Daihatsu Hijet Engine Wiring Diagram

• 3

  Contents

• 3

  General Information

• 4

  Disassembling

• 4

  Reassembling

• 5

  Important Safety Notice

• 5

  Warnings, Cautions and Notes

• 6

  Schematic Diagram of Components

• 6

  Servicing Procedure

• 8

  Abbreviation Codes

• 9

  Jacking Points and Supporting Points for Safety Stands

• 9

  Jacking Points for Garage Jack

• 10

  Vehicle Models

• 10

  Explanation of Vehicle Model Code

• 11

  Chassis Number Location

• 11

  Contents of Manufacturer's Plate

• 12

  Engine Number and Engine Type

• 12

  Body Color Information

• 12

  Trim Code

• 13

  Vehicle 4-Plane Diagrams

• 13

  Pickup

• 14

  Van

• 15

  Performance Diagrams

• 15

  Characteristic Power, Torque and Specific Consumption Curves

• 16

  Engine Specifications

• 18

  Power Train Specifications

• 20

  Lamp Specifications

• 21

  Engine Sectional View

• 22

  Clutch Sectional View

• 25

  Maintenance

• 26

  Maintenance Schedule

• 29

  Jacking Point

• 29

  Supporting Points for Safety Stands and Twinpost Lift Front/Rear Sides

• 29

  Supporting Points for Garage Jack Front/Rear Sides

• 30

  Engine Maintenance Operations

• 30

  Air Cleaner Element

• 30

  Valve Clearance

• 30

  Engine Oil & Filter Change

• 31

  Fuel Filter

• 31

  Fuel Line & Connection

• 31

  Regulator

• 31

  Adjustment of Idle Speed

• 32

  Coolant Level

• 32

  Coolant Leakage

• 32

  Coolant Change

• 33

  Alternator Belt

• 33

  Exhaust Emission Control System/Blow-By Gas Ventilation Hose

• 33

  Transmission System

• 33

  Clutch Pedal

• 34

  Manual Transmission

• 34

  Propeller Shaft

• 34

  Change of Differential Oil

• 34

  Change of Transmission Oil

• 35

  Suspension System

• 35

  Running System

• 35

  Spring

• 35

  Shock Absorbers

• 36

  Wheels

• 36

  Wheel Bearing

• 36

  Tires Wear

• 36

  Objects Caught in Tire Pattern

• 37

  Bearing Grease

• 37

  Steering Wheel

• 37

  Linkage & Dust Cover

• 37

  Wheel Alignment

• 38

  Brake Pedal

• 38

  Parking Brake

• 38

  Brake Hose and Tube

• 38

  Free Play

• 39

  Brake Fluid

• 39

  Brake Drums & Brake Linings

• 39

  Brake Disc & Disc Pad

• 39

  Brake Booster

• 40

  Chassix & Body

• 40

  Load Sensing Proportioning Valve

• 40

  Exhaust Pipe and Muffler

• 40

  Doors

• 41

  Glow Plugs

• 41

  Battery

• 42

  Wire Harness

• 42

  Lighting System Meter & Gauge

• 43

  Engine Mechanical

• 44

  Engine Overall Dimensions

• 47

  Engine Tune-Up

• 47

  Remove the Filter Cartridge

• 47

  Checking the Belt Deflection

• 48

  Checking the Valve Clearance

• 48

  Table of Valve Play Adjustment in Ignition Sequence

• 49

  Checking the Cylinder Compression

• 49

  Checking the Injection Timing

• 50

  Adjusting the Injection Timing

• 50

  Leveling Deliveries

• 54

  Idle Speed Tune-Up

• 54

  Full Load Speed Tune-Up

• 55

  Removing the Timing Belt

• 56

  Fitting the Timing Belt

• 59

  Oil Vapours Recirculation Diagram

• 60

  Removing the Engine from the Vehicle

• 62

  Fitting

• 62

  Preparing for the Bench Overhaul

• 63

  Removing the Cylinder Head

• 67

  Checking, Cleaning and Repairing Cylinder Head Components

• 67

  Cleaning the Piston Crowns and the Cylinder Block Ceiling

• 67

  Removing any Gasket Residues

• 68

  Cleaning the Valve Guides

• 68

  Cleaning the Head

• 68

  Checking the Head Surfaces

• 68

  Checking for any Cylinder Head Cracks

• 69

  Checking the Camshaft Play

• 69

  Checking and Grinding the Valves

• 70

  Checking and Cleaning the Valve Seats

