FOREWORD. This repair manual explains the repair points of the 1KD model engine equipped on the Toyota Industrial Vehicles.

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3 FOREWORD This repair manual explains the repair points of the 1KD model engine equipped on the Toyota Industrial Vehicles. Please use these manuals for providing quick, correct servicing of this engine. This manual deals with the above models as of October Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News.

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5 SECTION INDEX NAME SECTION GENERAL 0 TROUBLESHOOTING 1 ENGINE OVERHAUL 2 FUEL SYSTEM 3 COOLING SYSTEM 4 STRTING SYSTEM 5 LUBRICATION SYSTEM 6 CHARGING SYSTEM 7 APPENDIX

6 0-1 GENERAL SPECIFICATIONS ENGINE EXTERIOR VIEW ENGINE SECTIONAL VIEW HOW TO READ THIS MANUAL EXPLANATION METHOD TERMINOLOGY ABBREVIATIONS OPERATION PRECAUTIONS SPECIAL PRECAUTIONS GENERAL PRECAUTIONS INSPECTION OF ELECTRIC PARTS SIMULATION OF DEFECT PHENOMENA STANDARD BOLT AND NUT TIGHTENING TORQUE BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE PRECOAT BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON THREADS) SI UNITS HANDLING THE FIPG (LIQUID GASKET)

7 0-2 SPECIFICATIONS Engine model Type 1KD Diesel Cycle 4 Number of cylinder and arrangement In-line 4 cylinders, vertical Ignition order Starting method Fuel supply system Combustion chamber type Valve mechanism Intake and exhaust system Turbo charging system Pinion shift Common rail Direct injection Direct acting DOHC4 valve Belt and gear drive Crossflow Electronically-controlled variable nozzle turbo Bore x stroke mm (in.) 96.0 x 113 (3.78 x 4.06) Total displacement cm 3 (cu in) 2982 (181.97) Compression ratio 16.0 Compression pressure MPa/rpm 2.6/250 Maximum output kw (PS)/rpm 55 (75)/2200 Maximum torque N m/rpm 300/1200 to 1500 No-load static maximum speed rpm 2350, 2600 Idling speed rpm 720 to 780 Number of piston rings Cylinder liner type Intake valve opening & closing timing Exhaust valve opening & closing timing Ignition system Oil pump type Oil filter type Compression ring 2 Oil ring 1 No liner Open BTDC 3 Close ABDC 28 Open BBDC 48 Close ATDC 0 Compression ignition Cycloid gear Paper filter type Engine oil amount L No filter change 6.6 Filter change 7.0 Total capacity 7.8

8 ENGINE EXTERIOR VIEW 0-3

9 0-4 ENGINE SECTIONAL VIEW

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11 0-6 HOW TO READ THIS MANUAL EXPLANATION METHOD 1. Operation procedure The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with an illustration. Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summarized as "key point operations". Example of description in pattern B Disassembly, inspection and reassembly Non-reusable parts T = N m Parts to be replaced with new ones at disassembly/installation Tightening torque unit Step numbers are sometimes partially omitted in illustrations. When a part requiring tightening torque instruction is not indicated in the illustration, the part name is described in the illustration frame. T = to (2800 to 3780) [ to ] Disassembly and reassembly procedure The reassembly procedure is the reverse of the disassembly procedure. No. Item Disassembly Inspection Reassembly 1 Crank pulley 2 Timing gear cover 3 Idle gear No.1 [Point 1] 4 Oil pump assembly [Point 2] Point operation [Point 1] Inspection:Measure the backlash. Standard: 0.05 mm ( in.) Disassembly:Install the rotor in the position shown in the illustration. 3 Explanation of operation point with illustration Operation covered on the following page Abbreviation used for point operations Removal Reassembly Installation Adjustment Disassembly Inspection

