WORKSHOP MANUAL NHR « NKR * NPR ENGINE 4H SERIES SECTION 6 ISU2UMEMONOTICE Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section 0A under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL”. All material contained in this Manual is based on latest product information available at the time of publication. All rights are reserved to make changes at any time without prior Applicable Model N Series NKR66 NPS66 NQR71 NPR66 NPS71 NPR70 NaR66 NPR71 NaR70 This manual is applicable to 1996 year model and later vehicles except those sold in the United States of America, and Canada.THIS MANUAL INCLUDES THE FOLLOWING SECTIONS: SECTION NO. CONTENTS 00 Service Information 6A Engine Mechanical 6A3 Engine (4HF1/4HF1-2/4HE1-T/4HE1-TC/4HG1/4HG1-T) 6B Engine Cooling 6c Fuel System 6D Engine Electrical 6E Emission and Electrical Diagnosis oF Exhaust 6G TurbochargerSERVICE INFORMATION 00-1 SECTION 00 SERVICE INFORMATION Troubleshooting. Main Data and Specification: Service Standard Servici Fixing Torque... Special Tools... Lubricating System... CONTENTS. PAGE 00- 2 00-19 00 - 28 00 - 42 00 - 59 00 - 70 00 - 7200-2 SERVICE INFORMATION TROUBLESHOOTING CONTENTS, Hard Starting... Starter Motor Inoperative.. Starter Motor Operates but Engine does not turn over. Engine turns over but does not start Fuel is not being delivered to the injection pump .. Fuel is being delivered to the injection pump... Quick-on Start System ... Unstable Idling. Insufficient Power.. Excessive Fuel Consumption Excessive Oil Consumption. Overheating. White Exhaust Smoke Dark Exhaust Smoke Oil Pressure Does Not Abnormal Engine Noise .. Engine Knocking .. Gas Leakage Noise.. Continuos Noise Slapping Noiss Engine Cooling Trouble Starter Motor Does Not Stop. PAGE 00 - 00 - 00 - 00 - 00- 00 - Rk RO ww oo- 5 00- 10 00-11 00 - 12 00 - 12 00 - 13 00 - 13 00-14 00-14 00 - 15 00-15 00 - 15 00 - 15 00-16 00-17 00-18SERVICE INFORMATION 00-3 1. HARD STARTING 4. STARTER MOTOR INOPERATIVE. Checkpoint Possible cause Correction Battery Loose battery cable terminal Clean andior retighten the battery Poor connections due to rusting cable terminal Battery discharged or weak Recharge or replace the battery Fan belt loose or broken ‘Adjust or replace the fan belt Fusible link Fusible link shorted Replace the fusible link Starter switch Defective starter switch or starter relay Replace the starter switch or the starter relay Starter motor Defective magnetic switch or starter relay | Repair or replace the magnetic switch Defective starter motor Repair or replace the starter motor 2. STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER Battery Loose battery cable terminal Clean andlor retighten the battery Poor connections due to rusting cable terminal Battery discharged or weak Recharge or replace the battery Fan belt loose or broken Adjust or replace the fan belt Starter motor Defective pinion gear Replace the pinion gear Defective magnetic switch Repair or replace the magnetic switch Brush wear, Weak brush spring | Replace the brush andlor the brush spring Engine Piston, crank bearing seizure, or other | Repair or replace the related parts damage00-4 SERVICE INFORMATION 3, ENGINE TURNS OVER BUT DOES NOT START Checkpoint Possible cause Correction Engine stop Defective fuel cut solenoid valve Replace the fuel cut solenoid valve mechanism FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP Fuel Fuel tank is empty Fill the fuel tank Fuel piping Clogged or damaged fuel lines. Loose fuel__| Repair or replace the fuel lines line connection Retighten the fuel line connection Fuel fiter Fuel fier overfiow valve does not close Repair or replace the fuel fiter overflow valve Clogged fuel fer element, Replace the fuel fier element or the fiter cartridge Fuel system Air in the fuel system Bleed the air from the fuel system Fuel feed pump Defective feed pump Repair or replace the feed pump FUEL IS BEING DELIVERED TO THE INJECTION PUMP Injection nozzle Injection pump Injection nozzle sticking Injection nozzle injection starting pressure too low Improper spray condition Defective fuel injection nozzle resulting in the fuel drippage after fuel injection Defective injection pump control rack ‘operation Injection pump plunger worn or stuck Injection pump drive shaft seizure or other damage Injection pump governor spring seizure Fuel Use of the wrong fuel Use the correct fuel ‘Water particles in the fuel Charge the fuel Fuel system Air in the injection pump Bleed the air from the fuel system Replace the injection nozzle Adjust or replace the injection nozzle Replace the delivery valve Repair or replace the injection pump control rack Replace the injection pump plunger assembly Replace the injection drive shat Replace the injection pump governor spring‘SERVICE INFORMATION 00-5 4, QUICK-ON START SYSTEM Check point Possible cause Correction Glow plug indicator. 