Case 4JJ1 Isuzu Engine Repair Manual 87606795 - PDF DOWNLOAD

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General Information General Information Contents General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2 Reading the Model. . . . . . . . . . . . . . . . . . . . . . . 0A-6 General Information . . . . . . . . . . . . . . . . . . . . . . 0A-6

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General Information Service Precautions In order to carry out work safely 1. Always use an engine stand when taking the engine down from the vehicle.

Do not place the engine directly onto the ground, or place in a manner that interferes with the oil pan.

2. If you are working together with others, always pay attention to each other's safety.

3. If you are repairing any part of the electrical system, always remove the minus side cable from the battery terminal before starting work. If you are removing the battery cover, always remove the cover in a place that is away from sources of fire/ heat.

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6. All regular tools, gauges and special tools should be regularly inspected, and prepared before starting work. Do not use bent spanners, hammers with damaged edges, chipped chisels, or any other faulty or damaged tools.

4. Do not perform painting work or leave the engine running for long periods of time in an enclosed or badly ventilated indoor workshop.

5. Always use the correct specialized tool indicated in the instructions. Using the incorrect tool may cause damage to the parts or injury to the person using the tool.

7. Always pay close attention to safety and handling requirements when using grinders, cranes, welders, and other such equipment.

Moreover, always wear the correct protective garments and use the necessary safety tools for the job in hand.

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8. Always check that there are no fuel leaks when performing maintenance work on the fuel system.

(It may cause a fire.)

Replacement parts and part numbers.

1. Always replace packing, oil seals, o-rings, caulking lock nuts, folding lock plates, split pins and other such parts with brand new parts.

2. The parts numbers contained in this manual may not represent the supply condition of the parts, and the part numbers may be changed due to revisions.

Therefore, parts should always be checked against a parts catalogue before use.

Liquid gasket

9. Pay close attention to the risk of ignition if you are handling parts that carry a high voltage.

Furthermore, any oil or grease spilt onto rubber parts must be wiped off immediately, as it will cause deterioration of the rubber.

1. Each time you disassemble parts that use liquid gasket, completely remove the old gasket residue from each of the parts and matching sections using a scraper, then clean each of the parts to completely remove oil, water, and dirt etc. from the various surfaces. Using the specified type of liquid gasket, apply new liquid gasket to each of the surfaces before reassembling the parts.

2. In order to make it easier to clean liquid gasket surfaces, apply gasket remover liquid (Pando391D made by Three Bond Co., Ltd.) and leave the part to stand for approximately 10 minutes, after which the old liquid gasket residue will be easier to remove.

However, this should not be used on resin components or painted components.

3. Please take care not to apply too much or too little liquid gasket.

Also, you should always re-apply the liquid gasket upon itself when you start and finish application.

4. Make sure that there are no gaps when re-installing the liquid gasket parts to each other. If there are gaps between the two parts, re-apply the liquid gasket. Some parts, especially the oil pan, use the same size studs as a guide to eliminate the need for knock pin positioning etc.

5. Re-install these parts within 5 minutes of applying the liquid gasket.

Ù»²»®¿´ ·²º±®³¿¬·±² Ñßóì If more than 7 minutes passes, remove the previous liquid gasket and re-apply it.

6. Please wait for at least 30 minutes since the last part is installed before starting the engine.

Liquid gasket Seal section

Product name

Manufacturer's name

Between cylinder head and upper timing chain cover

1207B

Three Bond

Between cylinder block and crank case

1207B

Three Bond

Between oil cooler ASM and gear case cover

1207B

Three Bond

Between gear case and cylinder head

1207B

Three Bond

Between gear case and gear case cover

1207B

Three Bond

Among gear case and cylinder block and crank case

1207B

Three Bond

Between gear case cover and lower timing chain cover

1207B

Three Bond

Among cylinder block and crank case and retainer

1207B

Three Bond

Between cylinder head and cam end packing

1207B

Three Bond

262

Loctite

Cylinder block, head plug nipple, unit, switches • Always use the liquid gasket products listed above, or a liquid gasket identical to the ones listed above.

• Use the correct quantity of liquid gasket. Always follow the handling instructions for each product.

Application procedure 1. Wipe the contact surfaces clean of all water, fat or oil. The contact surfaces should be dry.

2. Apply a regular bead width of liquid gasket to one of the contact surfaces. Make sure that the bead does not break at this point.

Notes: If there are special regulations concerning the application procedure in the repair document, please follow those regulations.

Work procedure 1. Wipe the joint surfaces of the bolt, bolt hole, and screw thread section clean of water, fat and oil. The contact surfaces should be dry.

2. Apply Loctite to the top 1/3 of the screw.

3. Tighten the bolt to the correct tightening torque.

Important: After tightening the bolt, do not apply excessive torque or try to rotate the bolt until at least one hour has passed, and the Loctite has hardened.

Procedure for using the Plastigauge Type

Measurable range

mm (in)

PG-1 (Green)

0.025 – 0.076 (0.001 – 0.003)

PR-1 (Red)

0.051 – 0.152 (0.002 – 0.006)

PB-1 (Blue)

0.102 – 0.229 (0.004 – 0.009)

Example: Procedure for measuring the clearance between the connecting rod bearing and crank pin.

Ù»²»®¿´ ·²º±®³¿¬·±² ðßóë • Clean the connecting rod and bearing, and install the bearing to the rod.

• Cut the plastigauge to the same width as the crank pin, and while avoiding the oil pore of the crank pin lay the gauge parallel to the pin.

• Line up the marks on the connecting rod and cap and install the crank pin, apply molybdenum disulphide to the thread section and bearing surface of the fastening bolt, and rotate both cap and bolt to the correct torque.

Important: Do not move the connecting rod while using the plastigauge.

• Gently remove the cap and connecting rod, and measure the crushed width of the plastigauge (clearance between rod and pin) using the scale printed on the bag.

Example: Measuring the clearance between the crank bearing and crank journal

• Clean the clamp face of the cylinder block and crankcase bearing, and also the bearing, and install the cylinder block to the crankcase.

• Gently rest the crankshaft on the cylinder block, and rotate it approximately 30 degree to stabilize it.

• Cut the plastigauge to the same size as the journal width, and while avoiding the oil pore of the journal lay the gauge parallel to the journal.

• Gently rest the crank case on the cylinder block, apply molybdenum disulphide to the thread section and bearing surface of the fastening bolt, and tighten in sequence to the correct torque.

Important: Do not rotate the crankshaft while using the plastigauge.

• Gently remove the crankcase, and measure the crushed width of the plastigauge (clearance between bearing and journal) using the scale printed on the bag.

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Reading the Model Engine number stamping position

Front

Rear

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General Information Terminology, description of abbreviations Terminology definitions Term

Explanation

Maintenance standard

The generic name for reference values required for maintenance, such as nominal dimension, selection of a reference point, and limit.

Nominal dimension

Shows the standard value at the point of manufacture that does not include the common difference.

Selection of a reference point Shows the standard value after assembling, repairing, or adjusting.

Limit Front rear, left right, upper lower Unit

When this value (dimensions) is reached, it shows that the part has reached its full limit and must be replaced or repaired.

These show each orientations of parts installed to the vehicle when looking from the vehicle's forward direction.

Units written to SI conventions (mainly torque, pressure, force) [Example] Length: mm, Torque: N m {kgf m}

Warning

Items that carry the warning mark pose a danger to life or threat of serious injury if not strictly observed.

Caution

Items that carry the caution mark may cause injury or lead to accidents if not strictly observed.

Important

Items that carry the important mark may cause the vehicle to break down, or may prevent the guaranteed normal operation of the system or related parts if not strictly observed.

Ù»²»®¿´ ·²º±®³¿¬·±² ðßóé Term

Explanation

Notes

Items that should receive special mention within a work procedure.

Description of abbreviations Abbreviation AC

Abbreviation FWD

Forward Forward

F/C

Fuel Cut Fuel Cut

GND

Ground Earth

Description Alternating Current Alternating Current

ACC

Accessory Accessory

ACG

Alternating Current Generator Alternating current generator

IC

API

American Petrol Institute American Petroleum Institute

ID Plate

ASM (Assy) Assembly Assembly ATDC

After Top Dead Center After Top Dead Center

BAT, BATT

Battery Battery

BRG, Brg

Bearing Bearing

BKT, BRKT

Bracket Bracket

BTDC CO CONN

Before Top Dead Center Before Top Dead Center Carbon Oxide Carbon Monoxide Connector Connector

CPU

Central Processing Unit Central processing unit

C/U

Control Unit Control unit

DC

Direct Current Direct current

DI

Direct Injection Direct injection

ECU

Engine Control Unit / Electronic Control Unit Engine control unit / control unit

Description

IN ISO

I/PUMP JIS

Integrated Circuit Integrated circuit Identification plate Identification plate, ID plate Intake, Intake Intake International Standardization International Standardization

for

Organization

for

Injection Pump Injection Pump Japanese Industrial Standard Japanese Industrial Standard

L/H, LH

Left Hand Left hand side

M/V

Magnetic Valve Magnetic valve

NOx

Nitrogen Oxide Nitrogen Oxide

N-TDC

Organization

Number - Top Dead Center Top dead center rotational frequency

OPT

Option Option

P

Pole(S) Pole

PCV

Pump Control Valve/ Positive Crankcase Ventilation Pump control valve/ Positive crankcase ventilation

PM

Particulate Matter Particulate matter

PS

Pre-Stroke Pre-stroke

ECM

Engine Control Module Engine control module

EGR

Exhaust Gas Recirculation Exhaust gas recirculation

PTO

Power Take Off Power take off

Exhaust Exhaust

QOS

Quick On System Rapid preheating system

Exh, EXH Ft, FRT

Front Front

Rr, RR

Rear Rear

Ù»²»®¿´ ·²º±®³¿¬·±² Ñßóè Abbreviation R/H, RH

SI (International System of Units)

Description

With regards the conversion to SI (International System of Units)

Right Hand Right hand side

R/L

Relay Relay

STD

Standard Standard

SW

Switch Switch

TICS

Timing & Injection rate Control System A type of injection system

VGS Turbo

Variable Geometry turbocharger System Adjustable turbo, VGS turbo

W/L

The introduction of the SI systems aims to internationally unify the metric system and the various units used by different countries (traditional weights and measures, the foot pound method etc.), and to curb the confusion that occurs between the different units (conversion calculations etc.).

The new calculating method which adopted SI units was completely adopted in Japan in 1992, and is standardized by JIS-Z-8203.

All of the units in this manual are written in line with the International System of Units SI units, and conventional units are written in { } brackets.

SI French) Abbreviated name of Le Systeme International d’Unites

Warning Lamp Warning lamp

Connection between main SI units and conventional units SI

Conventional Unit

Length

m

m

Same as the conventional unit

Weight (Mass)

kg

kg

Same as the conventional unit

Force

N

* kg, kgf

Torque

Nm

* kg m, gf m

Pressure

Pa

2

*kg/cm , mmHg

Dynamic force, horsepower

W

PS

Capacity, air volume displacement Fuel consumption

m

3

Litle, L, cc

g/(kW h)

g/(PS h)

*1 Published service data may conveniently use kg for force and mass (weight) instead of kgf. *2 Some conversion results may be rounded off to 1 or 2 decimal places.

Converting expressions of quantity When converting, prefixes such as k (kilo) or m (mili) are used.

M k h d c m

Mega

10 6

1,000,000

3

Kilo

10

Hecto

102

1,000 100

Deci

10-1

0.1

Centi

10-2

0.01

Milli

10 -3

0.001

Micro

10-6

0.000001

• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa • 40 mmHg = 5,332 Pa = 5.3 kPa

Item, unit conversion

1 kgf = 9.80665 N 1 kgf m = 9.80665 N m 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa 1 PS = 0.74 kW 1 Litle = 1 dm3, 1 cc = 1mLitle = 1cm3 1 g/(PS h) = 1.360 g/(kW h)

Ù»²»®¿´ ·²º±®³¿¬·±² ðßóç Table of standard Isuzu tightening torque The tightening torque values in the table below apply to all situations unless a special tightening torque is specified.

Isuzu standard bolts, nuts N m {kgf m} Strength classification

4.8 4T

Bolt head Hexagon head bolt section shape * M10

7T

Flange bolt

Hexagon head bolt

Flange bolt

1.5

19.6 ~ 33.3 {2.0 ~ 3.4} 22.3 ~ 37.2 {2.3 ~ 3.8} 27.5 ~ 45.1 {2.8 ~ 4.6} 30.3 ~ 50.4 {3.1 ~ 5.1}

M12

1.25

49.0 ~ 73.5 {5.0 ~ 7.5} 54.9 ~ 82.3 {5.6 ~ 8.4} 60.8 ~ 91.2 {6.2 ~ 9.3}

* M12

1.75

45.1 ~ 68.6 {4.6 ~ 7.0} 51.0 ~ 76.5 {5.2 ~ 7.8} 56.9 ~ 84.3 {5.8 ~ 8.6} 62.7 ~ 94.0 {6.4 ~ 9.6}

68.1 ~ 102.1 {6.9 ~ 10.4}

1.5

76.5 ~ 114.7 {7.8 ~ 11.7}

83.0 ~ 124.5 {8.5 ~ 12.7}

93.2 ~ 139.3 {9.5 ~ 14.2}

100.8 ~ 151.1 {10.3 ~ 15.4}

2

71.6 ~ 106.9 {7.3 ~ 10.9}

77.2 ~ 115.8 {7.9 ~ 11.8}

88.3 ~ 131.4 {9.0 ~ 13.4}

94.9 ~ 142.3 {9.7 ~ 14.5}

1.5

104.0 ~ 157.0 {10.6 ~ 16.0}

115.6 ~ 173.3 {11.8 ~ 17.7}

135.3 ~ 204.0 {13.8 ~ 20.8}

150.1 ~ 225.2 {15.3 ~ 23.0}

2

100.0 ~ 149.1 {10.2 ~ 15.2}

109.4 ~ 164.2 {11.2 ~ 16.7}

129.4 ~ 194.2 {13.2 ~ 19.8}

142.5 ~ 213.8 {14.5 ~ 21.8}

M18

1.5

151.0 ~ 225.6 {15.4 ~ 23.0}

—

195.2 ~ 293.2 {19.9 ~ 29.9}

—

* M18

2.5

151.0 ~ 225.6 {15.4 ~ 23.0}

—

196.1 ~ 294.2 {20.0 ~ 30.0}

—

M20

1.5

206.0 – 310.0 {21.0 ~ 31.6}

—

269.7 ~ 405.0 {27.5 ~ 41.3}

—

* M20

2.5

190.2 ~ 286.4 {19.4 – 29.2}

—

249.1 ~ 374.6 {25.4 ~ 38.2}

—

M22

1.5

251.1 – 413.8 {25.6 ~ 42.2}

—

362.8 ~ 544.3 {37.0 ~ 55.5}

—

* M22

2.5

217.7 ~ 327.5 {22.2 ~ 33.4}

—

338.3 ~ 507.0 {34.5 ~ 51.7}

—

M24

2

358.9 ~ 539.4 {36.6 ~ 55.0}

—

430.5 ~ 711.0 {43.9 ~ 72.5}

—

* M24

3

338.3 ~ 507.0 {34.5 ~ 51.7}

—

406.0 ~ 608.0 {41.4 ~ 62.0}

—

M14 * M14 M16 * M16

The * mark indicates where soft materials have been used for internal thread sections, such as castings.

Ù»²»®¿´ ·²º±®³¿¬·±² Ñßóïð N m {kgf m} Strength classification Bolt head shape

section

9.8 9T

8.8 Hexagon head bolt

Flange bolt

Hexagon head bolt

Flange bolt

5.6 ~ 11.2 {0.6 ~ 1.1}

6.6 ~ 12.2 {0.6 ~ 1.2}

—

—

13.4 ~ 25.7 {1.4 ~ 2.6}

15.3 ~ 28.4 {1.6 ~ 2.9}

16.7 ~ 30.4 {1.7 ~ 3.1}

18.1 ~ 33.6 {1.9 ~ 3.4}

1.25

31.3 ~ 52.5 {3.2 ~ 5.4}

35.4 ~ 58.9 {3.6 ~ 6.1}

37.3 ~ 62.8 {3.8 ~ 6.4}

42.3 ~ 70.5 {4.3 ~ 7.2}

1.5

31.3 ~ 51.4 {3.2 ~ 5.2}

34.5 ~ 57.5 {3.5 ~ 5.8}

36.3 ~ 59.8 {3.7 ~ 6.1}

40.1 ~ 66.9 {4.1 ~ 6.8}

M12

1.25

69.3 ~ 104.0 {7.1 ~ 10.6}

77.7 ~ 116.5 {7.9 ~ 11.9}

75.5 ~ 113.8 {7.7 ~ 11.6}

85.0 ~ 127.5 {8.7 ~ 13.0}

* M12

1.75

64.8 ~ 96.1 {6.6 ~ 9.8}

71.4 ~ 107.2 {7.3 ~ 10.9}

71.6 ~ 106.9 {7.3 ~ 10.9}

79.5 ~ 119.2 {8.1 ~ 12.2}

1.5

106.2 ~ 158.8 {10.8 ~ 16.2}

114.9 ~ 172.3 {11.7 ~ 17.6}

113.8 ~ 170.6 {11.6 ~ 17.4}

123.4 ~ 185.1 {12.6 ~ 18.9}

2

100.6 ~ 149.8 {10.3 ~ 15.3}

108.2 ~ 162.2 {11.1 ~ 16.6}

106.9 ~ 160.0 {10.9 ~ 16.3}

115.5 ~ 173.3 {11.8 ~ 17.7}

1.5

154.3 ~ 232.5 {15.7 ~ 23.7}

171.1 ~ 256.7 {17.4 ~ 26.2}

160.0 ~ 240.3 {16.3 ~ 24.5}

176.9 ~ 265.3 {18.0 ~ 27.1}

2

147.6 ~ 221.4 {15.0 ~ 22.6}

162.5 ~ 243.8 {16.6 ~ 24.9}

153.0 ~ 229.5 {15.6 ~ 23.4}

168.5 ~ 252.7 {17.2 ~ 25.8}

M18

1.5

222.5 ~ 334.3 {22.7 ~ 34.1}

—

229.5 ~ 345.2 {23.4 ~ 35.2}

—

* M18

2.5

223.6 ~ 335.4 {22.8 ~ 34.2}

—

230.5 ~ 346.2 {23.6 ~ 35.3}

—

M20

1.5

307.4 ~ 461.7 {31.4 ~ 47.1}

—

316.8 ~ 475.6 {32.3 ~ 48.5}

—

* M20

2.5

284.0 ~ 472.1 {29.0 ~ 43.5}

—

293.2 ~ 440.3 {29.2 ~ 44.9}

—

M22

1.5

413.6 ~ 620.5 {42.2 ~ 63.3}

—

424.6 ~ 636.5 {43.3 ~ 64.9}

—

* M22

2.5

385.7 ~ 578.0 {39.3 ~ 58.9}

—

394.2 ~ 592.3 {40.0 ~ 60.4}

—

M24

2

490.8 ~ 810.5 {50.0 ~ 82.7}

—

554.1 ~ 830.6 {56.5 ~ 84.7}

—

* M24

3

462.8 ~ 693.1 {47.2 ~ 70.7}

—

520.7 ~ 781.6 {53.1 ~ 79.7}

—

M6

1

M8

1.25

M10 * M10

M14 * M14 M16 * M16

The * mark indicates where soft materials have been used for internal thread sections, such as castings.

Ù»²»®¿´ ·²º±®³¿¬·±² ðßóïï Designations for Isuzu standard bolt heads

Legend 1. Hexagon Head Bolt (4.8, 4T) 2. Hexagon Head Bolt (4.8, 4T) 3. Flange Bolt (4.8, 4T) 4. Flange Bolt (4.8, 4T) 5. Hexagon Head Bolt (7T) 6. Flange Bolt (7T) 7. Hexagon Head Bolt (Refined 8.8) 8. Hexagon Head Bolt (Refined 8.8)

9.

10.

11.

12.

13.

14.

15.

16.

Hexagon Head Bolt (Un-Refined 8.8) Hexagon Head Bolt Un-Refined 8.8) Flange Bolt (8.8) Flange Bolt (8.8) Hexagon Head Bolt (9.8, 9T) Hexagon Head Bolt (9.8, 9T) Flange Bolt (9.8, 9T) Flange Bolt (9.8, 9T)

Flare nut Pipe diameter

Flare nut tightening torque (service standard value) N m {kgf m}

tightening torque (for medium and large size vehicles)

Flare nut 2 side width (mm) Old

New

4.76 mm

12.8 ~ 18.6 {1.3 ~ 1.9}

14

14

6.35 mm

23.5 ~ 49 {2.4 ~ 5.0}

17

17

8.0 mm

23.5 ~ 49 {2.4 ~ 5.0}

19

17

10.0 mm

44.1 ~ 93.2 {4.5 ~ 9.5}

22

19

12.0 mm

58.8 ~ 137.3 {6.0 ~ 14.0}

27

24

15.0 mm

78.5 ~ 156.9 {8.0 ~ 16.0}

30

30

Ù»²»®¿´ ·²º±®³¿¬·±² Ñßóïî Taper screw from connectors (brass) N m {kgf m} Screw size

PT(R) 1/8

PT(R) 1/4

PT(R) 3/8

PT(R) 1/12

—

2.0 ~ 14.7 (0.2 ~ 1.5)

4.9 ~ 15.7 (0.5 ~ 1.6)

9.8 ~ 16.7 (1.0 ~ 1.7)

9.8 ~ 17.7 (1.0 ~ 1.8)

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Engine Engine Mechanical (4JJ1) Contents Isuzu Diesel Engine (4JJ1) . . . . . . . . . . . . . . . . . . 1A-3 Precautions on Service Work. . . . . . . . . . . . . . . 1A-3 Main Data and Specifications. . . . . . . . . . . . . . . 1A-8 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-9 Engine Foot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-11 Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 1A-13 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-13 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-15 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-16 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-17 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-17 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-18 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-20 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-23 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-25 Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-29 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-29 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-31 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-35 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Camshaft ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-37 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-38 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-41 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-43 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-43 Rocker Arm Shaft ASM . . . . . . . . . . . . . . . . . . . . 1A-44 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-44 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-44 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-45 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-47 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-47 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-48 Valve Stem Seal, Valve Spring . . . . . . . . . . . . . . 1A-49 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-49 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-49 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-50 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-51

Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-52 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-58 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-59 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-64 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-67 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-75 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-75 Piston, Connecting Rod . . . . . . . . . . . . . . . . . . . 1A-77 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-77 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-77 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-78 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-84 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-85 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-87 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-87 Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-88 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-88 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-88 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-89 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-89 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-91 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-91 Gear Case ASM. . . . . . . . . . . . . . . . . . . . . . . . . 1A-92 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-92 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-92 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-93 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-94 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . 1A-95 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-95 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-95 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-96 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-98 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-98 Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . . 1A-99 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-99 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-100 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-100 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-102 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . 1A-102 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-104 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-105 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-105 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-109 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-112 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . .1A-113 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-113 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-113

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóî Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-116 Lubrication System . . . . . . . . . . . . . . . . . . . . . . 1A-117 Precautions on Service Work . . . . . . . . . . . . . 1A-117 Functional Check . . . . . . . . . . . . . . . . . . . . . . 1A-118 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119 Oil Filter ASM . . . . . . . . . . . . . . . . . . . . . . . . . .1A-120 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-120 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-120 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-121 Oil Port Cover ASM . . . . . . . . . . . . . . . . . . . . . .1A-122 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-122 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-122 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-122 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-123 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-123 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-123 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-124 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-125 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-125 Oil Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . .1A-127 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-127 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-127 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-128 Crankcase, Oil Pan . . . . . . . . . . . . . . . . . . . . . .1A-130 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-130 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-130 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-131 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-132 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-132 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-134 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-135 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-135 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-135 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-137 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-137 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-137 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-139 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . .1A-142 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-142 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-142 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-142 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-143

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Isuzu Diesel Engine (4JJ1) Precautions on Service Work Matters that maintenance

require

attention

in

terms

of

To prevent damage to the engine and ensure reliability of its performance, pay attention to the following in maintaining the engine: When taking down the engine on the ground, do not make the bearing surface of the oil pan touch directly the ground. Use a wood frame, for example, to support the engine with the engine foot and the flywheel housing.

Because there is only a small clearance between the oil pan and the oil pump strainer, it can damage the oil pan and the oil strainer.

• When the air duct or air cleaner is removed, cover the air intake opening to prevent foreign matter from getting into the cylinder. If foreign matter gets in, it can considerably damage the cylinder and others while the engine is operating.

• When maintaining the engine, never fail to remove the battery ground cable. Otherwise, this may damage the wire harness or electrical parts. If you need electricity on for the purpose of inspection, for instance, watch out for short circuits and others.

• Apply engine oil to the sliding contact surfaces of the engine before reassembling it. This ensures adequate lubrication when the engine is first started.

• When valve train parts, pistons, piston rings, connecting rods, connecting rod bearings or crankshaft journal bearings are removed, put them in order and keep them.

• When installing them, put them back to the same location as they were removed.

• Gaskets, oil seals, O-rings, etc. must be replaced with new ones when the engine is reassembled.

• As for parts where a liquid gasket is used, remove an old liquid gasket completely and clean it up thoroughly so that no oil, water or dust may be clung to them. Then, apply the designated liquid gasket to each place anew before assembly.

• Surfaces covered with liquid gasket must be assembled within 5 minutes of gasket application.