• 71

  Replacing the Valve Seats

• 72

  Checking the Valve Stem - Valve Guide Coupling Play

• 73

  Replacing the Valve Guides

• 73

  Manual Valve Grinding

• 74

  Checking the Valves

• 74

  Checking the Rocker Arms and the Rocker Arms Pivot

• 75

  Measuring the Height of the Cam Hump

• 75

  Checking the Inlet Manifold

• 75

  Checking the Governor Leverages

• 76

  Fitting the Cylinder Head

• 79

  Checking the Piston Projections

• 80

  Installing the Head

• 81

  Fitting the Camshaft

• 82

  Fitting the Rocker Arm Pivot

• 82

  Adjusting the Play of the Valves

• 85

  Cylinder Block Components

• 86

  Preparing to Remove the Cylinder Block

• 87

  Removing the Cylinder Block

• 89

  Cylinder Block Checks

• 90

  Diameters of the Crankshaft and Connecting-Rod Pins

• 90

  Inside Diameters of Crankshaft and Connecting-Rod Big End Bearings

• 92

  Checking the Connecting Rods

• 93

  Checking the Piston Ring and Piston

• 94

  Checking the Cylinders

• 95

  Weighting the Pistons and the Connecting Rods

• 96

  Checking the Cylinder Plane

• 97

  Fitting the Cylinder Block

• 97

  Fitting the Crankshaft

• 102

  Exhaust System

• 102

  Diagram of Silencer Anchorages

• 103

  Removing the Exhaust System

• 103

  Fitting the Exhaust System

• 104

  Intake System

• 104

  Removing the Filter Box

• 104

  Fitting the Filter Box

• 105

  Special Tools

• 107

  Service Specifications

• 110

  Tightening Torques

• 111

  Fuel System

• 112

  Supplying and Injection System

• 113

  Remove the Fuel Pump

• 113

  Inspection of Fuel Pump

• 113

  Inspection of Push Rod Projection

• 114

  Removing the Solenoid Valve

• 114

  System Bleeding

• 115

  Pump Injector

• 116

  Remove the Pump Injector

• 117

  Disassembly the Pump Injector

• 117

  Inspect the Plunger

• 117

  Assembly the Pump Injector

• 118

  Unit Inspection

• 119

  Install the Pump Injector

• 122

  Measure and Adjust the Full Load Stoper

• 125

  Lubrication

• 126

  Components

• 127

  Troubleshooting

• 128

  Oil Quality Check

• 128

  Oil Level Check

• 128

  Oil Pressure Check

• 129

  Engine Oil Change & Oil Filter Replacement

• 130

  Oil Pump Components

• 131

  Oil Pump Removal

• 131

  Oil Pump Checks

• 131

  Installing the Oil Pump

• 132

  Oil Filter

• 133

  Ssts

• 135

  Cooling System

• 136

  Cooling System Outline

• 138

  Change of Engine Coolant

• 140

  Water Pumps Components

• 140

  Removal of Water Pump

• 141

  Inspection of Water Pump

• 141

  Installation of Water Pump

• 142

  Thermostat Components

• 142

  Removal of Thermostat

• 143

  Inspection of Thermostat

• 143

  Installation of the Thermostat

• 144

  Electric Cooling Fan and Radiator Components

• 144

  In-Vehicle Inspection of Electric Cooling Fan

• 145

  Electrical Diagram

• 149

  Removal of Electric Cooling Fan and Radiator

• 149

  Disassembly of Electric Fan

• 150

  Electric Cooling Fan

• 150

  Inspection of Radiator Thermo-Control Switch

• 153

  Starting System

• 154

  General Descriptions and Components

• 155

  Starting System Circuit

• 155

  Starting System Troubleshooting

• 156

  Starter Servicing Instructions

• 156

  In-Vehicle Inspection

• 156

  Removal

• 157

  Checking the Starter Motor

• 158

  Removing the Starter Motor

• 161

  Inspection

• 164

  Checking the Reduction Unit

• 166

  Installation on the Engine

• 167

  Preheating System

• 167

  Electric Table

• 168

  Preheating Glow Plugs: Removal and Check

• 168

  Preheating Glow Plugs Installation