1, Defective Fusible link wire Replace the fusible link wire light does not tum on. 2, Broken indicator light fuse. Replace the indicator light fuse 3. Defective indicator bulb Replace the indicator light bulb Preheating system 1,_Defective fusible link wire shorted Replace the fusible link wire dose not work 2. Defective glow plug relay connector Replace or Repair glow plug relay 3. Defective glow plug connector 4, Defective quick-on start timer connector Preheating time to 4. Defective thermo switch include long or to short defective wiring harness 2. Defective glow plug 3, Defective timer unit connector Replace or Repair glow plug connector Replace or Repair quick-on start timer connector Replace thermo switch Replace glow plug Replace timer unit00-6 SERVICE INFORMATION Check if battery is normal, then perform the following diagnosis. ‘STARTER DOES NOT RUN (CHECK BATTERY (CHARGING FAILURE OR UFE BATTERY IS NORMAL (CHECK BATTERY [CHECK TERMINAL CONNECTION ‘CONNECTION FAILURE ‘TERMINAL CONNECTION Is NORMAL CLEAN BATTERY TERMINALS, AND RECONNECT (CHECK STARTER OR STARTER SWITCH FAILURE REPAIR OR REPLACE, ‘TURN ON HEAD LAMP AND STARTER SWITCH HEAD LAMP DOES NOT COME ON HEAD LAMP ILLUMINATES, ‘OR ITS EXTREMELY DARK 2) DISCONNECT STARTER CIRCUIT 2) LACK OF BATTERY CHARGING b) DISCONNECT STARTER COIL b) SHORT-CIRCUIT IN STARTER COIL /¢)_ FAULTY STARTER SWITCH (©) FAULTY STARTER PARTSSERVICE INFORMATION 00-7 FAULTY MESHING OF PINION AND RING GEAR (CHECK IF BATTERY VOLTAGE IS PRESENT AT MAGNETIC SWITCH TERMINAL "S’ WHEN, 'STARTER SWITCH IS TURNED TO "START (ST)" = ie Si aoa eoarer seer ee racereeten en orate owner pierre oey omen | |amrmanee aaa ee Bae = [eo] rermnovrenac| —_|fepan cnnenace pee pecowecrouen | [aecerwneae Pec ere te |oecce commen ewwacsomeres” | [eomacronsew sy Srecvcweenc | |Somromtece a ny REPAIR ves | [no } FAULTY CONNECTIONOF | [DISCONNECTION OR STARTER SWITCH FAULTY CONNECTION BETWEEN STARTER SWITCH AND BATTERY REPLACE STARTER SWITCH a00-8 SERVICE INFORMATION MAGNETIC SWITCH DOES NOT OPERATE THOUGH [STARTER SWITCH IS TURNED TO START (ST" ‘CHECK IF VOLTAGE IS PRESENT AT MAGNETIC. ‘SWITCH TERMINAL °S" WHEN STARTER SWITCH IS ‘TURNED TO"START (ST)" ‘CHECK GROUND CABLE Yes No REPAIR oR PINION MAGNETIC SWITCH 'SUDING ‘OR COIL IS PART DOES DISCONNECTED OR NOTMOVE BURNED CUT REPAIR OR REPLACE STARTER, (CHECK IF INDICATOR LAMP ON teeny ae pases! Eecerrge parece fee Peres ae excocsranre] [Fase comecron Ere anna CHECK CLUTCH /START SWITCH REPLACE STARTER SWITCHSERVICE INFORMATION 00-9 PINION MESHES WITH RING GEAR BUT [ENGINE DOES NOT RUN (CHECK GROUND CABLE YES NO REPAIR OR REPLACE. GROUND CABLE FAULTY CONNECTION BURNED-OUT DISCONNECTION DISCONNECTION SLIP OF ‘OF BRUSH AND MAGNETIC OR DAMAGE OF OR DAMAGE OF PINION, ‘COMMUTATOR [STARTER SWITCH FIELD COIL ARMATURE COIL, JCLUTCH REPAIR OR REPLACE STARTER00-10 SERVICE INFORMATION 2. UNSTABLE IDLING Piston ring sticking between the valve and the valve seat Check point Possible cause Correction Idling system Idling improperly adjusted Adjust the idling Fast idling speed Defective fast idling speed control device —_| Repair or replace the fast idiing speed control device control device ‘Accelerator control Accelerator control system improperly Adjust the accelerator control system system adjusted Fuel system Fuel system leakage or blockage Repair or replace the fuel system Air in the fuel system Bleed the air from the fuel system Water particles in the fuel system ‘Change the fuel Fuel fiter Clogged fuel fer element Replace the fuel fier element or the fuel fter cartridge Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump Injection nozzle Injection nozzle sticking Replace the injection nozzle Injection nozzle injection starting pressure | Adjust or replace the injection nozzle teponer spray condition Injection pump Defective delivery valve resulting in fuel Replace the delivery valve drippage after fuel injection Injection pump Injection timing improperly adjusted ‘Adjust the injection timing (cone) Insufficient injection volume ‘Adjust the injection volume Defective idle spring Replace the idle spring Defective governor lever operation Repair or replace the governor lever Regulator valve improperly adjustment ‘Adjust or replace the regulator valve Broken plunger spring Replace the plunger spring ‘Wom plunger Replace the plunger assembly Wom cam disc Replace the cam disc Valve clearance Valve clearance improperly adjusted Adjust the valve clearance ‘Compression pressure Blown out cylinder head gasket Replace the related parts Wom oyinder linerSERVICE INFORMATION 00-11 3. INSUFFICIENT POWER Check point Possible cause Correction Air cleaner (Clogged air cleaner element Clean or replace the air cleaner element Fuel Water particle in the fuel Replace fuel Fuel filter ‘Clogged fuel fter element Replace the fuel fiter element or the fuel fiter cartridge Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump Injection nozzle Injection nozzle sticking Replace the injection nozzle Injection nozzle injection starting pressure too low Improper spray condition Adjust or replace the injection nozzle Fuel injection pipes Fuel injection pipes damaged or obstructed Replace the fuel injection pipes Injection pump Defective