electronic control throttle O O O O
Ignition coil Built in the distributor O O O O
Crank angle sensor O O O O
Power transistor O O O O
Air flow meter Air horn O O O O
Intake air temperature sensor Integral with the air flow meter O O O O
Engine coolant temperature sensor Thermostat housing section O O O O
Accelerator pedal position sensor 1, 2 Built in the accelerator work unit

O O O O
(accelerator pedal assembly.)
Fuel pump Built in the fuel tank O O O
Pressure regulator O O O
O2 sensor Exhaust manifold O O O O
Vehicle speed sensor (On the vehicle side) O O O O
ECCS control unit (On the vehicle side) O O O O
ECCS & ignition coil relay (On the vehicle side) O O O O
Stop lamp switch (On the vehicle side) O O O O
Throttle control motor relay (On the vehicle side) O O O O
Fuel pump relay (On the vehicle side) O O O
Vaporizer (On the vehicle side) O O O
LPG interception valve (On the vehicle side) O O O
EC-29
TROUBLE DIAGNOSIS
ECM
Mass air flow sensor Accelerator pedal assembly
Engine coolant temperature sensor Accelerator pedal position sensor
Mass air flow sensor Accelerator pedal
assembly
ECM
Air horn
Engine coolant
temperature sensor
Thermostat
housing
Distributor
Distributor
ECM0240
EC-30
TROUBLE DIAGNOSIS
Fuel tube
O2 sensor Injector
Fuel tube
Exhaust manifold
cover
O2 sensor Injector
Intake manifold
Main injector
Assistance injector
Main injector
Harness connector
for assistance injector
Harness connector
for main injector
Assistance injector
Holder
ECM0241
EC-31
Notes
1) This diagram indicates the schematic for the gasoline/LPG
combination-use type engine. For the gasoline exclusive type
engine and LPG exclusive type engine, refer to the following:
1. Fuel changing switch
Instructions given in the diagram
* Point B * Point E should be followed.
2. Gasoline exclusive type
110 RATT IGN 62 8 2 The parts and circuits marked with ★ should be deleted
REF 14 4 6 (N.C.).
1.25sq or more DIST
118 VR POS 13 3 7 3. LPG exclusive type
Common caulking or joint is necessary 1.25sq or more 121 VR 5 1 The parts and circuits marked with ▲ should be deleted
(N.C.).
B 2) INJ number and IGN number indicated in the diagram are
111 SSOFF same with the cylinder number.
(The engine cylinder numbers are 1-2-3-4-5-6 from the FAN
EGI RLY side.)
1.25sq or more FUEL CHANGING SW 3) Joint of each sensor to GND-A line should be located as
★ LPG INJ 1 119 LPGINIVP#1 close as possible to the ECM.
For combination use type For gasoline exclusive type
#1 2 120 LPGINI-#1 • Within 150 mm from ECM CONN.
1.25sq or more LPG 70 FUELSW#1
FUELSW#1 70 • GND system of AWU is to be the trunk line.
32 FUELSW#2 • Sensors should be joined to the trunk line in sequence.
NUTE
1.25sq or more 49 AVCC The distance from one joint to another should be within
★ LPG INJ 1 117 LPGINIVR#2 150 mm.
Gasoline
#2 2 114 LPGINI-#2 FUELSW#2 32 • Joint of the pressure-sensor system GND should be
1.25sq or more For LPG exclusive type preferentially taken as the ECM side.
AVCC 49
ETC MOTOR RLY 70 FUELSW#1 • Total resistance between each sensor and GND should
1.25sq or more 1.25sq or more 32 FUELSW#2 be 50 mΩ or less.
3 VMOT 4) • * Length of harness from *point A to *point E should be
49 AVCC
7000 mm or less
104 MOTRLV • * Length of harness from *point D to *point F should be
2000 mm or less
6 5 MOTOR1
• * Length of harness from *point J to *point F should be
3 4 MOTOR2 2000 mm or less
THROT 5 66 GND-A2 • * Length of harness from *point G to *point C should be
A CHAMBER 1000 mm or less (15 or more)
(ETC) 4 50 TPS1 6 4 + SPEED SEN
(PICK UP) • * Length of harness from *point K to *point J should be
(▲) ▲ 2 69 TPS2 VSPB 33 5 SPEED SEN UNIT 1 -
150 mm or less
ICN RELAY F/PUMP RLY 1 47 AVCC2 2 3
▲ F/PUMP • * Composite resistance of harness from *point A to *point B
should be 30 mΩ or less including a possible deterioration.
• * Composite resistance of harness from *point D to *point F
B (totally two systems) and from *point J to *point F should
be 30 mΩ or less including a possible deterioration.
• * Any load which is not instructed should not be connected
on the harness from *point D to *point F.
APS1 106 5 • *Any load which is not instructed should not be connected
on the harness from *point J to *point F.
AVCC 90 6 ACCEL 5) • * BODY EARTH 2 should be commonly caulked with ECM
113 FRR GND-A 82 3 WORK GND.
85 KLINE APS2 98 2 LIMIT • * To connect the above with other device GND together,
AVCC2 91 4 (APS) caulking should be done using one terminal instead of
two or more terminals.
CONSULT GND-A2 83 1 • * BODY EARTH 3 can be commonly caulked with a general
EARTH.
TROUBLE DIAGNOSIS
★
1 2 3 4 5 6 7 8 SLOW INJ 11 2 LPG ASSIST INJ 1 • * Both should be tightened at such a location that can be
9 10 11 12 13 14 15 16 electrically ensured in such a way as to electrically ensure
★ LPG FUEL ★ the connection. (It is recommended to tighten with an FT
SAE JI962 1 2 bolt.)
INTERCEPTION VALVE#
CONNECTOR 6) : It is required to shield the part from the
MAIN/C RLY 112 sensor or actuator to the proximity of ECM.
: It is required to process the part from the

PTC HEATER sensor or actuator to the proximity of ECM
★ ★
by means of a twisted-pair cable.
7) External load resistance
1. Regulatory control of maximum vehicle speed R1
EC-32
PTC/H 27
Load resistance kΩ Regulatory speed
Normal N.C. (open) Up to rated revolution
STEP1 25.0<R1 30.0±5% <m/h
STEP2 16.3<R1 18.5±5% <m/h
STEP3 11.0<R1 12.3±5% <m/h
103 IGNSW STEP4 7.4<R1 8.3±5% <m/h
STEP5 4.9<R1 5.6±5% <m/h
▲ STEP6 2.9<R1 3.5±5% <m/h
OFF ON ST 1 GAS INJ:#1 2 23 IN#1
Circult Diagram
B 1 GAS INJ:#2 2 42 IN#2 STEP7 1.4<R1 2.0±5% <m/h

IG 1 GAS INJ:#3 2 22 IN#3 2. Execution of TAS learning
ST 1 GAS INJ:#4 2 41 IN#4 • Normal mode
• Factory mode
R 1 GAS INJ:#5 2 21 IN#5
TROUBLE DIAGNOSIS
1 GAS INJ:#6 2 40 IN#6 8) For the case where CAN communication is not performed
AVCC 48 Burn-out bulb in ENG CHECK LAMP should be checked with
24 O2HFR GND-A 67 ECM. It should not be checked with a meter.
3
35 O2SFR
2 O2 SEN 1
GA+ 51 AIR FLOW 4
4 3
78 GND-A METER 5
8 5 1 CHARGING TA 34 2 AIR/TEMP SEN 1
WARNING LAMP BRAKE LAMP
ALTERNATOR (12V - 34W)
101 BRAKE TW 73 1 W/TEMP SEN 2
FROM BRAKE LAMP SW
LFGPRES 31 FUEL 2
H/LAMP 3
PRESS SEN 1
INHIBITTER RLY ★
23~63.7Ω 84 H/LMP
FROM H/LAMP SW For max. vehicle RESISTANCE R1
speed control (When unused is N.C.)
102 NEUT VARI VSP 54
ENGINE COOLANT TEMPERATURE SENSOR
1
* Point A THERMO THENDER
STARTER MOTOR For idle air RESISTANCE R2
+
OIL PRESSURE WARNING LAMP volume leaning (When normal is N.C.)
INHIBIT SW (12V - 34W)
(NUTE SW) 1 S TAS SW 52
BATTERY SW-OIL PRESS
12V At N:ON
ENG CHECK LAMP

- (12V - 34W) * Point J
30 LED
* Point K
Battery cable GND 1
bonding wire GND 2
GND 115
GND 116
BODY EARTH1 ENG EARTH
* Point C * Point G * Point D * Point F
B
BODY EARTH2 BODY EARTH3
ECM0514
TROUBLE DIAGNOSIS
ECM Terminal Layout
ECM0246
The symbol in ( ) next to terminal numbers indicates the data link

connector.
ECM Terminal Layout (Cont'd)
Terminal Description
1 ECM ground
2 ECM ground
3 Throttle control motor relay power supply
4 Throttle control motor (Close)
5 Throttle control motor (Open)
6 –
7 –
8 –
9 –
10 –
11 LPG assistance injector
12 –
13 Crankshaft position sensor 1° (POS)
14 Crankshaft position sensor 120° (REF)
15 –
16 –
17 –
18 –
19 –
20 –
21 Injector No. 5
22 Injector No. 3
23 Injector No. 1
24 Heated oxygen sensor heater
25 –
26 –
27 PTC heater relay
28 –
29 –
30 MIL
31 LPG fuel pressure sensor
32 Fuel changing switch 2 (Gasoline)
33 Vehicle speed
34 Intake air temperature sensor
EC-33
TROUBLE DIAGNOSIS

35 Heated oxygen sensor
36 –
37 –
38 –
39 –
40 Injector No. 6
41 Injector No. 4
42 Injector No. 2
43 –
44 –
45 –
46 –
47 Sensor power supply (Throttle position sensor)
48 Sensor power supply
49 Fuel changing switch power supply
50 Throttle position sensor 1
51 Mass air flow sensor
52 Idle air volume learning operation
53 –
54 Maximum vehicle speed shifting
55 –
56 –
57 –
58 –
59 –
60 –
62 Ignition signal (power transmission drive signal)
63 –
64 –
65 –
66 Sensor ground (Throttle position sensor)
67 Sensor ground (Mass air flow sensor)
68 –
69 Throttle position sensor 2
70 Fuel changing switch 1 (LPG)
71 –
72 –
73 Engine coolant temperature sensor
74 –
75 –
76 –
77 –
78 Sensor ground (Heated oxygen sensor)
79 –
82 Sensor ground (Accelerator pedal position sensor 1)
83 Sensor ground (Accelerator pedal position sensor 2)
84 Headlamp switch
85 (K LINE) K-line (ECM data transmit/receive)
EC-34
TROUBLE DIAGNOSIS

86 –
87 –
88 –
89 –
90 Accelerator pedal position sensor 1 power supply
91 Accelerator pedal position sensor 2 power supply
92 –
93 –
94 –
95 –
96 –
97 –
98 Accelerator pedal position sensor 2
99 –
100 –
101 Stop lamp brake switch
102 PNP switch
103 –
104 Throttle control motor relay
105 –
106 Accelerator pedal position sensor 1
107 –
108 –
109 (IGN) Ignition switch
110 BATT
111 Self shut off
112 LPG interception valve relay
113 Fuel pump relay
114 No 2 LPG INJ
115 (–) ECM ground
116 (–) ECM ground
117 Power supply for No 2 LPG INJ
118 Power supply for ECM
119 Power supply for No 1 LPG INJ
120 No 1 LPG INJ
EC-35
TROUBLE DIAGNOSIS
ECM Input/Output Signal Specifications

REFERENCE VALUE LIST
Voltages is measured with a circuit tester, and the sample
waveforms obtained with an oscilloscope are shown below for each
ECM terminal. Measurement data varies depending on variation in
parts as well as many other factors. Such factors include vehicle
history, driving conditions, environmental conditions, maintenance
status, measuring instrument/method, etc. Data shown below are
reference values.
ECM0247
ECM0248
ECM Input/Output Signal Specifications (Cont'd)

Terminal Signal name Condition Data (DC value)
24 Heated oxygen sensor heater At idle after warming up Approx. 0.3V
113 Fuel pump relay For approximately 1 second after Approx. 1V
ignition switch ON
After that Battery voltage
At cranking, engine running Approx. 1V
111 Self shut off For approximately 10 seconds when Approx. 1V
ignition switch ON and after ignition
switch OFF
Ignition switch OFF Battery voltage
EC-36
TROUBLE DIAGNOSIS

62 Ignition signal (power transmission At cranking At cranking: Approx. 0.5V

drive signal)
ECM0249
At idle after warming up At idling: Approx. 0.5V
ECM0250
At approx. 2,000 rpm Approx. 0.9V
ECM0251
101 Stop lamp brake switch Brake pedal released Approx. 0V

Brake pedal depressed Battery voltage
109 (IGN) Ignition switch Ignition switch OFF Approx. 0V
Ignition switch ON Battery voltage
102 PNP switch N position Approx. 0V
Other than above Battery voltage (A/T models)
85 (K LINE) K-line (ECM data transmit/receive) When connected to SST Approx. 6.6 - Battery voltage
When not connected to SST Approx. 6V
84 Headlamp switch Lighting switch OFF Approx. 0V
Lighting switch ON Battery voltage
67 Mass air flow sensor ground Always Approx. 0V
115 ECM ground Always Approx. 0V
116
1
2
EC-37
TROUBLE DIAGNOSIS

13 Crankshaft position sensor 1° (POS) At cranking At cranking: Approx. 2.6V
ECM0252
ECM0253
ECM0254
91 Accelerator pedal position sensor 2 Ignition switch ON, engine running Approx. 5V
power supply
48 Sensor power supply Ignition switch ON, engine running Approx. 5V
110 BATT Always Battery voltage
47 Electric throttle control actuator sensor Ignition switch ON, engine running Approx. 5V
power supply
78 Heated oxygen sensor ground Always Approx. 0V
82 Accelerator pedal position sensor 1 Always Approx. 0V
ground
90 Accelerator pedal position sensor 1 Ignition switch ON, engine running Approx. 5V
power supply
27 PTC heater relay At idle after warming up Approx. 0V
(Except north america)
Ignition switch ON when the engine Battery voltage
coolant temperature is 30°C (86°F) or
less (except for cranking)
EC-38
TROUBLE DIAGNOSIS