• 168

  Preheating System Check

• 171

  Charging System

• 172

  Alternator Components

• 173

  Charging System Circuit

• 173

  Charging System Troubleshooting

• 174

  On-Vehicle Verifications

• 175

  Removing the Alternator

• 175

  Disassembling the Alternator

• 177

  Checking the Rotor

• 177

  Checking the Stator

• 178

  Checking the Brushes and the Brush Holder

• 178

  Checking the Rectifier

• 179

  Assembly

• 181

  Installation

• 182

  Specific Tools

• 184

  Propeller Shaft Components

• 185

  Propeller Shaft Troubleshooting

• 185

  Propeller Shaft In-Vehicle Inspection

• 185

  Propeller Shaft Removal

• 186

  Propeller Shaft Inspection

• 187

  Propeller Shaft Installation

• 189

  Front Axle & Suspension

• 190

  Front Axle Components

• 190

  Front Axle Removal

• 192

  Front Axle Inspection

• 193

  Front Axle Installation

• 195

  Front Shock Absorber and Coil Spring Components

• 195

  Front Shock Absorber and Coil Spring Removal

• 196

  Coil Spring Disassembly

• 197

  Front Shock Absorber and Coil Spring Inspection

• 197

  Front Shock Absorber and Coil Spring Assembly

• 198

  Front Shock Absorber and Coil Spring Installation

• 200

  Suspension Lower Arm Components

• 200

  Suspension Lower Arm Removal

• 201

  Suspension Lower Arm Inspection

• 202

  Suspension Lower Arm Installation

• 204

  Front Wheel Alignment

• 204

  Checks Prior to Wheel Alignment Measurement

• 205

  Wheel Alignment Specified Values

• 209

  Brake

• 210

  Brake Pedal Removal

• 210

  Brake Pedal Inspection and Repairs

• 211

  Brake Pedal Installation

• 211

  Brake Pedal Specified Values

• 212

  Brake Pedal Adjustment

• 213

  Brake Reservoir Removal

• 214

  Brake Reservoir Installation

• 215

  Brake Master Cylinder Removal

• 216

  Booster Check Procedure after Installation

• 219

  Vacuum Pump Disassembly

• 219

  Vacuum Pump Exploded View

• 220

  Vacuum Pump Check

• 221

  Vacuum Pump Assembly

• 222

  Air Bleeding for Brake System

• 223

  Front Disc Brake Pad Removal

• 223

  Front Disc Brake Pad Installation

• 224

  Front Disc Brake Removal

• 225

  Front Disc Brake Caliper Disassembly

• 226

  Front Disc Brake Caliper Inspection

• 226

  Front Disc Brake Caliper Assembly

• 227

  Front Disc Brake Caliper Installation

• 228

  Operation after Installation

• 228

  Pedal Height Adjustment

• 229

  Rear Brake Removal

• 230

  Rear Brake Inspection

• 231

  Rear Brake Installation

• 234

  Parking Brake Lever Removal

• 235

  Parking Brake Lever Installation

• 236

  Parking Brake Cable Removal

• 237

  Parking Brake Cable Installation

• 238

  Parking Brake Cable Removal (Van)

• 241

  Load Sensing Proportioning Valve (LSPV)

• 242

  Load Sensing Proportioning Valve Description

• 243

  Load Sensing Proportioning Valve Adjustment

• 244

  Load Sensing Proportioning Valve Components

• 245

  Removal of LSPV

• 245

  Disassembly of LSPV

• 246

  Load Sensing Proportioning Valve Inspection

• 247

  Assembly of LSPV

• 248

  Load Sensing Proportioning Valve Installation

• 251

  Harness and Wiring Diagram

• 252

  Handling Instructions of Lock Type Connector

• 252

  Handling and Inspection

• 252

  Replacement

• 253

  Lock Type Connector Inspection

• 253

  Lock Type Connector Connection

• 254

  Operation of Wire Harness

• 255

  Wiring Harnesses

• 256

  Fuse Block

• 256

  Replacement of Fuses & Fusible Link

Source: https://www.manualslib.com/manual/1003224/Daihatsu-S85-Hijet.html

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