regulating valve Repair or replace the regulating valve Defective delivery valve Defective timer Repair or replace the timer ‘Wor cam disk Improper control lever operation Adjust or replace the control lever Defective injection timing Replace the govemnor spring Weak governor spring Wom plunger Replace the delivery valve Replace the cam disk ‘Adjust the injection timing Repair or replace the injection pump timer Replace the plunger assembly Compression pressure Blown out cylinder head gasket ‘Wom cytinder liner Piston ring sticking Replace the related parts Valve clearance Valve clearance improperly adjusted ‘Adjust the valve clearance Valve spring Valve spring weak or broken Replace the valve spring Exhaust system Exhaust pipe clogged Clean the exhaust pipe Full load adjusting screw seal ‘Open and improperly set adjusting screw seal Adjust and reseal the adjusting screw00 - 12 SERVICE INFORMATION 4. EXCESSIVE FUEL CONSUMPTION too low Improper spray condition Check point Possible cause Correction Fuel system Fuel leakage Repair or replace the fuel system related parts Air cleaner (Clogged air cleaner element Clean or replace the air cleaner element Idling speed Poorly adjusted idling speed Adjust the idling speed Injection nozzle Injection nozzle injection starting pressure __| Adjust or replace the injection nozzle Fuel injection timing Fuel injection timing improperly Adjust the fuel injection timing Injection pump Defective delivery valve resulting is fuel drippage after fuel injection Replace the delivery valve Valve clearance Valve clearance improperly adjusted Adjust the valve clearance Compression pressure Blown out cylinder head gasket Wom eylinder liner Piston ring sticking Replace the related parts, Oil seal and gasket Too much engine cil Oil leakage from the oilseal and/or the gasket Valve spring Valve spring weak or broken Replace the valve spring 5. EXCESSIVE OIL CONSUMPTION Check point Possible cause Correction Engine oil Engine oil unsuitable Replace the engine oil Correct the engine oil level Replace the oil seal andlor the gasket Air breather (Clogged air breather Clean the air breather Intake and exhaust valve ‘Wom valve stems and valve guides Replace the intake and exhaust valves and the valve guidesSERVICE INFORMATION 00-43 6. OVERHEATING Check point Possible cause Correction Cooling water Insufficient cooling water Replenish the cooling water Fan clutch Oil leakage from the fan clutch Replace the fan clutch Fan belt Fan belt loose or cracked causing slippage _| Replace the fan belt Radiator Defective radiator cap or clogged radiator | Replace the radiator cap or clean the core radiator core Water pump Defective water pump Repair or replace the water pump Cylinder head and cylinder body sealing cap Defective sealing cap resulting in water leakage Replace the sealing cap Thermostat Coating system Fuel injection timing Defective thermostat Cooling system clogged by foreign material Fuel injection timing improperly adjusted Replace the thermostat Clean the foreign material from the. cooling system Adjust the fuel injection timing 7. WHITE EXHAUST SMOKE Check point Possible cause Correction Fuel Water particles in the fuel Replace the fue! Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing Compression pressure Blown out cylinder head gasket Wom cylinder liner Piston ring sticking Replace the related parts, Inlet and exhaust valves Valves seals Defective valve seales Wom valves stems and valve guides Replace the valve seales, the valves, and the valve guides00-14 SERVICE INFORMATION 8. DARK EXHAUST SMOKE too low Improper spray condition Check point Possible cause Correction Air cleaner (Clogged air cleaner element Clean or replace the air cleaner element Injection nozzle Injection nozzle injection starting pressure __| Adjust or replace the injection nozzle Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing Injection pump Defective delivery valve resulting in fuel Replace the delivery valve drippage after fuel injection Excessive injection volume Adjust the injection volume 9. OIL PRESSURE DOES NOT RISE Check point Possible cause Correction Engine oil Improper viscosity engine oil Replace the engine oil Insufficient engine oil Correct the engine oil volume Oil pressure gauge or unit Oil pressure indicator light Ol fiter Relief valve and by-pass valve il pump Rocker arm shaft Camshaft Crankshaft and bearings Defective oil pressure gauge or unit Defective indicator light Clogged oil fter element Relief valve sticking and/or weak by-pass valve spring Clogged oil pump strainer Wor oil pump related parts Wom rocker arm bushing ‘Wom camshaft and camshaft bearing Worn crankshaft and bearings Repair or replace the oil pressure gauge or unit Replace the indicator light Replace the oil filter element or the oil filter cartridge Replace the relief valve andlor the by- pass valve spring Clean the oil pump strainer Replace the oil pump related parts Replace the rocker arm bushing Replace the camshaft and the camshaft bearing Replace the crankshaft and/or the bearingsSERVICE