14 Crankshaft position sensor 120° (REF) At cranking At cranking: Approx. 0.5V
ECM0255
ECM0256
ECM0257
51 Mass air flow sensor Ignition switch ON Approx. 0.5V

At cranking Approx. 2V
At idle after warming up Approx. 2V
At approx. 2,000 rpm Approx. 3V
50 Throttle position sensor 1 At idle after warming up Approx. 0.9V
Ignition switch ON with engine stopped Approx. 0.9V
Accelerator pedal is fully depressed
Accelerator pedal is released
69 Throttle position sensor 2 At idle after warming up Approx. 4.1V
106 Accelerator pedal position sensor 1 At Idle Approx. 0.67 - 0.87V
Ignition switch ON with engine stopped Approx. 0.67 - 0.87V
98 Accelerator pedal position sensor 2 At Idle Approx. 0.33 - 0.43V
EC-39
TROUBLE DIAGNOSIS

34 Intake air temperature sensor Intake air temperature is approx. 20°C Approx. 3.5V
(68°F).
Intake air temperature is approx. 80°C Approx. 1.2V
(176°F).
83 Accelerator pedal position sensor 2 Always Approx. 0V
ground
35 Heated oxygen sensor At idle after warming up Changes between approx. 0.1 - 0.4V
approx. 0.6 - 0.9V
ECM0258
At approx. 2,000 rpm Changes between approx. 0.1 - 0.4V

approx. 0.6 - 0.9V
ECM0259
73 Engine coolant temperature sensor Engine coolant temperature is approx. Approx. 5V

20°C.
Engine coolant temperature is approx. Approx. 1.2V
80°C.
21 Injector drive signal At cranking Approx. 10.5V
22
23
40
41
42
ECM0260
At idle after warming up Battery voltage
ECM0261
At approx. 2,000 rpm Relatively lower than battery voltage
ECM0262
118 Power supply for ECM Ignition switch ON, engine running Battery voltage
121
EC-40
TROUBLE DIAGNOSIS

104 Throttle control motor relay Ignition switch ON, engine running Approx. 1V
3 Throttle control motor relay power Always Battery voltage
supply
5 Throttle control motor (Open) At idle after warming up Approx. 0.1 to 0.15V
At approx. 2000 rpm
4 Throttle control motor (Close) At idle after warming up Approx. 2 - 2.5V
At approx. 2000 rpm
32 Fuel changing switch 2 (Gasoline) Changing switch ON (At gasoline side) Approx. 5V
Changing switch ON (At LPG side or Approx. 0V
neutral)
49 Fuel changing switch power supply Changing switch ON Approx. 5V
Changing switch OFF (At neutral) Approx. 0V
70 Fuel changing switch 1 (LPG) Changing switch ON (At LPG side) Approx. 5V
Changing switch OFF (At LPG side or Approx. 0V
neutral)
112 LPG interception valve relay When ignition switch is ON (Approx. 1 Battery voltage
second) and for approximately 10
seconds after ignition switch is OFF
Ignition switch OFF Approx. 0V
52 Idle air volume learning operation When connecting tools for idle air Approx. 1.5V (Usually learning)
volume learning Approx. 2.5V (Factory learning)
When not connecting tools for idle air Approx. 0V
volume learning
54 Maximum speed shifting It varies depending on setting
condition.
33 Vehicle speed sensor signal Vehicle stopped Approx. 11V or approx. 1V
EC-41
TROUBLE DIAGNOSIS
SST
DISPLAY ITEM LIST
HDM2000
Diagnosis item Malfunction Return Condition MIL Trip
Error display
NO DTC NO DTC • No malfunction is detected in any of the circuits. - -

Heated oxygen sensor HO2S1_HTR_(B1) • Heated oxygen sensor heater control voltage has been less ON 2
heater [P0031] than 0.12V for predetermined period.
Heated oxygen sensor HO2S1_HTR_(B1) • Heated oxygen sensor heater control voltage has been 4.7V or ON 2
heater [P0032] more for predetermined period.
Mass air flow sensor signal MAF_SEN/CIRCUIT • When engine is running and mass air flow sensor output ON 1
circuit [P0102] voltage has been 0.5V or less for predetermined period.
Mass air flow sensor signal MAF_SEN/CIRCUIT • When engine is stopped (ignition switch ON) and mass air flow ON 1
circuit [P0103] sensor output voltage has been 4.9V or more for predetermined
period.
Engine coolant tempera- ECT_SEN/CIRC • Engine coolant temperature sensor output voltage has been ON 2
ture sensor (ECTS) (CIR- [P0117] less than 0.06V (short) for predetermined period.
CUIT)
Engine coolant tempera- ECT_SEN/CIRC • Engine coolant temperature sensor output voltage has been ON 2
ture sensor (ECTS) (CIR- [P0118] approximately 4.8V or more (open) for predetermined period.
CUIT)
Throttle position sensor 2 TP SEN 2/CIRC • Throttle position sensor output voltage has been 0.3V or less ON* 1
circuit [P0122] (open) for predetermined period.
Throttle position sensor 2 TP SEN 2/CIRC • Throttle position sensor output voltage has been 4.8V or more ON* 1
circuit [P0123] (short) for predetermined period.
Heated oxygen sensor cir- HO2S1_(B1) • Heated oxygen sensor output voltage is higher than normal ON 2
cuit low input [P0132] (1.4V or more).
Heated oxygen sensor cir- HO2S1_(B1) • Heated oxygen sensor signal circuit is open. ON 2
cuit high input [P0134]
Throttle position sensor 1 TP SEN 1/CIRC • Throttle position sensor output voltage has been 0.3V or less ON* 1
circuit [P0222] (open) for predetermined period.
Throttle position sensor 1 TP SEN 1/CIRC • Throttle position sensor output voltage has been 4.8V or more ON* 1
circuit [P0223] (short) for predetermined period.
Crankshaft position sensor CMP SEN/CIRCUIT • At start-up, no camshaft position sensor signals (POS, REF) ON 2
signal circuit [P0340] have been detected for more than a predetermined period.
• During engine running, no camshaft position sensor signal
(POS or REF) has been detected for more than a
predetermined period.
• During engine running, crankshaft position sensor signal (POS
or REF) irregular waveform is detected for more than a
Vehicle speed sensor VEH SPEED SEN/ • Vehicle sensor signal has not been input under some condition ON 2
CIRC for a predetermined time during driving after warming up. (MIL light up)
[P0500]
ECM ECM • CPU system or circuits in ECM have a malfunction. ON* 1 or 2
[P0605] Ignition ON (Note)
cannot be
erased.
MIL MIL/CIRC • Valve or circuit malfunction occurs several times. - 2
[P0650]
ECM power supply circuit ECM BACK UP/CIRC • Power is not supplied to ECM for some time. ON 2
[P1065]
Electric throttle control ETC ACTR [P1121] • Because of mechanical malfunction of electric throttle control ON* 1
actuator actuator, electric throttle control actuator does not operate Ignition ON
normally. cannot be
erased.
Electric throttle control ETC FUNCTION/ • When a malfunction occurred due to the correlation between ON* 1
function CIRC [P1122] the target throttle position and the actual throttle position.
• Over current flows into throttle motor control circuit.
Throttle control motor ETC MOT BACK UP/ • Throttle control motor power supply circuit is shorted ON* 1
power supply circuit CIRC [P1124]
EC-42
TROUBLE DIAGNOSIS
SST (Cont'd)
HDM2000
Diagnosis item Malfunction Return Condition MIL Trip
Error display
Throttle control motor ETC MOT BACK UP/ • Throttle control motor power supply circuit is open. ON* 1
power supply circuit CIRC [P1126]
Throttle motor control sig- Throttle control motor • When throttle motor signal circuit has short-circuited ON* 1
nal circuit [P1128]
Engine over temperature Overheat [P1217] • Engine coolant temperature sensor output voltage has been ON 1
(Overheat) approximately 0.35V or lower for predetermined period
(with the coolant temperature sensor normal).
Overheat (STEP 1) OVERHEAT STEP-1 • Engine coolant temperature sensor output voltage has been ON 1
[P1218] approximately 0.6V or lower for predetermined period. (MIL light up)
Throttle valve closed posi- Throttle valve closed • Throttle valve closed position learning value is excessively low. ON 2
tion learning value (low) position learning
[P1225]
Throttle valve closed posi- Throttle valve closed • Throttle valve closed position learning cannot be performed. ON 2
tion learning value (mal- position learning
function) [P1226]
Sensor power supply cir- TP/APP SE BACK UP/ • Sensor power supply voltage has been 5.6V or more or less ON* 1
cuit CIRC [P1229] than 4.6V for predetermined period.
LPG injector 1 malfunction LPG F/INJ 1 malfunc- • Over current flows into LPG injector. ON* 1
(Injection area) tion (Injection) [P1240]
(No injection area) tion (No injection)
[P1241]
(Injection area) tion (Injection) [P1242]
(No injection area) tion (No injection)
[P1243]
LPG fuel pressure sensor LPG fuel pressure • LPG fuel pressure sensor circuit is shorted. ON 1
signal circuit low input sensor short [P1245]
LPG fuel pressure sensor LPG malfunctioning • LPG fuel pressure sensor circuit is open. ON 1
signal circuit high input fuel pressure is • Fuel pressure in fuel piping from LPG VIPO to injector has been
detected and fuel excessively increased for predetermined period.
pressure is exces-
sively high. [P1249]
Stop lamp switch signal BRAKE SW/CIRCUIT • While driving, stop lamp switch is stuck at OFF for a long time. ON 1
system [P1805] (MIL light up)
Accelerator pedal position APP SEN 1/CIRC • Accelerator pedal position sensor output voltage has been ON* 1
sensor 1 circuit [P2122] 0.15V or less (open) for predetermined period.
Accelerator pedal position APP SEN 1/CIRC • Accelerator pedal position sensor output voltage has been 5V ON* 1
sensor 1 circuit [P2123] or more (short) for predetermined period.
Accelerator pedal position APP SEN 2/CIRC • Accelerator pedal position sensor output voltage has been ON* 1
sensor 2 circuit [P2127] 0.15V or less (open) for predetermined period.
Accelerator pedal position APP SEN 2/CIRC • Accelerator pedal position sensor output voltage has been 5V ON* 1
sensor 2 circuit [P2128] or more (short) for predetermined period.
Throttle position sensor TP SENSOR • A malfunction occurs in relation between throttle position ON* 1
signal (nonconformance) [P2135] sensors 1 and 2.
system
Accelerator pedal position APP SENSOR • A malfunction occurs in relation between accelerator pedal ON* 1
sensor signal (nonconfor- [P2138] position sensors 1 and 2.
mance) system
NOTE:
Number of trips varies depending on diagnosis content.
CAUTION:
Some DTCs specified above may detect a malfunction in the self-diagnosis, excluding the engine system, when the DTC detects some
malfunctions. Check the self-diagnosis excluding the engine at this time
EC-43
TROUBLE DIAGNOSIS
SST (Cont'd)
DATA MONITOR
• Allows determination and identification of the possible source of
a malfunction based on self-diagnosis test results.
• Displays ECM input/output signal data in real time.
• Records and prints out the data before and after the engine
malfunction or stall, either automatically or manually.
Display Item List614ch Graph Display (Hold) Output

SST (Cont'd)
Monitor item Unit Description
ENG SPEED rpm Engine speed computed from crankshaft angle sensor signal
MAS A/F SE-B1 V Mass air flow sensor output voltage
B/FUEL SCHDL msec Value calculated by ECM
A/F ALPHA % Average of cycles for air-fuel ratio feedback correction coefficient
COOLANT TEMP/S °C Value converted into temperature from the output voltage of the engine coolant
temperature sensor.
HO2S1 V Output voltage of heated oxygen sensor
HO2S1 MNTR RICH/LEAN Air-fuel ratio is given as heated oxygen sensor output signal during air-fuel ratio
feedback control.
RICH: Heated oxygen sensor output is high. Controlling to lower the value for
leaner ratio.
LEAN: Heated oxygen sensor output is low. Controlling to raise the value for
richer ratio.
VHCL SPEED SE km/h Value computed from vehicle speed sensor
BATTERY VOLT V ECM battery voltage
ACCEL SEN 1 Accelerator pedal position sensor 1 output voltage
ACCEL SEN 2 Accelerator pedal position sensor 2 output voltage
THRTL SEN 1 Throttle position sensor 1 output voltage
THRTL SEN 2 Throttle position sensor 2 output voltage
START SIGNAL ON/OFF ON/OFF status as judged by each input signal
P/N POSI SW
IGNITION SW
BRAKE SW
INJ PULSE msec Value calculated by ECM
IGN TIMING °BTDC
Incalculable % Value is calculated engine load based on the fuel injection amount.
FUEL PUMP RLY ON/OFF Status of each control as calculated by ECM.
THRTL RELAY
HO2S1 HTR
Battery voltage Displays values measured by voltage probe.
Vehicle speed maximum limit km/h Vehicle speed maximum value
LPG fuel injection width ms Value calculated by ECM
LPG basic fuel injection
Air-fuel ratio correction (Gasoline) %
Air-fuel ratio correction (LPG) %
Fuel type GASOLINE/ Fuel changing switch connecting condition
LPG/NEUTRAL
LPG fuel pressure kg/cm2 Value converted into pressure from the output voltage of LPG fuel pressure
sensor.
EC-44
TROUBLE DIAGNOSIS
SST (Cont'd)
Monitor item Unit Description
Fuel changing switch 1 ON/OFF ON/OFF status as judged by each input signal
Fuel changing switch 2
LPG interception valve relay
Specification
COOLANT TEMP
Condition Condition
VHCL SPEED SE
Normal (1) Supported by support data.
(2) Graph is supported.
Battery voltage
Data value that is not applied to communication in
RUN mode is displayed as "- - -".
FUEL TEMP SE
Selection narrowing (1) Supported by support data.
(2) Graph is supported.
(3) Selected.
SAVE SELECT RANGE START
Data value that is not applied to communication in
ECM0372 RUN mode is displayed as "- - -".
Normal (LOAD) (1) Saved.
Selection narrowing (LOAD) (1) Saved.
(2) Selected.
ACTIVE TEST
Use this mode to determine and identify the details of a malfunction,
based on self-diagnosis test results and data obtained from DATA
MONITOR mode. SST, instead of the ECM on the vehicle, sends a
drive signal to actuators to check their operation.
Display item list
Active test item Description
Fuel injection test • Can increase or decrease the amount of fuel injection (±25%).
LPG fuel injection test • Can reproduce conditions resulting from air-fuel ratio related malfunctions (e.g. hesitation, poor
acceleration, poor racing, etc.) and help solve these malfunctions by pinpointing the causes.
Ignition timing test • Allows setting a correction coefficient for retarding (-10 - 0°)
POWER BALANCE (Gasoline) • Stops operation of specified injector. Also, displays engine speed at that time.
(LPG, Neutral) • Mainly used to inspect for misfiring cylinders.
EC-45
TROUBLE DIAGNOSIS
Self-diagnosis Function (without SST)