12 How to read components figures The components figure uses the illustration in the parts catalog for the vehicle model. Please see the catalog for checking the part name. 3. Matters omitted from this manual This manual omits descriptions of the following jobs, but perform them in actual operation: (1) Cleaning and washing of removed parts as required (2) Visual inspection (partially described) TERMINOLOGY (Example) Parts catalog FIG number 3201 WARNING: Important information and operation procedures, failure to observe which may cause accidents. Caution: Important information and operation procedures, failure to observe which may cause accidents. Note: Important information, failure to observe which may cause accidents, or information on operation procedures that requires special attention. Standard: The permissible range in inspection or adjustment Limit: The maximum or minimum value of the criterion in inspection or adjustment ABBREVIATIONS Abbreviation Original term Meaning ABDC After Bottom Dead Center After the bottom dead center position of the piston in the cylinder. ASSY Assembly An assembly is composed of two or more individual parts or subassembly parts that are put together. ATDC After Top Dead Center After the top dead center position of the piston in the cylinder. BBDC Before Bottom Dead Center Before the bottom dead center position of the piston in the cylinder. BTDC Before Top Dead Center Before the top dead center position of the piston in the cylinder. DTC Diagnostic Trouble Code Diagnostic trouble code ECD Electronically Controlled Diesel Electronically controlled diesel ECU Electronic Control Unit Electronic control unit EDU Electronic Driver Unit Electronic driver unit EGR Exhaust Gas Recirculation Exhaust gas recirculation system EX Exhaust Indicates the exhaust system. FB Feed Back Feed back FCM Fuel Control Module Fuel control module FIPG Formed In Place Gasket Formed in place gasket FR Front Front side IG Ignition Ignition IN Intake Indicates the intake system. LH Left Hand Left side LWR Lower Lower side M/T Manual Transmission Indicates a manual transmission. O/S Over Size For items that have worn over a long time, or where the fitting has loosened due to repeated removal and reassembly, by replacing the one side (fitting side) with an item that has a larger size, the other side can be reused. Sizes larger than this standard are indicated with O/S. RH Right Hand Right side RR Rear Rear side

13 0-8 Abbreviation Original term Meaning SST Special Service Tool Indicates special tools. STD Standard Indicates that the standard size is the size of the parts that were used for assembly at the manufacturer. SUB/ASSY Sub Assembly Two or more individual parts that are welded, cast or caulked together. T = Torque Tightening torque T/C Torque Converter Indicates an automatic transmission. TDC Top Dead Center Top dead center U/S Under Size In the same way as O/S, by replacing the one side (fitted side) with an item that has a smaller hole, the other side can be reused. Sizes smaller than this standard are indicated with U/S. W/ With/ The item following is attached. (Example: w/washer = with a washer)

14 0-9 OPERATION PRECAUTIONS SPECIAL PRECAUTIONS 1. Disassembly and reassembly operations for the engine assembly must be carried out while the engine is set on the engine stand. Never perform the operations on a work bench or the floor, since doing so is very dangerous. 2. Always wear gloves when holding or moving the cylinder head assembly or cylinder block: never use bare hands. GENERAL PRECAUTIONS 1. For safe operation (1) Correctly wear protection tools (cap, safety glasses, gloves, safety shoes, etc.). (2) Do not touch the radiator, muffler, exhaust pipe and other engine related parts immediately after stopping the engine to prevent scalding. (3) Do not bring clothes, tools and others close to rotating parts during engine operation. (4) Always turn the ignition switch OFF and remove the ignition key unless engine operation is necessary. 2. Preparation for disassembly (1) Prepare general tools, SST, measuring tools, greases, and non-reusable parts. (2) When disassembling a complicated assembly, put punch or matching marks at places not affecting the function to facilitate reassembly operations.

