Engine & identification
Vehicle identification
| No. of cylinders Type | 4/OHV |
|---|---|
| Capacity cc | 4104 |
| Compression ratio :1 | 17,8 |
Injection system
| Fuel/injection pump assembly Make | Denso |
|---|---|
| Pump type | Rotary |
| Injector nozzle Make | Denso |
| Nozzle and holder assembly Part No. | DLLA150P645 |
| Nozzle opening pressure - new/used bar | 1)177-186 2)185-195/162-186 |
| Leak rate (dribble) bar/secs | 9,8-19,6/10 |
Injection sequence
The injection sequence for the Toyota Coaster 4.1 (1998–2001) is 1-3-4-2.
| Injection sequence | 1-3-4-2 |
|---|
Valve clearances
Valve clearances for the Toyota Coaster 4.1 (1998–2001) are 0,20 mm inlet and 0,36 mm exhaust, measured hot.
| Valve clearance - INLET mm | 0,20 hot |
|---|---|
| Valve clearance - EXHAUST mm | 0,36 hot |
Engine oil & fluids
Engine oil
The Toyota Coaster 4.1 (1998–2001) takes 9.3 litres of engine oil with the filter.
See the reference table for the complete engine oil entries and their conditions.
Manual gearbox
The manual gearbox has a listed capacity of 3.2 litres. The specified oil is SAE 75W-90, with classification GL-4/5.
Grades, filling conditions and capacities
| Engine oil options | |
|---|---|
| Ambient temperature range | ➞10°C |
| Engine oil grade SAE | 5W-30 |
| Engine oil classification API/ACEA | CF/B1, B3 |
| Ambient temperature range | -18°C➞ |
| Engine oil grade SAE | 10W-30 |
| Engine oil classification API/ACEA | CF/B1, B3 |
| Ambient temperature range | -12°C➞ |
| Engine oil grade SAE | 15W-40 |
| Engine oil classification API/ACEA | CF/B2, B3 |
| Ambient temperature range | -7°C➞ |
| Engine oil grade SAE | 20W-50 |
| Engine oil classification API/ACEA | CF/B2, B3 |
| Engine with filter(s) litres | 9.3 |
| Other lubricants and capacities | |
| Manual transmission oil grade SAE | 75W-90 |
| Manual transmission oil classification | GL-4/5 |
| Manual transmission litres | 3.2 |
| Automatic transmission fluid Type | Dexron II/III |
| Automatic transmission (drain & refill) litres | 6.0 |
| Automatic transmission (dry fill) litres | 13.0 |
| Differential oil grade - rear SAE | 90 |
| Differential oil classification - rear | GL-5 |
| Differential rear litres | 3.8 |
| Cooling system - total capacity litres | — |
| Brake fluid Type | DOT 3 |
| Power steering fluid Type | Dexron II/III |
Brakes & wear limits
Brake disc thickness
Brake discs on the Toyota Coaster 4.1 (1998–2001) are replaced at a minimum thickness of 33 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 322 mm.
| Minimum disc thickness for replacement - ventilated Front | 33 mm |
|---|---|
| Maximum drum diameter for replacement Front | 322 mm |
| Maximum drum diameter for replacement Rear | 322 mm |
Brake disc and drum dimensions
| Disc runout Front | 0,12 mm |
|---|---|
| Minimum pad thickness Front | 3 mm |
| Minimum shoe thickness Front | 4,2 mm |
| Minimum shoe thickness Rear | 4,2 mm |
| Parking brake travel No. of notches | 6-8 |
Service & electrical
Tuning and emissions
| Plunger travel (pump) mm ABDC | 0,87-0,93 |
|---|---|
| Crankshaft position (n = ATDC) °BTDC | — |
| Adjusting method Engine/Pump | Pointer/Dial gauge |
| Idle speed rpm | 725±25 |
| Idle speed - alternative rpm | AC=950±50 |
| Rated no load speed rpm | 3900-4100 |
| Oil temperature °C | 80 |
| Idle speed - for smoke test rpm | 700-750 |
| Governed speed range - for smoke test rpm | 3900-4100 |
| Maximum time at governed speed secs | 1,0 |
| Test mode A/B | B |
| Probe type 1/2 | 1 |
| Conditioning Accelerations/rpm | 3 |
| Smoke opacity - EU limit m-1 (%) | 2,50 (66) |
Starting and charging
| Battery V/RC(Ah) | 12/24 |
|---|---|
| Alternator output A/V/rpm | 45/-/2000 24V=60/-/2000 |
Service checks and adjustments
| Compression pressure bar | 20-31,4 |
|---|---|
| Turbo boost pressure bar/rpm | 0,29-0,53/3700 |
| Oil pressure bar/rpm | 0,30 Min/725 |
| Radiator cap bar | 0,74-1,00 |
| Thermostat opens °C | 80-84 |
| Drive belt tension - alternator/PAS/AC mm | 8-11 |
| Drive belt tension - AC mm | 11-15 |
| Maximum wheel bearing end-float Front | 0,05 mm |
| Maximum wheel bearing end-float Rear | 0,10 mm |
Tightening torques
Cylinder head bolt torque
The cylinder head bolts on the Toyota Coaster 4.1 (1998–2001) are tightened in 3 stages: 49 Nm, then 90°, then a final 90°.