No. Diagnosis item Malfunction Return Condition MIL Trip
0340 Crankshaft position sensor • At start-up, no camshaft position sensor signals (POS, REF) have been ON 2
signal circuit detected for more than a predetermined period.
• During engine running, no camshaft position sensor signal (POS or REF)
has been detected for more than a predetermined period.
• During engine running, crankshaft position sensor signal (POS or REF)
irregular waveform is detected for more than a predetermined period.
0500 Vehicle speed sensor • Vehicle sensor signal has not been input under some condition for a ON 2
predetermined time during driving after warming up. (MIL light
up)
0605 ECM • CPU system or circuits in ECM have a malfunction. ON* 1 or 2

Ignition ON
cannot be
(Note)
erased.
0650 MIL • Valve or circuit malfunction occurs several times. - 2
1065 ECM power supply circuit • Power is not supplied to ECM for some time. ON 2
1121 Electric throttle control • Because of mechanical malfunction of electric throttle control actuator, ON* 1
actuator electric throttle control actuator does not operate normally. Ignition ON
cannot be
erased.
1122 Electric throttle control • When a malfunction occurred due to the correlation between the target ON* 1
function throttle position and the actual throttle position.
• Over current flows into throttle motor control circuit.
1124 Throttle control motor power • Throttle control motor power supply circuit is shorted ON* 1
supply circuit
1126 Throttle control motor power • Throttle control motor power supply circuit is open. ON* 1
supply circuit
1128 Throttle motor control signal • When throttle motor signal circuit has short-circuited ON* 1
circuit
1217 Engine over temperature • Engine coolant temperature sensor output voltage has been ON 1
(Overheat) approximately 0.35V or lower for predetermined period
(with the coolant temperature sensor normal).
1218 Overheat (STEP 1) • Engine coolant temperature sensor output voltage has been ON 1
approximately 0.6V or lower for predetermined period. (MIL light
up)
1225 Throttle valve closed • Throttle valve closed position learning value is excessively low. ON 2
position learning value (low)
1226 Throttle valve closed • Throttle valve closed position learning cannot be performed. ON 2
position learning value
(malfunction)
1229 Sensor power supply circuit • Sensor power supply voltage has been 5.6V or more or less than 4.6V for ON* 1
1240 LPG injector 1 malfunction • Over current flows into LPG injector. ON* 1
(Injection area)
(No injection area)
(Injection area)
EC-46
TROUBLE DIAGNOSIS
Self-diagnosis Function (without SST) (Cont'd)

No. Diagnosis item Malfunction Return Condition MIL Trip
(No injection area)
1245 LPG fuel pressure sensor • LPG fuel pressure sensor circuit is shorted. ON 1
signal circuit low input
1249 LPG fuel pressure sensor • LPG fuel pressure sensor circuit is open. ON 1
signal circuit high input • Fuel pressure in fuel piping from LPG VIPO to injector has been
excessively increased for predetermined period.
1805 Stop lamp switch signal • While driving, stop lamp switch is stuck at OFF for a long time. ON 1
system (MIL light
up)
1814 Air-fuel ratio does not cross • After engine warmed with gasoline fuel, when oxygen sensor signal is - 1
stoichiometry for a long time sticked and does not reverse at a condition of A/F ratio is excessively lean
during intended closed-loop or rich.
operation. (written in 40CFR
1148 Parts 1048.110.) • After engine is started with gasoline fuel, when closed-loop control does
not start within a predetermined period.
1815 Air-fuel ratio does not cross • After engine warmed with LPG fuel, when oxygen sensor signal is sticked - 1
stoichiometry for a long time and does not reverse at a condition of A/F ratio is excessively lean or rich.
during intended closed-loop
1817 operation. (written in 40CFR • After engine is started with LPG fuel, when closed-loop control does not
Parts 1048.110.) start within a predetermined period.
2122 Accelerator pedal position • Accelerator pedal position sensor output voltage has been 0.15V or less ON* 1
sensor 1 circuit (open) for predetermined period.
2123 Accelerator pedal position • Accelerator pedal position sensor output voltage has been 5V or more ON* 1
sensor 1 circuit (short) for predetermined period.
2127 Accelerator pedal position • Accelerator pedal position sensor output voltage has been 0.15V or less ON* 1
sensor 2 circuit (open) for predetermined period.
2128 Accelerator pedal position • Accelerator pedal position sensor output voltage has been 5V or more ON* 1
sensor 2 circuit (short) for predetermined period.
2135 Throttle position sensor • A malfunction occurs in relation between throttle position sensors 1 and 2. ON* 1
signal (nonconformance)
system
2138 Accelerator pedal position • A malfunction occurs in relation between accelerator pedal position ON* 1
sensor signal sensors 1 and 2.
(nonconformance) system
NOTE:
Number of trips varies depending on diagnosis content.
CAUTION:
Some DTCs specified above may detect a malfunction in the self-diagnosis, excluding the engine system, when the DTC detects some
malfunctions. Check the self-diagnosis excluding the engine at this time.
EC-47
TROUBLE DIAGNOSIS
Service Tool
Trip 1: If a malfunction is detected by self-diagnosis between the
time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as “trip”), Engine Warning lamp is lit. The
corresponding DTC is recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative DTC is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), Engine Warning lamp is lit and the corresponding final
DTC is recorded.
SELF-DIAGNOSTIC RESULTS TIMING

• For items of trip 1, timing “0” is displayed immediately after
detection of a malfunction.
• For items of trip 2, when a malfunction is detected for the first
time (trip 1), timing “1t” is displayed. When a malfunction is
detected again in the next trip (trip 2), it is displayed as “0”.
Accumulative counting is performed at the end of warming-up
operation,
CONDITIONS TO TURN OFF ENGINE WARNING

LAMP
• The Engine Warning lamp, marked with *, is turned off when
ignition switch is turned ON (engine starts) again after normal
state is resumed.
• For other self-diagnostic items, self-diagnostic results shall be
erased by turning ignition switch to OFF after normal operation
is resumed.
EC-48
TROUBLE DIAGNOSIS
Method of indicating failure code with

Service tool
Install troubleshooting software J1 from the CD-ROM to a personal
computer (PC) in advance.
1. Turn the key switch OFF.

2. Open the engine hood.
3. Disconnect the cap (1A) from the connector (1).
Connect J2 and J3 cables as shown.
1A 1
<Machine in this photo may be different

from actual machine>
4. Start the installed software and check the failure code.

• The method of using the software is shown in the CD-ROM.
EC-49
TROUBLE DIAGNOSIS
Example of indication of failure code
EC-50
TROUBLE DIAGNOSIS
SST Reference Value in Data Monitor

SST Reference Value in Data Monitor (Cont'd)
Monitor item Measuring condition Reference value
ENG SPEED Almost in accordance

MAS A/F SE • After engine warming up At Idle 1.8 - 2.0V
• Selector lever: N
At approx. 2,000 rpm 2.5 - 2.8V
• No load
B/FUEL SCHDL • After engine warming up At Idle 2.5 - 4 msec
• Selector lever: N
At approx. 2,000 rpm
• No load
A/F ALPHA-B1 • After engine warming up At Idle Approx. 90 - 110%
LPG A/F ALPHA-B1
COOLANT TEMP/S • After engine warming up Approx. 80°C or more
HO2S1 • After engine warming up At Idle Changes between approx. 0.1 -
0.4VÙ0.6 - 0.9V
Maintain at approx. 2,000 rpm Changes between approx. 0.1 -
0.4VÙ0.6 - 0.9V
HO2S1 MNTR • After engine warming up At Idle Switches slowly between
LEANÙRICH.
Maintain at approx. 2,000 rpm Switches between LEANÙRICH at
least 5 times for 10 seconds.
VHCL SPEED SE • Drive, and compare with the value displayed on speedometer. Almost in accordance
BATTERY VOLT • Ignition switch: ON (with engine stopped) 11 - 14V
ETC ACCEL SEN 1 • After engine warming up At Idle 0.6 - 0.65V
ETC ACCEL SEN 2
Approx. 2,000 rpm 0.75 - 0.80V
Ignition switch ON with accelerator 4.1 - 4.3V
pedal depressed (With engine
stopped)
THRTL SEN 1 • After engine warming up At Idle 0.5 - 0.55V
THRTL SEN 2
Approx. 2,000 rpm 0.65 - 0.70V
Ignition switch ON with accelerator Approx. 0.9V
pedal depressed (With engine
stopped)
P/N POSI SW • Ignition switch: ON N position ON
Other than above OFF
LOAD SIGNAL • Ignition switch: ON Headlamp switch: ON ON
Above switch: OFF OFF
IGNITION SW • Ignition switch: ONOFF ONOFF
BRAKE SW • Ignition switch: ON Brake pedal depressed ON
Brake pedal released OFF
INJ PULSE • After engine warming up At Idle 4 - 6 msec
LPG INJ PULSE • Selector lever: N
At approx. 2,000 rpm
• No load
IGN TIMING • After engine warming up At Idle Approx. 10°BTDC
• Selector lever: N At approx. 2,000 rpm 35 - 45°BTDC
• No load
FUEL PUMP RLY • For 1 second after ignition switch is ON ON
• While engine is running and cranking
• Other than above OFF
THRTL RELAY • Ignition switch: ONOFF ONOFF
HO2S1 HTR • After engine warmed up (at idle) At Idle OFF
Other than above ON
INTAKE AIR • Engine: After engine warming up Values according to intake air
TEMPERATURE SENSOR temperature
EC-51
TROUBLE DIAGNOSIS
SST Reference Value in Data Monitor (Cont'd)

Monitor item Measuring condition Reference value
CLOSED THROTTLE • Engine: After engine warming up Accelerator pedal is fully ON

POSIITON SWITCH • Ignition switch: ON (with engine depressed
stopped)
Accelerator pedal is released OFF
IDL A/V LEARN • After engine warmed up (at idle) Idle air volume learning Complete
• All electrical load switches: OFF completed.
• Selector lever: N Idle air volume learning not yet Not complete
• Throttle valve closed position
completed.
learning completed
Fail-Safe Function
When any of the critical sensors or systems sends a malfunction
message, the fail-safe function estimates the driving conditions with
other input signals and selects safer conditions for engine (vehicle)
control, based on data previously stored in ECM.
Malfunction
Related sensors Fail-safe MIL
condition
Mass air flow sensor Same as self- • Selects fuel injection pulse width depending on engine speed ON
diagnosis and throttle position so the vehicle can be driven. However, fuel
malfunction detection injection will be inhibited (fuel cut-off) when engine speed
conditions. exceeds approximately 800 rpm.
• Idle speed is 800 rpm.
Engine coolant • Uses the estimated engine coolant temperature (varies with ON
temperature sensor elapsed time after start) to perform controls so the vehicle can
be driven.
Accelerator pedal • Fuel injection will be inhibited when 1 circuit is opened. Release ON
position sensor valve mechanically until it can drive at low speed when
disconnecting connector.
Throttle position sensor • Fixes output to a preset value so the vehicle can be driven. ON
However, fuel injection will be inhibited (fuel cut-off) when
engine speed exceeds approximately 2,500 rpm.
MIL • Engine speed will be inhibited at approximately 1,300 rpm to -
prevent MIL malfunction if exhaust performance and driving
performance malfunctions are occurring.
EC-52
TROUBLE DIAGNOSIS

Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name Measurement condition Measured value
111 Self shut off Ignition switch ON and engine running Approx. 1V
Ignition switch OFF Battery voltage
109 (IGN) Ignition switch Ignition switch ON and engine running
121
110 BATT Always
1 Ground Approx. 0V
2
115
116
Circuit Diagram
EC-53
CRANKSHAFT POSITION SENSOR 1° (POS)
CRANKSHAFT POSITION SENSOR 1° (POS)

Check waveform between terminals shown below and ground using
an oscilloscope.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
13 Crankshaft position At cranking: Approx. 2.6V At idling: Approx. 2.5V Approx. 2.5V
sensor 1° (POS)
ECM0287 ECM0288 ECM0289
Numerical values (reference values) are obtained using an analog

circuit tester.
Circuit Diagram
EC-54
CRANK ANGLE SENSOR 120° (REF) SIGNAL SYSTEM
CRANK ANGLE SENSOR 120° (REF) SIGNAL SYSTEM