INFORMATION 00-15 10. ABNORMAL ENGINE NOISE 41. ENGINE KNOCKING Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure. Check point Possible cause Correction Fuel Fuel injection timing Injection nozzle Fuel unsuitable Fuel injection timing improperly adjusted Improper injection nozzle starting pressure ‘and spray condition Compression pressure Blown out head gasket Replace the fue! ‘Adjust the fuel injection timing Broken piston ring Adjust or replace the injection nozzle Replace the head gasket or the piston ring 2. GAS LEAKAGE NOISE Exhaust pipes Loosely connected exhaust pipes Broken exhaust pipes Tighten the exhaust pipe connections Replace the exhaust pipes Injection nozzles Loose injection nozzles and /or glow plugs Replace the washers ‘and/or glow plugs Tighten the injection nozzles andor the glow plugs, Exhaust manifold Loosely connected exhaust manifold andior | Tighten the exhaust manifold glow plugs connections Cylinder head gasket Damaged cylinder head gasket 3, CONTINUOUS NOISE. Replace the cylinder head gasket Fan belt Cooling fan Loose fan belt Loose cooling fan Readjust the fan belt tension Retighten the cooling fan ‘Water pump bearing Altemator or vacuum pump Valve clearance Wom or damaged water pump bearing Defective alternator or vacuum pump Clearance improperly adjust Replace the water pump bearing vacuum pump Repair or replace the alternator or the Adjust the valve clearance00-16 SERVICE INFORMATION 4. SLAPPING NOISE Check point Possible cause Correction Valve clearance Valve clearance improperly adjusted Adjust the valve clearance Rocker arm Damaged rocker arm Replace the rocker arm Flywheel Loose flywheel botts Retighten the flywheel bolts Crankshaft and thrust Worn or damaged crankshaft andior thrust | Replace the crankshaft and/or the bearings bearings thrust bearings Crankshaft and Wom or damaged crankshaft andor Replace the crankshaft and/or the ‘connecting rod connecting rod bearings connecting rod bearings bearings Connecting rod ‘Wom or damaged connecting rod bushing | Replace the connecting rod bushing bushing and piston pin and piston pin and/or the piston pin Piston and cylinder liner ‘Wom or damaged piston and cylinder liner Foreign material in the cylinder Replace the piston and the cylinder linerSERVICE INFORMATION 00-17 11. ENGINE COOLING TROUBLE Condition Possible cause Correction Engine overheating Low coolant level Replenish ‘Thermo unit faulty Replace Faulty thermostat Replace Faulty coolant unit Repair or replace Clogged radiator Clean or replace Faulty radiator cap Replace Low engine oil level or use of improper Replenish or change oil engine ol Replenish Damaged cylinder head gasket Replace ‘Clogged exhaust system Clean exhaust system or replace faulty parts Loose fan belt Adjust Excessive fuel injected Adjust Improper injection timing Adjust Engine overcooling _Fauity thermostat Replace “Too long engine Faulty thermostat Replace warm-up time ‘Thermo unit faulty Replace00 - 18 SERVICE INFORMATION 12. STARTER MOTOR DOES NOT STOP [STARTER DOES NOT STOP THOUGH STARTER [SWITCH IS RETURNED TO “ON” a DISCONNECTED STARTER SWITCH WIRING CONNECTOR, AND CHECK STARTER SWITCH OPERATION. starrer 1[2[s[4l+[z[«[s][e eee mon eel ace e [ow [er [|e [|e | w | w OFF Lock Ce ace | 0-0 oN on | o+0-+o ot—o START ‘THERE MUST BE NO CONTINUITY EXCEPT ABOVE LINES. ra] sol) MAGNETIC SWITCH CONTACTS ARE FUSED AND NOT MOVED. OR A RETURN SPRING IS BROKEN OR DETERIORATED REPLACE MAGNETIC SWITCHSERVICE INFORMATION 00-19 MAIN DATA AND SPECIFICATIONS MAIN DATA AND SPECIFICATIONS Engine Model Item Engine type Combustion chamber type Cylinder liner type Timing drive system No, of cylinders - Bore x stroke mm (in) No. of piston rings Total piston displacement om? (in?) Compression ratio to: Compression pressure kPa (kg/m? / psi) - rpm Fuel injection order Fel injection timing (BTDC) deg Specified fuel type Idling speed rpm Valve system Valve clearances (At cold): Intake mm (in) Exhaust mm (in) Valve timing (At valve clearances 0.4 mm (0.016 in)) Intake valves Open at (BTDC) deg Close at (ABDC) deg Exhaust valves Open at (BBDC) deg Close at (ATDC) deg Fuel system Injection pump type Plunger outside diameter mm (in) Plunger lift mm (in) Governor type Automatic timer type Fuel feed pump type Injection nozzle type Injection nazzle type Pressure MPa (kg / cm? / psi) Pressure adjustment Main fuel fter type 4HF1 HF 1-2 Four-cycle, overhead camshaft, water cooled Direct injection Dry liner, special compound metal Gear drive 4-112 110 (4-441 x 4.33) Compression rings: 2, Oring: 4 4334 (284.5) 19.0 3,040 (31/441)-200 | 3,226 (32.9/468) -200 1-3-4-2 8 12 7° (Taiwan only) SAE No. 2 diesel fuel 550 ~ 600 (W/T) 575 ~ 625 (MIT) 0.4 (0.016) 0.4 (0.016) 18 50 51 7 Bosch inne type with | Bosch “VE" distributor ‘automatic timer with automatic timer 9.5 (0.374) 12 (0.472) 11.0 (0.433) 2.8 (0.110) RLD-F mechanical Half all speed governor (Variable speed) SCDM, centrifugal, Hydraulic speed flyweight sensing type Piston Vane Hole type (with 5 orifices) 18.1 (185 / 2,631) ‘Shim adjusted