If more than 5 minutes have elapsed, remove the existing liquid gasket and apply new liquid gasket.

• When assembling or installing parts, fasten them with the specified tightening torque so that they may be installed properly.

Matters that require attention in specifically dealing with this engine.

Holes or clearances in the fuel system, which serve as a passage of fuel, including the inside of the injector, are made with extreme precision. They are therefore highly sensitive to foreign matter and the entry of foreign matter could cause serious damage. Take extreme care not to allow foreign matter to enter.

When servicing the fuel system, every precaution must be taken to prevent the entry of foreign material into the system.

• Before beginning the service procedure, wash the fuel line and the surrounding area.

• Perform the service procedures with clean hands.

Do not wear work gloves.

• Immediately after removing the fuel hose and/or fuel pipe, carefully tape vinyl bags over the exposed ends of the hose or pipe.

• Always replace the high-pressure pipe in fuel system with new one if it has been removed.

Reuse of it causes damage to the seal surface, resulting in fuel leakage.

• If parts are to be replaced (fuel hose, fuel pipe, etc.), do not open the new part packaging until installation.

Work procedure • The fuel opening must be quickly sealed when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and common rail.

• The eyebolts and gasket must be stored in a clean parts box with a lid to prevent adhesion of foreign matter.

• Fuel leakage could cause fires. Therefore, after finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóì How to read the model

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Rear

Front

ÉÍÖÖðððë

Name 1. Stamped Engine Model Explanations on functions and operation Electronic engine control With the control unit, the range from injection to air intake/exhaust, including fuel injection quantity, injection timing, EGR and idling speed, is controlled.

Cylinder block The cylinder block is cast-iron with the center distance of each bore being equal, is of the highly rigid, and is linerless.

Piston The piston is aluminum-alloy and a thermal-flow piston with a strut cast, while the combustion chamber is a round reentrant type.

Cylinder head The cylinder head is aluminum-alloy and there are 4 valves per cylinder. The angular tightening method of the cylinder head bolt further increases reliability and durability.

Crankshaft Do not grind the crankshaft to reuse, as tufftride treatment has been performed to the surface. Replace with new one if fault is present.

2. Stamped Engine Number EGR system Based upon data, including coolant temperature, engine speeds or engine loads, it is controlled via Engine Control Module (ECM) to purify exhaust by recycling part of it.

Its main components include an EGR valve, an EGR cooler and various sensors.

Connecting rod cap bolt The angular tightening method of the connecting rod cap bolt further increases reliability and durability.

Common rail-type electronic control injection system The common rail-type electronic control injection system is composed of a fuel supply pump that sets the target pressure of high-pressure fuel and supply it, a common rail that measures such high-pressure fuel and a fuel injector that turns it into a fine spray and injects it.

Each is controlled via ECM based upon various signals, while injection timing or fuel injection quantity is controlled under every possible driving condition.

Fuel injector The fuel injector is a 6-hole nozzle that adjusts fuel injection quantity or injection timing by opening or closing an electromagnetic valve on the head of the fuel injector.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóë ECM corrects the dispersion of fuel injection quantity among fuel injectors according to ID code data in memory. At the replacement of fuel injectors, ID code data should be stored in ECM. Fuel filter with sedimenter It is a fuel filter with sedimenter that gets rid of water by making use of the difference in specific gravity between light oil and water, which comes with an indicator that notifies you that it is filled with water.

Preheating system The preheating system consists of the ECM, the glow relay, glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant temperature is low, and make the engine easy to start.

Lubrication system It is an oil filter with full-flow bypass, which uses a water-cool oil cooler and oil jet to cool the piston.

Function check Inspection/adjustment of valve clearance 1. Inspection of valve clearance • Disconnect the fuel injector connector.

• Disconnect the leak off hose.

• Remove the cylinder head cover.

• Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC).

• Insert a 0.15 mm (0.006 in) thickness gauge into a clearance between the rocker arm roller and the camshaft to check it and adjust it if needed.

It is recommended to use a long thickness gauge.

Valve clearance

mm (in)

Intake valve

0.15 (0.006)

Exhaust valve

0.15 (0.006)

Caution: Perform adjustment when it is cold.

2. Adjustment of valve clearance a. Completely loosen all of the rocker arm adjusting nuts and adjusting screws (16 nuts and 16 screws). b. Place a 0.15 mm (0.006 in) thickness gauge between the No. 1 cylinder rocker arm roller and the camshaft. c. With a thickness gauge kept inserted, tighten an adjusting screw of the rocker arm lightly and make sure that the tip of the adjusting screw touches the end of valve axis and the movement of the thickness gauge has become tight. d. Use a valve clearance adjusting nut wrench to tighten the rocker arm lock nut.

Special tool Valve clearance adjusting nut wrench: 380300021 e. Remove the thickness gauge. f. Repeat above steps for the remaining cylinders.

Tightening torque: 18 N m (1.8 kg m/13 lb ft)

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ÉÍÖÖðððï

Name 1. TDC

î

ï ÉÍÖÖðîéì

Name 1. Valve Clearance Adjusting Nut Wrench 2. Thickness Gauge

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóê • If the No. 1 cylinder is the compression TDC, adjust a valve clearance with mark given on the table and if the No. 4 cylinder is the compression top dead center, that with mark.

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í

ÉÍÖÖððíè

Name 1. Exhaust Rocker Arm Shaft ASM 2. Valve Clearance 3. Intake Rocker Arm Shaft ASM

ÉÍÖÖðïèì

Adjustment table Cylinder No. Valve arrangement

1

2

3

4

IN EX IN EX IN EX IN EX

No. 1 cylinder Compression top dead center position No. 4 cylinder Compression top dead center position ÉÍÖÖðïèë

• Install the cylinder head cover.

Refer to the “Cylinder Head Cover”.

• Connect the leak off hose.

• Connect the fuel injector connector.

Compression pressure inspection • Warm-up the engine.

• Remove a negative terminal of the battery and remove all the glow plugs.

• Remove the connector of the fuel injector (no fuel will be injected).

Caution: When the harness connector is removed, ECM judges that it broke down and DTC is recorded. Upon completion of measurement, never fail to clear memory of ECM.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóé (For how to clear memory of ECM, refer to the Engine Control System Section)

Compression pressure Standard Limit Differences among the cylinders

ï

MPa (psi) / 200 rpm 2.84 — 3.24 (412 — 469) 1.96 (284) 294 kPa (43)

• Measure each cylinder one by one.

Caution: To keep engine speed at 200 rpm or more, use fully charged batteries.

• Remove a compression gauge (special tool).

• Remove a negative terminal of the battery.

• Connect the fuel injector connector.

• Install all the glow plugs. ÉÍÖÖðîîî

Tightening torque: 15 — 20 N m (1.5 — 2.0 kg m/11 — 15 lb ft) • Install the negative terminal of the battery.

Name 1. Fuel Injector Connector • Install the negative terminal of the battery.

• Turn on the starter to emit foreign matter within the cylinders.

• Install an adapter and a gauge of a compression gauge (special tool).

ÉÍÖÖðîéë

Compression gauge: 380002626 Compression gauge adapter: 380300015 • Turn on the starter to inspect compression pressure.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóè

Main Data and Specifications Items

Engine model 4JJ1

Type

Diesel/4-cycle/water cooled-type, in-line fourcylinder DOHC

Combustion chamber form

Direct injection type

Cylinder liner type

Linerless

Number of cylinders - cylinder bore strokes

mm (in)

Displacement

cc (cu.in)

Compression ratio Compression pressure

104.9 (4.13)

2999 (183) 17.5

MPa (psi)/rpm

Idle speed Valve clearance

4-95.4 (3.76)

rpm Intake

3 (435)/200 800

25

0.15 (0.006) (cold)

mm (in) Exhaust

0.15 (0.006) (cold)

Ignition type

Compressed ignition

Injection order

1-3-4-2

Lubricating system Lubricating type

Pressure type

Oil pump type Volume of lubricating oil

Gear type L (qts)

Oil filter type

15.0 (15.8) Full flow filter (cartridge type)

Oil cooling type

Built-in, water-cooling

Cooling system Cooling type

Water cooling type

Water pump type

Centrifugal, belt type

Thermostat type

Wax-type unit

Thermostat valve-opening temperature

C ( F)

85 (185)

Volume of coolant

L (qts)

6 (6.3) (Engine only)

Fuel system Injection pump type

Electronic control common rail type

Governor type

Electronic type

Timer type

Electronic type

Injection nozzle type

Multi-hole type 6-hole

Charging system Generator type Power output Regulator type

AC type V/A

24 - 50 IC

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóç Items

Engine model 4JJ1

Starting system Starter type

Reduction type

Power output

V-kw

Preheat system type Glow plug standard voltage/electric current

Special tool Illustration

24 - 4.0 Glow plug

Tool Number/Description / Special Tool

380002626 Compression gauge

380300015 Compression gauge adapter

380300021 Valve clearance adjust nut wrench

V/A

23 - 3.8

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïð

Engine Foot Components

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Name 1. Engine Foot RH

Removal 1. Lower the engine ASM. 2. Remove the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

3. Remove the generator.

Refer to “Generator” in Engine Electrical section.

4. Remove the fan shroud bracket RH and fan shroud stay RH.

2. Engine Foot LH

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïï 7. Remove the relief valve.

ÉÍÖÖðîëî

5. Remove the bolt with arrow mark which holds the water intake pipe to the engine foot RH.

ÉÍÖÖðîêð

8. Remove the engine foot.

Installation 1. Install the engine foot.

• Temporarily tighten the engine foot bolt.

• Install the bolt which holds the water intake pipe to the engine foot RH. • Tighten each bolt to the specified torque.

Tightening torque: M8 bolt: 25 N m (2.5 kg m/18 lb ft), M10 bolt: 51 N m (5.2 kg m/38 lb ft) 2. Install the relief valve.

• Install so as not to let the pipe stick out of the bottom of the engine foot.

Tightening torque: 25 N m (2.5 kg m/18 lb ft) ÉÍÖÖðîíé

6. Remove the bolt with arrow mark which holds the blow-by hose to the engine foot RH.

ÉÍÖÖðîëð

3. Install the bolt which holds the blow-by hose to the engine foot LH. ÉÍÖÖðîëç

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïî 4. Install the fan shroud bracket RH and fan shroud stay RH. Tightening torque: M8 bolt: 25 N m (2.5 kg m/18 lb ft), M10 bolt: 51 N m (5.2 kg m/38 lb ft) Nut: 25 N m (2.5 kg m/18 lb ft) 5. Install the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

6. Install the generator.

Refer to “Generator” in Engine Electrical section.

7. Put the engine ASM on.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïí

Cylinder Head Cover Components

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Name 1. Head Cover

2. Head Cover Packing

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïì

Removal 1. Remove the air intake duct.

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2. Disconnect the connector of the fuel injector.

• Remove the cover. (Varies depending on the machine.)

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ÉÍÖÖððíç

Name 1. Cam End Packing

ÉÍÖÖðîéê

Name 1. Cover 3. Disconnect the leak-off hose.

4. Disconnect the blow-by hose.

5. Remove the head cover.

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Name 1. Head Cover 6. Remove the packing.

7. Remove the cam end packing.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïë

Installation 1. Install the cam end packing.

• Apply liquid gasket (ThreeBond 1207B or equivalent).

• Install within five minutes after applying liquid gasket.

2. Install the packing on the head cover.

3. Install the head cover and tighten up according to the order shown in the illustration.

Tightening torque: 10 N m (1.0 kg m/87 lb in)

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Name 1. Cam End Packing 2. Liquid Gasket Applied Area.

3. 2.0 — 3.0 mm (0.079 — 0.118 in) • Install the cam end packing.

Apply liquid gasket (ThreeBond 1207B or equivalent) as shown in the illustration.

• Install within five minutes after applying liquid gasket.

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Name 1. 3.0 — 5.0 mm (0.118 — 0.196 in) 2. 3.0 — 5.0 mm (0.118 — 0.196 in)

4. Connect the blow-by hose.

5. Connect the leak-off hose.

6. Connect the fuel injector connector.

Caution: Push it in thoroughly until the claw of the lock is lifted.

• Install the cover.

7. Install the air intake duct.

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Torque Specifications Ò ³øµ¹ ³ñ´¾ ·²÷

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Intake Manifold Components

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Name 1. Intake Manifold 2. Air Intake Pipe

3. EGR Valve

Removal 1. Remove the fuel injector, EGR valve, glow plug, boost pressure sensor and boost temperature sensor connector.

2. Remove the air intake duct.

3. Remove the leak-off pipe.

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ÉÍÖÖðððì

Name 1. Leak-Off Pipe

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïè 4. Remove the EGR valve. ï

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ÉÍÖÖðððé ÉÍÖÖðîîí

Name 1. EGR Valve 5. Disconnect the fuel injection pipe (common rail to fuel injector).

Important: Do not reuse the high-pressure pipe in fuel system if it has been removed.

Refer to “Fuel Injector” in the Fuel System section.

6. Remove the air intake pipe.

Name 1. Intake Manifold 2. Gasket

Installation 1. Install the intake manifold and gasket, and tighten up according to the order shown in the illustration.

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

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Name 1. Air Intake Pipe 2. Intake Manifold 3. Gasket 7. Remove the intake manifold and gasket.

2. Connect the air intake pipe.

Tightening torque: 10 N m (1.0 kg m/87 lb in)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïç

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Name 1. Air Intake Pipe 2. Intake Manifold 3. Gasket

ÉÍÖÖðððì

Name 1. Leak-Off Pipe

3. Connect the fuel injection pipe (common rail to fuel injector).

Important: Replace the high-pressure pipe in fuel system with new one if it has been removed.

Refer to “Fuel Injector” in the Fuel System section.

4. Install the EGR valve.

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

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Name 1. EGR Valve 5. Install the leak-off pipe.

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

6. Install the air intake duct.

7. Install the fuel injector, EGR valve, glow plug, boost pressure sensor and boost temperature sensor connector. Each composite connector should make a loud click when it is securely attached.

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Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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Exhaust Manifold Components

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Name 1. Turbocharger ASM 2. Exhaust Adapter 3. Oil Return Pipe 4. Oil Feed Pipe

Removal 1. Loosen the radiator drain cock to drain coolant.

2. Disconnect the intake pipe from the intake duct and charge air cooler.

3. Disconnect the air intake pipe from the turbocharger and air cleaner.

4. Remove the charge air pipe from the turbocharger and the charge air cooler.

5. Remove the oil level gauge guide tube.

5. Exhaust Manifold 6. Water Feed Pipe 7. Water Return Pipe

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóîî

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6. Remove the EGR cooler.

Refer to “EGR Cooler” in the Exhaust System section.

7. Remove the oil feed pipe.

8. Remove the oil return pipe.

9. Remove the water feed pipe.

10. Remove the water return pipe. î

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Name 1. Exhaust Manifold 2. Turbocharger 3. Exhaust Adapter

Inspection • Inspection of exhaust manifold Inspect for distortion of the plane on which the manifold and the cylinder head are to be installed.

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Distortion of manifold installation surface Standard Limit

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mm (in)

0.3 (0.01) or less 0.5 (0.02)

Caution: If the distortion exceeds the limit, replace it.

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Name 1. Water Feed Pipe 2. EGR Cooler 3. Oil Feed Pipe 4. Water Return Pipe 5. Oil Return Pipe 11.

12.

13.

14.

Disconnect the front exhaust pipe.

Remove the exhaust adapter.

Remove the four turbocharger clamping nuts.

Remove the turbocharger from the exhaust manifold.

15. Remove the exhaust manifold.

ÉÍÖÖðîìë

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóîí • Check a crack in the exhaust manifold visually.

Carefully inspect the turbocharger for abrasion and/or excessive wear. Make any necessary adjustments, repairs, and/or part replacements.

Refer to “Turbocharger” in the Exhaust System section for inspection of turbocharger.

Installation 1. Put the gasket in to install the exhaust manifold.

Install the gasket so that the projection shown in the illustration faces the rear side of the engine.

• Tighten up with the eight nuts according to the order shown in the illustration.

Tightening torque: 52 N m (5.3 kg m/38 lb ft) Caution: Do not tighten up too much because it hampers expansion and contraction due to the heat from the manifold.

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Name 1. Exhaust Manifold 2. Turbocharger 3. Exhaust Adapter 4. Connect the front exhaust pipe.

5. Install the water feed pipe to the turbocharger.

• Tighten the joint bolts to the specified torque.

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Tightening torque: 22.5 N m (2.3 kg m/17 lb ft) • Install the pipe bracket and tighten each bolt and nut to the specified torque.

Tightening torque: 10 N m (1.0 kg m/87 lb in) • Connect the rubber hose between the water feed pipe and the thermostat housing.

ÉÍÖÖðîìì

2. Install the gasket and turbocharger to the exhaust manifold. Tighten the nuts to the specified torque.

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Tightening torque: 28 N m (2.9 kg m/21 lb ft) 3. Install the gasket and exhaust adapter. Tighten to the specified torque.

Tightening torque: 28 N m (2.9 kg m/21 lb ft)

ÉÍÖÖððïï

Name 1. Water Feed Pipe

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóîì 6. Install the water return pipe. Tighten the joint bolts to the specified torque.

Tightening torque: 22.5 N m (2.3 kg m/17 lb ft)

Tightening torque (crankcase side): 24.7 N m (2.5 kg m/18 lb ft)

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Name 1. Oil Return Pipe

Name 1. Water Return Pipe 7. Install the turbocharger oil feed pipe to the top of the turbocharger. Tighten the joint bolts to the specified torque.

9. Install the EGR cooler.

Refer to “EGR Cooler” in the Exhaust System section.

10. Install the oil level gauge guide tube.

• Apply a thin coat of engine oil to the O-ring.

Tightening torque: 22.5 N m (2.3 kg m/17 lb ft)

Tightening torque: Bolt: 25 N m (2.5 kg m/18 lb ft) Nut: 51 N m (5.2 kg m/38 lb ft)

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Name 1. Oil Feed Pipe 8. Tighten the oil return pipe bolts to the specified torque.

Tightening torque (turbocharger side): 10 N m (1.0 kg m/87 lb in)

ÉÍÖÖðððç

11. Connect the charge air pipe to the turbocharger and the charge air cooler.

12. Connect the air intake pipe to the turbocharger and the air cleaner.

13. Connect the intake pipe to the intake duct and the charge air cooler.

14. Add cooling water to the radiator.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóîë 15. Replenish the coolant.

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷ ïð ø ïòð ñ èè ´¾ ·²÷

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Timing Gear Train Components

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Name 1. Crankshaft Gear 2. Oil Pump Gear 3. Idle Gear A 4. Fuel Supply Pump Gear 5. Fuel Supply Pump Sprocket

Removal 1. Drain the coolant.

2. Disconnect the radiator upper hose.

3. Remove the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

4. Remove the fan ASM and water pump pulley.

Refer to the “Water Pump” in the Cooling System Section.

5. Remove the fan belt.

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7.

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10.

Idle Gear D Sprocket Idle Gear D Exhaust Camshaft Gear Intake Camshaft Gear Timing Chain

Refer to the “Water Pump” in the Cooling System Section.

6. Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC).

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóîé Special tool Crankshaft stopper

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Name 1. TDC

9. Remove the power steering pump hole cover.

7. Remove the starter motor.

• Remove the mounting bolt, and remove the starter motor and ground cable.

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Name 1. Power Steering Pump Hole Cover ÉÍÖÖððíî

8. Remove the crank pulley.

• Install the crankshaft stopper on the starter part of the flywheel housing to stop the crankshaft from rotating.

Caution: • Check if the stopper meshes with the ring gear without fail and is installed properly.

• Do not reuse the crankshaft pulley bolt and washer.

10. Remove the fan shroud bracket LH and fan shroud stay LH.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóîè

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ÉÍÖÖðïêç

13. Install the M6 bolt to the idle gear A.

Name 1. Fan Shroud Bracket LH 2. Fan Shroud Stay LH 11. Remove the vacuum pump hole cover.

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14. Remove the idle gear A, idle gear A flange and idle gear A shaft. ÉÍÖÖðîîë

Name 1. Vacuum Pump Hole Cover 12. Remove the gear case cover.

ÉÍÖÖðîèê

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóîç

Reassembly

15. Remove the crankshaft gear.

1. Install the scissors gear ASM. • Fix the idle gear A in a vise using a mouth ring.

Assemble the spring with its left end contacting the pin of idle gear A main gear to make a gap on the right.

• Assemble the sub gear so that its pin is inserted into the gap between the right side of pin of the idle gear A main gear and the right end of the spring.

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Disassembly 1. Remove the scissors gear ASM. • Fix the idle gear A in a vise using a mouth ring. Use snap ring pliers to remove the sub gear. ÉÍÖÖððìì

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Name 1. Snap Ring 2. Sub Gear 3. Spring 4. Idle Gear A

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• Use snap ring pliers to assemble the snap ring securely.

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Name 1. Snap Ring 2. Sub Gear 3. Spring 4. Idle Gear A

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Inspection 1. Measurement of idle gear backlash • Apply a dial gauge on the teeth of the idle gear to be measured and move the gear to right and left lightly to read how much the dial gauge shook (never fail to fix the gear).

• If the measurement exceeds the limit, replace the idle gear.

Backlash of the timing gear Standard Limit

mm (in)

0.10 — 0.17 (0.004 — 0.006) 0.30 (0.01)

2. Measurement of end clearance of the idle gear.

• Insert a thickness gauge between the idle gear and the thrust collar to measure a clearance.

• If the measurement exceeds the limit, replace either the idle gear or the thrust collar.

Axial play of idle gear Standard Limit

mm (in)

0.080 — 0.155 (0.003 — 0.006) 0.20 (0.008)

• Measure an end clearance of the idle gear before removing the idle gear A.

• Measure backlash of the idle gear before removing the idle gear A.

ÉÍÖÖðîèë

ÉÍÖÖðîèì

3. Outside diameter of idle gear shaft • Use a micrometer to measure an external diameter of the idle gear A shaft.

• If the measurement exceeds the limit, replace the shaft.

External diameter of the idle gear A shaft mm (in) Standard Limit

44.950 — 44.975 (1.7697 — 1.7707) 44.80 (1.764)

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Installation 1.

2.

• •

Install the crankshaft gear.

Install the idling gear A. Fix the idle gear A in a vise using a mouth ring.

Rotate the sub gear clockwise using the M6 bolt and lever to align the M6 bolt hole of the sub gear with that of the idle gear A. • Tighten the M6 bolt to the appropriate torque to prevent rotation of the sub gear.

ÉÍÖÖððìë

4. Clearance between the idle gear and the idle gear shaft • Measure an inside diameter of the idle gear bushing to calculate a clearance between the idle gear and the idle gear shaft.

• If the measurement exceeds the limit, replace either the idle gear or the shaft.

Clearance between the idle gear A and the shaft mm (in) Standard Limit

0.020 — 0.062 (0.0007 — 0.0024) 0.200 (0.0079)

ÉÍÖÖððìê

• Install the idle gear A, idle gear A flange and idle gear A shaft so that the marks on the flange and shaft face upward and the mark on the flange also faces outside.

• Apply engine oil to the part where the gear of the shaft is to be put together.

• Apply engine oil to the thread part and seating surface of the bolt, and temporarily tighten together with the flange.

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Name 1. Flange Mark 2. Shaft Mark • Install so that the timing marks of the crankshaft gear, idle gear A and fuel supply pump gear are aligned as shown in the illustration.

ÉÍÖÖððìé

3. Tighten the idle gear A installing bolt to the specified torque.

Tightening torque: 32 N m (3.3 kg m/24 lb ft)

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ÉÍÖÖðïèê

ÉÍÖÖððìç

6. Install the vacuum pump hole cover.

• Apply engine oil to the packing.

Name 1. Idle Gear A Bolt

Tightening torque: 25 N m (2.5 kg m/18 lb ft) 4. Remove the M6 bolt from the idle gear A. 5. Install the gear case cover.

• Apply liquid gasket (ThreeBond 1207B or equivalent) to the position shown in the illustration.

• Apply the liquid gasket and install the gear case cover within 5 minutes.

• Install the packing in the groove of the gear case cover.

• Tighten the installing bolt to the specified torque. ï

Tightening torque: 3.5 N m (0.4 kg m/31 lb in) ï

ÉÍÖÖðîîë

Name 1. Vacuum Pump Hole Cover 7. Install the fan shroud bracket LH and fan shroud stay LH. • After temporarily tightening the nut (1) as shown in the illustration, temporarily tighten the bolt (2).

• After fully tightening the nut (1) as shown in the illustration, fully tighten the bolt (2). ÉÍÖÖððìè

Name 1. Liquid Gasket Applied Area.

Tightening torque: M8 bolt: 25 N m (2.5 kg m/18 lb ft) M10 bolt: 51 N m (5.2 kg m/38 lb ft) Nut: 25 N m (2.5 kg m/18 lb ft)

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8. Install the power steering pump cover.

• Apply a coat of engine oil to the O-ring.

Tightening torque:

ÉÍÖÖðïïí

10. Install the starter motor and ground cable to the flywheel housing and tighten the bolt to the specified torque.

25 N m (2.5 kg m/18 lb ft)

Tightening torque: 97 N m (9.9 kg m/72 lb ft) 11. Install the water pump pulley, fan belt and fan ASM. Refer to the “Water Pump” in the Cooling System Section.

12. Install the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

13. Connect the radiator upper hose.

14. Replenish the coolant.

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Name 1. Power Steering Pump Cover 9. Install the crank pulley.