Inspect waveforms between the below-stated terminals and the
ground with an oscilloscope.
The numeric values are inspection values (reference values)
obtained by means of an analog circuit tester.
14 Crankshaft position At cranking: Approx. 0.5V At idling: Approx. 0.5V Approx. 0.5V
sensor 120° (REF)
signal
ECM0292 ECM0293 ECM0294
Circuit Diagram
ECCS & IGN
coil relay
118
121
ECCS
control
unit
ECM0295
Component Parts Inspection

CRANKSHAFT POSITION SENSOR
• Remove distributor (with the harness connector connected)
from the engine.
• Turn ignition switch ON.
• Slowly turn the crankshaft position sensor shaft by hand and
check voltage between terminal 3 and ground.
3 - Ground (1° signal):
Approx. 0.2 or 5V
CAUTION:
Check voltage after disconnecting the injector fuse to inhibit
injector operation.
ECM0291
Malfunctions may or may not be accurately detected by self-
diagnosis depending on how the shaft is turned. Note that there
is no malfunction in this case.
EC-55
MASS AIR FLOW SENSOR SYSTEM
MASS AIR FLOW SENSOR SYSTEM
SST Data Monitor Display

Monitor item At idle after warming up At approx. 2,000 rpm
MAS A/F SE Approx. 2V Approx. 3V

a circuit tester.
51 Mass air flow sensor Approx. 1.5V Approx. 2V Approx. 3V

67 Mass air flow sensor
Approx. 0V
ground
Circuit Diagram

MASS AIR FLOW SENSOR
1. Remove mass air flow sensor.
2. Turn ignition switch to ON. While blowing air into the mass air
flow sensor from the air cleaner case side, check output voltage
between terminal 3 and ground.
No air blowing:
Approx. 1V
With air blowing:
Approx. 1.3V
(The more the air is blown, the higher the voltage is.)
NOTE:
If air is blown from the air duct side, the voltage becomes lower.
EC-56
HEATED OXYGEN SENSOR SYSTEM
HEATED OXYGEN SENSOR SYSTEM

HO2S1 Changes between approx. 0.1 - 0.4VÙapprox. 0.6 - 0.9V

H02S1 MNTR RICH and LEAN alternate slowly. RICH and LEAN alternate at least 5 times in
10 seconds.

an oscilloscope.
Terminal Signal name At idle after warming up At approx. 2,000 rpm
35 Heated oxygen sensor Changes between approx. 0.1 - 0.4V Changes between approx. 0.1 - 0.4V
approx. 0.6 - 0.9V approx. 0.6 - 0.9V
(V) (V)
1.5 1.5
1.0 1.0
0.5 0.5
0 0
1s 1s
PBIA0529J PBIA0530J

circuit tester.
Circuit Diagram
ECM0304
EC-57
VEHICLE SPEED SENSOR SYSTEM
VEHICLE SPEED SENSOR SYSTEM

Monitor item At Idle Driving
VHCL SPEED SE Almost in accordance with the speedometer display

an oscilloscope.
Terminal Signal name Vehicle stopped Vehicle running at approx. 40 km/h (25 MPH)
33 Vehicle speed signal No output Approx. 2.3V
ECM0399
Circuit Diagram
EC-58
THROTTLE POSITION SENSOR SYSTEM
THROTTLE POSITION SENSOR SYSTEM

ETC THRTL SEN 1 Approx. 0.6V Approx. 0.7V

ETC THRTL SEN 2 Approx. 4.5V Approx. 4.4V

47 Sensor power supply (Throttle position sensor) Approx. 5V

66 Sensor ground (Throttle position sensor) Approx. 0V
50 Throttle position sensor 1 Approx. 0.6V Approx. 0.7V
69 Throttle position sensor 2(*) Approx. 4.5V Approx. 4.4V
* Throttle position sensor 2 signal (terminal 69) voltage is different from DATA MONITOR display of SST because it is converted in ECM.
Circuit Diagram
ECM0307

THROTTLE POSITION SENSOR 1, 2 (ELECTRIC
THROTTLE CONTROL ACTUATOR ASSEMBLY)
Check voltage between ECM terminal 50, 69 and ground.
Refer to EC section, "ECM Input/Output Signal Specifications" for
the voltage.
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
connector. If there are any water drops, completely wipe
ECM0308
them off.
• Do not apply voltage to throttle position sensor terminal.
• Perform "Throttle Valve Closed Position Learning" if
EC-59
ACCELERATOR PEDAL POSITION SENSOR SYSTEM
ACCELERATOR PEDAL POSITION SENSOR SYSTEM

Monitor item At Idle At approx. 2,000 rpm
ETC ACCEL SEN 1 0.67 - 0.87V Approx. 2.8V

ETC ACCEL SEN 2 0.33 - 0.43V Approx. 2.8V

a circuit tester.
Terminal Signal name At Idle At approx. 2,000 rpm
82 Sensor ground Approx. 0V

83 Accelerator pedal position sensor 2 ground Approx. 0V
90 Accelerator pedal position sensor 1 power supply Approx. 5V
91 Accelerator pedal position sensor 2 power supply Approx. 5V
98 Accelerator pedal position sensor 2 (*) 0.33 - 0.43V Approx. 1.4V
106 Accelerator pedal position sensor 1 0.67 - 0.87V Approx. 2.8V
When the accelerator pedal is depressed slowly from the fully-closed position, the voltage must increase in proportion to the opening of the
throttle. [Ignition switch ON (engine stopped)]
Ignition switch ON with engine Ignition switch ON with engine

Terminal Signal name stopped Accelerator pedal is fully stopped Accelerator pedal is fully
depressed released
98 Accelerator pedal position sensor 2 (*) 0.33 - 0.43V 2.2 - 2.3V

106 Accelerator pedal position sensor 1 0.67 - 0.87V 4.4 - 4.6V
* Accelerator pedal position sensor 2 signal (terminal 98) voltage is different from DATA MONITOR display of SST because it is converted in ECM.
Circuit Diagram
ECM0309
EC-60
INTAKE AIR TEMPERATURE SENSOR SYSTEM
INTAKE AIR TEMPERATURE SENSOR SYSTEM

Monitor item At idle At approx. 2,000 rpm
Intake air temperature sensor Values according to intake air temperature

a circuit tester.
Terminal Signal name At idle At approx. 2,000 rpm
34 Intake air temperature sensor signal Intake air temperature at 20°C (68°F): approx. 3.5V
Intake air temperature at 80°C (176°F): approx. 1.2V
Circuit Diagram

INTAKE AIR TEMPERATURE SENSOR (JOINED
WITH MASS AIR FLOW SENSOR)
Check resistance between intake air temperature sensor (mass air
flow sensor connector) terminals 1 and 2.
Resistance
Intake air temperature at approx. 20°C (68°F):
Approx. 2.5 Ω
Intake air temperature at approx. 80°C (176°F):
Approx. 0.3. Ω
ECM0312
EC-61
IGNITION SYSTEM
IGNITION SYSTEM

IGN TIMING Approx. 10°BTDC 35 - 45°BTDC

an oscilloscope.
62 Ignition signal (power Approx. 0.5V Approx. 0.5V Approx. 0.9V

transmission drive
signal)
ECM0317 ECM0318 ECM0319

circuit tester.
Circuit Diagram

SPARK PLUG
• Check electrode for dirt, damage, and wear and insulator for
damage.
• Replace spark plug if necessary.
CAUTION:
• Check terminals for looseness.
• Check insulator for cracks or damage.
• Check for contamination by oil, water, and dust.
• Make sure that the spark plug gap is normal, using a feeler
gauge.
ECM0321
Spark plug gap:
0.8 - 0.9 mm (0.031 - 0.035 in)
EC-62
FUEL INJECTOR SYSTEM (GASOLINE)
FUEL INJECTOR SYSTEM (GASOLINE)

INJ PULSE 4 - 6 msec

an oscilloscope.
21 Injector drive signal Approx. 10.5V Battery voltage Relatively lower than battery
22 voltage
23
40
41
42
ECM0324 ECM0325
ECM0326

circuit tester.
Circuit Diagram
ECM0327

INJECTOR
Check resistance between each cylinder injector terminals 1 and 2.
Standard resistance (all cylinders):
Approx. 14.5Ω; (at room temperature)
ECM0328
EC-63
THROTTLE CONTROL MOTOR SYSTEM
THROTTLE CONTROL MOTOR SYSTEM

a circuit tester.
5 Throttle control motor 2 (Open) Approx. 2 - 2.5V

4 Throttle control motor 1 (Close) Approx. 0.1 - 0.15V
Circuit Diagram
ECM0330

ELECTRIC THROTTLE CONTROL MOTOR
(ELECTRIC THROTTLE CONTROL ACTUATOR
ASSEMBLY)
Check resistance between electric throttle control motor (throttle
position sensor connector) terminals 3 and 6.
Resistance: Approx. 1 -15Ω; [at 25°C (77°F)]
CAUTION:
ECM0332 connector. If there are any water drops, completely wipe
them off.
• Do not apply voltage to electric throttle control motor
terminal.
EC-64
HEATED OXYGEN SENSOR HEATER SYSTEM
HEATED OXYGEN SENSOR HEATER SYSTEM

Monitor item At idle after warming up
HO2S1 MTR ON

a circuit tester.
Terminal Signal name At idle after warming up
24 Heated oxygen sensor heater open signal Approx. 0.3V
Circuit Diagram
ECM0334

HEATED OXYGEN SENSOR HEATER
Check resistance between heated oxygen sensor terminals 2 and 3.
Resistance: Approx. 1 - 1.5Ω
EC-65
LPG INJECTOR SYSTEM
LPG INJECTOR SYSTEM

an oscilloscope.
Terminal signal Description Measurement condition Measured value
117 LPG injector drive (H) Battery voltage

119 Time axis may change
according to setting data
and driving condition.
114 LPG injector drive (L) Battery voltage

120 Time axis may change
according to setting data
and driving condition.
Inspection
LPG INJECTOR
• Check resistance between terminals 1 and 2.
Resistance:
Approx. 1Ω (at room temperature)
• Remove fuse cover, and then check fuse for open.
CAUTION:
Do not apply voltage to LPG injector.
EC-66
LPG ASSISTANCE INJECTOR SYSTEM
LPG ASSISTANCE INJECTOR SYSTEM

an oscilloscope.
Terminal Signal name At Idle
11 LPG assistance injector Battery voltage
Circuit Diagram
EGI1 118
30 87
BAT 121
86 88
111
EGI2
30 87 To Crank angle ECM
sensor ignition
86 88
1
1 2 LPG assistance injector
2 11
ECM0524

• Check resistance between LPG assistance injector terminals 1
and 2.
Resistance:
Approx. 27Ω (at room temperature)
• Apply battery voltage directly to terminals 1 and 2, and then
check solenoid operation.
Battery voltage applied:
Continuity should exist.
No voltage:
Continuity should not exist.
ECM0123
EC-67
LPG FUEL PRESSURE SENSOR SYSTEM
LPG FUEL PRESSURE SENSOR SYSTEM

an oscilloscope.
Terminal Signal name At Idle
31 LPG fuel pressure sensor 0.78V
Circuit Diagram
ECM0419
EC-68
FUEL CUT FUNCTION
FUEL CUT FUNCTION
Inspection Procedure
WITH SST
1. Check "INJ PULSE-B1" (gasoline) or "LPG INJ PULSE" (LPG)
in DATA MONITOR menu, and increase the engine speed to
approximately 2,400 rpm after warming up engine.
2. Make sure that when the acceleration pedal is released, "INJ
PULSE-B1" (gasoline) or "LPG INJ PULSE" (LPG)
instantaneously drops.
Without SST
1. Warm up the engine sufficiently.
2. Disconnect harness connector of the injector and connect a test
lamp.
3. Release the accelerator pedal at the engine speed of
approximately 2,400 rpm, and confirm test lamp goes out for a
moment.
ECM0355
EC-69
INTERCEPTION VALVE SYSTEM
INTERCEPTION VALVE SYSTEM

Monitor item When stopping the engine During engine rotation
Main cut ralay OFF ON

a circuit tester.
Terminal Signal name When stopping the engine During engine rotation
112 Main cut ralay Approx. 0V Power supply voltage
Circuit Diagram
EGI1 118
30 87
BAT 121
86 88
111
EGI2
30 87 To Crank angle
sensor ignition
86 88 ECCS
contorl
unit
1 2
LPG interception valve
Interception valve relay
112
ECM0356
EC-70
FUEL CHANGING SWITCH SYSTEM
FUEL CHANGING SWITCH SYSTEM

Monitor item At neutral Gusoline LPG
FUEL SW1 OFF OFF ON

FUEL SW2 OFF ON OFF

a circuit tester.
Terminal Signal name At neutral Gusoline LPG
70 FUEL SW1 signal Approx. 0V Approx. 0V Approx. 5V

32 FUEL SW2 signal Approx. 0V Approx. 5V Approx. 0V
Circuit Diagram
Fuel changing SW
LPG
70
Neutral
ECCS
Gasoline
32 contorl
unit
49
ECM0109
EC-71
BLOW-BY GAS REDUCING DEVICE
BLOW-BY GAS REDUCING DEVICE
System Chart
Blow-by hose Blow-by control valve
Fuel gallery
Blow-by passage
(also used for slots for the engine
front part and 12 bushing rods)
Fresh air
Blow-by gas
Blow-by control valve

ECM0350
Removal and Installation of Blow-by Control

Valve
1) Removal and installation of the blow-by hose
2) Removal and installation of the blow-by control valve
Inspection of Blow-by Control Valve