| Cylinder head | |
|---|---|
| Tighten | 49 Nm |
| Tighten | 90° |
| Tighten | 90° |
| Cylinder head instructions | — |
|---|---|
| Cylinder head | |
| View more information | — |
| Other engine tightening torques | |
| Main bearings Renew bolts/nuts | No |
| Main bearings Stage 1 | 100 Nm |
| Main bearings Stage 2 | 200 Nm |
| Big end bearings Renew bolts/nuts | — |
| View more information | — |
| Big end bearings Stage 1 | 69 Nm |
| Big end bearings Stage 2 | 90° |
| Oil pump to cylinder block | 21 Nm 14mm=44 Nm |
| Sump bolts | 19 Nm |
| Sump drain bolt | 35 Nm |
| Flywheel/driveplate | 160 Nm |
| Clutch pressure plate | x6=20 Nm x8=39 Nm |
| Crankshaft pulley/damper centre bolt | 294 Nm |
| Camshaft sprocket/gear | 38 Nm |
| Camshaft/rocker cover | 11 Nm |
| Rocker shaft | 25 Nm |
| Inlet manifold to cylinder head | 19 Nm |
| Exhaust manifold to cylinder head | 44 Nm |
| Water pump | 25 Nm |
| Injector/clamp | 21 Nm |
| Injector pipe unions | 25 Nm |
| Fuel/injection pump sprocket/gear | 137 Nm |
| Fuel/injection pump flange | 42 Nm |
| Glow plugs | 13 Nm |
| Engine coolant temperature (ECT) sensor | 18 Nm |
| Chassis tightening torques | |
| Steering wheel | 34 Nm |
| Steering rack/box mounting | 145 Nm |
| Steering track rod end | 152 Nm |
| Steering box drop arm | 335 Nm |
| Leaf spring to axle U-bolts Rear | 200 Nm |
| Leaf spring to chassis/bracket Rear | 325 Nm |
| Leaf spring to shackle Rear | 135 Nm |
| Leaf spring shackle to chassis/bracket Rear | 225 Nm |
| Differential input shaft flange centre nut/bolt | 304 Nm |
| Propshaft flange to propshaft, centre nut/bolt at centre bearing | 167 Nm |
| Propshaft centre bearing to chassis | 37 Nm |
| ABS sensor Front | 18 Nm |
| ABS sensor Rear | 18 Nm |
| Road wheels | 515 Nm |
Air conditioning
| No. of AC service connectors | 2 |
|---|---|
| Air conditioning restrictor type | Expansion valve |
| Compressor clutch/magnetic coupling | Yes |
| Compressor variable displacement solenoid | No |
| Air conditioning refrigerant Type | R134a |
| Air conditioning refrigerant quantity grams | 1950±50 |
| Air conditioning oil group | PAG |
| Air conditioning oil Type | Dens Oil 8 |
| Air conditioning oil quantity cm³ | — |
| Air conditioning oil viscosity ISO | 46 |
Frequently asked questions
What is the injection sequence of the Toyota Coaster 4.1?
The injection sequence for the Toyota Coaster 4.1 (1998–2001) is 1-3-4-2.
How much oil does the Toyota Coaster 4.1 take?
The Toyota Coaster 4.1 (1998–2001) takes 9.3 litres of engine oil with the filter. See the reference table for the complete engine oil entries and their conditions.
What are the valve clearances for the Toyota Coaster 4.1?
Valve clearances for the Toyota Coaster 4.1 (1998–2001) are 0,20 mm inlet and 0,36 mm exhaust, measured hot.
What is the cylinder head torque for the Toyota Coaster 4.1?
The cylinder head bolts on the Toyota Coaster 4.1 (1998–2001) are tightened in 3 stages: 49 Nm, then 90°, then a final 90°.
What is the minimum brake disc thickness for the Toyota Coaster 4.1?
Brake discs on the Toyota Coaster 4.1 (1998–2001) are replaced at a minimum thickness of 33 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 322 mm.