15 Keeping out foreign matter If foreign matter such as dust, sand or metal pieces enter the engine, it could cause a malfunction. (1) Fully clean off any sand or mud from the outside of the engine. (2) Use plastic covers to protect the disassembled parts from dust. 4. Prevention of part damage If there is damage to rotating parts or the connection surface of parts, it could cause oil leaks or seizures. (1) Do not use a screwdriver when disassembling the connection surface of parts. Disassemble by striking the parts gently with a plastic hammer. (2) When securing parts in a vise, do not secure the parts directly. Use aluminum plates between the parts and the vise. 5. Washing the parts (1) Wash the parts thoroughly before reassembly, dry with compressed air, and coat with the specified oil. (2) Parts that must not be washed with alkaline solutions: Aluminum parts, rubber parts (O-rings, etc.) (3) Parts that must not be washed with cleaning oil (kerosene, white gasoline, etc.): Rubber parts (O-rings, etc.) 6. Removal and reassembly of fuel system parts (1) Work area for removing and reassembling fuel system parts (a) Perform the work in an area with good ventilation where there is no machinery that cause sparks, such as welders, grinders, drills, electric motors or stoves. (b) Do not work in or around a work pit where there is a danger of ignited fuel flowing in. (2) Removal and reassembly of fuel system parts (a) Prepare a fire extinguisher before starting to work. (b) To prevent static electricity, attach a ground wire to areas such as the fuel changer, vehicle and fuel tank, and pour water over the parts, but not so much that it will cause you to slip. (c) Do not use electric equipment such as power pumps and working lamps, because they could cause sparks or high temperatures. (d) Do not use tools such as iron hammers, because they could cause sparks during work. (e) Dispose of cloths that are saturated with fuel separately. 7. Reassembly position and direction (1) Reassemble the parts in the position and direction they were in before disassembly. (2) Install correct parts according to the correct procedure and observing the determined standards (tightening torques, adjustment values, etc.). (Reassemble at the median of the ranges for tightening torques and adjustment values.) (3) Always use genuine parts for replacement of existing parts. (4) Always use new oil seals, O-rings, gaskets, cotter pins, etc. (5) Coat the seal packing on the gaskets depending on where they will be used, coat the specified oil or the grease on the specified places on the sliding parts, and coat the MP grease on the oil seal lips before reassembly.

16 Tightening by extension tool attached torque wrench L1 L1 L2 L2 (1) For the case a torque wrench is used after extending the total length by combining with SST or another tool, the actual tightening torque becomes excessive when the reading on the torque wrench is at the specified torque. (2) This manual shows the specified torque only. To use a SST or extension tool, calculate the reading of torque wrench using the following formula. (3) Formula: T' = T x L2 / (L1 + L2) T' Reading of torque wrench [N m] T Specified tightening torque [N m] L1 L2 SST or tool length [in] Torque wrench length [in] 9. Handling the hose clamps (1) Before removing the hose, check the insertion depth of the hose and the clamp positions to make sure that reassembly is performed correctly. (2) Replace deformed or dented clamps with new ones. (3) When reusing the hose, install by aligning the clamps to the clamp marks on the hose. (4) With plate spring clamps, after installation apply pressure in the direction it is to be tightened. 10. Adjustment and checking work Adjust to the service standard values by using gauges and testers. 11. Disposal of waste fluid, etc. When draining waste fluid from the vehicle, receive it in a container. If oil, fuel, coolant, oil filters, batteries or other harmful substances are directly discharged or scrapped without permission, it will either adversely affect human health or destroy the environment. Always sort waste fluids etc. and treat them properly by requesting disposal by specialized companies. Further, always recover or wipe up any waste fluid that is spilt. 12. Protection of function parts Before connecting the battery terminal after vehicle inspection or maintenance, thoroughly check each connector for any connection failure or imperfect connection. Failure to connect the controller connectors or incomplete connection may damage the elements inside the controllers. INSPECTION OF ELECTRIC PARTS 1. Always disconnect the battery plug before performing electric part inspections or maintenance. 2. Electric parts resistance measurement condition Unless otherwise specified, the resistance of electric parts should be measured at an ambient temperature of 20 C. The resistance value is out of the specified range when measured at a high ambient temperature immediately after using a truck, therefore measure the resistance after the engine is cooled sufficiently.