• When the valve normally operates, hissing sound from the air
passage is heard.
• Inspect for continuity when blowing into the blow-by control
valve from its rocker cover side and when sucking air from the
valve from the same side.
At the time of blowing: There is continuity.
At the time of sucking: There is no continuity.
ECM0353
EC-72
ECM COPMONENTS
ECM COPMONENTS
ECM
REMOVAL AND INSTALLATION
1. Disconnect ECM connector.
2. Remove ECM.
3. Install in the reverse order of removal.
CAUTION:
Perform "Throttle Valve Closed Position Learning and Idle Air
Volume Learning" after installation if replacing ECM.
Check pin for bend and damage when installing ECM.
ECM0390
Crankshaft Position Sensor (Integrated Into

the Distributor)
Refer to EM section, "Removal and Installation".
Mass Air Flow Sensor

Screw
1. Remove harness connector.
2. Remove mass air flow sensor assembly from air horn.
Mass air flow sensor
Air horn
ECM0391
Engine Coolant Temperature Sensor

1. Disconnect radiator drain plug, and drain coolant.
CAUTION:
Make sure to drain when the coolant temperature is cold.

3. Remove coolant temperature sensor using a socket specially
designed for removing and installing coolant temperature
sensors [commercially available: thermosensor socket
manufactured by KTC (part No.: B20T-19)] and similar parts.
ECM0392
EC-73
ECM COPMONENTS
Heated Oxygen Sensor (With Heated Oxygen

Sensor Heater)
1. Remove harness connector from heated oxygen sensor.
2. Remove heated oxygen sensor using a socket designed for
heated oxygen sensor removal and installation (SST).
CAUTION:
Handle it carefully and avoid impacts.
Throttle Position Sensor (Electric Throttle

Control Actuator Assembly)
REMOVAL
Mass air flow Bolt
sensor 1. Remove air duct from air horn.
CAUTION:
Also, remove harness connectors of mass air flow sensor, LPG
Air horn
injector, and LPG fuel pressure sensor so that when removing
Screw
and installing air horn, LPG injection holder (LPG and
Combined) is performed at the same time.
3. Loosen bolts diagonally, remove air horn, LPG injection holder

(LPG or Combined) or air horn spacer (Gasoline), and then
remove electric throttle control actuator.
LPG injector holder

Electric throttle
control actuator
ECM0374
INSTALLATION
Caution for installation
Uniformly tighten bolts diagonally in several steps.
CAUTION:
connector. If there are any water drops, completely wipe
them off.
• Do not apply voltage to throttle position sensor terminal.
EC-74
ECM COPMONENTS
LPG Injector Holder

REMOVAL
Mass air flow Bolt
sensor 1. Remove air duct from air horn.
22 - 37
(2.2 - 3.8, 2. Remove harness connectors of mass air flow sensor, LPG
16 - 27) injector, and LPG fuel pressure sensor.
3. Loosen bolts in turn, remove air horn, and then remove injector
Air horn holder.
Screw
1.0 - 2.0
(0.1 - 0.2,
INSTALLATION
9 - 17) 1. Caution for installation
• Uniformly tighten bolts diagonally in several steps.
CAUTION:
when removing and installing each connector. If there are
any water drops, completely wipe them off.
LPG injector holder • Do not apply voltage to each terminal.
Electric throttle
control actuator
: N•m (kg-m, ft-lb)

: N•m (kg-m, in-lb)
ECM0375
EC-75
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Standard, Repair Limit

Fuel pressure [kPa (bar, kg/cm2, psi)] 353 (3.53, 3.6, 51)
Idle speed (rpm) N position 750±50
Ignition timing (°BTDC/rpm) N position 10±2/750
Firing order 1-5-3-6-2-4
Spark plug Manufacturer/type/gap [mm (in)] NGK/BPR4ES-D [0.8 - 0.9 (0.31 - 0.35)]
Ignition advance device Electronically controlled ignition advance
Density of CO at idle speed (%) /Density of HC at idle speed (ppm) 0.1/50 or less
EC-76
KOMATSU TB45 ENGINE FUEL SYSTEM
SECTION FL
CONTENTS
FUEL SYSTEM ................................................... FL-2 LPG PARTS ....................................................... FL-7
Description ..................................................... FL-2 LPG Device (Specifications for LPG and
Gasoline Specification ................................... FL-2 Gasoline/LPG) ............................................... FL-7
LPG Specification .......................................... FL-3 Injector Holder ............................................... FL-9
Specification for Combined Vaporizer ..................................................... FL-12
Gasoline and LPG .......................................... FL-3
FUEL INJECTOR (GASOLINE AND
COMBINED USE) ............................................... FL-4
Preparation .................................................... FL-4
Fuel Hose ....................................................... FL-4
Fuel Tube and Fuel Injector ........................... FL-4
Inspection ....................................................... FL-6
FUEL SYSTEM
FUEL SYSTEM
Description
Three fuel system specifications ("Gasoline", "LPG", "Combined
gasoline and LPG") have been applied.
Gasoline Specification
Fuel pump type integrated with fuel tank has been adopted.
Complete pump is composed of fuel pump, fuel filter, pressure
regulator, and fuel gauge. All of them together are called returnless
fuel supply system.
FLM0001
ENGINE COMPONENT PARTS LOCATION
FLM0046
CAUTION:
installation.
FL-2
FUEL SYSTEM
LPG Specification
• LPG gas injection system has been adopted.
• LPG injector holder is equipped with injector, assistance
injector, fuel pressure sensor, and relief valve, and they are
composed as an assembly. All of them are installed on
electronic throttle control actuator.
FLM0001
Specification for Combined Gasoline and

LPG
This specification is for combined gasoline specification and LPG
specification that are both described above.
FL-3
FUEL INJECTOR (GASOLINE AND COMBINED USE)
Preparation
• Air hose
• Moving engine harness connector
Fuel Hose
REMOVAL
Release the fuel pressure.
CAUTION:
Plug the fuel hose to prevent the fuel from draining after
removal.
INSTALLATION
• Insert hose until its end reaches 25 mm (0.98 in) or more from
fuel tube end. Install a clamp and securely tighten it. Do not
install the clamp on top of the bulge.
• Start engine, increase the engine speed, and make sure that
there is no fuel leakage after repairing.
Fuel Tube and Fuel Injector

REMOVAL
CAUTION:
Fuel remaining in the tube leaks during operation. This
operation should be done in a place free from fire.
• Remove fuel gallery bolts.

• Remove fuel gallery. Remove fuel injector and fuel gallery as a
set.
• Remove clips (6) using long-nose pliers. Disconnect fuel
injector and fuel gallery.
CAUTION:
Do not reuse clips.
INSTALLATION
Fuel Injector
1. Install fuel injector to fuel tube as shown in figure 1.
FL-4
Fuel Tube and Fuel Injector (Cont'd)

2. Precautions for installation of fuel injector
1) There is no contamination nor damage in O-ring contact area
that is caused by dirt. Do not clean O-ring with solvent.
2) Do not reuse removed O-ring.
3) Handle O-ring with bare hands.
4) Apply engine oil into O-ring and holder for assembly. (Do not
apply engine oil into fuel passages of fuel injector.)
5) Do not use damaged O-ring.
6) Do not apply excessive force that could damage O-ring.
7) Press clips into fuel injector when assembling. Securely fit clips
to fuel injector locating grooves (a) and (b). (Do not reuse clips.)
8) Always replace O-ring when clips contact O-ring.
9) Assemble fuel injector to fuel tube after installing clips to fuel
injector.
10) Fuel injector is pressed by a force of 196 N (20 kgf, 44 lb) or
less. Stop operation if a force of 147 N (15 kgf, 33 lb) or more is
necessary.)
11) Insert fuel injector to fuel tube while aligning fuel tube stopper
(c) with clip cutout (d) before installing. Securely fit (c) to (d) and
holder rib (e) to clip hole (f) after inserting.
12) Make sure that fuel injector is securely installed without rotation
and disconnection after installing to fuel tube.
FLM0002
Fuel Tube
1. Install fuel tube to intake manifold as shown in figure 2.
2. Satisfy precautions 1) to 6) for installation of fuel injector.
3. Insertion of fuel injector is performed by a force of 196 N (20
kgf, 44 lb) or less per fuel injector. Stop operation if a force of
147 N (15 kgf, 33 lb) or more is necessary.)
4. Do not contact O-ring with the edge that is made by each
process of intake manifold for assembly.
FLM0003
FL-5
Fuel Tube and Fuel Injector (Cont'd)

5. First tighten fuel tube bolt in position "a" in figure 3, and then
tighten it in position "b" in the same figure.
Repeat above tightening procedure 2 times.
Tightening torque
First tightening:
: 9 - 20 N•m (0.9 - 2.1 kg-m, 7 - 15 ft-lb)
Second tightening:
: 21 - 26 N•m (2.1 - 2.7 kg-m, 16 - 19 ft-lb)
FLM0004
Inspection
FUEL LEAKAGE AFTER INSTALLATION
Check for fuel leakage by racing several times after idling for 5 to 10
minutes.
FL-6
LPG PARTS
LPG PARTS
LPG Device (Specifications for LPG and

Gasoline/LPG)
DESCRIPTION
Inject a proper amount of fuel supplied from vaporizer based on
ECM command.
Components Parts Location

It is composed of injector holder and drive unit. The injector includes
mechanical valve with LPG injector, LPG assistance solenoid valve,
and fuel pressure sensor. The drive unit operates vaporizer and
injector that depress and perform carburetion of high-pressure fuel
flow from LPG tank to approximately 29 kpa (0.3kg/cm2, 4 psi).
LPG Injection System Components
FLM0045
FL-7
LPG PARTS
LPG Device (Specifications for LPG and

Gasoline/LPG) (Cont’d)
LPG INJECTION SYSTEM DRIVE TYPE
FLM0043
FL-8
LPG PARTS
Injector Holder
Inject a proper amount of fuel supplied from vaporizer based on
ECM command.
COMPONENTS PARTS LOCATION

It includes mechanical relief valve with LPG injector, LPG assistance
solenoid valve, and fuel pressure sensor.
(1) LPG injector

It is used for LPG gas injection.
(2) LPG assistance solenoid valve
Engine output may be insufficient in high-speed and high-load
area when using LPG injector only. LPG assistance solenoid
valve helps LPG injector to keep maximum engine output in
high-speed and high-load area.
(3) Fuel pressure sensor
Send a signal to control fuel injection at low fuel pressure (e.g.
in low temperature).
(4) Mechanical relief valve (built-in holder)
Operates it when fuel pressure is over set pressure. It opens
fuel circuit, and sends fuel to intake manifold, and protects fuel
piping to lower fuel pressure. It is provided in holder fuel
passage.
NOTE:
Repair each component specified in (1), (2), and (3) as an assembly
if a malfunction is detected in above components. Repair holder
assembly specified in (4). Refer to EC section for inspection
procedure.
HOLDER ASSEMBLY
Main injector
Harness connector
for assistance injector
Harness connector
Assistance injector for main injector
Holder
FLM0009
FL-9
LPG PARTS
Injector Holder (Cont’d)

LPG FUEL INJECTOR
• Disassemble and assemble as shown in the figure.
• Install LPG fuel injector and check LPG leakage using soapy
water after assembly.
• Insert straight and assemble O-ring and seal rubber on top after
changing to new ones and applying engine oil to the
circumference lightly.
*O-ring may be damaged when tilting and inserting forcibly.
*Do not use silicon oil when inserting.
FLM0010
*Use correct injector specified for each engine type.
(Check part number on fuel injector body label.)
Tightening torque of securing screw:
3.9 - 7.8 N•m (0.40 - 0.80 kg-m, 3 - 6 ft-lb)
Check and Cleaning
• Perform continuity test of harness connector.
If it is approximately 1Ω (at room temperature) with a tester, it is
normal.
If continuity should not exist, check for blown fuse.
*If fuse is blown, replace it with proper fuse (5A).
Check signal wave of related harnesses.
When a non-standard signal flows, a malfunction may occur
again.
Replace parts if the resistance is not normal.
FLM0011 • Clean injector.
Clean injector from fuel inlet side with compressed air for
approximately 5 minutes.
*Do not use cleaner such as carb cleaner because it negatively
affects rubber parts of inside.
LPG ASSISTANCE INJECTOR

• Rotate and remove hexagonal part of body using a spanner.
*When removing hexagonal part of body, inside spring, plunger,
and washer are removed together. Do not drop and lose them.
• Install after assembling inner components in their original
position. Replace aluminum washer with new ones.
Tightening torque:
11.8 - 26.5 N•m (1.2 - 2.7 kg-m, 9 - 20 ft-lb)
FLM0012
Check and Cleaning
If foreign materials such as tars are applied or collected on plunger
or its inside, remove them with compressed air.
FL-10
LPG PARTS
Injector Holder (Cont’d)

RELIEF VALVE (BUILT-IN HOLDER, 2)
Installation and Setting
• Two relief valves are built into holder.
Relief valve (2) • Relief valve (1) setting pressure is 78 kpa (0.8 kg/cm2, 11 psi).
Relief valve (2) setting pressure is 118 kpa (1.2 kg/cm2, 17 psi).
Check and Cleaning

Seal necessary part of each holder.
Relief valve (1) Apply compressed air from fuel connector.
Raise air pressure from 0 kpa (0 kg/cm2, 0 psi) (gauge pressure)
FLM0014
gradually. Check continuity of the passage at nearly above setting
pressure.
Clean with compressed air up to 490 kpa (5 kg/cm2, 71 psi) if
continuity should not exist.
Replace holder with a new one if continuity should not exist after
applying compressed air of 490 kpa (5 kg/cm2, 71 psi).
*Do not replace relief valve only.
FLM0015
FL-11
LPG PARTS
Vaporizer
DESCRIPTION
This is decompressed and carbureted high-pressure fuel flow from
LPG tank to approximately 29 kpa (0.3 kg/cm2, 4 psi).
FLM0016
(1) Primary side valve