• Apply liquid gasket (ThreeBond equivalent) to the tip of the key.

1207B

or

Caution: Replace the crankshaft pulley bolt and washer with new ones.

Tightening torque: 294 N m (30.0 kg m/217 lb ft)

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Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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Special Tool Illustration

Tool Number/Description /

Crankshaft stopper

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Camshaft ASM Components

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Name 1. Snap Ring 2. Camshaft Scissors Gear 3. Knock Pin 4. Damper Spring

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6.

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8.

Camshaft Gear Camshaft Bearing Cap Bolt

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Removal 1. Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC). ï

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Name 1. Baffle Plate ÉÍÖÖðððï

5. Remove the camshaft bearing cap.

• Check the stamp mark on the top of the bearing cap.

Name 1. TDC 2. Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

3. Install the M5 lock bolt which fixes the sub gear.

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4. Remove the baffle plate.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóíè 6. Remove the camshaft ASM.

ÉÍÖÖðïéð ÉÍÖÖððëî

Disassembly

2. Remove the camshaft gear.

• Pull out the camshaft gear using a press and socket.

1. Remove the scissors gear ASM. • Fix the hexagon portion of the camshaft in a vise using a mouth ring.

• Rotate the sub gear clockwise using the camshaft gear tool and remove the M5 lock bolt.

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Special tool Camshaft gear tool: 380300010

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ÉÍÖÖððëì

Name 1. Press 2. Socket 3. Camshaft Gear 3. Remove the knock pin. ÉÍÖÖððëí

• Use snap ring pliers to remove the sub gear.

Caution: Take care not to damage the cam portion and the journal portion of the camshaft.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóíç 4. Inspect the camshaft visually.

• Check if the journal and cam parts of the camshaft are worn or damaged, if so, replace it.

6. Check if the cam lobe is worn.

• Use a micrometer to measure the height of the cam lobe.

• If the height of the cam lobe is the limit or less, replace the camshaft.

Height of the cam lobe

mm (in)

Intake air

Exhaust

Standard

40.6 (1.60)

40.6 (1.60)

Limit

39.6 (1.56)

39.6 (1.56)

5. Check the axial play of the camshaft.

• Use a thickness gauge to measure an end clearance of the camshaft gear and the camshaft bracket.

• If the measurement exceeds the limit, replace the camshaft gear or the camshaft.

End clearance of the camshaft Standard Limit

mm (in)

0.085 — 0.205 (0.033 — 0.008) 0.25 (0.009)

Caution: Measure an end clearance of the camshaft before disassembling.

7. Check if the camshaft journal is worn.

• Use a micrometer to measure wear which is not even with a diameter of the camshaft journal.

• If the measured uneven wear exceeds the limit, replace the camshaft.

External diameter of the camshaft journal part mm (in) Standard Limit

29.909 — 29.930 (1.1775 — 1.1783) 29.809 (1.1736)

Partial wear of the camshaft journal part Limit

ÉÍÖÖððëë

0.05 (0.0019)

mm (in)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìð Clearance of the journal part Standard

mm (in)

0.025 — 0.087 (0.0009 — 0.0034)

Limit

0.15 (0.0059)

8. Check for bent of the camshaft.

• Place the camshaft on a V block to measure a bend with a dial gauge.

• Rotate the camshaft slowly to measure how much the dial indicator shook. If it exceeds the limit, replace the camshaft.

Bent of the camshaft Limit

mm (in) 0.05 (0.0019)

Reassembly 1. Install the knock pin.

2. Install the camshaft gear.

• Align the groove of the camshaft gear with the knock pin of the camshaft. Install the camshaft gear to the camshaft using a press.

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9. Measure a camshaft journal oil clearance. a. Measure an inside diameter of the camshaft bearing with a dial gauge. b. Read the difference between the inside diameter of the camshaft bearing and the diameter of the camshaft journal.

If the measured oil clearance exceeds the limit, replace the camshaft bearing.

ÉÍÖÖððëê

Name 1. Camshaft 2. Knock Pin 3. Camshaft Gear

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìï 3. Install the scissors gear ASM. • Fix the hexagon portion of the camshaft in a vise using a mouth ring. Assemble the spring with its left end contacting the pin of camshaft main gear to make a gap on the right.

• Assemble the sub gear so that its pin is inserted into the gap between the right side of pin of the camshaft main gear and the right end of the spring.

• Tighten the M5 bolt to the appropriate torque to prevent rotation of the sub gear.

Special tool Camshaft gear tool: 380300012

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ÉÍÖÖððëí

• Assemble it onto the cylinder head. ÉÍÖÖððëé

Installation 1. Rotate the crankshaft to make the No. 1 cylinder meet the compression TDC.

Name 1. Snap Ring 2. Sub Gear 3. Spring 4. Camshaft Gear • Use snap ring pliers to assemble the snap ring securely.

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ÉÍÖÖðððï

Name 1. TDC

ÉÍÖÖðïéð

• Before installing the camshaft to the cylinder head, rotate the sub gear clockwise using the camshaft gear tool to prevent the spring force which acts on the sub gear from affecting. Align the M5 hole of the sub gear with that of the camshaft main gear.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìî 2. Install the camshaft ASM. • Before installing the camshaft, completely loosen all of the rocker arm adjusting nuts and adjusting screws.

• Put together the camshaft ASM so as to make the “ ” mark of the camshaft gear aligned with the “ ” mark of the idle gear.

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ÉÍÖÖððëç

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Name 1. Camshaft Alignment Marks 2. Bearing Cap Alignment Marks • Apply engine oil to the thread part and seating surface, and tighten the bearing cap to the specified torque.

Tightening torque: 18 N m (1.8 kg m/13 lb ft)

Name 1. Exhaust Camshaft Gear 2. Intake Camshaft Gear 3. Idle Gear D

4. Remove the M5 lock bolt which fixes the sub gear.

3. Install the bearing cap.

• Apply engine oil to the camshaft journal portion and the bearing surface of the bearing cap.

• Confirm the stamp mark on the top of the bearing cap and install it on the cylinder head.

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ÉÍÖÖððëï

5. Adjust the valve clearance.

Refer to “Function Check”.

6. Install the baffle plate. Tighten the bolt to the specified torque.

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Tightening torque: 10 N m (1.0 kg m/87 lb in) ÉÍÖÖðïéî

• Check that the alignment marks on the camshaft and bearing cap are aligned.

7. Install the cylinder head cover.

Refer to “Cylinder Head Cover”.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìí

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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ÉÍÖÖðïéí

Special Tool Illustration

Tool Number/Description / Special Tool

380300012 Camshaft gear tool

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìì

Rocker Arm Shaft ASM Components î í î

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Name 1. Exhaust Rocker Arm Shaft ASM 2. Bolt (Long)

Removal 1. Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

2. Remove the camshaft ASM. Refer to “Camshaft ASM”.

3. Disconnect the fuel injection pipe (common rail to fuel injector).

Important: Do not reuse the high-pressure pipe in fuel system if it has been removed.

Refer to “Fuel Injector” in the Fuel System section.

4. Remove the fuel injector.

Refer to “Fuel Injector” in the Fuel System section.

5. Remove the rocker arm shaft ASM. Caution: Keep the removed rocker arm shaft ASM properly so that they may be put back to the original place.

3. Bolt (Short) 4. Intake Rocker Arm Shaft ASM

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìë

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Name 1. Exhaust Rocker Arm Shaft ASM 2. Bolt (Long) 3. Bolt (Short) 4. Intake Rocker Arm Shaft ASM

ÉÍÖÖðîçé

Name 1. Rocker Arm 2. Rocker Arm Shaft 3. Snap Ring

Caution: Pay full attention so as not to drop the parts in the gear case of the front part of the cylinder head or the hole into which oil pours back in the front.

3. Check if the oil hole is clogged of the rocker arm and the rocker arm shaft.

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Disassembly 1. Remove the snap ring.

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ÉÍÖÖðîçè

Name 1. Rocker Arm Oil Hole 2. Rocker Arm Shaft Oil Hole 4. Check if the rocker arm shaft is worn. ÉÍÖÖðîçê

2. Remove the rocker arm.

• Measure the outside diameter of the rocker arm shaft using a micrometer.

• If the measurement falls is the limit or less, replace the rocker arm shaft ASM.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìê

External diameter of the rocker arm shaft Standard

14.0 (0.551)

Limit

13.85 (0.545)

mm (in)

6. Inspect a clearance between the roller of the rocker arm and the rocker arm pin. a. Pass a string, for instance, through an opening between the rocker arm and the roller, pull it in the direction indicated with an arrow strongly and measure the gap between the rocker arm and the roller with the roller stuck out. Figure 1 b. After marking the measuring point, pull the string out and measure the gap of the marked place with the roller pushed deep into the end.

Figure 2 c. The gap between the measurement taken under a. and that under b. will be a clearance between the roller and the rocker arm pin. If it exceeds the limit, replace the rocker arm shaft ASM.

Clearance between the roller and the rocker arm pin mm (in) Standard Limit

0.068 — 0.099 (0.0026 — 0.0038) 0.2 (0.0079)

ÉÍÖÖðíðï

5. Inspect a clearance between the rocker arm and the rocker arm shaft.

• Use a cylinder gauge to measure an inside diameter of the rocker arm to measure a clearance between the external diameter of the shaft.

• Replace the rocker arm shaft ASM if the measurements exceed limit values.

Clearance between the rocker arm and rocker arm shaft mm (in) Standard Limit

0.010 — 0.046 (0.0004 — 0.0018) 0.2 (0.0079)

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ÉÍÖÖðîçç

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìé

Reassembly 1. Install the rocker arm.

• Apply engine oil in an inside diameter of the rocker arm, the roller and the rocker arm pin and install it on the rocker arm shaft.

Caution: Pay full attention so as not to drop the parts in the gear case of the front part of the cylinder head or the hole into which oil pours back in the front.

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ÉÍÖÖððêð ÉÍÖÖðíðî

2. Install the snap ring.

Name 1. Exhaust Rocker Arm Shaft ASM 2. Bolt (Long) 3. Bolt (Short) 4. Intake Rocker Arm Shaft ASM

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• Adjustment of valve clearance Refer to “Function Check”.

2. Install the fuel injector.

Refer to “Fuel Injector” in the Fuel System section.

3. Connect the fuel injection pipe (common rail to fuel injector).

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Important: Replace the high-pressure pipe in fuel system with new one if it has been removed.

Refer to “Fuel Injector” in the Fuel System section.

4. Install the camshaft ASM. Refer to “Camshaft ASM”.

í ÉÍÖÖðîçé

Name 1. Rocker Arm 2. Rocker Arm Shaft 3. Snap Ring

Installation 1. Install the rocker arm shaft ASM. • Loosen an adjusting screw of the rocker arm, apply engine oil over the roller part of the rocker arm and install it on No.1 to No.4 one by one.

Tightening torque: 21 N m (2.1 kg m/15 lb ft)

5. Install the cylinder head cover.

Refer to “Cylinder Head Cover”.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìè

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷ îï ø îòï ñ ïë ÷

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ÉÍÖÖðîêî

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóìç

Valve Stem Seal, Valve Spring Components î

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Name 1. Exhaust Rocker Arm Shaft ASM 2. Bolt (Long) 3. Bolt (Short) 4. Intake Rocker Arm Shaft ASM 5. Fuel Injector 6. Bolt 7. Nozzle Bracket

8.

9.

10.

11.

12.

13.

14.

Removal

4. Remove the valve stem end cap.

1. Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

2. Remove the camshaft ASM. Refer to “Camshaft ASM”.

3. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”.

Pin Valve Spring Seat Valve Stem Oil Seal Valve Spring Spring Upper Seat Split Collar Valve Stem End Cap

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëð Caution: • Keep the removed valve stem end caps properly so that they may be put back to the original place.

• Pay full attention so as not to drop the valve stem end cap in the gear case of the front part of the cylinder head or the hole into which oil pours back in the front.

5. Remove the split collar.

• Apply compressed air over the cylinder from the glow plug holes to keep the valve at the home position.

• Use a replacer to compress the valve spring to remove the split collar.

Put the removed valve springs in order by cylinder number.

8. Remove the valve stem oil seal.

• Use pliers to remove the oil seal.

Special tool Valve spring replacer: 380300018 Pivot: 380300019

ÉÍÖÖððêî

Caution: Do not reuse the removed oil seal.

9. Remove the valve spring seat.

Inspection Check the valve spring.

ÉÍÖÖððêï

6. Remove the spring upper seat.

• Remove the special tool to remove the upper seat.

7. Remove the valve spring.

Caution: Check the valve spring visually and if there is clear damage or wear-out, replace it.

1. Free length • Measure free length of the spring and if it is shorter than the specified limit, replace the spring.

Free length of the valve spring

mm (in)

Intake air

Exhaust

Standard

53.32 (2.099)

53.32 (2.099)

Limit

52.43 (2.064)

52.43 (2.064)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëï Tension of the valve spring

N (lb)

Intake air

Exhaust

Installation length mm (in)

37.80 (1.488)

37.80 (1.488)

Standard

213 (157)

213 (157)

Limit

188 (138)

188 (138)

2. Valve spring squareness • Use a surface plate and a square to measure the valve spring squareness.

If the measured value exceeds the specified limit, the valve spring must be replaced.

Valve spring squareness Limit

mm (in) 2.1 (0.083)

Installation 1. Install the valve spring seat.

2. Install the valve stem oil seal.

• Apply engine oil over the peripheral part of the valve guide and install the oil seal by using a valve stem seal installer.

Caution: After installing the valve stem oil seal, check if it is inserted nice and deep and the oil seal is not tilted or the garter spring has not come off.

3. Tension • Use a spring tester to compress the spring to the installation height. Measure tension of the compressed spring. If the measurement is lower than the limit, replace the spring.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëî Special tool Valve stem seal installer: 380300017

7. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”.

8. Install the camshaft ASM. Refer to “Camshaft ASM”.

9. Install the cylinder head cover.

Refer to “Cylinder Head Cover”.

Special Tool Illustration

Tool Number/Description / Special Tool

380300018 Valve spring replacer

ÉÍÖÖððêí

3. Install the valve spring.

4. Install the spring upper seat.

5. Install the split collar.

• Apply compressed air over the cylinder from the glow plug holes to keep the valve at the home position.

• Use a replacer to compress the valve spring and install the split collar.

Special tool Valve spring replacer: 380300018 Pivot: 380300019

380300019 Pivot ASM

380300017 Valve stem seal installer

ÉÍÖÖððêï

6. Apply engine oil to the valve stem end cap and install it.

Caution: Pay full attention so as not to drop the valve stem end cap in the gear case of the front part of the cylinder head or the hole into which oil pours back in the front.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëí

Cylinder Head Components

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Name 1. Glow Plug 2. Intake and Exhaust Valves 3. Cylinder Head Caution: To avoid electric shock; Set the switch to the “OFF” position and disconnect battery negative cable before checking or repairing the fuel injector, wiring or/and connectors.

Removal 1. Drain the coolant.

2. Disconnect the radiator upper hose.

4. Timing Chain Tensioner 5. Timing Chain Tension Lever 6. Timing Chain Guide 3. Remove the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

4. Remove the fan ASM. Refer to the “Water Pump” in the Cooling System Section.

5. Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC).

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëì

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Name 1. TDC 6.

7.

8.

9.

ÉÍÖÖðððì

Name 1. Leak-Off Pipe

Remove the battery.

Remove the intake pipe and duct.

Disconnect the connector of the fuel injector.

Disconnect the leak-off hose and pipe.

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10. Remove the EGR valve, boost pressure sensor, boost temperature sensor, ECT sensor and CMP sensor connector.

11. Remove the harness bracket.

12. Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

13. Remove the oil level gauge guide tube.

14. Remove the EGR cooler.

Refer to “EGR Cooler” in the Exhaust System section.

15. Disconnect the front exhaust pipe.

16. Disconnect the water return pipe on the turbocharger.

ÉÍÖÖðîíç

Name 1. Leak-Off Hose

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Name 1. Water Return Pipe

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëë 17. Disconnect the turbocharger.

water

feed

pipe

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ÉÍÖÖðîîð

ÉÍÖÖððïï

Name 1. Water Feed Pipe

Name 1. Oil Return Pipe 20. Disconnect the fuel injection pipe.

18. Disconnect the oil feed pipe on the turbocharger.

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Important: Do not reuse the high-pressure pipe in fuel system if it has been removed.

Refer to “Fuel Injector” in the Fuel System section.

21. Remove the timing chain cover lower.

Refer to “Fuel Supply Pump” in the Fuel System section.

22. Remove the fan shroud bracket upper and the fan shroud stay upper.

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ÉÍÖÖðîîì

Name 1. Oil Feed Pipe 19. Disconnect the oil return pipe on the turbocharger. ï ÉÍÖÖðîìç

Name 1. Fan Shroud Bracket Upper 2. Fan Shroud Stay Upper 23. Remove the timing chain cover upper.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëê Refer to “Fuel Supply Pump” in the Fuel System section.

24. Disconnect the bypass pipe.

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Name 1. Bypass Pipe

Name 1. Timing Chain Tensioner 2. Packing 3. Nut 32. Remove the idle gear D. • Drop the timing chain to the backside.

25. Remove the glow plug connector.

26. Remove the glow plug.

ÉÍÖÖððêê

33. Remove the pivot of the timing chain tension lever. ÉÍÖÖðîðé

27. Remove the camshaft ASM. Refer to “Camshaft ASM”.

28. Remove the fuel injector.

Refer to “Fuel Injector” in the Fuel System section.

29. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”.

30. Remove the valve stem end cap.

31. Remove the timing chain tensioner.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëé

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ÉÍÖÖððêé

34. Remove the timing chain from the supply pump sprocket.

35. Remove the bolt of the chain guide from the cylinder head.

ÉÍÖÖððêè

Name 1. Nut 2. Bolt 37. Remove the cylinder head bolt.

• Loosen the cylinder head bolts in the order shown in the illustration.

Caution: Do not reuse the cylinder head bolt. ï

ÉÍÖÖðïèè

36. Remove the bolt and nut which hold the cylinder head to the gear case.

ÉÍÖÖððêç

Name 1. Cylinder Head Bolt

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëè

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6. Remove the split collar.

• Use a replacer to compress the valve spring to remove the split collar.

Special tool Valve spring replacer: 380300018 Pivot: 380300019

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ÉÍÖÖððéð

38. Remove the cylinder head ASM. • Remove the cylinder head gasket.

Caution: Replace the head gasket with a new one once it was removed.

Disassembly 1. Remove the intake manifold ASM. Refer to “Intake Manifold”.

2. Remove the turbocharger.

Refer to “Exhaust Manifold”.

3. Remove the exhaust manifold.

Refer to “Exhaust Manifold”.

4. Disconnect the water outlet pipe.

5. Remove the thermostat.

ÉÍÖÖððêï

7. Remove the spring upper seat.

• Remove the special tool to remove the upper seat.

8. Remove the valve spring.

• Sort the removed valve springs by cylinder number.

9. Remove the intake and exhaust valves.

• Sort the removed valves according to cylinders by using tags and others.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóëç 10. Remove the valve stem oil seal.

• Use pliers to remove the oil seals.

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ÉÍÖÖððíç

ÉÍÖÖððêî

11. Remove the valve spring seat.

12. Remove the valve guide.

• Use the valve guide remover and installer to pull out the valve guides from the bottom of the cylinder head.

Name 1. Cam End Packing 14. Remove the oil seal.

Special tool Valve guide remover and installer: 380300016

ÉÍÖÖððéî

Inspection

ÉÍÖÖððéï

13. Remove the cam end packing.

1. Check the cylinder head ASM. • Remove varnish, soot and others adhered on the metal surface completely. Use metal brush and others so that the surface where the gasket is installed is not damaged.

• Check the following causes in the case of leak, corrosion and air leak on the seal surface of the cylinder head, or defective gasket.

- Improper installation - Defective tightening of the cylinder head - Winding seal surface of the cylinder block a. Inside the combustion chamber, glow plug hole.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêð • Check whether there is a crack between the valve seats and in the cylinder head of the exhaust port part, and replace the cylinder head if there is serious damage or crack. Check the collar if necessary.

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Ú Ý

Ü Þ

ÉÍÖÖððéì

Cylinder head height (H) (Reference) Standard

mm (in)

143.4 (5.646)

ÉÍÖÖðïèç

b. Flatness of the under surface of the cylinder head • Use a straight edge ruler and thickness gauge to measure the four sides and diagonal lines as shown in the illustration, and replace if they exceed the limit.

Distortion of the under surface of the cylinder head mm (in) Standard Limit

Ø

0.05 (0.002) or less 0.20 (0.0079)

Note: Do not place the cylinder head with its surface that contacts the cylinder block facing downward. ÉÍÖÖððéë

c. Flatness of the installation surfaces of the exhaust manifold and intake manifold • Use a straight edge ruler and thickness gauge to measure the four sides (right, left, top, and bottom) and diagonal lines as shown in the illustration. If the measurement exceeds the limit value but is less than the maximum allowable grinding value, grind the manifold installation surface of the cylinder head. If the measurement exceeds the maximum allowable grinding value, replace it.

ÉÍÖÖððéí

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêï Distortion of the installation surface of the manifold mm (in) Standard

0.05 (0.002) or less

Limit

0.2 (0.0079)

Maximum allowable grinding value

0.4 (0.0157)

2. Visual check on the valve stem end cap • Inspect for excessive abrasion and damage on the surface where the cap and the rocker arm adjusting bolt contact, and replace as required.

3. Check the valve guide.

Caution: If there is a scratch or abnormal abrasion on the valve stem and the inner diameter part of the valve guide, replace the valve and valve guide together. a. Measure the valve guide clearance.

• Measure the diameter of the valve stem with a micro meter.

If the diameter of the valve stem is smaller than the limit, replace the valve and valve guide together.

The external diameter of the valve stem

mm (in)

Standard

Limit

Intake valve

6.955 — 6.970 (0.2738 — 0.2744)

6.935 (0.2730)

Exhaust valve

6.939 — 6.949 (0.2732 — 0.2736)

6.920 (0.2724)

ÉÍÖÖððéê

d. Flatness of the exhaust manifold • Use a straight edge ruler and thickness gauge to measure the flatness. If it exceeds the limit, replace the exhaust manifold.

Distortion of the exhaust manifold Standard Limit

mm (in)

0.05 (0.002) or less 0.2 (0.0079)

• Measure the inner diameter of the valve guide.

• If the clearance between the valve stem outside diameter and the valve guide inner diameter exceeds the limit, replace the valve guide and valve together.

Gap between the valve guide and valve stem mm (in)

Intake valve ÉÍÖÖðîìë

Standard

Limit

0.039 — 0.071 (0.00154 — 0.00280)

0.20 (0.00787)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêî Valve seat

Gap between the valve guide and valve stem mm (in)

Exhaust valve

Standard

Limit

0.064 — 0.096 (0.00252 — 0.00378)

0.25 (0.00984)

• Remove carbon, water stain and others on the under surface of the cylinder head.

Install the valve in the cylinder head.

Measure the depth of the valve from the under surface of the cylinder head, using a depth gauge or straight edge ruler.

If the value exceeds the limit, replace the valve insert or the cylinder head ASM. Depth of the valve

mm (in)

Standard

1.8 (0.07)

Limit

2.5 (0.0984)

ÉÍÖÖððéé

4. Check the valve.

Thickness of valve • Measure the thickness of the valve.

• If the measured value exceeds the limit, replace the valve and valve guide altogether. ÉÍÖÖððéè

Thickness of valve

mm (in)

Standard

1.32 (0.052)

Limit

1.1 (0.045)

• Measure the contact width of the valve seat. If the seat contact surface has a scratch or is rough, or if the abrasion of the contact surface exceeds the limit, modify or replace it.

Contact width of the valve seat

mm (in)

Standard

Limit

Intake valve

1.7 (0.067)

2.2 (0.087)

Exhaust valve

2.0 (0.079)

2.5 (0.098)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêí Repair of the seat surface • Remove carbon from the surface of the valve seat.

• Use a seat cutter to minimize the scratch and other roughness (15/45/75 -blade), thereby returning the contact width to the standard value.

ÉÍÖÖððéç

Contact surface of the valve seat • If the contact surface of the valve seat is defective, modify it or replace the valve, valve guide and valve seat altogether.

Angle of the contact surface: 45°

Caution: Remove only scratches and roughness, and do not cut the surface too much.

Use the free adjustment valve cutter pilot.

Do not let the valve cutter pilot waver inside the valve guide.

• Attach compound in the valve insert seat.

• Insert the valve into the valve guide.

• Apply compound to the valve seat surface, rotate the valve and hit it lightly to grind them, and confirm that it has even contact all round.

Caution: Remove compound completely after grinding.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêì Install the valve seat insert • Carefully place a washer (the outer diameter is smaller than the valve seat insert) on the valve seat insert.

• Use the press to apply pressure gradually on the washer, thereby pushing the valve seat insert.

• After replacing the valve seat insert, apply compound to the valve seat surface, rotate the valve and hit it lightly to grind it, and confirm that it has even contact all round.

Caution: Do not apply too much pressure with the press.

Remove compound completely after grinding.

Replacement of valve seat insert Remove the valve seat insert.

• Arc-weld the entire inner diameter of the valve seat insert.

• Cool the valve seat insert for two to three minutes. It contracts as it cools down, making it easier to remove the valve seat insert.

• Remove the valve seat insert, using a screw driver. Be sure not to hurt the cylinder head.

Name 1. Washer 2. Valve Seat 3. Press

Reassembly 1. Install the oil seal.