17 Handling the connectors (2) Release the lock (1) Push to the fitted side (1) To disconnect a connector with lock, push the connector to the fitted side to ease the tab of the lock and then release the lock. (2) Hold the connector, not the harness, to disconnect the connector. (3) Before connecting the connector, check it for deformation, damage or looseness of the terminal. (4) Insert the connector with lock securely until it clicks. (5) To inspect the connector using a tester, it should be performed at the back (harness side) using a mini test lead. Caution: Since the waterproof connector cannot be inspected at the back, a sub harness needs to be connected. Do not damage the terminal by carelessly moving a tester probe after inserting it. 4. Connector inspection Looseness of swaged area Core breakage Pull lightly Terminal deformation (1) With the connector connected, hold the connector housing and check for insertion and locking conditions. (Fitting condition) (2) With the connector disconnected, pull the wire harness lightly. (Check for terminal disconnection, condition of swaged area and core breakage) Caution: Always use a gold plated male terminal to test a gold plated female terminal. (3) Visually check the connector for a presence of rust, metal chip or water, and bend of the terminal. (Check for corrosion, intrusion of foreign matter and terminal deformation) (4) Check the terminal contact pressure by inserting a male terminal prepared for inspection into the female terminal to check the fitting and sliding conditions. Male terminal for inspection

18 Repairing the connector terminal 6. Connector grease (1) If the contact area is contaminated, clean it using an air gun or cloth. Never polish the contact area with a sandpaper. Doing so causes the plating on the surface to come off. (2) Replace the female terminal if the contact pressure is abnormal. At this time, use a gold plated female terminal when the male terminal to be connected on the part is plated with gold. Likewise, use a tin plated female terminal (silver) when the male terminal to be connected on the part is plated with tin. (3) When no abnormality is found in the contact area, clean it using an air gun and then coat it with connector grease. (This can prevent oxidation and wear of the contact.) (1) The connectors in the areas prone to be exposed to water are filled with grease to prevent corrosion of terminals. (2) When the connector grease is insufficient or the terminal is repaired, add the connector grease to the female terminal by hand. Caution: Keep dirt away. Do not use tools such as screwdriver to add the connector grease. (3) It is no problem that the grease is attached to the O-ring or rubber plug of the waterproof connector; however, the attachment of grease on the other rubber parts (including a wire harness grommet) should be avoided to prevent deterioration or discoloration. Wipe grease off these parts promptly if attached. 7. Handling the wire harness (1) Before removing the harness, check the route and clamp positions to make sure that reassembly is performed correctly. (2) Do not twist, pull or make the harness sag unnecessarily. (3) Do not bring the harness into contact with hot, rotating, sliding or vibrating parts or sharp edges (panel end, screw end, etc.). (4) Do not squeeze the harness in installing parts. (5) Do not break the sheath of the harness. If it is broken, replace it with new one or repair it securely using vinyl tape or the like.

19 Be very careful when handling electric parts. (1) Do not subject electric parts such as computers or relays to impacts. (2) Do not subject electric parts to high temperatures or humidity. (3) Do not touch the connector terminals, because deformation or static electricity could cause a malfunction. 9. Use a circuit tester that suits the measurement object and objective. Analog type: This type is convenient for observing movement during operation and the operating condition. The measured values are used as a reference or as a guideline. Digital type: A fairly accurate reading is possible. However, it may be difficult to observe variation or movement. (1) Difference between results of measurement with analog and digital types The results of measurements using the analog type and the digital type may be different. See the instruction manual when using a circuit tester. The information below describes the precautions required when there are polarity differences between analog and digital circuit testers. Black tester rod Forward Red tester rod Red tester rod Reverse Black tester rod (a) Analog circuit tester Example of measurement result Tester range: kω range Forward: Continuity 11 kω Reverse: No continuity Red tester rod Forward Black tester rod Black tester rod Reverse Red tester rod (b) Digital circuit tester Example of measurement result Tester range: 2 MΩ range Forward: Continuity 2 MΩ Reverse: No continuity 1