Disposal spin-on cartridge and remote mounted water separator00 - 20 SERVICE INFORMATION Engine Model HFA HF 1-2 Item Lubricating system Lubrication method Full flow pressure circulation ‘Specified engine oil (API grade) CD or above Oil pressure kPa (kg /em? / psi) - 1pm 447 (1.5 / 21-700 (we 40W-30 API CD grade engine oll at 80°C (176°F) oll pump type Gear type il fiter type Spin-on cartridge Oil capacity lit (US/UK gal) 10.5 (2.77 /2.31) Oil cooler type Weater cooled Cooling system Radiator type Corrugated fin with reserve tank Coolant capacity lit(US/ UK gal) 12 (3.17 2.64) Water pump type Centrifugal impeller, V-belt drive Pump to crankshaft speed ratio to:1 Delivery volume lit (US / UK galyimin Pump bearing type ‘Thermostat type Valve initial opening temperature °C("F) Valve lift mm (in) Air cleaner type Battery type Volt-amp.hr. Generator Type Voltage v Drive and rotation Ground polarity Maximum output A Maximum speed rpm 4.46 (175 / 151) 200 (52.8 / 44.0) Pump speed at 3,300 rpm Water temperature at 82°C (180°F) Double row shaft Wax pellet ‘With jiggle valve Primary : 8581.6 (182 - 188) Without jiggle valve (Heaterless) Primary : 8541.5 (182 - 188) Secondary: 821.5 (177 - 182) 8 (0.3) or more at 95°C (203°F) Dry paper element 85D23R / 12-60 : 2 pos AC brush with IC regulator and vacuum pump 24 V-belt, clockwise viewed from the drive pulley Negative 36 at 5,000 rpm (For Thailand and Indonesian) {60 at 5,000 rpm 80 at 5,000 rpm 7,500 ~ 10,000 0 at 6,000 rpmSERVICE INFORMATION 00-21 Engine Model i 4H 412 Regulator Type Ic Regulating voltage v 28-29 Vacuum pump -500 mmHg (-9.67 psi /-66.7 KPa) build-up time Maximum vacuum Starter motor Type Model Rated voltage v Rated output kW. Load characteristics Terminal voltage v Load current. A Torque Nem (kgem/ Ibs) Preheating system Exhaust system Pipe outside diameter X thickness Front pipe mm (in) Middle pipe mm (in) Rear pipe mm (in) Silencer Type Inside diameter mm (in) 13 seconds or less at 1,000 rpm 4 seconds or less at 5,000 rpm 680 mmbig (-13.1 psi! -90.7 kPa) ‘or more at §,000 rpm Magnetic solenoid-controlled $25-168, 24 40 18.55 250 14,22 (1.45 / 10.49) at 1,500 rpm or more Quick-On- Start System It 60.5 x 2.0 (2.38 x 0.079) 60.5 x 2.0 (2.38 x 0.079) 60.5 x 1.6 (2.38 x 0.063) Circular section-shell construction of triple ‘skin and end plates, internal construction of baffles and perforated tubes Approximately 200 (7.87)00 - 22 SERVICE INFORMATION MAIN DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Engine Model Item Engine type Combustion chamber type Cylinder liner type Timing drive system No, of cylinders - Bore « stroke mm (in) No, of piston rings Total piston displacement em? (in?) Compression ratio to: Compression pressure kPa (kg / cm? / psi) - rpm Fuel injection order Fuel injaction timing (BTDC) deg Specified fuel type Idling speed rpm Valve system Valve clearances (At cold): Intake mm (in) Exhaust mm (in) Valve timing (At valve clearances 0.4 mm (0.016 in)) Intake valves Open at (BTDC) deg Close at (ABDC) deg Exhaust valves Open at (BBDC) deg Close at (ATDC) deg Fuel system Injection pump type Plunger outside diameter mm (in) Plunger lift mm (in) Govemor type ‘Automatic timer type Fuel feed pump type Injection nozzle opening Injection nazzle type Pressure MPa (kg / cm? / psi) Pressure adjustment Main fuel fiter type 4HGt 4HG1-T Four-cycle, overhead camshaft, water cooled Direct injection Dry liner, special compound metal Gear drive 4-115 110 (4-453 + 4.33) Compression rings: 2, Oil ring: + 4570 (278.9) 19.0 3,226 (32.9/468) - 200 1-3-4-2 9 7 (Except Colombia) ‘9 (For Colombia) SAE No. 2 diesel fuel 550 ~ 600 (WIT) 600 ~ 650 (MT) 0.4 (0.016) 0.4 (0.016) 18 50 51 v7 Bosch in-line type with automatic timer 9.5 (0.374) 10.5 (0.413) 11.0 (0.433) RLD-F mechanical (Variable speed) ‘SCDM, centrifugal, flyweight Piston Hole type (with 5 orifices) 18.1 (185 /2,631) Ast 18.1 (185 /2,631) 2nd 21.4 (218 /3,087) ‘Shim adjusted Disposal spin-on cartridge and remote mounted water separatorSERVICE INFORMATION 00 - 23 Engine Model tem 4HG1 4HG1-T Lubricating system Lubrication method Specified engine oil (API grade) Oil pressure kPa (kg /om? / psi) - rpm oll pump type il iter type Oil capacity Oil cooler type Cooling system Radiator type Coolant capacity Water pump type Pump to crankshatt speed ratio. to:1 Delivery volume lit (US / UK gayi lit(US/ UK gal lit (US / UK gal) Pump bearing type ‘Thermostat type Valve initial opening temperature °C("F) Valve lift mm (in) Air cleaner type Battery type Volt-amp.hr. Generator Type Voltage v Drive and rotation Ground polarity Maximum output A Maximum speed rpm Full flow pressure circulation CD or above 447 (1.51 21-700 ‘SAE 10W-30 APICD gate) engine oll at 80°C (176°F) Gear ype Spin-on cartridge 10.5 (277/231) Weater cooled Corrugated fin with reserve tank 12.