• Install on the surface of injection pipe insert.

• Hammer it in so that the seal does not incline.

Name 1. Arc-Weld 2. Valve Seat Insert 3. Screwdriver

Caution: Be careful not to damage the lip.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêë Special tool Injection pipe oil seal installer: 380300028

Special tool Valve guide remover and installer: 380300016

ÉÍÖÖððéî ÉÍÖÖððèï

Height from the upper surface of the cylinder head to the edge surface of the valve guide: 12.6 0.1 mm (0.50 0.0039 in)

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Caution: When replacing the valve guide, it must be replaced together with the valve.

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ÉÍÖÖððèð

Name 1. Cylinder Head 2. Injection Pipe Oil Seal Installer 3. 2 mm (0.079 in) 2. Install the valve guide.

• Hammer in the valve guide from the upper surface of the cylinder head, using the valve guide remover and installer.

Note: The valve guide cannot be set to the specified height using the valve guide remover and installer. Hammer in the valve guide while measuring the height during the work.

ÉÍÖÖððèî

3. Install the valve spring seat.

4. Install the valve stem oil seal.

• Apply engine oil on the outer diameter of the valve guide, use the valve stem seal installer to install the oil seal.

Caution: After installation of the valve stem seal, confirm that the oil seal is not inclining and the garter spring is in place.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêê Special tool Valve stem seal installer: 380300017

9. Install the thermostat.

• Install the thermostat on the position shown in the illustration.

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5. Install the intake and exhaust valves.

• Apply engine oil on the valve stem part and install the valve.

6. Install the valve spring.

7. Install the spring upper seat.

8. Install the split collar.

• Use a replacer to compress the valve spring and install the split collar.

ÉÍÖÖðïéç

Name 1. Thermostat 2. Jiggle Valve 10. Connect the water outlet pipe.

• Tighten the water outlet pipe to the specified torque.

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

Special tool Valve spring replacer: 380300018 Pivot: 380300019

11. Install the exhaust manifold.

Refer to “Exhaust Manifold”.

12. Install the turbocharger.

Refer to “Exhaust Manifold”.

13. Install the intake manifold.

ÉÍÖÖððêï

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêé Refer to “Intake Manifold”.

Installation 1. Install the cylinder head gasket.

• Select the cylinder head gasket.

• Clean the head of the piston and the upper surface of the cylinder block.

• Use a dial gauge to measure the extrusion amount of the piston at the location shown in the illustration.

• Measure as close to the cylinder bore as possible.

Caution: Note that there are three options for the head gasket according to the amount of extrusion of piston shown in the following table.

• Measure at the measurement positions 1, 2, 3 and 4 for each cylinder, and find the differences between 1 and 2, and between 3 and 4.

• Calculate the average piston extrusion amount of each cylinder.

• Calculate the maximum amount based on the average amount of each cylinder.

• Select a gasket of an appropriate grade based on the maximum extrusion amount.

• Select the gear case gasket with the same grade as the cylinder head gasket.

ÉÍÖÖððèí

ÉÍÖÖððèë

Combination of cylinder head gasket mm (in)

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Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêè 3. Install the cylinder head bolt.

• Use a torque wrench and angle gauge to tighten the head bolts in the order described in the illustration.

Caution: Replace the cylinder head bolt with new one.

Tightening torque: 1st step= 70 N m (7.1 kg m/51 lb ft) 2nd step= 70 N m (7.1 kg m/51 lb ft) 3rd step= 60 4th step= 60 Special tool Angle gauge: 380300009 ÉÍÖÖððèé

Note: The amount of the extrusion for each piston should be equal or within 0.05 mm (0.002 in).

• Apply liquid gasket (ThreeBond 1207B or equivalent) to the position shown in the illustration.

• Install the cylinder head within five minutes after applying liquid gasket.

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4. Install the bolt and nut which hold the cylinder head to the gear case.

• Tighten the bolt and nut in the order shown in the illustration.

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

ÉÍÖÖððèè

Name 1. 2 — 3 mm (0.079 — 0.118 in) 2. 3 — 4 mm (0.118 — 0.157 in) • Install the cylinder head gasket.

2. Install the cylinder head ASM. • Install the cylinder head, adjusting the knock pin of the cylinder block.

Caution: Be sure not to hurt the head gasket when installing it.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóêç

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5. Connect the bypass pipe.

• Apply soap water to the O-ring.

ÉÍÖÖðïèè

9. Install the timing chain tension lever.

10. Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC).

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

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Name 1. Bypass Pipe 6. Install the valve stem end cap.

• Apply engine oil.

7. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”.

8. Install the bolt of the chain guide to the cylinder head.

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

Name 1. TDC 11. Install the timing chain together with the idle gear D. • Apply engine oil to the threads and the seating surface of the bolt, and to the part where the gear of the idle gear shaft is to be put together.

Tightening torque: 59 N m (6.0 kg m/43 lb ft)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéð

ÉÍÖÖððçð

12. Align the timing marks at two locations as shown in the illustration.

• Align the timing marks of the camshaft sprocket with the dark plate of the timing chain link.

ÉÍÖÖððêé

14. Push down the cam of the timing chain tensioner, and push the plunger in. Hook on the pin to hold the plunger depressed. ï

• Align the timing marks of the supply pump sprocket with the yellow plate of the timing chain link.

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Name 1. Timing Mark 2. Dark Plate 3. Timing Mark 4. Yellow Plate 13. Install the timing chain tension lever pivot.

Tightening torque: 27 N m (2.8 kg m/20 lb ft)

ÉÍÖÖððçï

Name 1. Pin 2. Plunger 3. Cam 4. Body 5. Hook 15. Install the timing chain tensioner and packing.

Tightening torque: 10 N m (1.0 kg m/87 lb in)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéï Refer to “Camshaft ASM”.

18. Rotate the crank pulley two turns (720 ).

• Check that the alignment mark and the timing mark are aligned as shown in the illustration.

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Name 1. Timing Chain Tensioner 2. Packing 3. Nut

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16. Push the timing chain lightly.

• This causes the plunger to be pushed to unhook.

Caution: Perform the above steps securely, and make sure that the plunger pushes the timing chain tension lever.

Name 1. Exhaust Camshaft Gear 2. Intake Camshaft Gear 3. Idle Gear D î

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17. Install the camshaft ASM.

ÉÍÖÖððçï

Name 1. Timing Mark 2. Dark Plate 3. Timing Mark 4. Yellow Plate 19. Install the timing chain cover upper.

Refer to “Fuel Supply Pump” in the Fuel System section.

20. Install the fan shroud bracket upper and fan shroud stay upper.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéî Refer to “Camshaft ASM”.

26. Install the cam end packing.

• Apply liquid gasket (ThreeBond equivalent).

Tightening torque: M8 bolt: 25 N m (2.5 kg m/18 lb ft) M10 bolt: 51 N m (5.2 kg m/38 lb ft) Nut: 25 N m (2.5 kg m/18 lb ft)

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Name 1. Fan Shroud Bracket Upper 2. Fan Shroud Stay Upper 21. Install the timing chain cover lower.

Refer to “Fuel Supply Pump” in the Fuel System section.

22. Adjust the valve clearance.

Refer to “Function Check”.

23. Install the fuel injector.

Refer to “Fuel Injector” in the Fuel System section.

Name 1. Cam End Packing 2. Liquid Gasket Applied Area.

3. 2.0 — 3.0 mm (0.078 — 0.118 in) 27. Install the cylinder head cover.

Refer to “Cylinder Head Cover”.

28. Install the glow plug.

Tightening torque: 15 — 20 N m (1.5 — 2.0 kg m/11 — 15 lb ft)

24. Install the fuel injection pipe.

Important: Replace the high-pressure pipe in fuel system with new one if it has been removed.

Refer to “Fuel Injector” in the Fuel System section.

25. Install the baffle plate.

ÉÍÖÖðîðé

29. Install the glow plug connector.

Tightening torque: 1.5 — 2.0 N m (0.15 — 0.20 kg m/ 13 — 17 lb in)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéí

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Name 1. Glow Plug Connector 2. Nut

ÉÍÖÖðîîì

Name 1. Oil Feed Pipe 33. Connect the water feed pipe on the turbocharger.

• Tighten the joint bolts to the specified torque.

30. Connect the connectors of the EGR valve, boost temperature sensor, boost pressure sensor, ECT sensor, CMP sensor and fuel injector.

31. Connect the oil return pipe on the turbocharger.

Tightening torque: 22.5 N m (2.3 kg m/17 lb ft)

Tightening torque: M8 bolt: 24.7 N m (2.5 kg m/18 lb ft) M6 bolt: 10 N m (1.0 kg m/87 lb in)

Tightening torque: 10 N m (1.0 kg m/87 lb in)

• Install the pipe bracket and tighten each bolt and nut to the specified torque.

• Connect the rubber hose between the water return pipe and the thermostat housing.

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Name 1. Oil Return Pipe 32. Connect the oil feed pipe on the turbocharger.

Tightening torque: 22.5 N m (2.3 kg m/17 lb ft)

Name 1. Water Feed Pipe 34. Connect the return pipe on the turbocharger.

Tightening torque: 22.5 N m (2.3 kg m/17 lb ft)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéì

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Name 1. Water Return Pipe 35. Connect the front exhaust pipe.

36. Install the EGR cooler.

Refer to “EGR Cooler” in the Exhaust System section.

37. Install the oil level gauge guide tube.

• Apply a coat of engine oil to the O-ring.

• Tighten the bolt to the specified torque.

ÉÍÖÖðîíç

Name 1. Leak-Off Hose

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Tightening torque: Bolt: 25 N m (2.5 kg m/18 lb ft) Nut: 51 N m (5.2 kg m/38 lb ft) 38. Install the fan ASM. Refer to the “Water Pump” in the Cooling System Section.

39. Install the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

40. Connect the radiator upper hose.

41. Install the harness bracket.

42. Connect the leak-off hose and pipe.

Tightening torque: 25 N m (2.5 kg m/18 lb ft) Caution: Do not open the clip too widely. This may damage the clip.

ÉÍÖÖðððì

Name 1. Leak-Off Pipe 43. Connect the intake pipe and duct.

44. Replenish the coolant.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéë

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷ éð ø éòï ñ ëï ÷ éð ø éòï ñ ëï ÷

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Special Tool Illustration

Tool Number/Description / Special Tool

380300016 Valve guide remover and installer

Illustration

Tool Number/Description / Special Tool

380300017 Valve stem seal installer

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéê Illustration

Tool Number/Description / Special Tool

380300009 Angle gauge

Injection pipe oil seal installer 380300028 ëèèìðîèîðð

380300018 Valve spring replacer

380300019 Pivot ASM

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéé

Piston, Connecting Rod Components

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Name 1. Snap Ring 2. Piston Pin 3. Piston Ring 4. Piston

Removal 1. Lower the engine ASM. 2. Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

3. Remove the camshaft ASM. Refer to “Camshaft ASM”.

4. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”.

5. Remove the cylinder head.

5. Connecting Rod 6. Bearing 7. Connecting Rod Cap

Refer to the “Cylinder Head”.

6. Remove the gear case ASM. Refer to “Gear Case ASM”.

7. Remove the oil pan.

Refer to “Crankcase, Oil Pan”.

8. Remove the connecting rod cap.

Caution: Sort the removed bearings according to cylinders by using tags.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéè

Disassembly 1. Remove the piston ring.

• Use ring pliers to remove the piston ring.

Caution: Sort the piston rings in the order of cylinders when reusing them so that they will not be confused with the pistons and piston rings of other cylinders.

9. Remove the piston and connecting rod.

• Remove carbon on the upper side of the cylinder block with a scraper.

• Pull out the piston and connecting rod towards the cylinder head.

Caution: Be sure not to damage the oil jet and cylinder block when pushing out the connecting rod.

2. Remove the snap ring.

• Remove the snap ring while inserting and scraping with a fine screwdriver at the position shown in the illustration.

ÉÍÖÖðïêé

10. Remove the connecting rod bearing.

Caution: Sort the bearings in the order of cylinders when reusing them so that they will not be confused with the bearing of other cylinders.

ÉÍÖÖðîîé

3. Remove the piston pin.

Caution: Sort the disassembled piston pins, pistons and connecting rods together in the order of cylinders.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóéç

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4. Remove the connecting rod from the piston.

5. Piston • Clean carbon carefully that is adhered to the head of the piston and the groove of the piston ring.

Caution: Do not use wire brush to clean the piston because it scratches the piston.

Inspect the piston with eyes for cracks, burns and other excessive wear, and replace it if there is any abnormality.

6. Measure the gap between the piston and the inner diameter of the cylinder block.

Cylinder block inner diameter • Use a cylinder gauge to measure the cylinder block inner diameter both in the thrust and radial directions in the specified position.

• Measurement position (from the upper surface of the cylinder block) 1. 20 mm (0.79 in) • Measure the liner inner diameter based on the average value of the actual measurement values on 2 positions.

Cylinder block inner diameter

mm (in)

95.421 — 95.450 (3.75673 — 3.75787)

Name 1. 20 mm (0.79 in) 2. Radial Direction 3. Thrust Direction Piston outside diameter • Use a micrometer to measure the outside diameter of the piston in the right angle to the piston pin in the specified position.

• Measurement position (from the lower surface of the piston) 11 mm (0.43 in) Piston diameter (supply parts)

mm (in)

Grade

Standard

A

95.330 — 95.339 (3.75314 — 3.75350)

B

95.340 — 95.349 (3.75354 — 3.75389)

C

95.350 — 95.359 (3.75393 — 3.75428)

Gap between the piston and the inner diameter of the cylinder block Standard

mm (in)

0.082 — 0.100 (0.0032 — 0.0039)

Caution: If the gap between the cylinder block inner diameter and the piston exceeds the standard value, replace the piston or cylinder block.

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Measure the joint of the piston ring (remove carbon on the ring joint).

• Insert the piston ring into the cylinder liner.

• Use the piston to push the ring up to the measurement position (1) or (2) where the cylinder bore diameter is the smallest. Keep the ring in a horizontal position.

ÉÍÖÖððçç

7. Piston replacement • You do not need to select more than one grade because there is only one grade for each of the piston and the cylinder block inner diameter.

• Refer to “Cylinder Block” if you replace the cylinder block.

Caution: The head of piston has a marking of grade B or C when it is shipped from the factory.

• Use a thickness gauge to measure the gap of the ring joint.

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Name 1. Front Mark Cut 8. Inspect the piston ring.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóèï Measurement position (1): 10 mm (0.4 in)

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Measurement position (2): 120 mm (4.7 in) • If the measurement exceeds the limit, replace the piston ring.

Piston ring gap

mm (in) Standard

Limit

Top ring

0.3 — 0.5 (0.0118 — 0.0197)

1.5 (0.059)

Second ring

0.3 — 0.5 (0.0118 — 0.0197)

1.5 (0.059)

Oil ring

0.25 — 0.45 (0.0098 — 0.0177)

1.5 (0.059)

Measure the clearance between the piston ring groove and the piston.

• Remove carbon on the piston ring groove completely.

• Put the piston ring in the piston ring groove, and use a thickness gauge to measure the gap between them.

• If the clearance between the piston ring groove and the piston exceeds the limit, replace the piston and the piston ring.

Piston ring and piston ring groove clearance Piston ring

mm (in)

Standard

Limit

—*

—*

Second ring

0.05 — 0.09 (0.0020 — 0.0035)

0.15 (0.0059)

Oil ring

0.03 — 0.07 (0.0012 — 0.0028)

0.15 (0.0059)

Top ring

* Measurement is impossible.

9. Inspect the piston pin.

• Inspect the piston pin with eyes for cracks, scratches and other damages, replace it if necessary.

• Use a micrometer to measure the outer diameter of the piston pin. If the measured value exceeds the limit, replace the piston pin.

Piston pin outer diameter Standard Limit

mm (in)

33.995 — 34.000 (1.33838 — 1.33858) 33.970 (1.33740)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóèî

• Inspect to make sure that there is a resistance to the extent which the piston can push the piston pin lightly in normal temperatures.

• If it is too loose or rattles when it is put in the normal temperatures, replace the piston or piston pin.

10. Measure the clearance between the piston and the piston pin.

• Apply engine oil on the piston pin. Use your finger to push it in the piston hole and rotate it. If the pin smoothly rotates without rattling, the clearance is normal. If there is rattling, measure the clearance.

If the clearance exceeds the limit, replace the piston and the piston pin.

Piston pin and piston pin hole clearance Standard Limit

mm (in)

0.004 — 0.017 (0.0002 — 0.0007) 0.04 (0.0016)

11. Measure the connecting rod alignment.

• Use a connecting rod aligner to measure the torsion and parallelism of the big end hole and the small end hole. If the measured value exceeds the limit, replace it.

Connecting rod alignment (per length of 100 mm {3.94 in})

• Measure the bushing in the small end of the connecting rod. If the clearance between the bushing inner diameter and the pin diameter exceeds the limit, replace the connecting rod ASM and the pin.

Piston pin and connecting rod small end bushing clearance Standard Limit

mm (in)

0.008 — 0.020 (0.0003 — 0.0008) 0.05 (0.0020)

mm (in)

Standard

Limit

Torsion

0.08 (0.003) or less

0.20 (0.008)

Parallelism

0.05 (0.003) or less

0.15 (0.006)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóèí

ÉÍÖÖðîîè

12. Measure the bearing oil clearance.

• Measure the oil clearance between the connecting rod bearing and the crank pin with the following method.

- Remove the connecting rod cap. Sort the removed caps according to the cylinder number.

- Clean the bearing and the shaft pin.

- Check the bearing. If it is damaged or worn seriously, replace the bearing ASM. • Place the plastigauge on the crankshaft pin.

• Install the bearing cap and tighten the bolt with the specified torque.

Apply engine oil to the threads and the bearing surface.

Connecting rod bearing cap bolt torque:

- Remove the cap.

- Measure the largest width of the plastigauge to calculate the oil clearance. If the clearance exceeds the limit, replace the bearing or crankshaft.

Crank pin and bearing clearance Standard Limit

mm (in)

0.029 — 0.083 (0.0011 — 0.0026) 0.10 (0.0039)

- Remove the plastigauge from the bearing and crank pin.

Nm (kg m/lb ft)

1st step

29.4 (3.0/22)

2nd step

45

Caution: Do not rotate the crankshaft.

ÉÍÖÖðîìð

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóèì

Reassembly 1. Install the piston.

2. Install the connecting rod.

• Install it so that the front mark of the head of the piston and the connecting rod forging mark (projecting) on the connecting rod face the same direction.

• Install the snap ring on either side.

5. Use the piston ring setting tool to install the piston ring.

• Install the piston ring in the order shown in the illustration.

• Install the piston ring with the “N” mark facing upward.

• Install the second ring so that the yellow paint on the outer circumference comes to the right side of the end gap.

Special tool Piston ring setting tool: 380300005

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Name 1. Snap Ring 2. Front Mark 3. Forging Mark (Projecting)

ÉÍÖÖðïðì

3. Apply enough engine oil on the piston pin, push it in the piston and the connecting rod small edge.

4. Assemble the snap ring.

Caution: Make sure that the snap ring is installed in the ring groove properly. Make sure that the connecting rod moves smoothly.

ÉÍÖÖðïðë

Name 1. Top Ring 2. Second Ring 3. Oil Ring 4. Coil Expander Caution: Note that the shapes are different for each piston ring.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóèë Make sure that there is no gap in the position shown in the illustration when the oil ring coil expander is installed.

Special tool Piston ring compressor: 380300022

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Installation 1. Install the connecting rod bearing.

• Install the bearing on the connecting rod, apply engine oil on the bearing.

2. Install pistons and connecting rod ASM. • Apply enough engine oil on the piston ring, ring groove and piston side surface.

• Position each end gap of piston rings in the following positions; (1) for top ring, (2) for 2nd ring, (3) for oil ring, and (4) for coil expander, as shown in the illustration.

• Face the front mark (arrow) on the piston forward, and use the piston ring compressor to insert the piston in the cylinder block.

3. Install the connecting rod cap.

• Install the bearing on the connecting rod cap and apply engine oil.

• Install the cap, matching the numbers (1, 2, 3, 4) of the caps and connecting rods.

• Face the front mark on the cap forward, so that the cylinder number indication comes to the left side.

Caution: • Be sure not to make the connecting rod touch the oil jet when pushing in the piston.

• Be sure not to hurt the inside of the block when pushing in the piston.

ÉÍÖÖðïðé

• Apply engine oil to the threads and the seating surface of the tightening bolt and tighten it to the specified torque.

Tightening torque: 1st step= 29.4 N m (3.0 kg m/22 lb ft) 2nd step= 45°

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóèê Special tool Angle gauge: 380300009 Caution: Make sure that the crankshaft rotates smoothly.

ÉÍÖÖðïðè

4. Install the oil pan.

Refer to “Crankcase, Oil Pan”.

5. Install the gear case ASM. Refer to “Gear Case ASM”.

6. Install the cylinder head.

Refer to the “Cylinder Head”.

7. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”.

8. Install the camshaft ASM. Refer to “Camshaft ASM”.

9. Install the cylinder head cover.

Refer to “Cylinder Head Cover”.

10. Put the engine ASM on.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóèé

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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ÉÍÖÖðïðç

Special Tool Illustration

Tool Number/Description Special Tool

380300022 Piston ring compressor

380300005 Piston ring setting tool

Illustration

Tool Number/Description Special Tool

380300009 Angle gauge

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóèè

Flywheel Components

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Name 1. Flywheel ASM

2. Washer

2. Remove the washer and flywheel.

Removal 1. Remove the starter motor.

• Remove the mounting bolt, and remove the starter motor and ground cable.

ÉÍÖÖððíî

• Install the crankshaft stopper to the starter installing portion of the flywheel housing.

Caution: Make sure that the stopper is properly fitted and engaged with the ring gear.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóèç Special tool Crankshaft stopper

• Gradually loosen the flywheel installation bolts in the order shown in the illustration so that the flywheel does not rotate.

• After loosening all the bolts, remove the stopper to remove the flywheel.

3. Take out the ring gear.

• Put a bar on the ring gear and hit it with a hammer to remove it.

ÉÍÖÖðïèî

Inspection 1. Visual check • Inspect the flywheel friction surface for cracks and damages, and replace it if it has abnormality.

• Inspect the tooth part of the ring gear, and replace the ring gear if it has damage or serious wear.

• Check the flywheel installing bolt, and replace the bolt if it is damaged.

Installation 1. Install the ring gear.

• After heating the ring gear with a gas burner equally, install it in the flywheel. Do not let the gas burner temperature exceeds 200°C (390°F).

Caution: • Install the ring gear so that the side with a pattern faces forward.

• Shrink fit the ring gear to the flywheel.

Make sure that flywheel and ring gear adhesion is complete.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçð

2. Install the flywheel and washer.

• Install the flywheel to the crankshaft, and tighten in the order shown in the illustration.

• Apply engine oil to the threads of the bolt.

• Install the crankshaft stopper to the starter installing portion of the flywheel housing.

3. Install the starter motor and ground cable to the flywheel housing and tighten the bolt to the specified torque.

Tightening torque: 97 N m (9.9 kg.m/72 lb ft)

Tightening torque: 1st step= 59 N m (6.0 kg.m/43 lb ft) 2nd step= 60° — 90° Special tool Crankshaft stopper Angle gauge: 380300009

ÉÍÖÖððíî

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçï

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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Special Tool Illustration

Tool Number/Description / Special Tool

Crankshaft stopper

380300009 Angle gauge

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçî

Gear Case ASM Components

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Name 1. Gear Case ASM

Removal 1. Lower the engine ASM. 2. Remove the cylinder head.

Refer to the “Cylinder Head”.

3. Remove the generator adjust plate.

4. Remove the water pump.

Refer to the “Water Pump” in the cooling system section.

5. Remove the fuel supply pump.

Refer to “Fuel Supply Pump” in the Fuel System section.

6. Remove the crankshaft pulley.

Refer to “Crankshaft Front Oil Seal”.

7. Remove the gear case cover.

Refer to the “Timing Gear Train”.

8. Remove the idle gear A, idle gear A flange and idle gear A shaft.

Refer to the “Timing Gear Train”.

9. Remove the oil pump.

2. Gasket

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçí Refer to the “Oil Pump”.

10. Remove the timing gear case and gasket.

• The bolt (1) shown in the illustration is installed to the inside of the timing gear case, and the bolt (2) is installed to the crankcase side. Do not forget to remove the bolts.

2. Install the timing gear case.

• Aligning with the knock pin, install the timing gear case and tighten the bolt as shown in the illustration.

• Tighten the bolt to the specified torque.

Tightening torque: 25 Nm (2.5 kg.m/18 lb ft) Caution: Be careful not to forget to fasten the bolt indicated with an arrow.

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Installation

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1. Install the gasket.

• Apply liquid gasket (ThreeBond 1207B or equivalent) on the joint of the cylinder block and the crankcase, and then install the gasket.

• After installing the gasket, apply liquid gasket (ThreeBond 1207B or equivalent) to the gasket surface as well.

• Install within five minutes after applying liquid gasket.

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Name 1. Timing Gear Case 2. Bolt: L = 16 3. Bolt: L = 20 4. Bolt: L = 35 5. Bolt: L = 45 6. Bolt: L = 60 3. Install the oil pump.

Refer to the “Oil Pump”.

4. Install the idle gear A, idle gear A flange and idle gear A shaft.

Refer to the “Timing Gear Train”.

5. Install the gear case cover.

Refer to the “Timing Gear Train”.