20 0-15 (2) Differences in results of measurement with circuit testers (ma) Forward current Germanium diode Silicon diode The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used. The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage. The diode characteristics are shown in the figure. The resistance values of the same semiconductor measured with two types of circuit testers having different power supply voltages are different. This manual describes the results of measurement with a circuit tester whose power supply voltage is 3.0 V. Forward voltage (V) (3) Differences in results of measurement by measurement range Current flow Resistor 0 Ω Variable resistance Resistor Meter In the analog type circuit tester, changing the measurement range switches over the internal circuit to vary the circuit resistance. Even when the same diode is measured, the measurement result varies with the measurement range. Range: x 10 Resistor Range: x 1 (SW1) (SW2) Voltage: 1.5 V Red Black

21 0-16 SIMULATION OF DEFECT PHENOMENA Troubleshooting is difficult when defect phenomena are not recognized. In this case, it is necessary to conduct a thorough analysis on a defect and replicate the condition and environment where the defect occurred. Performing troubleshooting without checking the defect phenomena may cause oversight of important points in repair work or result in a deadlock. For example, a defect that occurred while the engine is cool cannot be identified while the engine is hot. Likewise, a defect that resulted from the vibration during truck operation cannot be identified while the truck is stopped. Vibration, heat or intrusion of water (humidity) is a cause of defect which cannot be replicated easily. The replication methods of defect phenomena described here are effective in that external factors exert an influence on a truck while it is stopped. Note: In replicating defect phenomena, the area or location of defect needs to be found as well as checking the defect phenomena. To do this, find the circuit that may include a defect according to the defect phenomena and connect a tester to it before testing. After that, try the defect replication method and check the circuit for abnormality and also defect phenomena. To narrow the causes of defect phenomena, refer to the list of defect phenomena of each system. To replicate the diagnosis code output, the method based on the detection condition/time of the diagnosis code is required. 1. Vibration method: For defects that may be caused by vibration Vibrate lightly (1) Parts and sensors Cause vibration on the suspected part by tapping it lightly by hand to see if the defect occurs. Note: Note that applying a strong impact on relays may cause the point to open. (2) Connector Shake the connector up and down, or right and left lightly. (3) Wire harness Shake the wire harness up and down, or right and left lightly to see if the defect occurs. Shake lightly Note: Pay special attention to the root of the connector, fulcrum of vibration and penetrated area of the body. Shake lightly Defect Coolant 2. Cooling/heating method: For defects that may occur in a cooled or heated state (1) Heat or cool the suspected part using a hair dryer or coolant to see if the defect occurs. Caution: Do not heat the part to 60 C or above (too hot to touch). Do not open the cover of ECU or other parts to heat/cool the electric part directly.

22 Watering method: For defects that may occur in rainy or high temperature conditions (1) Pour water on a truck to see if the defect occurs. Caution: Do not pour water directly on the engine room. Spray water onto the front surface of radiator to change the temperature and humidity indirectly. Do not pour water directly on the electric parts. 4. Others: For defects that may be caused by excessive electric load (1) Increase the electric load by operating the electric parts such as headlamp to see if the defect occurs.

23 0-18 STANDARD BOLT AND NUT TIGHTENING TORQUE Standard bolt and nut tightening torques are not indicated. Judge the standard tightening torque as shown below. 1. Determine the tightening torques of the standard seat hexagon head bolts, welded bolts and stud bolts by identifying the strength class in the table below, and checking the torque in the tightening torque table. 2. Determine the tightening torque of hexagon flange bolts by identifying the strength class, and checking the torque in the tightening torque table. 3. Determine the tightening torque of nuts by applying the method in item 1 above to the connecting bolt. BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE Identification by bolt shape Type Shape and strength class Strength class 4 = 4T 5 = 5T Bolt head No. 6 = 6T 7 = 7T 8 = 8T Hexagon bolt (standard bearing surface) No mark Two embossed lines 4T 5T Three embossed lines 7T Four embossed lines 8T Welded bolt 4T No mark 4T Stud bolt About 2 mm (0.08 in.) groove(s) on one/both edge(s) 6T