(2) Primary side valve seat
(3) Primary (decompression) room
(4) Primary side diaphragm
(5) Primary side diaphragm spring
(6) Hook (claw)
(7) Primary side valve lever
(8) Balance diaphragm
Fuel is supplied from LPG tank to vaporizer via LPG solenoid valve.
Fuel from solenoid valve is supplied to primary decompression room
through between primary side valve (1) and primary side valve seat
(2).
Fuel pressure supplied to primary room is 29 kpa (0.3 kg/cm2, 4 psi)
or more. Primary diaphragm (4) pushes up diaphragm spring (5),
and hook (6) is working together. It becomes the operation that one
side of primary valve lever (7) is lifted up. Therefore, the power that
pushes primary valve (1) toward valve seat side (2) is increased,
and fuel flow is cut off.
Primary diaphragm is pushed down by increasing the tension of
diaphragm spring (5) higher than the fuel pressure when the fuel of
primary room is consumed and the pressure of primary room inside
is decreased to 29 kpa (0.3 kg/cm2, 4 psi) or less, and hook (6) is
working together to push primary valve lever (7) down. Therefore,
open primary valve (1) and flow fuel in.
Repeat above operations to keep primary room pressure
approximately 29 kpa (0.3 kg/cm2, 4 psi).
Variation of pressurization can be suppressed by balance
diaphragm (8) even if pressure in LPG tank changes.
FL-12
LPG PARTS
Vaporizer (Cont’d)
Set primary valve lever as shown in the figure.
EFM0044
Pressure Inspection
Check primary room pressure with the following procedure:
1. Remove primary room test hole plug, and install pressure gage
using appropriate connector.
2. Start engine, and check for primary room fuel leakage at idle
after warming up.
Standard:
30.7 - 33.1 kpa (0.313 - 0.338 kg/cm2, 4.45 - 4.81 psi)
3. Rotate pressure adjusting screw if measured pressure is
outside the standard.
CAUTION:
Apply sealant and keep air tightness when reinstalling test hole
plug.
Idle Adjustment in Electric Controlled LPG Specifications

It is not necessary because it is performed with control unit.
Removal of Impurity
LPG includes incombustible materials (e.g. tar).
These materials will be collected in vaporizer if they are continued to
be included. This may cause operating malfunction of fuel system.
It is necessary to release and drain periodically with engine warmed
up.
FL-13
LPG PARTS
COMPONENT OF VAPORIZER
Fuel connector
(Outlet side)
Vacuum connector
Hot water connector
Fuel connector (Inlet side)

Hot water connector
Tamper screw
FLM0017
TAR REMOVING
• Take the warmth of the engine with LPG.
• Close tank cock, and then consume LPG in fuel line.
• Remove drain plug, and then drain tar from vaporizer.
*Put the tray below so as not to make engine room dirty.
• Apply sealant to drain plug and assemble after finishing work.
• Install LPG fuel injector and check LPG leakage using soapy
water after assembly.
Drain plug
FLM0018
REMOVAL
• Close tank cock, and then consume LPG in fuel line.
• Disconnect battery cable at negative terminal.
• Drain engine coolant from radiator drain plug.
• Disconnect hot water hose. Use shop cloth and tray because
water may come out.
• Disconnect vacuum hose.
• Disconnect fuel hose and fuel tube.
*Treat each hose so that foreign materials should not enter the
inside.
Or, be careful to prevent each tube insertion part from being
damaged.
• Remove mounting bolt to bracket of vaporizer.
FL-14
LPG PARTS
INSTALLATION
• Install in the reverse order of removal.
• Install vaporizer bracket.
Standard:
16 - 21 N•m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
• Connect each hose and tube.
*Securely tighten each clamp.
• Connect battery cable at negative.
• Check LPG leakage.
Start the engine and apply soapy water to each connection of
fuel hose, fuel pipe, hot water hose vacuum hose, and drain
plug. Check for LPG leakage.
Apply soapy water to mating surface of case and cover. Check
for LPG leakage.
CAUTION:
• Flush and clean vaporizer with compressed air.
• *Do not use chemical cleaner because it negatively affects
rubber parts and Teflon coated parts.
DISASSEMBLY
Primary Side
Primary pressurization • Remove mounting screws (2) of bracket for tamperproof using
screw
SST.
• Remove primary adjusting screw lock nut {WAF: 23 mm (0.91
in)}.
Lock nut • Remove primary adjusting screw.
• Remove primary room cover screws (2) using SST.
• Remove other screws (8) using commercial service tool.
• Remove fuel connector (inlet side) screws (2) using commercial
service tool.
FLM0020
• The figure shows the condition that primary room cover is

Primary room removed.
cover
Be careful not to lose primary pressurization spring that is on
back of cover when removing.
Sliding
Primary pressurization
spring
Primary diaphragm
FLM0021
FL-15
LPG PARTS
• The figure shows the condition that primary diaphragm is
Primary side valve removed.
Remove the diaphragm while sliding it in the arrow direction
• Check primary diaphragm for breakage or damage. Replace if
necessary.
Primary
diaphragm
Securing screw
FLM0022
• The figure shows the condition that lever and valve seat are
removed.
Balance diaphragm When removing lever mounting screws (2) shown in the above
figure, lever and valve seat can be removed as a set. Do not
lose the lever because it is fixed with only the pin.
Primary side valve
FLM0023
FL-16
LPG PARTS
• The figure shows the condition that valve lever, valve seat, and
pin are removed. Furthermore, the figure below shows the
condition that valve is removed.
FLM0025
FLM0024
• The figure shows the condition that balance diaphragm is

removed.
Balance Balance diaphragm can be removed by loosening 4 screws of
diaphragm plate.
Rod
Plate
FLM0026
Secondary Side
Secondary room • Secondary room cover is fixed by 6 screws.
seal rubber
Secondary room cover can be removed by loosening each
screw.
• The figure shows the condition that secondary room cover is
removed.
FLM0027
FL-17
LPG PARTS
• The figure shows that secondary room side is assembled.
Secondary side
cover
FLM0028
High-pressure Side Cover

Loosen and remove high-pressure side cover mounting screws (8).
High-pressure side cover
FLM0029
INSPECTION
Primary Side Valve
• Check around primary side valve and valve seat.
• Check valve lever for smooth operation.
• Replace valve and lever assembly if necessary.
Each Diaphragm
• Check for cracks, damage, and hardening.
• Replace each diaphragm if necessary.
FLM0030
FL-18
LPG PARTS
ASSEMBLY
High-pressure Side Cover
• Clean disassembled parts completely.
• Clean filter from inside with compressed air.
• Replace O-ring with a new one.
• Tighten mounting bolts (6) evenly.
Standard:
: 6.3 - 8.3 N•m (0.64 - 0.85 kg-m, 4.6 - 6.1 ft-lb)
High-pressure side cover
FLM0031
Secondary Side
Secondary room • Clean disassembled parts other than seal rubber completely.
seal rubber
• Replace seal rubber with a new one.
Securely insert circumference O-ring of seal rubber into groove.
• Gently place primary room cover (steel), and then install with
securing screws (6).
Standard:
: 3.8 - 5.1 N•m (0.39 - 0.52 kg-m, 2.8 - 3.8 ft-lb)
FLM0032
Primary Side
• Clean disassembled parts other than diaphragm completely.
Balance • Set balance diaphragm and plate in this order, and then secure
diaphragm
them using screws.
Standard:
Rod
: 1.0 - 2.9 N•m (0.1 - 0.3 kg-m, 0.7 - 2.2 ft-lb)
Plate • Lastly, put the rod on center.
Top convex side faces to lever side.
FLM0033
• Assemble primary side valve.

• Clean disassembled parts completely.
• Install valve to lever as shown in the figure.
• Face convex part of wave washer to clip side.
• Check for looseness after installing.
Bend and adjust the wave washer if necessary.
FLM0034
FL-19
LPG PARTS
• Assemble primary side lever.
• Replace O-ring with a new one.
Standard:
: 1.0 - 2.9 N•m (0.1 - 0.3 kg-m, 0.7 - 2.2 ft-lb)
• Measure dimension H of lever.
FLM0035
Balance diaphragm
Primary side valve
FLM0036
• Measure dimension H using vaporizer height gauge (SST).

• Measure while inserting L-part of height gauge into tip of lever.
Standard:
13.6 - 14.1 mm (0.54 - 0.56 in)
FLM0037
FL-20
LPG PARTS
• If it is outside the standard, insert both end grooves of vaporizer
height gauge (SST) into lever, and then bend and adjust the
lever.
CAUTION:
Be careful not to damage valve.
FLM0038
• Check primary valve airtighteness.

(1) Put vaporizer into oil tank. Apply air pressure of 0.29 - 0.49 MPa
(3 - 5 kg/cm2, 43 - 71 psi) from fuel inlet connector.
(2) Under the above condition, close primary valve by pulling
primary valve lever by hand, and then make sure that air does
not leak from primary valve and O-ring.
FLM0039
• In the reverse order of disassembly, place primary diaphragm

Primary room over the body, slide it to the center, and then secure primary
cover diaphragm.
• Place primary room cover over the body.
(At this time, be careful not to drop primary adjusting spring
from primary room cover.)
• Tighten 2 screws of mounting bolts using SST, and then tighten
Sliding the other 8 screws using commercial service tool.
Primary pressurization
spring Standard:
Primary diaphragm : 3.8 - 5.1 N•m (0.39 - 0.52 kg-m, 2.8 - 3.8 ft-lb)
FLM0040
• Perform primary room adjustment.

• Remove plug of primary room oil pressure output port, install
adopter (SST), and then set LPG pressure gauge (SST).
• Install #100 JET to fuel outlet connector. (Flow: approx. 10L/
min)
• Apply air pressure of 0.29 MPa (3 kg/cm2, 43 psi) from fuel inlet
connector.
Standard:
32.1 - 33.5 kPa (0.327 - 0.342 kg/cm2, 4.65 - 4.86 psi)
• If the value is outside the standard, adjust it as described below.
FLM0041
Adjust primary room with the following procedure if adjustment
with vaporizer only is difficult.
• Install vaporizer to the vehicle.
• Remove plug of primary room oil pressure output port,
install adopter (SST), and then set LPG pressure gauge
(SST).
• Start and warm up the engine.
• Check pressure of pressure gauge at idle after warming up.
Standard:
30.7 - 33.1 kPa (0.313 - 0.338 kg/cm2, 4.45 - 4.81 psi)
FL-21
LPG PARTS
• If the value is outside the standard, adjust it as described
below.
*Vaporizer primary pressure setting value is different
between the unit condition and the condition of installing
vaporizer to engine and having hot water flowing
(approximately 80°C (176°F)).
• Tighten lock nut after setting to standard pressure by rotating

primary pressure adjusting screw.
• Tighten primary pressure adjusting screw using double spanner
Standard:
: 11.8 - 26.5 N•m (1.2 - 2.7 kg-m, 9 - 20 ft-lb)
• Apply soapy water to mating surface of cover. Check leakage.
• Place tamperproof bracket over primary room cover, and then
tighten mounting screw using SST.
Standard:
: 3.8 - 5.1 N•m(0.39 - 0.52 kg-m, 2.8 - 3.8 ft-lb)
FLM0042
FL-22
KOMATSU TB45 ENGINE ELECTRICAL SYSTEM
SECTION EL
CONTENTS
STARTING SYSTEM ...........................................EL-2 CHARGING SYSTEM .......................................... EL-5
Component Parts Location ............................. EL-2 Component Parts Location ............................. EL-5
Starter Motor ................................................... EL-2 PROCEDURE FOR DISASSEMBLING AND
STARTING MOTOR EXPRODED ....................... EL-3 INSPECTING THE ALTERNATOR ..................... EL-6
MAINTENANCE OF STARTER ...........................EL-4 Component Parts Location ............................. EL-6
Starter Motor ................................................... EL-4 Disassembly ................................................... EL-7
Armature Coil .................................................. EL-4 Inspection ....................................................... EL-9
Data related to brush commutators ................. EL-4 HIGH-TENSION CABLE ................................... EL-13
Assembly ...................................................... EL-13
STARTING SYSTEM
STARTING SYSTEM
ELM0247
CAUTION:
Be sure to disconnect negative battery cable before operation.
Starter Motor
REMOVAL
1. Disconnect terminals S and B.
2. Remove bolts (2).
3. Remove starter motor.
INSTALLATION
Install in the reverse order of removal.
EL-2
STARTING MOTOR EXPRODED
STARTING MOTOR EXPRODED
23 17 20
18
19 24
22
15 14
12 13 16
21 11
9 10 3 2 6 5
8 1 4 7 ELM0249
Manufacturer's part
No. Tree Parts name Quantity Hitachi part number Product name code
number
STARTING MOTOR S114-482 23300 52H00 70443222
1 1 ARMATURE ASSEMBLY 1 2114-71104 23310 V5300 70459119

2 2 BALL BEARING 1 2114-15502 23319 M4900 84472190
3 2 BALL BEARING 1 2114-25502 23338 M4900 84472200
4 1 FIELD COIL ASSEMBLY 1 2144-12006 23306 52H00 84478030
5 2 BALL CORE SET SCREW 4 2114-3215 23305 09500 84410260
6 2 BRUSH (+) 2 2114-69003 23380 07G00 84476210

7 1 REAR COVER 1 2114-83003 23337 M4901 84472880
8 1 BURSH HOLDER 1 2114-29008 23378 07G00 84472880
9 2 BRUSH (-) 2 2114-29008 23379 07G00 84476220
10 2 BURSH SPRING 4 2114-8314 23333 M4901 84472710
11 1 PINION CLUTCH ASSEMBLY 1 2114-45014 23312 03J00 70459366

12 2 PINION SHAFT 1 2114-95501 23357 W1700 84473510
13 2 CLUTCH ASSEMBLY 1 2114-55550 23354 07G00 84475950
14 3 BALL BEARING 1 2114-95502 84477020
15 3 BALL BEARING 1 2240-4101 23325 0T010 84453710
16 2 PINION STOPPER SET 1 2114-29006 23465 M4900 84471920

