FU-46 FUEL SYSTEM - Injection Pump
INSTALLATION OF INJECTION PUMP
(See page FU-3)
NOTICE: Do not put the injection pump (2L-T and
w l HAC) at an angle more than 45" from the horizontal.
1. INSTALL FUEL INLET AND OUTLET PIPES TO
INJECTION PUMP
Torque: 250 kgcm (18 ft-lb, 25 N-m)
INSTALL INJECTION PUMP
(a) Align the period lines (or matchmarks) of the injec-
tion pump and timing belt case.
(b) Install the two nuts holding the injection pump to the
timing belt case.
Torque: 210 kg-cm (15 ft-lb, 21 N-m)
(c) Install the pump stay with the four bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N-m)
CHECK INJECTION TIMING (See page EM-24 or 25)
INSTALL INJECTION PIPES
(a) Place the two lower clamps on the intake manifold.
( b ) I nstall the four injection pipes.
Torque: 250 kpcm (18 ft-lb, 25 N-m)
Pipe NOTICE: On vehicles with the PIJ (2L-T Austria), do
not interfere with the PIJ actuator with the spanner. Use a
14 mm spanner when tightening the union nut of No. 2
injection pipe.
(c) Secure the injection pipes with the two upper clamps
and bolts.
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FUEL SYSTEM - lniection P u m ~ FU-47
CONNECT FUEL HOSES TO INJECTION PUMP
CONNECT INJECTION PUMP CONNECTOR(S)
(2L-T)
CONNECT WATER BY-PASS HOSES TO THERMO WAX
(w/ AIC)
CONNECT AIC IDLE-UP VACUUM HOSE
(2L-T)
CONNECT BOOST COMPENSATOR HOSE
INSTALL ACCELERATOR LINKAGE
INSTALL INJECTION PUMP DRIVE PULLEY
Torque: 650 kg-cm (47 ft-lb, 64 N.m)
SET NO. 1 CYLINDER TO TDCICOMPRESSION
INSTALL TIMING BELT
CHECK VALVE TIMING
INSTALL NO. 1 TIMING BELT COVER
INSTALL CRANKSHAFT PULLEY
Torque: 1,700 kg-cm (123 ft-lb, 167 N-m)
INSTALL WATER PUMP PULLEY, FLUID COUPLING
AND FAN
(2L-T)
INSTALL TURBO WATER HOSE
(2L-T)
FILL WITH ENGINE COOLANT (See page CO-5)
START ENGINE AND CHECK FOR FUEL LEAKS
CHECK IDLE SPEED AND MAXIMUM SPEED
(See page EM-27)
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COOLING SYSTEM
REFER TO 2L, 3L ENGINE REPAIR MANUAL
(Pub. No. RM123E)
NOTE: The following pages contain only the points which
differ from the above listed manual.
Page
DESCRIPTION...................................................... CO-2
TROUBLESHOOTING ............................................. CO-4
CHECK AND REPLACEMENT OF ENGINE
COOLANT ........................................................ CO-4
THERMOSTAT (2L-T) .;.......................................... CO-6
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CO-2 COOLING SYSTEM - Description
DESCRIPTION
This engine utilizes a pressurized water forced circulation cooling system which includes a thermostat equip-
ped with a by-pass valve mounted on the inlet side.
2L-T
- From Heater
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COOLING SYSTEM - Description CO-3
The cooling system is composed of the water RESERVOIR TANK
jacket (inside the cylinder block and cylinder head), The reservoir tank is used to catch coolant
*
radiator, water pump, thermostat, cooling fan, which overflows the cooling system as a result of
hoses and other components. Coolant which is volumetric expansion when the coolant i s heated.
heated in the water jacket is pumped to the radia- When the cod~anttemperature drops, the coolant
tor, where it is cooled by the cooling fan and the in the reservoir tank returns to the radiator, thus
vehicle windstream. Coolant which has been keeping the radiator full at all times and avoiding
cooled is then sent back to the engine by the water needless coolant loss. To find out if the coolant
pump, where it cools the engine. The water jacket needs to be replenished, check the reservoir tank
is a network of channels in the shell of the cylinder level.
block and cylinder head through which coolant
passes. It is designed to provide adequate cooling WATER PUMP
of the cylinders and combustion chambers which The water pump is used for forced circulation of
become the hottest during engine operation.
coolant through the cooling system. It is mounted
RADIATOR on the front of the cylinder block and driven by a
drive belt.