24 0-19 Identification by part number Type Example of part number Shape Hexagon bolt Length (mm) Diameter (mm) Strength class Length Diameter Stud bolt Length (mm) Diameter (mm) Strength class Length Diameter Tightening torque table Strength class Diameter mm (in.) Pitch mm (in.) Standard tightening torque N m 4T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039) T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039) T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039) T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039) T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039)

25 0-20 Identification by bolt shape (Hexagon flange bolt) Strength class 4.8T 6.8T 8.8T 10.9T 11.9T No mark Hexagon flange bolt No mark Tightening torque table (Hexagon flange bolt) Strength class Diameter mm (in.) Pitch mm (in.) Standard tightening torque N m 4.8T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039) T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039) T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039) T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039) T 6 (0.23) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 1.0 (0.039)

26 0-21 PRECOAT BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON THREADS) Seal lock agent 1. Do not use precoat bolts in any of the following cases: (1) When a precoat bolt is removed. (2) When a precoat bolt is moved as a result of tightening torque check, etc. (Loosened or tightened.) Note: Check the torque with the lower limit of the tightening torque. If it moves, retighten it according to the following procedure: 2. Reusing of precoat bolts (1) Wash the bolt and threaded hole. (The threaded hole must be washed even when replacing the bolt with new one.) (2) Dry it well with compressed air. (3) Apply the specified seal lock agent to the bolt threaded portion.

27 0-22 SI UNITS What are SI units? The SI unit system has been introduced for this manual. SI units unify the various unit systems that were previously used in different countries. It is an international unit system established to ensure the smooth exchange of technology. New units arising from SI unit introduction Item New unit Previous unit Conversion value *1 (1 [Previous unit] = X [SI unit]) Force*2 N (Newton) kgf 1 kgf = N Torque*2 (Moment) N m kgf cm 1kgf cm = N m Pressure *2 Pa (Pascal) kgf/cm 2 1 kgf/cm 2 = kpa = MPa Pressure *2 Pa (Pascal) mmhg 1 mmhg = kpa Rotation speed r/min rpm 1 rpm = 1 r/min Spring constant*2 N/mm kgf/mm 1 kgf/mm = N/mm Volume L cc 1 cc = 1 ml Power W PS 1 PS = kw Heat quantity W h cal 1 kcal = W h Fuel consumption ratio g/w h g/ps h 1g/PS h = g/kw h Reference: *1: X is the value of 1 unit of the previous unit converted into the SI unit. This value can be used as the conversion factor for the previous unit and SI unit. *2: The [kg] kilogram unit expressing mass is used instead of the [kgf] kilogram force unit expressing "force" that was previously used. Conversion between previous units and SI units Conversion formula SI unit value = conversion factor x previous unit value Previous unit value = SI unit value / conversion factor Conversion factor: The figure corresponding to X in the conversion value field in the table above Caution: Make sure that the unit of the previous or SI unit value used in the calculation is the same as the unit in the conversion value field in the table above. For example, when converting 100 W into the previous PS unit, convert it into 0.1 kw before dividing it with the conversion factor of

28 0-23 HANDLING THE FIPG (LIQUID GASKET) Use 1280B made by THREEBOND or seal packing black for the FIPG. The part number is set as Example of coating location Coating method and parts reassembly procedure Caution: When removing the gasket, make sure that shreds from the gasket do not enter the engine. 1. Clean the connection surface of parts and their connecting parts with a cloth to eliminate any oil, moisture or dirt. 2. Coat the part to be reassembled with FIPG. The parts that require coating are described in the key point operations in each section. 3. Do not coat excessively or insufficiently, and be sure to overlap FIPG the beginning and end of the coat. 4. Do not move the parts after they are reassembled. 5. Reassemble within 3 minutes of coating the parts. 6. Do not charge coolant, supply oil or start the engine for 2 hours after the reassembly.