17 1 GEAR CASE 1 2114-36611 23318 03J00 84476920
18 1 GEAR SHIFT LEVER SET 1 2114-56012 23322 H9100 84472090
19 1 MAGNETIC SWITCH ASSEMBLY 1 2114-87601 23343 03J00 70459727
20 1 DUST COVER SET 1 2114-98012 23470 11M00 84476250
21 1 BEARING RETAINER 1 2130-2615 23359 W2800 84441730

22 1 DUST COVER (D) 1 2114-88004 23324 N5900 84472900
23 1 BOLT M6X32 1 2114-5866 23353 G7000 84472250
24 1 THROUGH BOLT 2 2114-58005 23340 N5900 84471770
EL-3
MAINTENANCE OF STARTER
MAINTENANCE OF STARTER
Starter Motor
• Inspect for continuity between the field coil and the ground.
Judgment
If there is continuity between the coil and the ground, the starter
motor has a short circuit. In this case, change the starter motor
with a new one.
When there is no continuity between the coil and the ground,
the starter motor is normal.
CAUTION:
Field coil assembly Carefully carry out the inspection since a compound motor is
EEM0127
structurally grounded even when continuity between the field
coil and the ground is checked with a tester.
Armature Coil
• Inspect for continuity between commutators.
Judgment
Commutators
When there is continuity between the commutators, the starter
motor is normal.
When there is no continuity between the commutators, the
starter motor has a break. In this case, change the starter motor
with a new one.
Armature coil Assembly

EEM0128
Armature coil Assembly • Inspect for continuity between the armature coil and the ground.
Judgment
If there is continuity between the coil and the ground, the starter
motor has a short circuit. In this case, change the starter motor
with a new one.
When there is no continuity between the coil and the ground,
the starter motor is normal.
EEM0129
Data related to brush commutators

Brush wear (mm) 12 - 16 (wear allowance: Up to 4)
Chamfer 0.5 - 0.8mm Brush-spring pressure (kg) 1.8 - 2.2
• If the commutator has a rough surface, smoothen with #500 or

#600 sandpaper.
• High mica of the commutator should be corrected if the depth of
insulation is 0.2 mm or less.
Commutators
EEM0130
EL-4
CHARGING SYSTEM
CHARGING SYSTEM
ELM0248
EL-5
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR

23100-FU410 [A007TA3377] (STD)
Rear bearing
Rotor
12.7-18.6 N • m
Front braket Retainer

3.4-5.4 N • m Front
bearing
2.9-4.9 N • m
98-137 N • m Rear bracket
Rectifier
Brush
2.9-4.9 N • m
Pulley
Regulator assembly
Stator
ELM0250
23100-GU60A [A003TB6377] (Dust-proof specifications)
Rotor Rear bearing
5.9-9.8 N • m
Front braket
Retainer
3.4-5.4 N • m Front
bearing
2.9-4.9 N • m
98-137 N • m
Rear bracket
Rectifier
Brush
2.9-4.9 N • m
Pulley
Regulator assembly
Stator
ELM0251
EL-6
Disassembly
Through-bolt 1. Remove four through-bolts from the front assembly and rear
Through-bolt assembly.
Through-bolt
Through-bolt
Front assembly ELM0252
Slotted screwdriver
2. Separating the front assembly and rear assembly.
Slotted screwdriver Inserting the tip of a slotted screwdriver into the clearance
between stator and front bracket, separate the front assembly
and rear assembly.
NOTE:
Take care not to damage the stator coil or peel laminations from the
stator core with a screwdriver.
Front bracket Stator

ELM0253
3. Disassembling the front assembly

a) Secure the rotor with a vice to protect the rotor pole or fan
Front bracket against being deformed.
assembly b) Remove the tightening nut from the pulley. Detach the pulley,
Pulley spacer and front bracket assembly.
NOTE:
When securing the rotor with a vice, jaws of the vice must hold the
Rotor bottom part of the rotor pole to prevent the pole from being
deformed.
Vice When loosening the vice, take care not to allow the relevant parts to
ELM0254
drop.
4. Detaching the front bearing

Front bracket To change the front bearing, detach the tightening screw from
assembly Jig
the retainer and push out the bearing by means of a jig (outside
diameter of which is close to that of the spacer) using a hand
press or the like.
NOTE:
Check the bearing, before disassembling the front assembly, for
abnormal noise, play and grease leakage (may be wiped off as long
as the leaked quantity is minute). If no such a trouble is found, the
bearing does not need to be replaced with a new one.
ELM0255
EL-7
Disassembly (Cont’d)
5. Detaching the rear bearing
Rear bearing Rotor Detach the rear bearing with a commercially available bearing
puller.
NOTE:
• The clearance provided between the bearing and slip ring is
small. Take care not to damage the mold part of the slip ring
with the bearing-puller claw.
• The rear bearing which is once removed is not reusable.
Bearing-puller
ELM0256
Two tightening screws (M5 screws) 6. Detaching the regulator

from the regulator assembly a) Remove two tightening screws (M5 screws) from the regulator
assembly.
ELM0257
Regulator assembly b) Separate soldered joints (at two locations) of the regulator
Stator
assembly to raise the stator. Then, detach the regulator assembly.
NOTE:
It is suggested to remove plate R first and lightly push the connector
part for easy removal of the regulator assembly Since the soldered
joints are caulked, try to widen an opening of the caulked part for
easy separation of the joints.
Soldered joints (at two locations) ELM0258
Stator Rectifier assembly

7. Detaching the stator
Unsolder the stator coil lead wire. Detach the stator from the
rectifier assembly.
NOTE:
The stator coil lead wire is soldered onto the rectifier terminal with high-
temperature solder (melting point: 230°C type). Unsolder quickly with a
soldering iron of 100 W to 250 W while taking care not to overheat the
soldered joints rectifier so as to prevent the diode from being damaged by heat.
(at four locations)
Since the diode lead wire is caulked, try to widen an opening of the
caulked part for easy separation.
ELM0259
EL-8
Disassembly (Cont’d)
Eectifier assembly 8. Detaching the rectifier assembly
a) Remove the tightening screw from the rectifier.
b) Detaching B terminal
Example (1): For press-fitted side-removal B terminal
Detach the round cover and nut. Pressurize the
top of B terminal bolt from the rear side to detach
the press-fitted B terminal.
Example (2): Rear-removal B terminal
Detach the nut and mold from B terminal.
Tightening screw from the rectifier ELM0260
Inspection
1. Inspecting the stator coil
a) Inspection of coil for continuity (circuit tester)
Inspect two coil lead wires for mutual continuity.
N lead wires Check for continuity between N lead wires (bundled wire) and
Stator
each phase (for all of the three phases).
Judgment criteria:
Resistance between lead wires 0.05 to 0.5 (Ω)
Coil lead wires
ELM0261
b) Inspection of the coil for insulation (insulation resistance tester

of 500 V/M)
Check for insulation between the coil lead wires and the core.
Judgment criteria:
1MΩ or more
Coil lead wires
Core
ELM0262
2. Inspecting the rotor

a) Inspection of the slip ring (vernier calipers or visual observation)
Check the slip ring for wear and rough surface.
Judgment criteria:
Outer diameter of slip ring:Standard value 22.7mm
Limit of use 22.1mm
NOTE:
• It is not allowed to change only the slip ring. If the slip ring has
such a rough surface that cannot be corrected or has exceeded
the wear limit, the entire rotor has to be changed with a new one.
• Remove soil or foreign materials with compressed air or a piece
of clean cloth while taking care not to damage the slip ring.
EL-9
Inspection (Cont’d)
b) Inspection of the rotor for insulation (insulation resistance tester
of 500 V/M)
Check for insulation between the slip ring and the fan.
Fan
Judgment criteria:
Rotor
1MΩ or more
Slip ring ELM0263
c) Inspection of a value of coil resistance (circuit tester)

Slip ring Measure a resistance between the slip rings.
Judgment criteria:
Standard value : 2.41 - 2.82Ω (for A007TA3377)
12.42 - 14.57Ω (for A003TB6377)
Rotor
ELM0264
3. Inspecting the bearing (manual)

Turn the bearing by hand.
Judgment criteria:
Check the bearing for abnormal noise, play and grease
leakage (may be wiped off as long as the leaked quantity
is minute). If no such a trouble is found, the bearing
does not need to be replaced with a new one.
NOTE:
The bearing is not reusable once it is removed.
4. Inspecting the rectifier assembly

Rectifier assembly
a) Inspection of the plus diode (circuit tester)
Diode
Functional check of the diode
Check for continuity between the plus heat sink and each diode
terminal.
Judgment criteria:
There should be continuity in the forward direction.
There should be no continuity in the reverse direction.
Plus heat sink
• If there is continuity in both directions, the diode has a
short-circuit error.
Tester: Example of measurement in forward direction • If there is no continuity in both directions, the diode
under DI mode
ELM0265 has an open-circuit error.
EL-10
b) Inspection of the minus diode (circuit tester)
Rectifier assembly
Functional check of the diode
Diode
Check for continuity between the minus heat sink and each
diode terminal.
Judgment criteria:
Minus heat sink • If there is continuity in both directions, the diode has a
• If there is no continuity in both directions, the diode
Tester: Example of measurement in forward direction
has an open-circuit error.
under DI mode
ELM0266
c) Inspection of the trio diode (circuit tester)

Functional check of the diode (three small diodes)
Inspect for continuity among the trio diode terminals.
Judgment criteria:
* If the trio diode is provided
• If there is continuity in both directions, the diode has a
• If there is no continuity in both directions, the diode
has an open-circuit error.
5. Inspecting the brush set (vernier calipers and scale)

70
Brush holder a) Inspection of the brush extension

60
Judgment criteria:
50
The brush extension is to be 10 mm or longer.

40
If the brush extension is equal to or shorter than the

30
standard value, change the brush set (brush, spring and

20
terminal) with a new one.

10
b) Cleaning around the brush holder

Clean up the brush and brush holder with a piece of clean cloth
to remove abrasion powder.
Brush
ELM0267
c) Inspection of the brush spring
Check to be sure that the brush smoothly slides inside the brush
holder and that the spring pressure is normal.
EL-11
6. Inspecting the regulator (verification of the completed alternator
+ -
Fuse on the vehicle)
B A
Alternator S
ON a) Inspection of the adjusted voltage
Starting
E
ST Switch
+
(1)Turn off all electrical loads.
V Battery
- (2)Check to be sure that the voltmeter indicates a voltage which
To Starting motor
is equal to or lower than the overcharge voltage (15V) during
ELM0268
idling. Then, gradually increase the engine revolutions.
(3)Continuously checking that the voltmeter gives a value below
the overcharge voltage, read the voltage (adjusted voltage)
when the engine revolutions reach 2500 rpm.
Judgment criteria:
14.5 ± 0.3V
NOTE:
In this case, the ammeter should give a current which is equal to or
lower than the specified electric current (10A). If the electric current
exceeds the specified value, continue charging for a while until the
electric current becomes equal to or lower than the specified value.
b) Inspection of an output current

+ -
Fuse (1)Turn on all the electrical loads as far as possible.
B A
Alternator S
ON (2)Quickly read the maximum value shown on the ammeter
Starting
E
ST Switch
+
when the engine revolutions are increased to 2500 rpm or
V Battery
- more.
To Starting motor
Judgment criteria
ELM0269
The output current is to be 80% or more of 50A
(for A007TA3377)
The output current is to be 80% or more of 35A
(for A003TB6377)
NOTE:
In the case of on-vehicle inspection, the nominal output current may not
be reached even when all electrical loads are applied. It is therefore the
output current which is 80% or more of the nominal value represents
the normal state.
EL-12
HIGH-TENSION CABLE
HIGH-TENSION CABLE
Assembly
ELM0322
EL-13
KOMATSU TB45 ENGINE TUNE-UP
SECTION ET
CONTENTS
VALVE CLEARANCE .......................................... ET-2 ENGINE OIL ........................................................ ET-6
Description ...................................................... ET-2 Inspection ....................................................... ET-6
Inspection ........................................................ET-2 Replacement ................................................... ET-7
Adjustment ...................................................... ET-3 Oil Filter Replacement .................................... ET-8
ENGINE DRIVE BELT ......................................... ET-4 COMPRESSION PRESSURE ........................... ET-10
Inspection ........................................................ET-4 Inspection ..................................................... ET-10
Belt Tension Adjustment ................................. ET-5 SPARK PLUG ................................................... ET-11
Removal and Installation .............................. ET-11
Inspection After Removal .............................. ET-11
VALVE CLEARANCE
VALVE CLEARANCE
Description
Whenever rocker arm and rocker shaft assembly are removed and
installed, or symptoms due to changes in valve clearance as a result
of aging (poor starting, rough idle, unusual noise) are obvious, check
and adjust valve clearance with the following procedure:
Inspection
1. Stop the engine after warming up.
2. Remove rocker cover.
3. Rotate the crankshaft pulley clockwise (as viewed from
crankshaft pulley side) and align orange notch with the timing
indicator (protrusion) on the front cover.
4. Make sure that there is valve clearance in intake/exhaust side of
No. 1 cylinder. (No. 1 cylinder is at TDC on its compression
stroke.)
• If not, rotate the crankshaft pulley one more turn.
ETM0065
5. Refer to the figure, and measure valve clearance for the table
item below with a circle using a feeler gauge.
Standard:
0.35 mm (0.0138 in) (Hot, intake/exhaust)
CAUTION:
Make sure that the standard under hot condition is appropriate
if adjustment is made under cold condition.
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
1 cylinder at TDC of
its compression { { { { { {
stroke
NOTE:
Firing order: 1 - 5 - 3 - 6 - 2 - 4
6. Turn crankshaft 360 degrees to set No. 6 cylinder at TDC of its

compression stroke.
ET-2
VALVE CLEARANCE
Inspection (Cont'd)
7. Measure valve clearance at points marked with { in the
following table.
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
6 cylinder at TDC of
its compression { { { { { {
stroke
NOTE:
If No. 1 cylinder is not at TDC on its compression stroke in step 4, it
is acceptable to measure the item with No. 6 cylinder at TDC on its
compression stroke (step 7) without rotating crankshaft pulley.
8. Adjust with the following if outside the standard value.
Adjustment
NOTE:
Adjust the same measuring points in the same condition of
"Inspection" with the following procedure:
1. Loosen valve clearance adjusting screw lock nut.
2. Turn adjusting screw in the loosening direction using a
screwdriver.
3. Insert a standard feeler gauge in between rocker arm and valve
stem end surface, and then tighten until it contacts with
adjusting screw.
4. Tighten lock nut while securing it using a screwdriver so as not
to rotate adjusting screw.
: 16 - 21 N•m (1.6 - 2.2 kg-m, 12 - 15 ft-lb)
5. Crank engine several times, check valve clearance again, and
make sure that it is within the standard.
ETM0066
ET-3
ENGINE DRIVE BELT
ENGINE DRIVE BELT
Inspection
• Inspection should be done only when engine is cold or over 30
minutes after the engine is stopped.
• Measure the belt deflection by applying load of 98 N (10 kg, 22
lb) to T as shown in the figure.
CAUTION:
• First set the tension to the standard when measuring belt
tension immediately after the belt is installed. Rotate the
crankshaft more than two turns in order to eliminate
variance in the belt deflection between pulleys. Then
measure and adjust tension to the standard.
• Visually check belts for wear, damage, and cracks on inside
and edges.
ETM0136
• Retighten if belt deflection is too low (excessive tension)
and too high (outside retightening limit).
Unit: mm (in)
Location Belt deflection