6. Install the crankshaft pulley.

Refer to “Crankshaft Front Oil Seal”.

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Name 1. Liquid Gasket Applied Area.

ÉÍÖÖðîîç

7. Install the fuel supply pump.

Refer to “Fuel Supply Pump” in the Fuel System section.

8. Install the water pump.

Refer to the “Water Pump” in the Cooling System Section.

9. Install the generator adjusting plate.

• Tighten the bolt to the specified torque.

Tightening torque: 25 Nm (2.5 kg.m/18 lb ft)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçì 10. Install the cylinder head.

Refer to the “Cylinder Head”.

11. Put the engine ASM on.

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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ÉÍÖÖðïéë

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçë

Crankshaft Front Oil Seal Components

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Name 1. Crankshaft Pulley

Removal 1. Remove the fan ASM. Refer to the “Water Pump” in the Cooling System Section.

2. Remove the fan belt.

2. Crankshaft Front Oil Seal

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçê

Refer to the “Water Pump” in the Cooling System Section.

3. Remove the starter.

• Remove the mounting bolt, and remove the starter motor and ground cable.

5. Remove the crankshaft front oil seal.

• Remove the oil seal off with a screwdriver or the like avoiding damage to the oil seal contact surface on the gear case cover and the shaft.

Installation 1. Install the crankshaft front oil seal.

• Press fit the oil seal using an front oil seal installer.

Special tool Front oil seal installer kit: 380300020

ÉÍÖÖððíî

4. Remove the crankshaft pulley.

• Loosen the pulley bolt after blocking the crankshaft from turning by placing a crankshaft stopper on the starter mounting position on the flywheel housing.

Caution: • Make sure that the stopper is properly fitted and engaged with the ring gear.

• Do not reuse the crankshaft pulley bolt and washer.

ÉÍÖÖðïïï

• Apply engine oil to the lip and the outer circumference of the oil seal, and push it in up to the measurement shown in the illustration.

Special tool Crankshaft stopper

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ÉÍÖÖðïïî

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçé Measurement (A): 1.5 mm (0.06 in) 2. Install the crankshaft pulley.

• Apply liquid gasket (ThreeBond 1207B or equivalent) to the tip of the key.

• Install the crankshaft pulley while aligning it with the key on the crankshaft.

Caution: Replace the crankshaft pulley bolt and washer with new ones.

Tightening torque: 294 N m (30.0 kg m/217 lb ft)

ÉÍÖÖðïïí

3. Install the starter motor and ground cable to the flywheel housing and tighten the bolt to the specified torque.

Tightening torque: 97 N m (9.9 kg m/72 lb ft) 4. Install the fan belt.

Refer to the “Water Pump” in the Cooling System Section.

5. Install the fan ASM. Refer to the “Water Pump” in the Cooling System Section.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçè

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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Special Tool Illustration

Tool Number/Description

Crankshaft stopper

380300020 Front oil seal installer

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóçç

Crankshaft Rear Oil Seal Components

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Name 1. Crankshaft Rear Oil Seal 2. Retainer

3. Flywheel Housing 4. Flywheel

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðð

Removal 1. Remove the flywheel.

Refer to the “Flywheel”.

2. Remove the flywheel housing.

• Loosen the bolt shown by the arrow while holding the nut located on the back using a tool.

4. Remove the slinger.

• Use slinger puller to remove the slinger.

Caution: When replacing the oil seal, it must be replaced together with the slinger.

Special tool Slinger puller: 380002574

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Name 1. Flywheel Housing

ÉÍÖÖðîìï

3. Remove the retainer.

• After removing the retainer, remove the crankshaft rear oil seal from the retainer.

Installation 1. Install the retainer.

• Apply the liquid gasket (ThreeBond 1207B or equivalent) and mount within 5 minutes.

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

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Name 1. Retainer ÉÍÖÖðïíç

Name 1. 2.0 — 2.5 mm (0.079 — 0.098 in) 2. 2.0 — 2.5 mm (0.079 — 0.098 in)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðï 2. Use an oil seal installer to install the slinger and oil seal.

Special tool Oil seal installer: 380300010

ÉÍÖÖðïïê

• After inserting the oil seal, check that the distance from the crankshaft tip to the oil seal is within the specified range.

Caution: Replace the oil seal together with the slinger.

3. Install the flywheel housing.

• Tighten the bolt (4) while holding the nut located on the back using a tool.

Tightening torque of the flywheel housing: N m (kg m/lb ft) 1 = 51 (5.2/38) 2 = 82 (8.4/60) 3 = 97 (9.9/72) 4 = 51 (5.2/38)

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4. Install the flywheel.

Refer to the “Flywheel”.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðî

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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Special Tool Illustration

Tool Number/Description / Special Tool

380002574 Slinger puller

380300010 Oil seal installer

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðí

Crankshaft Components

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Name 1. Bearing Cap 2. Lower Bearing 3. Thrust Bearing 4. Key

Removal 1. Lower the engine ASM. 2. Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

3. Remove the camshaft.

Refer to “Camshaft ASM”.

4. Remove the rocker arm shaft.

Refer to “Rocker Arm Shaft ASM”.

5.

6.

7.

8.

Gear Crankshaft Upper Bearing Rotor

5. Remove the cylinder head.

Refer to the “Cylinder Head”.

6. Remove the fuel supply pump.

Refer to “Fuel Supply Pump” in the Fuel System section.

7. Remove the common rail.

Refer to “Common Rail” in the Fuel System section.

8. Remove the crankshaft front oil seal.

Refer to “Crankshaft Front Oil Seal”.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðì 9. Remove the crankshaft rear oil seal.

Refer to the “Crankshaft Rear Oil Seal”.

10. Remove the water pump.

Refer to the “Water Pump” in the Cooling System Section.

11. Remove the gear case cover.

Refer to the “Timing Gear Train”.

12. Remove the timing gear train.

Refer to the “Timing Gear Train”.

13. Remove the oil pump.

Refer to the “Oil Pump”.

14. Remove the gear case ASM. Refer to “Gear Case ASM”.

15. Remove the crankshaft gear.

18. Remove the bearing cap.

• Gradually loosen the installation bolts of crankshaft bearing cap in the order shown in the illustration.

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• Remove the gear using a gear puller.

ÉÍÖÖðïìç

19. Remove the lower crankshaft bearings.

20. Remove the crankshaft ASM. 21. Remove the thrust bearing.

22. Remove the upper crankshaft bearings.

Disassembly 1. Remove the CKP sensor rotor.

ÉÍÖÖðïïé

16. Remove the crankcase and oil pan.

Refer to “Crankcase, Oil Pan”.

17. Remove the piston and connecting rod.

Refer to the “Piston, Connecting Rod”.

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Name 1. CKP Sensor Rotor 2. Bolt

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðë

Reassembly 1. Install the CKP sensor rotor.

• Install the rotor with the protruded teeth facing forward.

• Apply Loctite No. 262 or equivalent to the threads of the bolt (if new bolt is used, Loctite is not necessary). ï

ÉÍÖÖðïîð

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Name 1. CKP Sensor Rotor 2. Bolt

2. Main bearing clearance • Remove the bearing cap.

Set out disassembled main bearings in the order of the numbers.

• Remove the crankshaft. Remove the main bearing.

• Clean the crankshaft journal and the upper and lower bearings.

• Check the bearings for damage or excessive wear.

If you find damage or excessive wear in the check, replace the bearings in pairs.

• Gently place the crankcase on the cylinder block.

Place the crankshaft horizontally to install.

Inspection 1. Thrust clearance • Measure the thrust clearance of the crankshaft at its center journal part.

• If the thrust clearance exceeds the limit, replace the thrust bearings in a pair.

Axial play of the crankshaft

mm (in)

Standard

0.10 (0.004)

Limit

0.30 (0.012)

Caution: Measure the thrust clearance before dismounting.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðê Caution: Turn the crankshaft about 30° to allow the bearings to settle in.

• Place Plastigauge on the crankshaft journal as shown.

Caution: Do not rotate the crankshaft after tightening the bearing cap.

• Loosen the bolt, and gently remove the bearing cap.

• Place each lower bearing at the original position on the bearing cap.

• Tighten the bearing cap, and measure the widest part of the Plastigauge flattened to determine the clearance.

Journal oil clearance

mm (in)

Standard

0.032 — 0.077 (0.0013 — 0.0030)

Limit

0.11 (0.0043)

ÉÍÖÖðïîï

• Install the bearing cap and tighten the bolt with the specified torque.

• Tighten the crankcase in the order shown in the illustration using a torque wrench.

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Tightening torque: 166 N.m (16.9 kg.m/122 lb ft)

• If the journal oil clearance exceeds the limit, replace the main bearings altogether or the crankshaft.

• Remove the plastigauge from the bearing and crank pin.

Inspection of crankshaft • Check the crankshaft journal and crank pin surfaces for wear and damage. Check the oil seal contact surface for excessive wear and damage.

• Check the oil port for clogging.

3. Crankshaft run-out Carefully set the crankshaft on the V block. Slowly turn the crankshaft to measure the run-out. If the crankshaft run-out exceeds the limit, replace the crankshaft.

Crankshaft run-out Standard Limit

mm (in) 0.05 or less (0.0020 or less) 0.08 (0.003)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðé Selection of crankshaft bearing • When installing new crankshaft bearings or replacing bearings in use, make reference to the Bearing Selection Table.

• Select and install new bearings paying close attention to the cylinder block journal internal diameter grade and the crankshaft journal diameter grade.

• The number 1, 2 or 3 of the cylinder block journal part is stamped on the right rear of the cylinder body.

ÉÍÖÖðïîí

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4. Measure the journal and the crank pin diameters and uneven wear.

• Measure outer diameters of the journal and the pin and calculate differences between the maximum and the minimum values. Take measurements at four positions for both the journal and the pin. ï

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Name 1. No. 1 2. No. 2 3. No. 3 4. No. 4 5. No. 5 • The number (1 or “-”, 2 or “--”, 3 or “---”) of the crankshaft journal diameter is stamped on each crank arm.

Crankshaft outside diameter

mm (in)

Standard

Limit

Journal

69.917 — 69.932 (2.7526 — 2.7532)

69.91 (2.7524)

Pin

52.915 — 52.930 (2.0833 — 2.0839)

52.9 (2.083)

Caution: Tufftriding (soft nitriding treatment) is applied to enhance strength of the crankshaft. Therefore, you shall not polish the surface of the crankshaft.

Note: The number of the No. 4 journal diameter is stamped on either the front or the rear side of the No. 4 crank arm.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðè

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Caution: Be careful about difference in the shape of the bearings when installing them.

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Name 1. Lot No. 2. Size Code

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïðç Bearing selection table Combination of grades

Oil clearance

Cylinder block Grade

Crank journal Grade

Bearing Grade mark

1

1 or “-”

4

1

2 or “--”

1

3 or “---”

5

0.034 — 0.053 (0.00134 — 0.00209)

2

1 or “-”

2

0.033 — 0.052 (0.00130 — 0.00205)

2

2 or “--”

3

0.032 — 0.051 (0.00126 — 0.00201)

2

3 or “---”

4

0.031 — 0.050 (0.00122 — 0.00197)

3

1 or “-”

1

0.031 — 0.049 (0.00122 — 0.00193)

3

2 or “--”

2

0.030 — 0.048 (0.00118 — 0.00189)

3

3 or “---”

mm (in)

0.030 — 0.049 (0.00118 — 0.00193) 0.035 — 0.054 (0.00138 — 0.00213)

0.035 — 0.053 (0.00138 — 0.00209)

Installation 1. Install the crankshaft upper bearing.

• The upper bearing has the oil hole and oil groove, whereas the lower bearing does not.

• Carefully wipe foreign matter from the upper bearing.

• When reusing the upper bearing, install on its original position.

• Install the upper bearing in the cylinder block and apply oil.

Caution: When replacing the crankshaft bearings, select grades referring to the Crankshaft Bearing Grade Selection. Do not apply oil to the bearing installation surface on the cylinder block and external surface of the bearing. ÉÍÖÖðïîè

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïð 2. Install the crankshaft ASM. • Apply engine oil to the crankshaft journal and gently place the crankshaft on the cylinder block.

5. Install the bearing cap.

• Install the bearing cap so that its arrow faces toward the front of the engine.

• Apply liquid gasket (ThreeBond 1207B or equivalent) to the installation surfaces of the No. 5 crankshaft bearing cap and the cylinder body as shown in the illustration.

• Install the bearing cap within five minutes after applying liquid gasket.

• Tighten the installing bolt to the specified torque according to the order shown in the illustration.

Note: Remove oil from the bearing cap installing surface completely before applying liquid gasket.

Apply liquid gasket so that it does not adhere to the cylinder bolt hole and bearing.

Tightening torque: 166 N.m (16.9 kg.m/122 lb ft)

ÉÍÖÖðïîç

Caution: Confirm that the crankshaft turns smoothly.

3. Install the thrust bearing.

• Apply engine oil to the thrust bearing, and install it to the crankshaft at the center journal part.

Caution: Install the thrust bearing so that the oil groove contacts the crankshaft.

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ÉÍÖÖðïíð

4. Install the lower crankshaft bearing.

ÉÍÖÖðïíï

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïï

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ÉÍÖÖðïéé

6. Install pistons and connecting rods.

Refer to the “Pistons, Connecting Rod”.

7. Install the crankcase and oil pan.

Refer to “Crankcase, Oil Pan”.

8. Install the crankshaft gear.

ÉÍÖÖðîïë

9. Install the gear case ASM. Refer to “Gear Case ASM”.

10. Install the oil pump.

Refer to the “Oil Pump”.

11. Install the timing gear train.

Refer to the “Timing Gear Train”.

12. Install the gear case cover.

Refer to the “Timing Gear Train”.

13. Install the water pump.

Refer to the “Water Pump” in the Cooling System Section.

14. Install the crankshaft front oil seal.

Refer to “Crankshaft Front Oil Seal”.

15. Install the crankshaft rear oil seal.

Refer to the “Crankshaft Rear Oil Seal”.

16. Install the common rail.

Refer to “Common Rail” in the Fuel System section.

Install the fuel supply pump.

Refer to “Fuel Supply Pump” in the Fuel System section.

Install the cylinder head.

Refer to the “Cylinder Head”.

Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”.

Install the camshaft ASM. Refer to “Camshaft ASM”.

Install the cylinder head cover.

Refer to “Cylinder Head Cover”.

Put the engine ASM on.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïî

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïí

Cylinder Block Components

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Name 1. Cylinder Block

Removal 1. Lower the engine ASM. 2. Remove the cylinder head cover.

Refer to “Cylinder Head Cover”.

3. Remove the camshaft ASM. Refer to “Camshaft ASM”.

4. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”.

5. Remove the cylinder head.

Refer to the “Cylinder Head”.

6. Remove the fuel supply pump.

Refer to “Fuel Supply Pump” in the Fuel System section.

7. Remove the common rail.

Refer to “Common rail” in Fuel System section.

8. Remove the oil cooler.

Refer to “Oil Cooler”.

9. Remove the crankshaft front oil seal.

Refer to “Crankshaft Front Oil Seal”.

10. Remove the crankshaft rear oil seal.

Refer to the “Crankshaft Rear Oil Seal”.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïì 11. Remove the water pump.

Refer to the “Water Pump” in the Cooling System Section.

12. Remove the gear case cover.

Refer to the “Timing Gear Train”.

4. Visually inspect the cylinder block.

• Conduct color check and hydraulic (or pneumatic) test and if you find crack or other damage, replace the cylinder block.

13. Remove the timing gear train.

Refer to the “Timing Gear Train”.

14. Remove the oil pump.

Refer to the “Oil Pump”.

15. Remove the gear case ASM. Refer to “Gear Case ASM”.

16. Remove the crankcase and oil pan.

Refer to “Crankcase, Oil Pan”.

17. Remove the piston and connecting rod.

Refer to the “Pistons, Connecting Rod”.

18. Remove the crankshaft.

Refer to the “Crankshaft”.

19. Disconnect the piston cooling pipe.

ÉÍÖÖððíì

5. Wear measurement of cylinder block • Check the internal surface of the block for scratch or damage.

• Use a cylinder gauge to measure the block inner diameter both in the thrust (2-2) and radial (3-3) directions in the specified position (1).

• Measurement position (from the top surface of the cylinder block) 20 mm (0.79 in) Replace the cylinder block or perform boring if the wear amount exceeds the limit value.

ÉÍÖÖðïíì

Inspection ï

1. Carefully remove water stains or other foreign matters on the surface of the cylinder block.

• Be careful not to damage the cylinder block.

2. Carefully remove the liquid gasket on the crankcase mounting surface.

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3. Clean up the cylinder block.

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Cylinder block bore diameter Standard Limit

mm (in) 95.421 — 95.450 (3.7567 — 3.7579) 95.48 (3.7590)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïë 6. Cylinder boring • Select an oversize piston that fits the maximum cylinder bore size which is previously measured.

• Use a micrometer to measure the outside diameter of the piston at a right angle to the piston pin in the specified position.

Measurement position (from the bottom surface of the piston) 11 mm (0.43 in) • Calculate the necessary amount of cylinder boring for each cylinder.

• Perform boring and honing of each cylinder as required.

• Measure the diameter of each cylinder bore again.

Differences among the cylinders

mm (in)

0.02 (0.0008) or less 7. Cylinder block upper face warpage • Measure four sides and two diagonals of the top surface of the cylinder block using a straight edge (1) and a thickness gauge (2).

• Replace the cylinder block if the measurements exceed limit values.

Cylinder block upper face warpage

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Standard

mm (in)

0.05 or less (0.002 or less)

Limit

0.20 (0.079)

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ÉÍÖÖððçç

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Name 1. 11 mm (0.43 in) Formula Boring inner diameter = D + C - H ± E D = Piston outside diameter (Measurement of oversize piston) C = Clearance between piston and cylinder bore 0.082 — 0.100 mm (0.0032 — 0.0039 in) H = Honing allowable amount 0.03 mm or less (0.0012 in or less) E = Boring machine error Piston size Standard Oversize

mm (in) 95.330 — 95.359 (3.7531 — 3.7543)

(0.25)

95.580 — 95.609 (3.7629 — 3.7641)

(0.50)

95.830 — 95.859 (3.7728 — 3.7739)

(0.75)

96.080 — 96.109 (3.7826 — 3.7838)

ÉÍÖÖðïíë

Cylinder block height Standard

mm (in) 259.945 — 260.055 (10.2340 — 10.2384)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïê

Ø

ÉÍÖÖðïíê

Installation 1. Install the piston cooling pipe.

• Align the knock pin of the piston cooling pipe with the pin hole of the cylinder block and tighten with the relief valve and bolt.

Tightening torque: Relief valve: 30 N.m (3.1 kg.m/22 lb ft) M8 bolt: 25 N.m (2.5 kg.m/18 lb ft) M6 bolt: 8 N.m (0.8 kg.m/69 lb in) Caution: Be careful not to deform or damage the piston cooling pipe.

ÉÍÖÖðïíì

2. Install the crankshaft.

Refer to the “Crankshaft”.

3. Install pistons and connecting rods.

Refer to the “Pistons, Connecting Rod”.

4. Install the crankcase and oil pan.

Refer to “Crankcase, Oil Pan”.

5. Install the gear case ASM. Refer to “Gear Case ASM”.

6. Install the oil pump.

Refer to the “Oil Pump”.

7. Install the timing gear train.

Refer to the “Timing Gear Train”.

8. Install the gear case cover.

Refer to the “Timing Gear Train”.

9. Install the water pump.

Refer to the “Water Pump” in the Cooling System Section.

10. Install the crankshaft rear oil seal.

Refer to the “Crankshaft Rear Oil Seal”.

11. Install the crankshaft front oil seal.

Refer to “Crankshaft Front Oil Seal”.

12. Install the oil cooler.

Refer to “Oil Cooler”.

13. Install the common rail.

Refer to “Common Rail” in the Fuel System section.

14. Install the fuel supply pump.

Refer to “Fuel Supply Pump” in the Fuel System section.

15. Install the cylinder head.

Refer to the “Cylinder Head”.

16. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”.

17. Install the camshaft ASM. Refer to “Camshaft ASM”.

18. Install the cylinder head cover.

Refer to “Cylinder Head Cover”.

19. Put the engine ASM on.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïé

Lubrication System Explanations on functions and operation

Precautions on Service Work • During each disassembly, remove the old gasket adhering to each part and mating part completely using a scraper at the location, where the fluid gasket is to be used, clean the traces of oil, moisture and dirt completely using waste cotton, and apply the specified new fluid gasket at each location.

• Avoid excessive or insufficient coating volume.

Note that seizure may occur in case of excessive coating due to clogging of the oil gallery and oil jet, and oil and water leakage may occur if the coating is insufficient.

• Always, the start and end of the application should be overlapped.

The lubrication system uses the filter element combined with a full flow bypass, water-cooled oil cooler, and oil jet for piston cooling.

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Name 1. Oil Pump Relief Valve Opening Pressure: 490 — 686 kPa (71 — 100 psi) 2. Oil Cooler Relief Valve Opening Pressure: 176 — 216 kPa (26 — 31 psi) 3. Oil Filter Relief Valve Opening Pressure: 80 — 120 kPa (11 — 17 psi)

4. Oil Pressure Switch Operating Pressure: 29.4 — 49.0 kPa (4.3 — 7.1 psi) 5. Regulating Valve: 176 — 216 kPa (26 — 31 psi)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïè

Functional Check Oil pressure check 1. Check whether the engine oil is contaminated with dirt, light oil, or water. If contaminated with dirt, light oil, or water (after examining the cause and taking the appropriate measures for light oil or water contamination), replace the oil.

2. Check the engine oil level. The oil level should be between the two holes of the level gauge. If the oil level is insufficient, replenish it.

3. Remove the oil pressure switch from the nipple.

4. Install the oil pressure gauge on the nipple.

Special tool Oil pressure gauge: 380300024 Hose: 380300025 Connector: 380300026 Oil pressure testing adapter: 380300027

7.

8.

9.

10.

Stop the engine.

Remove the oil pressure gauge.

Install the oil pressure switch.

Start the engine and check for oil leakage.

Engine oil • Ensure the engine is at a level ground. Before starting the engine or when 5 minutes or more have elapsed after stopping the engine, check the engine oil volume using the level gauge. The volume is appropriate if the engine oil is between the upper and lower limits of the level gauge.

Replenish the engine oil, if level is below the lower limit. Also, check for contamination of the engine oil.

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Name 1. Oil Pressure Testing Adapter 2. Connector 3. Hose 4. Oil Pressure Gauge 5. Nipple 5. Warm-up the engine.

6. Measure the oil pressure, to check whether it is more than 343 kPa (50 psi) at 2000 rpm.

ÉÍÖÖðîïê

Name 1. Upper Limit 2. Lower Limit

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïïç Engine oil leakage • In the lift up condition, confirm that there are no leaks from the cylinder head cover and oil pan.

Special Tool Illustration

Tool Number/Description / Special Tool

380300024 Oil pressure gauge

380300025 Hose

380300026 Connector

380300027 Oil pressure testing adapter

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîð

Oil Filter ASM Components

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ÉÍÖÖðîíî

Name 1. Oil Filter

Removal 1. Put a tray under the oil filter.

2. Remove the oil drain plug (1).

3. Loosen the bolt (2), and remove the oil filter ASM. 4. Remove the element (4) from the filter case (3).

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Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîï

Installation 1. Install the element to the filter case.

2. Install the oil filter ASM. Tightening torque: 44.1 N.m (4.5 kg.m/33 lb ft) 3. Install the oil drain plug.

Tightening torque: 24.5 N.m (2.5 kg.m/18 lb ft)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîî

Oil Port Cover ASM Components

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ÉÍÖÖððïé

Name 1. Oil Port Cover

Removal 1. Put a tray under the oil port cover.

2. Remove the oil port cover.

3. Remove the O-ring. î

Installation 1. Install the oil port cover and O-ring.

• Apply a coat of engine oil to the O-ring.

• Apply engine oil to the O-ring of the bolt, and tighten to the specified torque.

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Tightening torque: 44.1 N.m (4.5 kg.m/33 lb ft)

ÉÍÖÖðïçð

Name 1. Oil Port Cover 2. O-Ring

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîí

Oil Cooler Components

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ÉÍÖÖððïè

Name 1. Oil Cooler

Removal 1. Lower the engine ASM. 2. Remove the exhaust manifold.

Refer to “Exhaust Manifold”.

3. Remove the generator.

Refer to “Generator” in Engine Electrical section.

4. Remove the generator adjust plate.

5. Remove the engine foot RH. Refer to “Engine Foot”.

6. Remove the water bypass pipe.

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Name 1. Water Bypass Pipe 7. Remove the water intake pipe.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîì

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Name 1. Water Intake Pipe 2. Engine Foot RH

ÉÍÖÖðïçì

Name 1. Nut 2. Remove the element.

3. Remove the packing.

8. Remove the oil cooler ASM.

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9. Remove the O-ring.

Disassembly 1. Remove the element mounting nut.

ÉÍÖÖðïçí

Name 1. Element 2. Packing

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîë

Reassembly

Installation

1. Install the packing to the oil cooler case.

2. Install the element.

3. Tighten the element fixing bolts using the specified torque.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

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1. Install the oil cooler ASM. • Apply liquid gasket (ThreeBond 1207B or equivalent) to the flange surface groove (cylinder block). Bead diameter must be between 2 — 3 mm (0.08 — 0.12 in).