(3.17/2.64) Centrifugal impeller, V-belt drive 1.19 (1751 147) 200 (52.8 / 44.0) ( Pump speed at 3,200 rpm ) Water temperature at 82°C (180°F), Double row shaft Wax pellet With jiggle valve Primary : 8521.5 (182 - 188) ‘Without jiggle valve (Heaterless) Primary : 85#1.5 (182 - 188) Secondary: 82:H1.5 (177 - 182) 8 (0.3) or more at 95°C (203°F) Dry paper element or cil bath 7SD23R / 12-65 : 2 pos ‘AC brush with IC regulator and vacuum pump 24 | 120024 V-belt, clockwise viewed from the drive pulley Negative 35 at 6,000 rpm 50 at 6,000 rpm {60 at 5,000 rpm 80 (12V) at 5,000 rpm 7,800 ~ 10,00000 - 24 SERVICE INFORMATION Engine Model Exhaust system Pipe outside diameter x thickness Front pipe mm (in) Middle pipe mm (in) Rear pipe mm (in) Silencer type Inside diameter mm (in) i 4HG1 4HG1-T Regulator Type Ic Regulating voltage vi) 28-29 144e03 | 28-29 Vacuum pump -66.7kPa (-500 mmHg /-9.67 psi) build-up time 13 seconds or less at 1,000 rpm 4 seconds or less at 5,000 rpm Maximum vacuum -90.7 kPa (-680 mmHg /-13.1 psi) ‘or more at 5,000 rpm Starter motor Type Magnetic solenoid-controlled Model 825-168 R30 $25 - 168, Rated voltage v 24 2 24 Rated output KW 40 3.0 40 Load characteristics ‘Terminal voltage v 18.55 14.0 18.55 Load current A 250 890 (MAX) 250 Torque Nem ¢kgem / Ibe) 14.22 204 14.22 (1.45/10.49) | (2.99/21.63) | (1.45/ 10.49) at 1,500 rpm at 860 rpm. at 1,500 rpm or more or more or more Preheating system ‘Quick-On-Start System Il 60.5 x 2.0 (2.38 x 0.078) 60.5 x 2.0 (2.38 x 0.078) 60.5 x 1.6 (2.38 x 0.063) Circular section-shell construction of triple skin and end plates, internal construction of baffles and perforated tubes Approximately 200 (7.87)SERVICE INFORMATION 00 - 25 MAIN DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Engine Model tem Engine type Combustion chamber type Cylinder liner type Timing drive system No. of cylinders - Bore « stroke No. of piston rings mm (in) com* in’) to: kPa (kg / cm? / psi) - rpm Total piston displacement Compression ratio Compression pressure Fuel injection order Fuel injection timing (BTDC) deg Specified fuel type Idling speed rpm Valve system Valve clearances (At cold): Intake mm (in) Exhaust mm (in) Valve timing (At valve clearances 0.4 mm (0.016 in)) Intake valves Open at (BTDC) deg Close at (ABDC) deg Exhaust valves Open at (BEDC) deg Close at (ATDC) deg Fuel system Injection pump type Plunger outside diameter mm (in) Plunger lift mm (in) ‘Governor type ‘Automatic timer type Fuel feed pump type Injection nozzle opening Injection nozzle type Pressure MPa (kg / cm? / psi) Pressure adjustment Main fuel fiter type HET 4HE1-1C Four-cycle, overhead camshaft, water cooled Direct injection Dry liner, special compound metal Gear drive 4-110» 125 (44.33 x 4.92) ‘Compression rings 2, oil | Compression rings 3, oil ring 1 ring 1 4751(289.3) 18 173 3,040 (31/441) - 200 1+3-4-2 7 8 SAE No. 2 diesel fuel 550 ~ 600 (WIT) 775 ~ 825 (MIT) 640 ~ 690 (NT) 775 ~ 825 (AT) 0.4 (0.016) 0.4 (0.016) 14 51 49 6 Bosch in-line type with automatic timer 10 (0.394) 11 (0.433) 9.0 (0.354) 12 (0.472) RLD-F mechanical RLD-M mechanical (Variable speed) (Variable speed) SCDM, centrifugal, flyweight Piston Hole type Hole type (with § orifices) (with 6 orifices) 4st 17.5 (180 / 2,560) 21.87 (2201 3,128) 2nd 21.87 (220/ 3,128) ‘Shim adjusted Disposal spin-on cartridge and remote mounted water separator00 - 26 SERVICE INFORMATION Engine Model tem HEAT 4HE1-TC Lubricating system Lubrication method Specified engine oil (API grade) Oil pressure kPa (kg /om? / psi) - rpm oll pump type il iter type il capacity Oil cooler type Cooling system Radiator type Coolant capacity Water pump type Pump to crankshatt speed ratio. to:1 Delivery volume lit (US / UK gayi lit(US/ UK gal lit (US / UK gal) Pump bearing type Thermostat type Valve initial opening temperature °C CF) Valve lift mm (in) Air cleaner type Battery type Model / Vott-amp.lr. Generator Type Voltage v Drive and rotation Ground polarity Maximum output VAI pm Maximum speed fom Full flow pressure circulation CD or above 447 (1.51 21-700 ‘SAE 10W-30 API CD grade engine oil at 80°C (176°F) Gear ype ‘Spin-on cartridge 13 (3.43 / 2.88) Water cooled Corrugated fin with reserve tank 14 (3.70/ 3.08) Centrifugal impeller, V-belt drive 1.16 200 (52.8 / 44.0) Pump speed at 3,300 rpm 1 Water temperature at 82°C (180°F). Double row shaft Wax pellet Without jiggle valve With jiggle valve Primary : 80 - 184 835-865 (176- 183) (182 - 188) Secondary: 83 - 87 - (181 - 189) 8 (0.3) or more 8 (0.3) oF more at 95°C (203°F) at 100°C (212°F) Dry paper element or wet paper element ‘75D23R / 12-65 : 2 pes B80D26R / 12-65 : 2 pes ‘AC brush with IC regulator and vacuum pump 24 120124 \V-belt, clockwise viewed from the drive pulley Negative 241 35 at 5,000 (Denso) | 24/50 at 5,000 (Hitachi) 241.60 at 6,000 (Hitachi) | 12 / 80 at 6,000 (Hitachi) 7,500 ~ 10,000‘SERVICE INFORMATION 00 - 27 Engine Model 4HEAT 4HEI-TC, Item Regulator Type Ic Regulating voltage vi) 28-29 144203 | 28-29 Vacuum pump -800 mmHg (-9.67 psi /-66.7 kPa) build-up time Maximum vacuum mmbg (psi / kPa) Starter motor Type Model Rated voltage v Rated output kw Load characteristics Terminal voltage v Load current A Torque Nem (kgem / bef) Preheating system Exhaust system Pipe outside diameter x