[When pressed by a force of 98 N (10 kg, 22 lb)]
Belt
specification After
Item New belt Limit
adjustment
Alternator belt/ Low-edge belt 10 - 12 13 - 15 16 (0.63)

FAN belt (0.39 - 0.47) (0.51 - 0.59)
ETM0135
CAUTION:
• Tighten slightly stronger than used belt when belt is
replaced with new one, because new belt will not fully seat
in the pulley groove.
• Adjust the tension to the value after adjustment when used
belt tension exceeds retightening limit.
• Make sure that belt is correctly engaged with the pulley
groove when installing.
• Adjust the belt by applying tension, but do not rotate pulley
in each pulley stop condition.
• Do not tighten with excessive tension.
• Do not allow oil or water to get on the belt.
• Do not twist or bend the belt strongly.
ET-4
ENGINE DRIVE BELT
Belt Tension Adjustment

ALTERNATOR BELT
• Loosen alternator bolt and adjusting bar bolt, and adjust them
with alternator installing angle.
• Tighten adjusting bar bolt and alternator bolt.
Adjusting bar bolt:
: 18 - 23 N•m (1.8 - 2.4 kg-m, 13 - 17 ft-lb)
Alternator bolts (2):
: 50 - 67 N•m (5.1 - 6.9 kg-m, 37 - 49 ft-lb)
FAN BELT
• Loosen lock nut and two nuts for fan pulley, and adjust fan belt
with adjust bolt.
• Tightening lock nut and nut for fan pulley.
Lock nut:
: 9 - 13 N•m (0.9 - 1.3 kg-m, 7 - 10 ft-lb)
Nut for fan pulley:
: 9 - 13 N•m (0.9 - 1.3 kg-m, 7 - 10 ft-lb)
ET-5
ENGINE OIL
ENGINE OIL
Inspection
OIL LEVEL AND CONTAMINATION
CAUTION:
Forklift must be level when checking oil level.
• Check oil level before starting engine. Stop engine and leave it
at least 10 minutes if engine has been started. Then check
level.
• Check if the oil level is within the range shown on the left.
• Check engine oil for white contamination or considerable dirt.
• If oil has white or pale contamination, it may be caused by
mixing with engine coolant. Repair the suspect parts.
• Adjust oil level if it is outside the range.
ETM0068
OIL LEAKAGE
Check the following parts for engine oil leakage.
• Oil pan
• Oil pan drain plug
• Oil pressure switch
• Oil filter bracket
• Oil filter
• Lower side of cylinder block back
• Mating surfaces of cylinder block and cylinder head
• Mating surfaces of cylinder head and rocker cover
• Front cover
• Around crankshaft pulley
OIL PRESSURE
1. Check oil level.
2. Remove oil pressure switch and connect an oil pressure gauge.
3. Make sure that the proper oil pressure corresponding to engine
speed is obtained after warming up the engine.
NOTE:
Oil pressure is displayed highish when low oil temperature.
ENGINE OIL PRESSURE

Engine speed (rpm) At Idle 2,000
kPa (bar, kg/cm 2, psi) Approx. 49 (0.49, 0.5, 7) Approx. 118 (1.18,1.2, 17)
or more or more
4. Install oil pressure switch after checking the oil pressure with the
following procedure.
1) Remove old sealant on the switch and engine.
2) Apply Three Bond 1201 or equivalent to the threads and then
tighten.
: 13 - 17 N•m (1.25 - 1.75 kg-m, 9 - 12 ft-lb)
CAUTION:
Be careful not to get burned when engine or engine oil is
heated.
ET-6
ENGINE OIL
Replacement
NOTE:
Perform inspection "after refilling oil and after replacing oil" after
replacing oil filter if engine oil and oil filter have been replaced.
PERIODIC REPLACEMENT INTERVAL

Replace with the following period:
Oil grade SJ, SL: 1 month or every 200 hours
REPLACEMENT PROCEDURE
CAUTION:
Be careful not to get burned when engine or engine oil is
heated.
1. Warm up engine, and check that there is no oil leakage.
2. Stop the engine. Leave it for 10 minutes.
3. Remove oil filler cap, and remove drain plug of oil pan.
4. Drain engine oil.
5. Install drain plug. Refill with new engine oil.
Drain plug tightening torque:
: 54 - 59 N•m (5.5 - 6.0 kg-m, 40 - 43 ft-lb)
ETM0070
OIL LEVEL
Unitt: (US qt, lmp qt)
H-level Approx. 8.7 (9-1/4, 7-5/8)
L-level Approx. 7.6 (8, 6-3/4)
Only refill level when changing oil
Approx. 8.3 (8-3/4, 7-1/4)
(When drained from drain plug)
Refill level when changing both oil lifter and oil
Approx. 8.6 (9-1/8, 7-5/8)
(When drained from drain plug)
INSPECTION AFTER REPLACING OIL

1. Check oil filter for engine oil leakage when replacing oil drain
plug and oil filter after warming up engine.
2. Check oil level with the engine oil inspection procedure
described above.
ET-7
ENGINE OIL
Oil Filter Replacement

COMPONENT PARTS LOCATION
ETM0071
PERIODIC REPLACEMENT INTERVAL

Replace with the following period:
1 month or every 200 hours
REMOVAL
Remove oil filter using an oil filter wrench (SST).
CAUTION:
• Be careful not to get burned when engine or engine oil is
heated.
• Use a shop cloth to absorb engine oil leakage when
removing.
• Be careful not to spill engine oil on the engine drive belt.
• Completely wipe off any engine oil spilled on the engine
and vehicle.
ET-8
ENGINE OIL
Oil Filter Replacement (Cont'd)

INSTALLATION
1. Completely remove any foreign materials on the attaching
surfaces of oil filter.
2. Apply engine oil to the full circumference of an oil seal on a new
oil filter.
3. Screw in the oil filter by hand until it contacts oil filter bracket
surface, and then add another 2/3 of a turn.
Oil filter:
: 15 - 20 N•m (1.5 - 2.1 kg-m, 11 - 15 ft-lb)
4. Check for engine oil leakage after warming up the engine.

ETM0073
ET-9
COMPRESSION PRESSURE
COMPRESSION PRESSURE
Inspection
1. Warm up the engine sufficiently.
2. Release the fuel pressure.
3. Turn ignition switch OFF.
4. Disconnect air hose from throttle body and move it out of
position.
5. Remove all spark plugs.
CAUTION:
Blow spark plug clean with compressed air when removing it.
6. Install a rev counter or electronic system diagnosis tester (SST).
7. Remove injector harness connector.
8. Attach an adapter to Allen compression gauge (commercial
service tool) and set it to the engine.
9. Depress accelerator pedal fully. Turn ignition switch to "START"
and crank the engine. Record the compression pressure and
the engine speed after the gauge indication stabilizes. Repeat
the measurement on each cylinder.
Compression pressure kPa (bar, kg/cm2, psi)/rpm
Standard:
1,187 (11.87, 12.1, 172)/200
Repair limit:
892 (8.92, 9.1, 129)/200
Difference limit among cylinders:
98 (0.98, 1.0, 14)/200
• Check battery for the specific gravity if engine speed is not
within the standard, and measure again under normal
conditions.
• Check valve clearance and components around the
combustion chamber (valve, valve seat, pistons, piston
rings, cylinder bore, cylinder head, cylinder head gasket) if
compression pressure is not within the standard, and
measure again.
• Add a small amount of engine oil from spark plug hole if
compression pressure of some cylinders is low, and
measure again.
• It is possible that piston ring is worn or damaged if
compression pressure is improved by adding engine oil.
Check piston ring, and replace it if necessary.
• There may be a valve malfunction if compression pressure
is not improved by adding engine oil. Check valve, and then
replace valve or cylinder head if necessary.
• If compression pressures of adjacent two cylinders are low,
and if pressures cannot be improved by adding engine oil,
gasket is leaking. Replace cylinder head gasket.
10. Install removed parts.
ET-10
SPARK PLUG
SPARK PLUG

Use a spark plug wrench (commercial service tool).
Blow compressed air around spark plug when removing it.
: 20 - 29 N•m (2.0 - 3.0 kgf-m,15 - 21 ft-lb)
Inspection After Removal

• Visually check electrode for dirt and damage and insulator for
burning.
• Check if the electrode gap is within the standard using a plug
gap gauge.
Standard:
0.8 - 0.9 mm (0.031 - 0.035 in)
• Adjust if outside the standard.
• Replace if necessary.
ETM0075
ET-11

Shop Manual

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Shop Manual

Încărcat de

Drepturi de autor:

Formate disponibile

cover.

LIFT TRUCK MODEL SERIAL No.

2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan

LIFT TRUCK MODEL SERIAL No.

2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan

HOW TO READ THIS MANUAL ..........................................................................................EG-4

TROUBLE DIAGNOSIS .......................................................................................................EG-7

ECM GENERAL SERVICE INFORMATION ......................................................................EG-11

PRECAUTIONS FOR WORK ............................................................................................EG-15

SERVICE DATA .................................................................................................................EG-21

EXHAUST MANIFOLD ........................................................................................................EM-4

ROCKER COVER ............................................................................................................... EM-8

ROCKER ARM AND ROCKER SHAFT ASSEMBLY ......................................................... EM-9

CYLINDER HEAD ............................................................................................................. EM-12

TIMING CHAIN .................................................................................................................. EM-20

CYLINDER BLOCK ........................................................................................................... EM-27

ENGINE COOLING SYSTEM

WATER PUMP ..................................................................................................................... LU-3

ENGINE CONTROL SYSTEM ............................................................................................. EC-8

TROUBLE DIAGNOSIS ..................................................................................................... EC-13

CRANKSHAFT POSITION SENSOR 1° (POS) ................................................................. EC-54

CRANK ANGLE SENSOR 120° (REF) SIGNAL SYSTEM ............................................... EC-55

MASS AIR FLOW SENSOR SYSTEM .............................................................................. EC-56

HEATED OXYGEN SENSOR SYSTEM ............................................................................ EC-57

VEHICLE SPEED SENSOR SYSTEM ............................................................................... EC-58

ACCELERATOR PEDAL POSITION SENSOR SYSTEM .................................................EC-60

INTAKE AIR TEMPERATURE SENSOR SYSTEM ...........................................................EC-61

IGNITION SYSTEM ............................................................................................................EC-62

FUEL INJECTOR SYSTEM (GASOLINE) .........................................................................EC-63

THROTTLE CONTROL MOTOR SYSTEM ........................................................................EC-64

HEATED OXYGEN SENSOR HEATER SYSTEM .............................................................EC-65

LPG INJECTOR SYSTEM .................................................................................................EC-66

LPG ASSISTANCE INJECTOR SYSTEM .........................................................................EC-67

LPG FUEL PRESSURE SENSOR SYSTEM .....................................................................EC-68

FUEL CUT FUNCTION ......................................................................................................EC-69

INTERCEPTION VALVE SYSTEM ....................................................................................EC-70

BLOW-BY GAS REDUCING DEVICE ............................................................................... EC-72

ECM COPMONENTS ......................................................................................................... EC-73

SERVICE DATA AND SPECIFICATIONS (SDS) .............................................................. EC-76

ENGINE FUEL SYSTEM

FUEL INJECTOR (GASOLINE AND COMBINED USE) ......................................................FL-4

LPG PARTS ..........................................................................................................................FL-7

ENGINE ELECTRICAL SYSTEM

STARTING MOTOR EXPRODED ........................................................................................ EL-3

CHARGING SYSTEM .......................................................................................................... EL-5

HIGH-TENSION CABLE .................................................................................................... EL-13

ENGINE DRIVE BELT .......................................................................................................... ET-4

ENGINE OIL ......................................................................................................................... ET-6

COMPRESSION PRESSURE ............................................................................................ ET-10

SPARK PLUG .................................................................................................................... ET-11

Precautions for Radio Equipment Installation

Reference : Supplementary explanation for the ease of work.

CONVERSION OF MAJOR UNITS

Quantity SI unit Conventional unit Coefficient of conversion into SI

Acceleration m/s2 G 9.80665

Torque and moment Nm kgf•m 9.80665

kPa mmHg 0.133322

Spring constant N/mm kgf/mm 9.80665

*1. Conventional unit may be used in SI.

Component Parts Location

Component Parts Location (Cont'd)

ECM Trouble Diagnosis

ECM Trouble Diagnosis (Cont'd)