Refer to the illustration for the offset position (less than 1 mm (0.04 in)).

• Install the O-rings to the oil passage inlet and outlet. In doing this, you may attach the O-ring to the oil cooler with grease. Do not allow the liquid gasket to contact the O-ring.

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Name 1. Element 2. Packing

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Name 1. O-Ring 2. Liquid Gasket - Align the oil cooler holes with the cylinder block studs.

- Install the oil cooler to the cylinder block.

- Tighten the bolts to the specified torque in the order shown in the illustration.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft) • Liquid gasket quickly hardens.

Finish installation within 5 minutes after applying the liquid gasket.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîê

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Name 1. Bolt: L = 35 2. Bolt: L = 70 3. Bolt: L = 90 4. Nut

ÉÍÖÖðîíí

Name 1. Water Intake Pipe 2. Engine Foot RH 3. Connect the water bypass pipe.

• Apply soap water to the O-ring and install it to the water bypass pipe.

• Tighten to the specified torque.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

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2. Connect the water intake pipe.

• Apply soap water to the O-ring and install it to the water intake pipe.

• Install the water intake pipe to the oil cooler.

• Tighten the bolt to the specified torque.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

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4. Install the engine foot RH. Refer to “Engine Foot”.

5. Install the generator adjusting plate.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft) 6. Install the generator.

Refer to “Generator” in Engine Electrical section.

7. Install the exhaust manifold.

Refer to “Exhaust Manifold”.

8. Put the engine ASM on.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîé

Oil Relief Valve Components î

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Name 1. Oil Cooler 2. Oil Relief Valve (Oil Cooler Side)

Removal 1. Remove the oil cooler.

Refer to “Oil Cooler”.

2. Remove the oil relief valve on the oil cooler side.

• Loosen the plug and remove so as not to let the spring stick out.

• Remove the spring, valve and valve sheet.

ÉÍÖÖðíðë

3. Oil Relief Valve (Oil Filter Side)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîè

Installation 1. Install the oil relief valve on the oil filter side. î

• Insert the spring and valve.

• Install the valve seat and fasten until it contacts.

Make sure that the snap ring is installed in the ring groove properly.

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Note: There is no specified torque for fastening the valve seat. Adequate care should be taken as over-tightening may lead to damage.

• Install the snap ring.

ÉÍÖÖðíðí

Name 1. Plug 2. Spring 3. Valve (The Ball) 4. Valve Seat

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3. Remove the oil relief valve on the oil filter side.

• Remove the snap ring.

• Loosen the valve seat and remove so as not to let the valve and spring stick out.

• Remove the valve and spring.

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Name 1. Snap Ring 2. Valve Seat 3. Valve (The Ball) 4. Spring 2. Install the oil relief valve on the oil cooler side.

• Insert the valve seat, valve and spring.

• Install the plug and tighten using the specified torque.

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Tightening torque: 24.5 N.m (2.5 kg.m/18 lb ft)

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Name 1. Snap Ring 2. Valve Seat 3. Valve (The Ball) 4. Spring

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïîç

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ÉÍÖÖðíðí

Name 1. Plug 2. Spring 3. Valve (The Ball) 4. Valve Seat 3. Install the oil cooler.

Refer to “Oil Cooler”.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíð

Crankcase, Oil Pan Components

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Name 1. Oil Pan 2. Oil Strainer

Removal 1. Lower the engine ASM. 2. Drain engine oil.

3. Crankcase

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíï • Loosen the oil drain plug.

5. Remove the flywheel.

Refer to the “Flywheel”.

6. Remove the flywheel housing.

Refer to the “Crankshaft Rear Oil Seal”.

7. Remove the cylinder head.

Refer to the “Cylinder Head”.

8. Remove the gear case ASM. Refer to “Gear Case ASM”.

9. Remove the retainer.

Refer to the “Crankshaft Rear Oil Seal”.

10. Remove the slinger.

Refer to the “Crankshaft Rear Oil Seal”.

11. Remove the crankcase.

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ÉÍÖÖðîíì

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3. Remove the oil level gauge guide tube.

ÉÍÖÖðîíë

Name 1. Crankcase 2. O-Ring

ÉÍÖÖðððç

4. Remove the oil pan.

Disassembly 1. Remove the oil strainer.

ÉÍÖÖðïçé

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíî

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ÉÍÖÖðïçè

Name 1. Oil Strainer 2. Bolt 3. Packing 4. Crankcase

ÉÍÖÖðïíè

Name 1. 2.0 — 3.0 mm (0.079 — 0.118 in) 2. 4.0 — 5.0 mm (0.157 — 0.179 in) 2. Install the oil pan and packing.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

Reassembly 1. Assemble the packing into the oil strainer, and install it to the crankcase.

• Apply engine oil to the packing.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

Installation 1. Install the crankcase.

• Apply liquid gasket (ThreeBond 1207B or equivalent) to the cylinder block.

• Be careful that the liquid gasket does not run over the oil passage shown by the arrow mark.

• Apply the liquid gasket and install the crankcase within 5 minutes.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

ÉÍÖÖðïçé

3. Install the oil drain plug.

Tightening torque: 78.4 N.m (8.0 kg.m/58 lb ft) 4. Install the retainer.

Refer to the “Crankshaft Rear Oil Seal”.

5. Install the slinger and oil seal.

Refer to the “Crankshaft Rear Oil Seal”.

6. Install the gear case ASM. Refer to “Gear Case ASM”.

7. Install the cylinder head.

Refer to the “Cylinder Head”.

8. Install the flywheel housing.

Refer to the “Crankshaft Rear Oil Seal”.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíí 9. Install the flywheel.

Refer to the “Flywheel”.

10. Install the oil level gauge guide tube.

• Apply engine oil over the O-ring nice and thin and install it.

Tightening torque: Bolt: 25 N.m (2.5 kg.m/18 lb ft) Nut: 51 N.m (5.2 kg.m/38 lb ft)

ÉÍÖÖðððç

11. Put the engine ASM on.

12. Add engine oil.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíì

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷ îë ø îòë ñ ïè ÷

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Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíë

Oil Pump Components

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ÉÍÖÖððîð

Name 1. Oil Pump ASM

Removal

3. Disconnect the radiator upper hose.

4. Remove the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

1. Drain engine oil.

• Loosen the oil drain plug.

5. Remove the fan ASM, fan belt and water pump pulley.

Refer to the “Water Pump” in the Cooling System Section.

6. Remove the power steering pump hole cover.

ÉÍÖÖðîíì

2. Drain the coolant.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíê

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ÉÍÖÖðîîê

Name 1. Power Steering Pump Hole Cover

ÉÍÖÖðîîë

Name 1. Vacuum Pump Hole Cover

7. Remove the fan shroud bracket LH and fan shroud stay LH.

9. Remove the starter motor.

• Remove the mounting bolt, and remove the starter motor and ground cable.

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Name 1. Fan Shroud Bracket LH 2. Fan Shroud Stay LH 8. Remove the vacuum pump hole cover.

ÉÍÖÖððíî

10. Remove the crank pulley.

• Install the crankshaft stopper to the starter installing portion of the flywheel housing.

Caution: • Make sure that the stopper is properly fitted and engaged with the ring gear.

• Do not reuse the crankshaft pulley bolt and washer.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíé

Disassembly

Special tool Crankshaft stopper

1.

2.

3.

4.

Remove the spring pin.

Remove the spring seat.

Remove the spring.

Remove the valve.

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11. Remove the gear case cover.

ÉÍÖÖðïìï

Reassembly 1.

2.

3.

4.

Install the valve.

Install the spring.

Install the spring seat.

Install the spring pin.

Inspection

ÉÍÖÖðïêç

12. Remove the oil pump ASM.

1. Measure the clearance between the driven gear shaft and bushing, and between the drive gear shaft/driven gear shaft and pump case hole.

• Measure the outside diameters of the drive gear shaft and driven gear shaft using a micrometer.

Outside diameter of the drive gear shaft/ driven gear shaft Standard Limit

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ÉÍÖÖðïìð

15.989 — 16.000 (0.62949 — 0.62992) 15.900 (0.62598)

mm (in)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíè • Measure the inside diameters of the bushing of the oil pump body and the pump case hole using the dial gauge.

• If the clearance between the driven gear shaft and bushing, or between the drive gear shaft/driven gear shaft and pump case hole exceeds the limit, replace the oil pump ASM. Clearance between the driven gear shaft and bushing, and between the drive gear shaft/driven gear shaft and pump case hole

mm (in)

Standard

0.04 — 0.07 (0.0016 — 0.0028)

Limit

0.20 (0.0079)

ÉÍÖÖðïìí

2. Measure the clearance between the oil pump gear side surface and the oil pump housing gear side surface.

• Measure the width of the driven gear/drive gear. ÉÍÖÖðïìî

Width of driven gear/drive gear Standard

mm (in)

14.5 (0.5709)

ÉÍÖÖðïìì

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïíç • Measure the depth between the gear case housing surface and the oil pump housing gear case side.

Depth between the gear case housing surface and the oil pump housing gear case side Standard

mm (in)

14.500 — 14.527(0.5709 — 0.5719)

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ÉÍÖÖðïìð

Name 1. Oil Pump • Confirm that the pump gear turns smoothly.

2. Install the gear case cover. ÉÍÖÖðïìë

Clearance between the oil pump gear side surface and the oil pump housing gear side surface

mm (in)

Standard

0.063 — 0.027(0.0025 — 0.0011)

Limit

0.20(0.0079)

• Apply liquid gasket (ThreeBond 1207B or equivalent) to the position shown in the illustration.

• Apply the liquid gasket and install the gear case cover within 5 minutes.

• Install the packing in the groove of the gear case cover.

• Tighten the installing bolt to the specified torque.

Tightening torque: 3.5 N.m (0.4 kg.m/31 lb in) ï

Installation 1. Install the oil pump ASM. Apply engine oil to the pump case in which oil pump is installed.

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

ÉÍÖÖððìè

Name 1. Liquid Gasket Applied Area.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïìð

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ÉÍÖÖððìç

3. Install the crankshaft pulley.

• Apply liquid gasket (ThreeBond 1207B or equivalent) to the tip of the key.

• Install the crankshaft pulley while aligning it with the key on the crankshaft.

Caution: Replace the crankshaft pulley bolt and washer with new ones.

Tightening torque: 294 N.m (30.0kg.m/217 lb ft)

ÉÍÖÖðîîë

Name 1. Vacuum Pump Hole Cover 6. Install the fan shroud bracket LH and fan shroud stay LH. • After temporarily tightening the nut as shown (1) in the illustration, temporarily tighten the bolt (2).

• After fully tightening the nut as shown (1) in the illustration, fully tighten the bolt (2).

Tightening torque: M8 bolt: 25 N.m (2.5 kg.m/18 lb ft) M10 bolt: 51 N.m (5.2 kg.m/38 lb ft) Nut: 25 N.m (2.5 kg.m/18 lb ft)

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ÉÍÖÖðïïí

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4. Install the starter motor and ground cable to the flywheel housing and tighten the bolt to the specified torque.

Tightening torque: 97 N.m (9.9 kg.m/72 lb ft) 5. Install the vacuum pump hole cover.

• Apply engine oil to the packing.

• Tighten the installing nut to the specified torque.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

ÉÍÖÖðîëï

7. Install the power steering hole cover.

• Apply a coat of engine oil to the O-ring.

• Tighten the mounting nut to the specified torque.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïìï

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ÉÍÖÖðîîê

Name 1. Power Steering Pump Hole Cover 8. Install the fan, fan belt and water pump pulley.

Refer to the “Water Pump” in the Cooling System Section.

9. Install the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

10. Connect the radiator upper hose.

11. Replenish the coolant.

12. Install the oil drain plug and add engine oil.

Tightening torque: 78.4 N.m (8.0 kg.m/58 lb ft)

ÉÍÖÖðîíì

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïìî

Oil Pressure Switch Components

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Name 1. Oil Pressure Switch

Removal 1. Remove the oil pressure switch.

2. Remove the nipple.

2. Nipple

Inspection Check for continuity between the switch terminal and the body grounding in the no-load condition.

If there is no continuity, replace with normal parts.

Û²¹·²» Ó»½¸¿²·½¿´ øìÖÖï÷ ïßóïìí Circuit check 1. Turn the key switch to ON. 2. Disconnect the oil pressure switch connector, and confirm that the oil pressure-warning lamp lights when the connector on the harness side is grounded.

If the warning lamp does not light up, check the circuit between the meter and the oil pressure switch, and repair the disconnected locations.

Installation 1. Install the nipple.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft) 2. Install the oil pressure switch.

Tightening torque: 40 N.m (4.1 kg.m/30 lb ft)

ݱ±´·²¹ ͧ-¬»³ ïÞóï

Engine Cooling System Contents Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Precautions on Service Work. . . . . . . . . . . . . . 1B-2 A List of Defective Phenomena . . . . . . . . . . . . 1B-7 Main Data and Specifications. . . . . . . . . . . . . . 1B-7 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-12 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-16 Fan Clutch, Cooling Fan . . . . . . . . . . . . . . . . . . 1B-17 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17

ݱ±´·²¹ ͧ-¬»³ ïÞóî

Cooling System Precautions on Service Work WARNING: Do not remove the radiator cap when the cooling water is at high temperature. Steam or boiling water will gush out and you may be burnt. To open the radiator cap, cover the cap with a thick cloth when the cooling water is cool, release the pressure by slowly turning the cap, and then remove the cap.

Explanations on functions and operation Cooling water system The engine cooling system consists of the radiator, water pump, cooling fan and thermostat.

The water pump and thermostat circulates the coolant to rapidly raise the engine coolant temperature for smooth operation of the engine. In doing so, the coolant returns to the cylinder block through the bypass pipe.

The coolant is not circulated through the radiator in the beginning; however, when it reaches the specified temperature, the thermostat starts to open, allowing the coolant flow in the radiator to increase gradually.

When the coolant reaches the specified temperature, the thermostat fully opens allowing all coolant to flow through the radiator, thus to cool down the engine efficiently.

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Name 1. Cylinder Block 2. Water Pump 3. Cooling Fan 4. Radiator 5. Reserve Tank 6. Thermostat

7.

8.

9.

10.

11.

Turbocharger EGR Cooler Cylinder Head Oil Cooler Heater

ݱ±´·²¹ ͧ-¬»³ ïÞóì Water pump The water pump, which uses the centrifugal impeller system, is driven by the engine fan belt.

The water pump is a non-disassembled part.

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Name 1. Fan Center 2. Bearing

3. Impeller 4. Seal Unit

ݱ±´·²¹ ͧ-¬»³ ïÞóë Thermostat The thermostat is a wax pellet type. It is a bottom bypass type, and starts to open at the temperature of 82 °C (180 °F). It is mounted in the thermostat-housing unit.

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Name 1. Valve 2. Piston Coolant 1. About the engine coolant concentration • Take the concentration corresponding to the minimum temperature because the freezing temperature varies according to the concentration of the engine coolant.

3. Jiggle Valve

• Use only genuine Isuzu engine coolant.

• Use engine coolant with a mix ratio in the range of 30 to 60% because over heating is likely to occur if the ratio is greater than 60% and corrosion prevention is inadequate if the ratio is less than 30%.

ANTIFREEZE CONCENTRATION (%)

2. Engine coolant concentration measurement

ݱ±´·²¹ ͧ-¬»³ ïÞóê Methods for measuring specific gravity • Measure the specific gravity and the temperature of the cooling water using an anti-freeze specific gravity meter and thermometer.

• Take precautionary measures as the boiled cooling water may gush out at high temperatures if the cap is removed.

• Fix the temperature of the cooling water being measured in the range of 0 to 50 °C (32 to 122 °F).

• Measure the temperature and specific gravity and determine the concentration from the table given below.

• Use a deep container to suit the height of the specific gravity meter.

Name 1. Anti-Freeze Specific Gravity Meter 2. Radiator

TEMPERATURE (°C) LNW46BMH000101

Coolant scooping method • Measure the concentration using the coolant scoop.

ݱ±´·²¹ ͧ-¬»³ ïÞóé

A List of Defective Phenomena • Engine overheats • Engine overcools Engine overheats Condition Engine overheats

Possible Cause

Correction

Cooling water volume is deficit.

Add.

Thermometer unit is defective.

Replace.

Thermostat is defective.

Replace.

Radiator pump is defective.

Replace.

Radiator is clogging.

Clean or replace.

Radiator cap is defective.

Replace.

Engine oil volume is deficient or incorrect engine oil is used.

Add or change engine oil.

Cylinder head gasket is defective.

Replace.

The fan belt is loose.

Adjust.

Exhaust system is clogging.

Clean or replace.

The fuel injection quantity is in surplus.

Diagnose system.

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Fuel injection timing is incorrect.

Diagnose system.

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Starting pressure of fuel injection is low.

Diagnose system.

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control

Engine overcools Condition Engine overcools

Possible Cause Thermostat is defective.

Correction Replace.

Main Data and Specifications Water pump

Centrifugal impeller type

Pulley ratio

1.03

Thermostat

Wax pellet system

Valve opening temperature

°C (°F)

With jiggle valve 85 (185)

Temperature when fully open

°C (°F)

With jiggle valve 100 (212)

Valve lift amount at full open

mm (in)

10 (0.39)

ݱ±´·²¹ ͧ-¬»³ ïÞóè

Water Pump Components ï ì

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Name 1. Fan 2. Spacer

3. Water Pump Pulley 4. Water Pump ASM

Removal 1. Drain the coolant.

2. Disconnect the radiator upper hose.

3. Remove the fan shroud and fan guard.

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4. Remove the fan ASM, spacer and water pump pulley.

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Name 1. Fan 2. Spacer 3. Water Pump Pulley 4. Bolt

Name 1. Water Pump 7. Remove the gasket.

5. Loosen the tension adjusting bolt (1) of the generator and remove the fan belt.

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Name 1. Tension Adjusting Bolt 2. Lock Nut 3. Bolt 4. Nut 6. Remove the water pump ASM.

Inspection 1. Appearance check • Check for cracks or damage in the pump body.

• Check for cracks and corrosion in the impeller.

• Check for water leakage from the seal unit.

• If you find abnormalities, replace with the water pump ASM. 2. Bearing nut check • Check the play in the thrust direction.

Standard: 0.2 mm or less (0.0078 in or less) • Rotate the fan center while pushing it along the radial direction. Confirm that there is no abnormal noise and no excessive play.

• If you find abnormalities, replace with the water pump ASM.

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ݱ±´·²¹ ͧ-¬»³ ïÞóïð M

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Installation 1. Install the gasket.

2. Install the water pump ASM. • Tighten the bolt and nut to the specified torque.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft) 3. Temporarily tighten the bolt until the water pump pulley is properly seated in the water pump ASM. 4. Mount the fan belt, and tighten the tension adjusting bolt of the generator to adjust the tension.

• Refer to the “Drive Belt”.

5. After fan belt adjustments, tighten the generator using the specified torque.

ÉÍÖÖððíë

Name 1. Tension Adjusting Bolt 2. Lock Nut 3. Bolt 4. Nut 6. After fan belt adjustment, tighten the temporarily fitted water pump pulley to the specified torque.

Tightening torque: 10 N.m (1.0 kg.m/87 lb in) 7. Install the fan ASM and spacer.

Tightening torque: M8 : 25 N.m (2.5 kg.m/18 lb ft) M10: 52 N.m (5.3 kg.m/38 lb ft)

Tightening torque: Bolt: 51 N.m (5.2 kg.m/38 lb ft) Lock nut: 25 N.m (2.5 kg.m/18 lb ft) ï í

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Name 1. Fan ASM 2. Spacer 3. Water Pump Pulley 4. Bolt

ݱ±´·²¹ ͧ-¬»³ ïÞóïï 8. Install the fan shroud and fan guard.

Tightening torque: 51 N.m (5.2 kg.m/38 lb ft)

ÉÍÖÖðîêí

9. Connect the radiator upper hose.

10. Pour coolant.

ݱ±´·²¹ ͧ-¬»³ ïÞóïî

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷ îë ø îòë ñ ïè ÷

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ݱ±´·²¹ ͧ-¬»³ ïÞóïí

Thermostat Components

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Name 1. Water Outlet Pipe

2. Thermostat

Removal 1. Drain the coolant. Prepare the container for discharging and use it for replenishment when mounting the thermostat. Set the discharge of cooling water such that the water does not flow out of the thermostat housing.

2. Disconnect the radiator upper hose.

3. Remove the engine harness clip.

4. Disconnect the water outlet pipe.

• Disconnect the turbocharger water feed hose from the water outlet pipe.

5. Remove the thermostat.

• Be careful not to damage the thermostat.

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Name 1. Thermostat 2. Jiggle Valve

ݱ±´·²¹ ͧ-¬»³ ïÞóïì

Inspection

Installation

• Place the thermostat in water and increase the temperature while stirring it sufficiently.

• Measure the temperature when the valve is just opened and when it is fully open.

Thermostat valve-opening temperature

1. Install the thermostat on the position shown in the illustration.

• Install the thermostat with its jiggle valve (2) facing the front of the engine.

°C (°F)

85 (185) Thermostat full-open temperature

°C (°F)

100 (212) Valve lift amount at full open

mm (in)

10 (0.39)

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Name 1. Thermostat 2. Jiggle Valve 2. Connect the water outlet pipe.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft) í

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Name 1. Thermometer 2. Stirrer 3. A Piece of Wood

• Connect the turbocharger water feed hose to the water outlet pipe.

3. Install the engine harness clip.

4. Connect the radiator upper hose.

5. Replenish the cooling water stored during the discharge, and check the volume of the cooling water.

ݱ±´·²¹ ͧ-¬»³ ïÞóïë

Drive Belt Components

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Name 1. Crankshaft Pulley 2. Generator Drive Belt 3. Bolt 4. Generator

Inspection Check for the presence of wear or damage in the drive belt and renew the parts if necessary.

Check the tension of the belt and adjust if necessary.

Inspection procedure Apply a pressure of 98 N (22 lb) at the center of the long span of each belt and check the deflection of the belt.

Deflection of generator drive belt When the belt is new 5 — 6 mm (0.20 — 0.24 in) When the belt is reused 7 — 8 mm (0.28 — 0.32 in)

5.

6.

7.

8.

Tension Adjusting Bolt Lock Nut Generator Adjusting Plate Water Pump Pulley

Drive belts adjustment Adjustment procedure Adjust simultaneously the generator drive belt for adjustment of belt.

1. Loosen the adjusting plate lock nuts and the mounting bolts of generator on the underside of the generator.

• Loosen the installing bolt under the generator while holding the nut on the back using a tool.

2. Rotate the adjusting bolts of generator and adjust the belt (remove and fit).

3. After adjustments, tighten the adjusting plate lock nuts and the mounting bolts of generator on the underside of the generator using the specified torque.

ݱ±´·²¹ ͧ-¬»³ ïÞóïê • Loosen the installing bolt under the generator while holding the nut on the back using a tool.

Tightening torque: Nut: 25 N.m (2.5 kg.m/18 lb ft) Bolt: 51 N.m (5.2 kg.m/38 lb ft)

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Name 1. Crankshaft Pulley 2. Bolt 3. Generator 4. Tension Adjusting Bolt 5. Lock Nut 6. Water Pump Pulley 7. Generator Drive Belt

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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ݱ±´·²¹ ͧ-¬»³ ïÞóïé

Fan Clutch, Cooling Fan 2. Inspection (single unit)

Inspection If wear, damage or any fault is found during the inspection, replace or repair as required.

Visually check for damage, silicon grease leakage or other faults.

1. Inspection (on-vehicle) 1) Before starting the engine, rotate the fan clutch when it is cold by hand to check if it rotates easily.

2)

1)

Warm up the bimetal area of the fan clutch using a heat gun until the temperature reading on the thermistor reaches approx. 85°C. Then check if considerable force (clutch torque) is required to rotate the fan clutch. At this time, if the fan clutch rotates easily, this indicates that the silicon grease is leaked inside. Replace the fan clutch with new one.

Start the engine and warm it up until the temperature of the fan clutch reaches approx.

85°C. Then stop the engine, and rotate the fan clutch by hand to check if considerable force (clutch torque) is required to rotate. However, if the fan clutch rotates easily, this indicates that the silicon grease is leaked inside. Replace the fan clutch with new one.

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Ú«»´ ͧ-¬»³ ïÝóï

Engine Fuel System Contents Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-2 Precautions on Service Work. . . . . . . . . . . . . . .1C-2 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-8 Fuel Filter ASM . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9 Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . .1C-10 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12 Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-15 Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-17 Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-19 Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .1C-20 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-20 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-24 Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-29

Ú«»´ ͧ-¬»³ ïÝóî

Fuel System Precautions on Service Work Parts of the fuel system such as the internal part of the fuel injector, holes and clearances that form passages for fuel are finished to a very high degree of accuracy.

They are therefore highly sensitive to foreign matter and the entry of foreign matter could cause damage to the fuel passage. Take extreme care not to allow foreign matter to enter.

If water removal agent is used in the fuel then it will absorb moisture in the light oil and may cause rust.

Therefore, do not use water removal agent in the fuel tank.

When servicing the fuel system, every precaution must be taken to prevent the entry of foreign material into the system.

• Before beginning the service procedure, wash the fuel line and the surrounding area.

• Perform the service procedures with clean hands.

Do not wear work gloves.

• Immediately after removing the fuel hose and/or fuel pipe, carefully tape vinyl bags over the exposed ends of the hose or pipe.

• Always replace the high-pressure pipe in fuel system with new one if it has been removed.