The radiator performs the function of cooling
the coolant which has passed through the water THERMOSTAT
jacket and become hot, and it is mounted in the The thermostat has a wax type by-passvalve and
front of the vehicle. The radiator consists of an is mounted in the water outlet housing. The
upper tank and lower tank, and a core which con- thermostat is a type of automatic valve operated
nects the two tanks. The upper tank contains an
inlet for coolant from the water jacket and a filler
by fluctuations in the coolant temperature. This
valve closes when the coolant temperature drops,
inlet. It also has a hose through which excess preventing the circulation of coolant through the
coolant or steam can flow. The lower tank has an radiator and thus permitting the engine to warm up
outlet and drain cock for the coolant. The core rapidly. The valve opens when the coolant temper-
contains many tubes and cooling fins through ature has risen, allowing the circulation of coolant.
which coolant flows from the upper tank to the Wax inside the thermostat expands when heated
lower tank so that coolant has been heated up as it and contracts when cooled. Heating the wax thus
passes through the water jacket is cooled here by
generates pressure which overpowers the force of
the air sucked through the radiator by the cool- the spring which keeps the valve closed, thus
ing fan, as well as by the wind generated by the. opening the valve. When the wax cools, its con-
vehicle's travel. Models with an automatic trans- traction causes the force of the spring to take
mission include an automatic transmissions fluid
effect once more, closing the valve. The thermo-
cooler built into the lower tank of the radiator.
stat in this engine operates a t a temperature of
RADIATOR CAP 88°C (191°F).
The radiator cap is a pressure type cap which
seals the radiator, resulting in pressurization of the
radiator as the coolant expands. The pressuriza-
tion prevents the coolant from boiling even when
the coolant temperature exceeds 100" C (212" F).
A relief valve (pressurization valve) and a vacuum
valve (negative pressure valve) are built into the
radiator cap. When the pressure generated inside
the cooling system exceeds the limit (coolant tem-
perature: 110 - 120°C, 230 - 248" F, pressure;
0.3 - 1.0 kg/cm2, 4.3 - 14.2 psi, 29.4 - 98.1 kPa)
the relief valve is opened by the pressure and lets
steam escape through the overflow pipe. The
vacuum valve opens to allow atmospheric air to
enter to alleviate the vacuum which develops in the
cooling system after the engine is stopped and the
coolant temperature drops. The valve's opening
allows the pressure in the cooling system to return
to the reservoir tank.
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CO-4 COOLING SYSTEM -Troubleshooting, Check and Replacement of Engine Coolant
TROUBLESHOOTING
Problem Possible cause Remedy Page
Engine overheats Fan belt loose or missing Adjust or replace belts CH-3
Dirt, leaves or insects on radiator or condenser Clean radiator or condenser
Hoses, water pump, thermostat housing, radiator, Repair as necessary
heater, core plugs or head gasket leakage
Thermostat faulty Check thermostat CO-6
Injection timing retarded , Adjust timing EM-24 or
Fluid coupling faulty Replace fluid coupling 25
Radiator hose plugged or rotten Replace hose
Water pump faulty Replace water pump
Radiator plugged or cap faulty Check radiator
Cylinder head or block cracked or plugged Repair as necessary
HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do
not remove the thermostat, even if the engine tends to overheat.
CHEC K AND REPLACEMENT OF
ENGlF IE COOLANT
CHECK ENGINE COOLANT LEVEL AT RESERVOIR
TANK
The coolant level should be between the "LOW" and
"FU LL" lines.
I f low, check for leaks and add coolant up to the "FULL"
line.
CHECK ENGINE COOLANT QUALITY
There should not be any excessive deposits of rust or scales
around the radiator cap or radiator filler hole, and the
coolant should be free from oil.
I f excessively dirty, replace the coolant.
REPLACE ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION: To avoid the danger of being burned, do not
remove it while the engine and radiator are s t i l l hot, as
fluid and steam can be blown out under pressure.
(b) Drain the coolant from the radiator and engine drain
cocks.
Radia (c) Closethedraincocks.
Drain
Torque (Engine drain cock):
300 kg-cm (22 ft-lb, 29 N-m)
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