thickness Front pipe mm Middle pipe mm Rear pipe mm Silencer type Inside diameter mm (in) (in) din) (in) 13 seconds or less at 1,000 rpm 4 seconds or less at 5,000 rpm 680 (-13.1 / -90.7) ‘or more at 5,000 rpm Magnetic solenoid-controlled S25-305A R30 S25-305A, 24 2 24 45 3.0 45 14.30 140 14.30 400 890 (MAX) 400 28.44 29.4 28.44 (2.90/2098) | (299/216) | (2.90/20.28) at1,500 rpm =| at 860 rpm | at 1,500 1pm. or more or more or more ‘Quick-On-Start System Il 60.5 x 2.0 (2.38 x 0.079) 60.5 x 2.0 (2.38 x 0.079) 60.5 x 1.6 (2.38 x 0.063) Circular section-shell construction of triple skin and end plates, internal construction of baffles and perforated tubes ‘Approximately 200 (7.87)00 - 28 SERVICE INFORMATION SERVICE STANDARD tem Service Standard Service Limit ENGINE ‘Compression Pressure KPa (kg om? / psi) / rpm 3040 (31/441) or more \Variance in pressure between the cylinders: less than 294 (3 / 43) / 200 2,187 (22/312) CYLINDER HEAD Inlet and Exhaust Valve Seat Depression : mm (in) 0.7 -1.2 (0.028 -0.047) 2.5 (0.098) all Measurement should be taken by {| using a new valve, Cylinder Head Lower Face Warpage mm (in) 0.05 (0.002) or less 0.2 (0.008) Do not regrind the cylinder head lower face. Manifold Fitting Face Warpage mm (in) 0.05 (0.002) or less 0.2 (0.008) Water Leak Test Repair or replace KPa (kg / om? psi) 490 (6/71) -3 minutes these having water Cylinder Head Gasket Selection mm (in) | 4HFAUGHFA-214HG1-T Fore Gyfinder Head Gasket Selection mm (in) otal sown by seme retches ace Timex | °*iRctence) Remeber | To | SEER, | ron 8 | o—~ _| ctzss-o0as1) | 175:0088) © [om at-288, [inca AHEA-TIMHEA-TC Cylinder Head Gasket Selection mm (in) Gasket Grade Timex | Reece A | O~ _| cobaoe eed) |_ 17210000) B | = _| cteao-doc6n|_ 17500958) © | or _|ecteer=aasmn | 189000708)SERVICE INFORMATION 00 - 29 tem ‘Service Standard ‘Service Limit CAMSHAFT ‘Cam Height mm (in) 52.75 - 62.91 (2.076 - 2.083) 51.8 (2.039) Camshaft Journal Uneven Wear mm (in) 0.016 (0.0006) or less. 0.05 (0.002) Camshaft Journal Wear mm (in) | 39.950 - 39.976 (1.5728 - 1.5738) 39.860 (1.569) ‘Camshaft Journal and Bearing Clearance mm (in) | 0.025 - 0.087 (0.00098 - 0.00343) 0.15 (0.0059) ‘Camshaft Run-Out mm (in) 0.04 (0.0016) or less 0.05 (0.002) against the adjacent journal ROCKER ARM AND ROCKER ARM SHAFT Rocker Arm Shaft Wear mm (in) | 21.979 ~ 22.000 (0.8653 ~ 0.8661) 24.85 (0.880) Rocker Arm Bushing Wear mm (in) | 22.010 22.036 (0.8665 ~ 0.8675) 22.18 (0.872) Rocker Arm and Rocker Arm 0.010 - 0.056 (0.0004 - 0.0022) 0.2 (0.008) Shaft Clearance mm (in) Rocker Arm Shaft Run-Out mm (in) 0.3 (0.012) Rocker Arm Roller and Pin Clearnace mm (in) 0.040 - 0.084 (0.0016 - 0.0033) 0.5 (0.020) Roller Surface ‘When there is an ‘excessive wear or ‘deformation found, replace it. ‘When it is damaged ‘only slightly, correct itwith an oll stone. VALVE Valve Stem Wear inlet 8.946 - 6.961 (0.3522 - 0.3528) 8.88 (0.35) mm (in) [Exhaust 8.921 - 6.926 (0.3512 - 0.3529) 8.80 (0.34) Wave Siem ard vane inlet 0.036 - 0.074 (0.0046 - 0.0028) 0.20 (0.0079) eee eaten nm Gin [Exhaust (0.064 - 0,096 (0.0025 - 0.0038) 0.25 (0.0098)00 - 30 SERVICE INFORMATION tem Service Standard Service Limit VALVE (CONT.) Valve Guide and Cylinder Head [0.005 - 0.040 (0.0020 - 0.0016) Interference Press itin with the valve guide applied mm (in) |with engine ol. Valve Thickness mm (in) Jinlet Nominal size 1.80 (0.071) 1.3 (0.051) j Exhaust ‘Nominal size 1.76 (0.069) 1.3 (0.051) ‘Valve Contact Width mm (in) J inlet Nominal size 2.5 (0.088) 3.0 (0.118) \ x4 zl ic > Exhaust Nominal size 2.0 (0.078) 25 (0.098) Valve Guide mm (in) 14,140.2 (0.555+0.008) Upper End Height Valve Stem Seal Lip Wear mm (in) 8.3 -8.7 (0.3268 - 0.3425) 8.8 (0.346) Valve Spring Tension N(kg/te)| 414477 (42.2 - 48.6 / 93 - 107) 40.9 (98 / 401) Set length 47.0 mm (1.85 in) Valve Spring Free Height mm (in) Nominal size 62.5 (2.46) 59.4 (2.34) Valve Spring Squareness mm (in) 1.0 (0.04) Valve Clearance (At cold) mm (in) 0.4 (0.016) Valve Stem Cap Wear mm (in) 05 (0.02) Replace it when worn lor deformed excessively ciSERVICE INFORMATION 00-34 Tem Savvice Standard ‘Service Limit CYLINDER BODY Cylinder Liner Bore Wear mm (in) pas ip, 112021- 112.050 (4.4103. 4.4114) 112.20 (4.417) ® AGT: 118.021 - 118.080 (4.6284 4.5205) | 115,20 (4.535) 4uGHT: 4HETT: 140,041 - 110,080 (4.3923 4.3938) | 118.20 (4.535) © 20mm (0.79 in) eee © 0mm (356 in) © 160 mm (6.30 in) ‘ylinder Liner Grade Selection AE VAHET2 Line ]Gylinder Bore Service Liner Outside Remarks: Grade [Diameter _mm(in)| Grade _|Diameter _ mm (in) Cylinder Bore Grade Mark Position + | 15001-115.010 | 4, | 114991- 115.000 The grade mark (1, 2 or 3) ofthe cylinder (4.5276 - 4.5279) (4.5272 - 45276) bore is stamped on the position just 2 | 118011-115.020 beside each cylinder on the upper let side 45280-45283) | 4, | 115001-115.010 {the upper portion ofthe oil cooler 315.021 - 115.030 (4.5276 - 4.5279) installation face) of the cylinder body. 3 | (45284-4.5287) 4HGT4HGT-T Cylinder Liner Grade Mark Postion 118.001- 118.010 | 1X | 117.991- 118.000 The outside diameter grade mark (1, 2 or 1 | (a64s7 - 4.6461) (4.6453 - 4.6457) 3) ofthe cylinder liner is stamped on the 418.011 118.020 position approximately 160mm from the a (4.6461 - 4.6464) 448.001 - 118,010 top face of the liner. 