Reuse of it causes damage to the seal surface, resulting in fuel leakage.

• If parts are to be replaced (fuel hose, fuel pipe, etc.), do not open the new part packaging until installation.

Discard gaskets and O-rings and replace them with new ones.

Work procedure • The fuel opening must be quickly sealed when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and common rail.

• The eyebolts and gasket must be stored in a clean parts box with a lid to prevent adhesion of foreign matter.

• Fuel leakage could cause fires. Therefore, after finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine.

Ú«»´ ͧ-¬»³ ïÝóí Explanations on functions and operation Fuel system diagram

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Name 1. Fuel Tank 2. Fuel Feed Hose 3. Pre-Fuel Filter 4. Fuel Feed Pump 5. Fuel Filter 6. Relief Valve

7.

8.

9.

10.

11.

12.

Fuel Supply Pump Common Rail Fuel Injector Fuel Leak-Off Pipe Fuel Return Hose Fuel Cooler

Ú«»´ ͧ-¬»³ ïÝóì Caution: • Be careful foreign material does not into the fuel system, because the precise fuel system is used.

Common rail

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Name 1. Pressure Limiter

2. Pressure Sensor

Ú«»´ ͧ-¬»³ ïÝóë Fuel supply pump

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Name 1. Fuel Temperature Sensor 2. Suction Control Valve 3. High Pressure Pipe

4. Camshaft Key 5. Camshaft Nut

Ú«»´ ͧ-¬»³ ïÝóê Fuel injector

Fuel filter

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Name 1. Terminals 2. ID Code 3. Leak-Off Pipe 4. QR Code 5. Parts Number 6. Part to Connect Injection Pipe 7. O-Ring

Name 1. Priming Pump 2. Air Bleed 3. Case 4. Drain Plug Function check Air bleeding 1. Before starting the engine a. Place a tray under the fuel filter (under the air bleed plug). b. Turn the key switch to ON, and activate the electromagnetic pump. c. Loosen the plug adequately and operate the priming pump more than 20 times until the fuel overflows near the plug. d. Tighten the plug, and operate the priming pump more than 10 times until it is filled with fuel. After waiting for approximately a minute, loosen the plug and bleed out the air in the fuel filter. (This work must be repeated a minimum of three times until no more air comes out from the plug.) e. Tighten the plug firmly and wipe the spilled fuel on the surrounding area. Operate the priming pump (10 to 15 times) till it is filled with fuel and then send fuel to the engine.

Ú«»´ ͧ-¬»³ ïÝóé 2. After starting the engine a. Start the engine without operating the engine speed on the machine side. b. After starting, maintain the idling rotation for 5 seconds. c. Slowly raise the engine speed and maintain it for 3 minutes. d. Set to “maximum speed” on the machine side in order to increase the speed to the maximum.

(Repeat this operation several times) e. Return to the idling.

Caution: If the air bleeding work is insufficient then it could lead to faults in the engine. Therefore, the procedures after starting the engine should always be implemented.

Water drain It is designed that the float inside of the water sedimenter floats when water accumulates.

When the float level goes up to the aluminum body section, be sure to drain the water.

Water draining procedure Loosen the air bleeder plug at the top of the water sedimenter. Then loosen the drain plug to drain the water inside of it. After draining, tighten each plug securely. Then bleed air from the fuel.

Fuel system vacuum check Use this procedure to measure the vacuum (negative pressure) discharge side the fuel system.

Important: The fuel pressure/vacuum gauge ASM (gauge (1)) and the fuel pressure/vacuum gauge adapter (adapter (5)) must be cleaned before connecting to the fuel line.

Otherwise, foreign material adherent to the tools may damage the fuel supply pump.

1. Disconnect the fuel hose from the fuel filter housing. (fuel supply pump side).

2. Install the adapter.

Special tool Fuel pressure/vacuum gauge adapter: 380300023 3. Connect the gauge (1) with hose to the adapter (3).

Special tool Fuel pressure/vacuum gauge ASM: 380002629

Name 1. Fuel Pressure/Vacuum Gauge ASM 2. Fuel Pipe (Discharge Side) 3. Fuel Pressure/Vacuum Gauge Adapter 4. Loosen the air bleed plug on the supply pump.

5. Use your hand to operate the fuel filter priming pump. Operate the pump until all the air has been bled from the system.

6. Start the engine and allow it to idle.

7. Note the gauge (1) reading. If the reading is normal, go to Step 8. If the fuel vacuum is greater than the specified value, there is a problem in the fuel system. Perform the procedures outlined below.

Standard fuel vacuum Less than 17 kPa (170 mbar)

Ú«»´ ͧ-¬»³ ïÝóè • Replace the cartridge fuel filter element.

• Check the fuel delivery pipe. If it is clogged, it must be replaced.

• Remove the fuel pipe at the fuel filter inlet. Use high-pressure air forced through the fuel pipe to clean the fuel system.

Caution: • Remove the fuel filler cap before applying highpressure air.

• Do not perform this procedure if the fuel tank is nearly full (fuel approaching or flowing into the fuel filler neck). The forced air will spray fuel from the fuel filler neck.

8. Remove the gauge (1) and hose from the adapter (3).

9. Remove the adapter (3).

10. Connect the fuel hose.

11. Use your hand to operate the fuel filter priming pump. Operate the pump until all the air has been bled from the system.

12. Start the engine and allow it to idle.

13. Inspect the fuel system for fuel leakage.

Special Tool Illustration

Tool Number/Description / Special Tool

380300023 Fuel pressure/vacuum gauge adapter

380002629 Fuel pressure/vacuum gauge ASM

Ú«»´ ͧ-¬»³ ïÝóç

Fuel Filter ASM Components

Name 1. Priming Pump 2. Air Bleed 3. Case 4. Drain Plug

Removal 1. Remove the feed hose and the return hose from the fuel filter and plug the hoses so that the fuel does not flow out.

2. Remove the bolts for mounting the fuel filter.

3. Remove the fuel filter ASM.

Installation 1. Install the fuel filter ASM. 2. Install the bolts for mounting the fuel filter.

3. Install the feed hose and the return hose.

4. Bleed the air.

• Refer to “Fuel System”.

Ú«»´ ͧ-¬»³ ïÝóïð

Fuel Filter Element Removal 1. Remove the case using the filter wrench.

Special tool Fuel main filter wrench: 8-9801-3170-0 2. Remove the fuel filter element.

Installation 1. Assemble the fuel filter element.

2. To simplify air bleeding, fill light oil in the case.

3. Tighten the case by hand. During this process take adequate care that the light oil that is inside does not flow out.

4. Use the filter wrench and tighten rotating by 1/3 to 2/3.

Special tool Fuel main filter wrench: 380002630

Special Tool Illustration

Tool Number/Description / Special Tool

380002630 Fuel main filter wrench

Name 1. Priming Pump 2. Air Bleed 3. Case 4. Drain Plug

Ú«»´ ͧ-¬»³ ïÝóïï

Fuel Injector Components

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Name 1. Fuel Injection Pipe Clip 2. Fuel Injection Pipe 3. Fuel Injector The fuel system consists of many tiny holes and spaces that allow the movement of fuel from one place to another. These holes and spaces are milled to extremely high precision. This is especially true of the fuel injectors.

The fuel injector is very sensitive to foreign material.

Foreign material will result in fuel system breakdown.

Exercise great care not to allow the entry of foreign material into the fuel system or fuel injectors during the removal and installation procedure.

4. Nozzle Bracket 5. Nozzle Bracket Bolt

Caution: To avoid electric shock; Set the switch to the “OFF” position and disconnect battery negative cable before checking or repairing the fuel injector, wiring or/and connectors.

Ú«»´ ͧ-¬»³ ïÝóïî

Removal 1. Remove the cylinder head cover.

Refer to “Cylinder Head Cover” in Engine Mechanical section.

2. Remove the fuel injection pipe clips and the injection pipes.

• If replacing one or more fuel injectors: Black out the replaced cylinder of injector ID code on the injector ID code label with a marking pen or equivalent.

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Name 1. Fuel Injection Pipe 2. Pipe Clip 3. Loosen the nozzle bracket fixing bolts and remove the fuel injectors.

Caution: Do not remove the fuel injector sleeve.

4. Mark each fuel injector with the number of the cylinder from which it was removed. Store the fuel injectors in a safe place. Position the fuel injector so that the nozzle is protected.

Caution: • Do not tamper with the electromagnetic portion of the fuel injector. Reduced electromagnetic function will result in injector failure.

Recording “Injector ID Code” on the connector of the replaced fuel injector housing; Record ID code information of all the replaced fuel injectors.

Note: If replacing the fuel injector, perform the following procedures.

• If replacing all fuel injectors: Remove the injector ID code label on the cylinder head cover.

Name 1. Injector ID Code 2. Fuel Injector

Installation Important: Install each of the fuel injectors on its original position. (the cylinder from which it was removed) 1. Install a new gasket and O-ring to each fuel injector. Refer to the illustration.

Ú«»´ ͧ-¬»³ ïÝóïí Important: Do not reuse the clip.

6. Apply a thin coat of engine oil to the outside of the fuel injector side sleeve nuts, and the O-ring.

7. Install each fuel injection pipe to the position shown in the illustration.

8. Temporarily fix the fuel injection pipe clip.

9. Use a wrench to tighten carefully until the fuel injection pipe contacts the fuel injector and common rail.

• When temporarily tightening, tighten at the common rail side, then tighten at the fuel injector side.

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Name 1. Fuel Injector 2. Leak-Off Pipe 3. Clip 4. O-Ring 5. Gasket

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2. Install the nozzle bracket to the fuel injector. Refer to the illustration.

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ÉÍÖÖðîëí

Name 1. Fuel Injection Pipe 2. Pipe Clip

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ÉÍÖÖðïëî

Name 1. Fuel Injector 2. Bolt 3. Nozzle Bracket 3. Apply engine oil to the threads of each bracket bolt, the seating surface of it, and between the washer and bracket.

4. Install each nozzle bracket to the cylinder head.

5. Temporarily tighten each bracket bolt.

10. Fully tighten the nozzle bracket bolts to the specified torque.

Tightening torque: 26 N.m (2.7 kg.m/20 lb ft) 11. Tighten the injection pipes to the specified torque.

• When fully tightening, tighten at the fuel injector side, then tighten at the common rail side.

Tightening torque: 29.5 N.m (3.0 kg.m/22 lb ft) 12. Tighten the fuel injection pipe clips to the specified torque.

Tightening torque: 7.8 N.m (0.8 kg.m/69 lb in) 13. Install the cylinder head cover.

Refer to “Cylinder Head Cover” in Engine Mechanical section.

Ú«»´ ͧ-¬»³ ïÝóïì Before programming the fuel injector ID code Important: Do not program the fuel injector ID code data unless you are directed by a service instruction or by a service bulletin issued by the manufacturer. Programming the fuel injector at any other time does not always meet a customer’s demand.

Ensure the following conditions are met before programming the ECM. • System voltage for the machine - There is no charging system concern. All charging system concerns must be repaired before programming the ECM. - Battery voltage is 12 V or 24 V (varies depending on the machine). The battery must be charged before programming the ECM if the battery voltage is low.

- A battery charger is not connected to the machine's battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or ECM damage.

- Turn off the system and electrical component that may put a load on the machine’s battery.

• The key switch is in the proper position. Do not change the position of the key switch during the programming procedure, unless instructed to do so.

• All tool connections are secure.

- RS-232 - The connection at the data link connector (DLC) is secure.

- Power supply circuit • Do not disturb the tool harness while programming.

If an interruption occurs during the programming procedure, programming failure or ECM damage may occur.

• Surrounding environment - Surrounding temperature is between 0 and 50°C (32 and 122°F) during the programming procedure. Excessively low or high temperature may cause the programming failure or ECM damage.

- Electromagnetic interference (EMI) on the tool harness and ECM may cause the programming failure or ECM damage.

Injector ID code programming procedure Perform the injector ID code programming according to “Injector Replacement” in EMPS or EMPS III Operating Instructions manual.

Ú«»´ ͧ-¬»³ ïÝóïë

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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Ú«»´ ͧ-¬»³ ïÝóïê

Common Rail Components

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ÉÍÖÖðîéí

Name 1. Common Rail 2. Common Rail Bracket Parts of the fuel system such as the internal part of the fuel injector, holes and clearances that form passages for fuel are finished to a very high degree of accuracy.

They are therefore highly sensitive to foreign matter and the entry of foreign matter could cause damage to the fuel passage. Take extreme care not to allow foreign matter to enter.

3. Fuel Feed Pipe 4. Leak-Off Pipe

Removal 1. Remove the starter motor.

• Refer to “Starter” in Engine Electrical section.

2. Remove the fuel feed pipe from the fuel supply pump.

Ú«»´ ͧ-¬»³ ïÝóïé Note: Cover the areas exposed during part removal to prevent the entry of foreign material into the fuel system. ï

Important: Do not reuse the high-pressure pipe in fuel system if it has been removed.

Refer to “Fuel Injector”.

7. Remove the common rail and the common rail bracket.

Caution: • Do not grasp the pressure sensor, during the common rail removal procedure.

• Take care not to damage the connector unit of the pressure sensor.

ï ÉÍÖÖðïëì

î

Name 1. Fuel Feed Pipe 3. Disconnect the fuel return hose.

4. Disconnect the leak-off pipe and hose.

Note: Cover the areas exposed during part removal to prevent the entry of foreign material into the fuel system.

ÉÍÖÖðïëê

Name 1. Common Rail Bracket 2. Common Rail

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Installation 1. Install the common rail and common rail bracket, then tighten them in the order shown in the illustration.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

ÉÍÖÖðïëë

Name 1. Leak-Off Pipe and Hose 5. Disconnect the common rail pressure sensor connector.

6. Disconnect the fuel injection pipe.

Ú«»´ ͧ-¬»³ ïÝóïè Caution: • Do not grasp the pressure sensor during the common rail installation procedure.

• Take care not to damage the connector unit of the pressure sensor.

5. Connect the fuel hose.

6. Connect the fuel feed pipe to the fuel supply pump, and tighten to the specified torque.

Tightening torque: 44.1 N.m (4.5 kg.m/33 lb ft)

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ì

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ÉÍÖÖððíê

2. Install the fuel injection pipe.

Important: Replace the high-pressure pipe in fuel system with new one if it has been removed.

Refer to “Fuel Injector”.

3. Connect the common rail pressure sensor connector.

4. Tighten the leak-off pipe and hose using the eyebolt to the specified torque.

Tightening torque: 7.9 — 12.7 N m (0.8 — 1.3 kg m/81 — 112 lb ft)

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ÉÍÖÖðïëë

Name 1. Leak-Off Pipe and Hose

ÉÍÖÖðïëì

Name 1. Fuel Feed Pipe 7. Install the starter motor.

Refer to “Starter” in Engine Electrical section.

Ú«»´ ͧ-¬»³ ïÝóïç

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷ ììòï ø ìòë ñ íí ÷

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Ú«»´ ͧ-¬»³ ïÝóîð

Fuel Supply Pump Components

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ÉÍÖÖðîéî

Name 1. Fuel Supply Pump The fuel system consists of many tiny holes and spaces that allow the movement of fuel from one place to another. These holes and spaces are milled to extremely high precision. This is especially true of the fuel injectors.

The fuel injector is very sensitive to foreign material.

Foreign material will result in fuel system breakdown.

Exercise great care not to allow the entry of foreign material into the fuel system or fuel injectors during the removal and installation procedure.

Ú«»´ ͧ-¬»³ ïÝóîï

Removal 1. Drain the coolant.

2. Disconnect the radiator upper hose.

3. Remove the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

4. Remove the fan ASM. Refer to the “Water Pump” in the Cooling System Section.

5. Remove the battery.

6. Remove the common rail.

Refer to “Common rail”.

7. Remove the cylinder head cover.

Refer to “Cylinder Head Cover” in Engine Mechanical section.

8. Disconnect the connectors of the fuel temperature sensor, suction control valve and CMP sensor.

9. Remove the fan shroud bracket upper and the fan shroud stay upper.

10. Remove the timing chain cover upper.

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Name 1. Timing Chain Cover Lower 2. Bolt 3. Nut 12. Align the timing marks at three locations as shown in the illustration.

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Name 1. Timing Chain Cover Upper 2. Fan Shroud Stay Upper 3. Fan Shroud Bracket Upper 11. Remove the timing chain cover lower.

ÉÍÖÖðððï

Name 1. TDC

Ú«»´ ͧ-¬»³ ïÝóîî

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Name 1. Camshaft Alignment Marks 2. Bearing Cap Alignment Marks

ÉÍÖÖðïëè

Name 1. Nut 15. Remove the timing chain tensioner.

13. Remove the starter motor.

Refer to “Starter” in Engine Electrical section.

14. Loosen the nut.

• Loosen the nut after blocking the crankshaft from turning by placing a crankshaft stopper on the starter mounting position on the flywheel housing.

Caution: Make sure that the stopper is properly fitted and engaged with the ring gear.

Special tool Crankshaft stopper î ï í ÉÍÖÖððêë

Name 1. Timing Chain Tensioner 2. Packing 3. Nut 16. Remove the timing chain tension lever pivot.

17. Remove the nut and sprocket.

Ú«»´ ͧ-¬»³ ïÝóîí

î

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Name 1. Tension Lever Pivot 2. Sprocket 3. Nut 18. Move the timing chain upward.

ÉÍÖÖðïêð

20. Use a gear puller to remove the fuel supply pump gear.

ÉÍÖÖðïëç

19. Put alignment marks between the idle gear A and fuel supply pump gear.

ÉÍÖÖðïêï

21. Disconnect the fuel feed hose.

22. Remove the fuel supply pump and supply pump bracket.

Ú«»´ ͧ-¬»³ ïÝóîì

Installation 1. Install the O-ring to the fuel supply pump.

2. Install the fuel supply pump.

• Apply soap water to the O-ring and install it.

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Caution: Take care not to twist the O-ring.

3. Install the supply pump bracket.

• Temporarily tighten the bolts and nuts on the gear case side.

• Temporarily tighten the bolts on the cylinder body side.

• Tighten the bolt and nut on the gear case side to the specified torque.

• Tighten the bolt on the cylinder body side to the specified torque.

î

ÉÍÖÖðîðí

Tightening torque: 25 N m (2.5 kg m/18 lb ft)

Name 1. Fuel Supply Pump 2. Fuel Supply Pump Bracket Caution: • Do not hold the high pressure pipe, during the supply pump removal procedure.

• Do not grasp the high pressure pipe, when moving the supply pump form one location to another.

23. Remove the O-ring.

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ÉÍÖÖðîðí

Name 1. Fuel Supply Pump 2. Fuel Supply Pump Bracket

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ÉÍÖÖðîðî

Name 1. Fuel Supply Pump 2. O-Ring 3. High Pressure Pipe

4. Connect the fuel feed hose.

5. Install the supply pump gear.

• Confirm that the supply pump camshaft key faces the direction shown in the illustration, and is horizontal.

• Install the supply pump gear and make sure that the alignment marks are aligned.

• Make sure that the supply pump gear is properly fitted and engaged with the main gear of the idle gear A. If the supply pump gear is properly fitted and engaged with the sub gear of the idle gear A, push the supply pump gear until it fits and engages with the main gear.

Ú«»´ ͧ-¬»³ ïÝóîë 6. Install the timing chain in each sprocket then install the supply pump sprocket in pump shaft.

• Align the timing marks of the camshaft sprocket with the dark plate of the timing chain link.

• Align the timing marks of the supply pump sprocket with the yellow plate of the timing chain link.

• Install the supply pump sprocket to pump shaft aligning with the knock pins on the supply pump gear.

• Tighten the supply pump shaft nuts by hand. î

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Name 1. Timing Mark 2. Dark Plate 3. Timing Mark 4. Yellow Plate

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Name 1. Alignment Mark for Supply Pump Gear 2. Alignment Mark for Idle Gear A 3. Idle Gear A Main Gear 4. Idle Gear A Sub Gear

ÉÍÖÖððçï

7. Install the timing chain tension lever pivot.

• Tighten the pivot bolts by hand.

• Check if the tension lever moves smoothly.

ÉÍÖÖððêé

Ú«»´ ͧ-¬»³ ïÝóîê 8. Push down the cam of the timing chain tensioner, and push the plunger in. Hook on the pin to hold the plunger depressed.

• This causes the plunger to be pushed to unhook.

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ÉÍÖÖððçì

ÉÍÖÖððçî

Name 1. Pin 2. Plunger 3. Cam 4. Body 5. Hook

Caution: Perform the above steps securely, and make sure that the plunger pushes the timing chain tension lever.

11. Tighten the supply pump shaft nut to the specified torque.

Tightening torque: 130 N.m (13.3 kg.m/96 lb ft)

9. Install the timing chain tensioner.

Tighten the nut to the specified torque.

Tightening torque: 10 N.m (1.0 kg.m/87 lb in)

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ÉÍÖÖðïëè

Name 1. Supply Pump Shaft Nut

î ï í ÉÍÖÖððçí

Name 1. Timing Chain Tensioner 2. Packing 3. Nut 10. Push the timing chain lightly.

12. Tighten the timing chain tension lever pivot bolt to the specified torque.

Tightening torque: 27 N.m (2.8 kg.m/20 lb ft) 13. Rotate the crank pulley two turns (720°).

14. Check that alignment marks of the intake camshaft and exhaust camshaft are aligned with that of the bearing cap.

Ú«»´ ͧ-¬»³ ïÝóîé • Tighten the bolt and nut to the specified torque.

Tightening torque: 25 N.m (2.5 kg.m/18 lb ft)

ï

19. Install the fan shroud bracket upper and fan shroud stay upper.

• Tighten the bolt and nut to the specified torque.

Tightening torque: M8 bolt: 25 N.m (2.5 kg.m/18 lb ft) M10 bolt: 5.2 N.m (5.2 kg.m/38 lb ft) Nut: 25 N.m (2.5 kg.m/18 lb ft)

î ï ÉÍÖÖððëç

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Name 1. Camshaft Alignment Marks 2. Bearing Cap Alignment Marks 15. Install the starter motor.

Refer to “Starter” in Engine Electrical section.

16. Install the cylinder head cover.

Refer to “Cylinder Head” in Engine Mechanical section.

17. Apply liquid gasket (ThreeBond 1207B or equivalent) to the timing chain upper as shown in the illustration.

• Install within five minutes after applying liquid gasket.

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í ÉÍÖÖðîêê

Name 1. Timing Chain Cover Upper 2. Fan Shroud Stay Upper 3. Fan Shroud Bracket Upper 20. Connect the connector of the CMP sensor.

21. Apply liquid gasket (ThreeBond 1207B or equivalent) to the timing chain cover lower as shown in the illustration.

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í í

ÉÍÖÖðïêí

Name 1. Timing Chain Cover Upper 2. Liquid Gasket Applied Area.

3. 2.0 — 2.5 mm (0.079 — 0.098 in) 18. Install the timing chain cover upper.

Ú«»´ ͧ-¬»³ ïÝóîè • Install within five minutes after applying liquid gasket. ï

Important: In order to make the fuel supply pump characteristic learn into the ECM, let the engine idle until warm-up. If the fuel system DTC is stored in the meantime, once clear the DTC and warm-up the engine again.

í í

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ÉÍÖÖðïêë

Name 1. Timing Chain Cover Lower 2. Liquid Gasket Applied Area.

3. 2.0 — 2.5mm (0.079 — 0.098 in) 22. Install the timing chain cover lower.

• Tighten the bolt and nut to the specified torque.

Tightening torque: 10 N.m (1.0 kg.m/87 lb ft)

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25. Install the battery.

26. Install the fan ASM. Refer to the “Water Pump” in the Cooling System Section.

27. Install the fan shroud and fan guard.

Refer to the “Water Pump” in the Cooling System Section.

28. Connect the radiator upper hose.

29. Replenish the coolant.

30. Start and idle the engine.

í ÉÍÖÖðïêê

Name 1. Timing Chain Cover Lower 2. Bolt 3. Nut 23. Connect the fuel temperature sensor and the suction control valve connector.

24. Install the common rail.

Refer to “Common rail”.

Ú«»´ ͧ-¬»³ ïÝóîç

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

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Û²¹·²» Û´»½¬®·½¿´ ïÜóï

Engine Engine Electrical Contents Service Precautions . . . . . . . . . . . . . . . . . . . . . . 1D-2 General Procedure. . . . . . . . . . . . . . . . . . . . . . 1D-2 Charging System. . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 General Description . . . . . . . . . . . . . . . . . . . . . 1D-3 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-6 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1D-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . 1D-14 General Description . . . . . . . . . . . . . . . . . . . . 1D-14 Service on the Machine: Starting System . . . 1D-15 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17 Torque Specifications . . . . . . . . . . . . . . . . . . . 1D-17 Main Data and Specifications. . . . . . . . . . . . . 1D-18 Preheating System . . . . . . . . . . . . . . . . . . . . . . 1D-22 Glow Plug Replacement . . . . . . . . . . . . . . . . 1D-22 Precautions on Service Work. . . . . . . . . . . . . 1D-22 A List of Defective Phenomena . . . . . . . . . . . 1D-22 Main Data and Specifications. . . . . . . . . . . . . 1D-23

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóî

Service Precautions General Procedure When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound are not indicated in the illustration. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóí

Charging System General Description The main charging system components are the batteries, the generator and the battery discharge indicator light circuit. The generator is a self-rectifying type with a built-in regulator. ì

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Name 1. Lower Mounting Bolt 2. Nut 3. Generator 4. Generator Adjusting Plate 5. Bolt

Ô»° çóçìîððÛÒ

6.

7.

8.

9.

Sliding Piece Adjusting Nut Washer Tension Adjusting Bolt

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóì Maintenance

Electrical Tests

The most common indication of charging system troubles is an undercharged or overcharged battery.

Since the battery itself may be defective, check the battery first. Check if the battery is discharged because of short circuit, or electrical components left turned on for extended periods.

Keep the generator and all other electrical system terminals clean and tight. A loose or badly corroded terminal connection will create excessive resistance in the circuit and result in hard starting, dim lights, etc.

Inspect the generator system at regular intervals and correct any potential causes of trouble before machine performance is affected.

Before performing the following generator electrical tests on the vehicle, be certain that the system wiring is not defective and generator belts are not slipping. Also, the battery must be fully charged for a valid test of the charging system.

Notice: To avoid damage to the vehicle electrical system, always observe the following precautions: • Do not polarize the generator.

• Do not short across or ground any of the terminals in the charging circuit except as specifically instructed herein.

• NEVER operate the generator with the output terminal open-circuited.

Diagnosis of Charging System Trouble in the charging system will be evidenced as one or more of the following three conditions: 1. The battery discharge warning light will stay on.

2. An undercharged battery as evidenced by slow cranking.

3. An overcharge, or overvoltage, condition.

Undercharged Battery

Inspection 1. Accessories were not left turned on for extended periods.

2. Drive belt for proper tension.

3. The ECM main relay has been stuck ON with the key switch in OFF position. (Battery voltage is consumed.)

4. Wiring and connections for corrosion or looseness.

Overcharge (or Overvoltage) condition A charging rate in excess of 29.5-volts for a prolonged period may cause early electrical system failure.

Blown fuses, light bulbs burned out, and even battery failure may result. If this condition exists, test the generator as described under “Generator Output Test” later in this section.

Noisy Generator

Inspection

• Be sure the generator and battery have the same ground polarity.

• When connecting a charger or other battery to the machine’s battery, connect negative to negative and positive to positive.

1. With the engine control switch “ON” and engine not running, connect a voltmeter from terminal “E” to ground. The voltmeter should show 0 volts.

2. With the engine control switch “ON” and engine not running, connect a voltmeter from terminal “B” to ground. The voltmeter should read at least 24 volts.

3. With the engine control switch “ON” and the engine not running, connect a voltmeter from white wire side of the connector to ground. The voltmeter should show 24 volts.

4. With the engine control switch “ON” and the engine not running, the “charge” light should be on. This shows that the other circuit in the connection is working.

5. With the engine running and the headlight high beams (if equipped) turned on, read the voltage at the “B” post on the generator. The voltmeter should read at least 24 volts.

6. If steps 1 through 4 are not OK, check connectors in the harness for looseness or corrosion and retest.

7. If step 5 voltage is low, substitute a known good regulator and test again. If the voltage is still low, bench test the generator.

1. Drive pulley for looseness.

2. Mounting bolts for looseness.

3. Bearings for dirt, damage, or wear.

Generator noise may also be caused by worn or damaged diodes and/or starter.

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóë

Generator

ÉÍÖÖðîçí

Removal • 1.

2.

3.

4.

Ô»° çóçìîððÛÒ

Battery negative cable.

Electrical wiring at the generator.

Loosen the adjusting nut.

Loosen the ACG adjusting bolt.

Loosen the lower mounting bolt.

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóê • Loosen the lower mounting bolt while holding the nut located on the back using a tool.

5. Drive belt 6. Generator

Installation 1. Generator • Tighten the lower mounting bolt while holding the nut located on the back using a tool.

2. ACG adjusting bolt 3. Adjusting nut Tightening torque: Adjusting nut 25 N.m (2.5 kg.m/18 lb ft) 4. Electrical wiring at the generator.

• Battery negative cable.

Tightening torque: Lower mounting bolt 51N.m (5.2 kg.m/38 lb ft)

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷ îë ø îòë ñ ïè ÷

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Ô»° çóçìîððÛÒ

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Û²¹·²» Û´»½¬®·½¿´ ïÜóé

Specifications

Connector terminal

Isuzu Part No.

8980182040

Nominal output

(V-A)

24-50

Rated speed

(rpm)

5000

Regulator-type

IC type

Regulated voltage

(V)

28.5 1

Weight

(kg)

9.5

Terminal symbol

Lead wire color

Wire specifications

R

R

AEX 0.75f

L

L

AEX 0.75f

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Name 1. R Terminal 2. L Terminal

Internal connections

Þ

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Û²¹·²» Û´»½¬®·½¿´ ïÜóè

Disassembly of generator ë ê é

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Disassembly Procedure 1. Screw 2. Cover 3. Through Bolt 4. Rotor, Front Bracket Assembly 5. Nut, Washer 6. Pulley 7. Fan 8. Collar 9. Screw 10. Retainer 11. Ball Bearing 12. Front Bracket

Ô»° çóçìîððÛÒ

13. Collar 14. Ball Bearing 15. Rotor Assembly 16. Screw 17. Field Coil Assembly 18. Stator Assembly 19. Holder 20. Regulator Assembly 21. Bolt (B Terminal) 22. Condenser 23. Rectifier Assembly Assembly is the reverse order of disassembly.

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóç

Inspection and repair of generator 1. Diode Check for continuity of forward and inverse directions with a tester. Normal diodes show low resistance in forward direction and high resistance in inverse one.

Judge that they are faulty other than those above.

2. Condenser Charge the condenser with a tester (at x 1000 range), and connect a tester lead inversely. Judge it as normal if the needle on a meter deflects a little and returns to the original position.

Judge that they are faulty other than those above.

Ô»° çóçìîððÛÒ

3. Diode for initiating excitation, Resistor Check for continuity between connector terminals R and L with a tester (at x 100 range). Normal diodes and resistors show low resistance in forward direction and high resistance in inverse one.

Judge that they are faulty other than those above.

4. Field coil • To judge the insulating condition of field coil, measure between the protrusion portions and core of the coil with a tester (at x 1000 range). Judge as faulty if it has continuity.

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïð • Measure between the protrusion portions of field coil with a tester, and judge as normal if the resistance is about 6.7 (20°C {68°F}).

5. Stator coil • To judge the insulating condition of stator coil, measure between the stator coil and core with a tester (at x 1000 range). Judge as faulty if it has continuity.

Ô»° çóçìîððÛÒ

• Judge as normal if there is continuity between N lead of stator coil and three leads.

6. Bearing • Check if the bearing rotates smoothly or has no noise.

If the result of the inspection is unsatisfactory, replace the bearing.

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïï

Performance test In the performance test of generator, connect as follows and measure the regulated voltage and output current.

Actual wiring diagram for performance test of IC regulator built-in generator

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Disassembly Procedure 1. Voltmeter 2. R Terminal 3. L Terminal 4. Charging Lamp 24 V-3 W

5. Clamp Tester Ammeter 6. Battery 24 V 7. Variable Resistor

Regulated voltage measurement of regulator

Measurement of the output current

Close SW1 switch, and warm-up five to ten minutes at approx. 1500 rpm in generator until an ammeter shows 6 A or less.

After confirming that an ammeter shows between 2 and 6 A, set the generator between approx. 3000 to 4000 rpm. If an voltmeter shows between 27.5 and 29.5 V, the regulated voltage of regulator is normal.

If the ammeter shows 6A or more, charge the battery for a while or replace it with full-charged battery.

Replace the regulator if the voltmeter shows out of range between 27.5 and 29.5 V.

Close SW1 and SW2 switches, and raise the generator speed to 5000 rpm. While keeping the voltmeter showing 27 V, measure the maximum value of output current with a variable resistor.

In this time, judge as normal if the output current is 50 A or more.

Specified value of regulated voltage 27.5 — 29.5 V (+25°C {77°F})

Ô»° çóçìîððÛÒ

Caution: • Do not cut off battery circuit during generator rotating.

• Do not connect to L terminal if the charging lamp (24 V-3 W) is not used.

Never connect L terminal and B circuit directly.

Diode for excitation may be broken.

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïî

Handling of generator Be careful with the following when handling a generator.

• Connecting the polarities of battery inversely causes generator diode to be broken.

• While the engine runs, NEVER disconnect the wiring of battery terminal and charging circuit.

• Wiring connection to terminal must be performed properly according to terminal symbol.

• Do not perform megger test on semiconductor device.

• Be sure to disconnect the battery terminal ( ) before inspection on equipment.

• Do not open/close the battery relay switch while the engine runs.

• Disconnect the battery terminal when charging from external source such as quick charge.

• Do not pour steam cleaner or water directly on it.

• After connecting to B terminal and E terminal, tighten them to the following torque.

B terminal 4.9 N.m {50 kgf.cm/43 lb in} E terminal 4.9 N.m {50 kgf.cm/43 lb in} • Refer to “Belt Adjustment" for tension adjustment of V-belt.

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïí

Trouble and action Trouble symptom Charging is impossible.

Trouble location

Action to be taken

Wiring and ammeter

Open or short circuit, disconnection

Generator

Open circuit, short to ground, short circuit in each coil

Replace

Broken diode

Replace

Defective regulator

Replace

Regulator Insufficient charging

Trouble cause

Repair

Poor contact in terminal of regulator

Repair

Wiring

Open or short circuit, looseness in connection

Repair

Generator

Looseness of generator driven belt

Repair

Layer or short circuit in field coil

Replace

Layer or short circuit in stator coil

Replace

Defective diode

Replace

Poor contact in each terminal Regulator

Defective regulator Poor contact in terminal of regulator

Repair Replace Repair

Excessive charging

Regulator

Defective regulator

Unstable charging current

Wiring

Intermittent contact or nearly disconnected connection in wiring

Repair

Generator

Looseness of generator driven belt

Repair

Short circuit or nearly disconnected connection in field coil

Repair

Short circuit or nearly disconnected connection in stator coil

Repair

Poor contact in each terminal

Repair

Regulator

Noisy generator

Generator

Defective regulator

Replace

Poor contact in terminal of regulator

Repair

Improper installation of generator

Repair

Defective bearing Contact of rotor core and stator core

Ô»° çóçìîððÛÒ

Replace

Replace Repair

Defective diode

Replace

Short circuit in stator coil

Replace

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïì

Starting System General Description Starter and Glow Plug Relays The starter is a 4kw, reduction drive model.

The gear housing and armature end bearing housings are aluminum. The brush ASM has replaceable brushes. The commutator bars are mica insulated and are undercut.

The starter circuit starts at the batteries. The battery cable goes to the large terminal on the starter.

From that terminal wires lead to the engine control switch and the starter relay.

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Name 1. Starter 2. Bolt Maintenance Keep the starter's exterior clean. Remove corrosion from the terminals, leads, and connectors. Ô»° çóçìîððÛÒ

3. Ground Cable

Tighten the starter to engine mounting bolts and the electrical cable retaining nuts.

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïë Diagnosis of Starting System

Service on the Machine: Starting System

No Cranking, No Sound

Maintenance

• Discharged batteries. Check for the cause of the discharged batteries.

• Sulfated battery terminals. Clean all the battery terminals and cable ends.

• A starter that draws too much current.

• Starter relay won't work. Attempt to start and listen for a “click” at the starter relay. If there is no “click,” check the starter relay control terminals with a test light. If the test light shows that power is getting to the starter relay, check the ground circuit with the test light. If the ground circuit is OK, replace the starter relay.

Keep starter terminals and all other terminals in the electrical system clean tight. A loose or corroded connection or terminal will cause excessive resistance in the system that will result in hard starting. At regular intervals, inspect the starting system to locate and correct potential causes of trouble before the system performance is affected. Starting motors do not require lubrication.

• Engine control switch start circuit won't close.

With the engine control switch turned to start, check the starter relay with a test light. If the test light doesn't come on, check the starter circuit at the engine control switch with the test light. If the test light comes on, check the harness for an open and repair. If the test light does not come on, replace the engine control switch.

• Starter relay power circuit isn't closing. Attempt to start. Starter relay clicks. Check the secondary terminals with a test light. If the test light lights on the battery side only, replace the starter relay. If the test light lights on both terminals, check for an open at the starter.

• Starter clicks when start is attempted. Check all power connections for corrosion.

Clean connections if corrosion is present. Terminal on starter should have at least 18 volts on it when cranking the engine. If voltage is OK, replace the starter.

Slow Cranking, Magnetic Switch Clicks or Chatters • Discharged batteries. Check for cause of discharged batteries.

• Check the battery terminal for corrosion. Hint: Test for warm terminals. Clean all the battery terminals and connectors.

• Loose or dirty connections. Measure the cranking voltage at the battery terminals. If the voltage is less than 18 volts, load test the battery. If the battery is bad, replace the battery. If the battery is good, repair the starter.

If the voltage is 18 volts or more, measure the voltage from the battery negative terminal to the engine block. If the voltage is 0.5 volt or more, repair the ground cable and connections.

If the voltage is less than 0.5 volt, measure the voltage at the battery cable terminal on the starter. If the voltage is 18 volts or more, repair the starter. If the voltage is less than 18 volts, clean and tighten the positive cable connections. If the voltage is still less than 18 volts, replace the positive cable.

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïê

Starter The starter is a non-disassembled part as dip painting is applied to improve waterproof effect.

ÉÍÖÖðîèè

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ÉÍÖÖðîèç

Removal 1. Battery negative cable from the battery.

2. Cables and electrical leads from the starter.

3. Two mounting bolts.

4. Starter.

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïé

Installation 1. Starter 2. Two mounting bolts.

3. Cables and electrical leads to the starter.

4. Battery negative cable to the battery.

Tightening torque: Mounting bolt 97 N.m (9.9 kg.m/72 lb ft)

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

çé ø çòç ñ éî ÷

ÉÍÖÖðîðê

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïè

Main Data and Specifications Model (Manufacturer) Rating

Hitachi, Ltd.

Voltage Power output Time

V

24

kw

4.0

Sec.

30

Number of pinion teeth

11

Revolution direction (viewed toward pinion side)

Clockwise

Weight (approx.)

N {kg}

61.8 {6.3}

No load characteristic

Current/Voltage

A/V

120 or less/23

Speed

rpm

3500 or more

Load characteristic

Current/Voltage

A/V

250 or less/18.6

Torque

N m {kgf m}

13.2 {1.3} or more

Speed

rpm

1590 or more

Current/Voltage

A/V

1100 or less/10

N m {kgf m}

47 {4.8} or more

Locking characteristic

Ô»° çóçìîððÛÒ

Torque

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóïç

Connections (Hitachi, Ltd.)

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Name 1. Starter Relay 2. Battery

S.S Ar Fc C1 C2 P

3. Motor 4. Magnetic Switch

Starter switch Armature Field coil Pressure coil Holding coil Contactor

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóîð

Inspection and repair of starter

Handling of starter

1. Magnetic switch Never perform operational check on magnetic switch as single unit.

Inspection of coil • Check each continuity between S terminal and M terminal, S terminal and case, M terminal and case of magnetic switch. If no continuity is present in either one of them, replace the starter since the coil is open.

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1. Precautions on handling • Improper gap between pinion and ring gear causes faulty mesh. (Gap 2 — 5 mm {0.079 — 0.197 in}) • Also, the front bracket is installed on the engine side securely.

• Be sure to turn off the battery switch before removal/installation of stater.

• Tightening/inserting wiring must be performed properly. Improper work causes starting trouble due to high contact resistance.

2. Precautions on starting • Be careful with charging status of battery.

Insufficiently-charged battery causes starting trouble.

• After checking engine starting, turn off the stater switch immediately.

Í

Ó

• One continuous use should be less than 10 seconds. If re-starting is needed, wait until the pinion stops completely.

• If the starter does not stop rotating when the starter switch is turned off, turn off the battery switch immediately. In this case, check the wiring, switch, etc.

ÉÍÖÖðîçï

Contact Point Check Measure the load current on starter. Replace it if voltage drop between terminals B and M is 0.3 V or more per 100 A. Caution: Use a digital voltmeter to measure voltage drop. Using an analog voltmeter may damage itself.

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóîï

Trouble countermeasure Trouble symptom Starter does not operate when starter switch is turned on.

Trouble cause 1.

2.

3.

4.

Full discharge of battery Open circuit, poor contact Poor contact in starter switch or improper tightening of terminal Poor contact in starter relay or plug terminal

5.

Short or open circuit in magnetic switch coil

Pinion moves forward but it does not 1. engage with ring gear.

2.

3.

4.

Insufficient capacity of battery Improper gap of pinion and ring gear Wear of pinion or ring gear tooth edge Dust on pinion shaft

5.

Insufficient auxiliary rotation of armature due to insufficient thrust gap of motor

Pinion engages and rotates motor but it does not run engine.

1.

2.

Slippage of clutch Breakage of reduction gear

Pinion engages but it does not run engine.

1.

2.

Insufficient capacity of battery Too high rotational resistance of engine

3.

4.

5.

Improper tightening of wiring circuit terminal Short circuit of armature or field coil Contamination of commutator

6.

7.

8.

Fatigue or wear of brush spring Locking of bearing Poor contact in magnetic switch

1.

2.

3.

Retuning failure of starter switch contact Retuning failure of starter relay contact Short circuit in magnetic switch coil

When turning starter switch off after engine starts, starter does not stop.

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóîî

Preheating System Glow Plug Replacement

Precautions on Service Work

Precautions during maintenance

Adequate care should be taken as over-tightening the glow plug could lead to damage.

Adequate care should be taken as over-tightening the glow plug could lead to damage.

Explanations on functions and operation

Removal Procedure 1. Remove the glow plug connector.

2. Remove the glow plug.

The preheating system consists of the ECM, the glow relay, glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant temperature is low, and make the engine easy to start.

Glow plug check • Use the circuit tester and measure the resistance of the glow plug.

• If the measured value deviates from the specified value, then replace the glow plug.

• Resistance value of glow plug is approximately less than 6 .

Caution: Use a set of glow plug from the same manufacturer.

ÉÍÖÖðîðé

Installation Procedure 1. Install the glow plug.

Tightening torque: 15 — 20 N m (1.5 — 2.0 kg m/11 — 15 lb ft) 2. Install and tighten the glow connector with the designated torque.

Tightening torque: 1.5 — 2.0 N m (0.15 — 0.20 kg m/13 — 17 lb in)

A List of Defective Phenomena • The glow indicator lamp does not light up.

• Preheating does not work.

• Preheating time is too long or too short.

Ô»° çóçìîððÛÒ

×--«»¼ ðîóðê

Û²¹·²» Û´»½¬®·½¿´ ïÜóîí Trouble Shooting The glow indicator lamp does not light up.

Condition The glow indicator lamp does not light up.

Possible Cause

Correction

Slow blow fuse has blown.

Replace the slow-blow fuse.

Fuse is unavailable.

Replace the fuse.

Indicator valve is burnt out.

Replace the indicator valve.

Engine control system is faulty.

Refer to Engine Control System section.

Preheating does not work.

Condition Preheating does not work.

Possible Cause

Correction

Slow blow fuse has blown.

Replace the slow-blow fuse.

Defective or faulty glow plug relay connector contact.

Re-mount or replace the glow plug relay.

Engine control system is faulty.

Refer to Engine Control System section.

Preheating time is too long or too short.

Condition Preheating time is too long or too short.

Possible Cause

Correction

Thermo-sensor fault and break in circuit or short circuit.

Replace the thermo-sensor. Repair the circuit.

Fault in glow plug.

Replace or tighten the glow plug.

Engine control system is faulty.

Refer to Engine Control System section.

Main Data and Specifications Items

Model

Preheating device model Glow plug rated voltage/ current

Ô»° çóçìîððÛÒ

Glow plug (V-A)

23 – 3.5

×--«»¼ ðîóðê

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóï

Engine Exhaust System and Turbocharger Contents EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-2 Precautions on Service Work. . . . . . . . . . . . . . . 1F-2 Explanations on Functions and Operation . . . . . 1F-2 EGR Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4 Torque Specifications . . . . . . . . . . . . . . . . . . . . . 1F-6 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-7 A List of Defective Phenomena . . . . . . . . . . . . . 1F-7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 1F-7 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-8 Measurement Tool. . . . . . . . . . . . . . . . . . . . . . . . . 1F-9 Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-9

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóî

EGR System Precautions on Service Work

Explanations on Functions and Operation

Perform EGR related assembly according to the usual procedure of temporarily fitting and then permanently tightening the parts so that unnecessary stresses are not applied on the parts.

Re-circulate a part of the exhaust gas of the EGR system in the intake manifold. Reduce the combustion temperature and inhibit NOx generation since inert gases may be mixed up in the intake air.

An electronic control system is used in this EGR to balance the requirements of operability and low emissions. A DC motor is operated using the control current of the Engine Control Module (ECM) to control the EGR. Refer to the chapter on Engine Control System for details on fault diagnosis of the EGR system.

Name 1. EGR Cooler 2. Engine Control Module (ECM)

3. EGR Valve DC Motor

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóí

EGR Cooler Components

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Name 1. EGR Cooler 2. Coolant Pipe (In)

3. Coolant Hose (Out)

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóì

Removal

Installation

1. Drain the coolant.

2. Remove the bolt that fixes the water feed pipe bracket of turbocharger to the EGR cooler.

3. Remove the coolant pipe and hose.

4. Remove the EGR cooler.

1. Install the EGR cooler.

• Temporarily tighten the bolts and nuts according to the order given on the illustration.

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ÉÍÖÖðîíê

Name 1. EGR Cooler 2. Coolant Pipe and Hose (In) 3. Coolant Pipe and Hose (Out) Caution: After removing the EGR cooler, seal so that foreign matter does not enter.

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Name 1 — 6 Show the Order to Tighten Bolts and Nuts.

Inspection Gas leak check • Check for gas leak in various parts of the EGR gas line.

If the results of the check show abnormalities, repair or replace the defective parts.

EGR valve check • Refer to the chapter on Engine Control System for details on the method of checking the EGR valve.

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóë • Temporarily tighten the bolts and nuts to the specified torque according to the order given on the figure.

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ÉÍÖÖðîêë

3. Install the bolt that fixes the water feed pipe bracket of turbocharger to the EGR cooler.

Tightening torque: 10 N.m (1.0 kg.m/87 lb in) 4. Replenish the coolant.

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Name 1 — 6 Show the Order to Tighten Bolts and Nuts.

Tightening torque M8 bolt: M10 bolt: Nut:

27 N.m (2.8 kg.m/20 lb ft) 52 N.m (5.3 kg.m/38 lb ft) 27 N.m (2.8 kg.m/20 lb ft)

2. Connect the coolant pipe and hose.

Tighten the bolt to the specified torque.

Tightening torque M6 bolt: M8 bolt:

10 N.m (1.0 kg.m/87 lb in) 25 N.m (2.5 kg.m/18 lb ft)

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóê

Torque Specifications Ò ³øµ¹ ³ñ´¾ º¬÷

ïð ø ïòð ñ èè ´¾ ·² ÷

ëî ø ëòí ñ íè ÷

îé ø îòè ñ îð ÷

îé ø îòè ñ îð ÷

ïð ø ïòð ñ èè ´¾ ·² ÷

îë ø îòë ñ ïè ÷ îë ø îòë ñ ïè ÷

ÉÍÖÖðîèî

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóé

Exhaust System A List of Defective Phenomena • Vibration or rattling noise from the exhaust system • Clogging of exhaust system • Exhaust leakage or noise

Troubleshooting Vibration or rattling noise from the exhaust system Condition Vibration or rattling noise from the exhaust system

Possible Cause Loose or misaligned components

Correction Match the joints and then re-tighten.

Or, check for damage in the hanger, mounting brackets and clamps.

Clogging of exhaust system Condition Clogging of exhaust system

Possible Cause

Correction

Clogging or deformation of the exhaust piping

Repair or replace the exhaust piping.

Possible Cause

Correction

Defect or misalignment in mounting

Match the joints and then re-tighten.

Damage or burn-out of exhaust piping or silencer

Replace the damaged part.

Defective components in the exhaust system (clamps, pipes, silencer)

Replace the defective part.

Internal damage to silencer

Replace the silencer

Exhaust leakage or noise Condition Exhaust leakage or noise

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóè

Turbocharger Turbocharger inspection Inspection Caution: Turbocharger on 4JJ1 engine cannot be overhauled structurally.

Perform only the following inspection.

• Measurement of axial play of turbine shaft Axial play Service limit

mm (in) 0.11 (0.004)

• Check of radial play of turbine shaft Insert a thickness gauge into the gap between the compressor impeller and housing, and measure the clearance.

The thickness gauge to be inserted must be 0.2 mm (0.0078 in) or less.

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóç

Measurement Tool Shape

Name

Part number

Usage

—

Measurement of the seal ring groove width Measurement of inner diameter of the seal ring insertion part Measurement of turbine shaft journal outer diameter Measurement of thrust bushing groove clearance Measurement of thrust bearing thickness Measurement of floating metal inner/outer diameter Measurement of inner diameters of the center housing metal portion and ring portion

Caliper

Dial gauge

Measurement of turbine shaft axial gap, radial gap and runout —

Other Material Name

Usage

Besco super engine oil

Floating metal sliding portion Thrust bushing sliding portion Thrust bearing sliding portion Turbine shaft journal portion

ThreeBond No. 1207

Housing installing surface of the seal plate Flange of the compressor housing

Loctite No. 242

Seal plate tightening screw thread

Û¨¸¿«-¬ ͧ-¬»³ ¿²¼ Ì«®¾±½¸¿®¹»® ïÚóïð