3 | ta02t-118030 | % | 6457-46464) (4.6465 - 4.6468) AEST 4HE1-1C 3 | "5001-115.010 [1X | 115.021- 116.030 (4.5276 - 4.5279) (4.5284 - 4.5287) > | 115011-115.020 (4.5280 - 4.5283) 3x__| 118031- 118.040 3 | 115.021 118.030 (4.5289 - 4.5291) (4.5284 - 4.5287) Cylinder Liner Projection mm (in) Cylinder Body Upper Face Warpage mm (in) Water Leak Test kPa (kg/cm? / psi) (0:10 - 0.14 (0.0038 - 0.0055) ‘The difference in the cylinder liner projection height between any two adjacent cylinders must not exceed 0.03 (0.0012) 0.05 (0.002) or less Do not regrind the cylinder body upper face. 490 (5/71) - 3 minutes There must be a projection on the oylinder liner. 0.02 (0.008) Repair or replace those having water leak.00 - 32 SERVICE INFORMATION ttem Service Standard ‘Service Limit CRANKSHAFT ‘Crankshaft Jurnal and Crankpin Uneven Wear mom (in) 0.05 (0.002) ae Journal No. 1, 2,4 and 5 81.905 - 81.925 (3.2246 - 3.2254) 81.85 (3.2224) lear mm (in)_No.3 81.890 - 81.910 (3.2240 - 3.2248) 81.85 (3.2224) Crankshaft Journal No, 1, 2,4 and 0,037 - 0,072 (0.0015 - 0.0028) 0.11 (0.0043) and Bearing Clearance” _mm (in) No.3 0.051 - 0.086 (0.0020 - 0.0034) 0.11 (0.0043) pais euecen ‘Crankshaft Journal No. 1, 2, 4 and 5 mm (in) Bearing Housing Crankshaft Journal Crankshaft Remarks: Grade] (Reference) | Grade | (Reference) Bearing Crankshaft Bearing Housing | | Mark | Inside Diameter | Mark | Outside Diameter | Color Code Grade Mark Position 1 | 87.905-81.915 a The crankshaft bearing 4 | 87.000-87.009 (8.2246 - 3.2250) housing grade marks (1 or (34262-34255) |) | 81.916- 81.925 2) are stamped collectively (8.2250 - 3.2254) ES for all cylinders on the 1 81.905 - 81.915 Blue peer ie aoe 2 | 87.010-87.019 (3.2246 - 3.2250) i G (8.4286 -3.4259) 81.916 - 81.925 ee 2 | (2250-32254) Black Reacher sournal Grade | crankshaft Journal No. 3 “The crankshaft journal Bearing Housing ‘Crankshaft Journal Crankshaft grade marks (1 or 2) are Grade} —_ (Reference) Grade (Reference) Bearing ‘stamped collectively for ‘Mark | Inside Diameter_| Mark | Outside Diameter Color Code all cylinders on the front 1 | 81.890-87.900 a side of the crankshaft | 87.000-87.009 (8.2240 - 3.2244) No. 1 balancer (3.4282 - 3.4255) 81.901 -81.910 2 | 2244-32248) bal Crankshaft Bearing Grade isons e150 ‘Mark Position 1 : Blue The 87.010 -87.019 (3.2240 - 3.2244) identification color Ba ercee Barc code (black, brown or blue) ¢ a Ree Black of the crankshaft journal {3.2244 - 3.2248) bearing arade mark is applied on the side of each bearing.SERVICE INFORMATION 00-33 tem Service Standard ‘Service Limit CRANKSHAFT (CONT.) Crankpin Wear 4HF1, 4HG1, 4HGI-T: 165.902 - 65.992 (2.5946 - 2.5954) 66.85 (2.6925) HEAT, 4HE4-TC: 72.850 (2.8681) 72.920 - 72.922 (2.8709 - 2.8433) ‘Crankshaft Journal Bearing Spread mm) 87 (3.43) Crankshaft End Play mm(in)| 0.104 - 0.205 (0.0041 - 0.0081) 0.35 (0.014) Crankshaft Run-Out mm (in) 0.05 (0.002) or less 0.3 (0.012) Crankshaft Front and Rear Gil Seal and ‘Slinger Wear When there is an oil leak found, the oil seal and slinger must be replaced as a set. Insertit seourely with a spedal too PISTON Piston and Cylinder Liner Clearance (AHF: 0.08% - 0.17 (0.002 - 0.0044) rm (in) HG: 0.081 - 0.116 (0.0032 - 0.0044) 4HE1-T: 0,091 - 0.131 (0.0036 - 0.0062) AHE%-TC: 0,091 - 0.131 (0,0036 - 0.0052) Piston Grade Selection mm (in) [Piston Grade , ; Piston ; Engine | cyinder Liner Bore Piston Outside Remarks: model | ‘Diameter mm (in)| Swe? | Diameter mm (in) Piston Grade Mark Position ‘The piston grade marks (ie. A, B, C) anei | 112.041-112.060 | _——=«|117,947- 117.960 are stamped on the piston upper face. avez | (44111-44118) (4.4074 = 4.4079) 4HG1_| 118,040-116.050| ‘| 114.944- 114.959, Bilon Ouse Diameter Measuring avert | (45201-45299) (4.5253 - 4.5259) jon 109,944 - 109.959, ‘Take measurement ofthe Piston atthe ax : poston 82mm (2.23 in) from he top inthe | AWE. | 140086 - 007s = st direction ofthe longer dlameter. ox | Wage Te ers00 - 34 SERVICE INFORMATION tem Service Standard Service Limit PISTON PIN Piston Pin Wear mmo] EE sass souan 4HG1 (1.8171 = 1.4173) peer ey) 4HGIT 4HE‘-T 39,095 - 40.000, 4HEI-TC (1.8746 - 1.5748) Seeeeenee Piston and Piston Pin Clearance mm{(in)| 0.004 -0.017 (0.0002 - 0.0007) 0.04 (0.0016) Clearance should be wide enough for the piston pin to be inserted under the conaition where the piston is heated to the ‘When an abnormal striking sound is heard, replace the piston and temperature of 80°C to 100°C (176°F to | the piston pin. 22°F) PISTON RING “ist Compression Ring 0.24 0.30 (0.0084- 0.0153) 1.50 (0.0591) ree 2nd Compression Ring 0.35 - 0.50 (0.0138 - 0.0197) 1.50 (0.0591) Oil Ring 0.02 - 0.40 (0.0008 - 0.0157) 1.50 (0.0591) ‘1st Compression Ring 0.24 -0.39 (0.0004 - 0.0153) 1.50 (0.0591) risen |4HS1 and Compression Rng_| 0.36 0.50 (0.0738-0.0187) 7.500.581) ea il Ring (0.15 - 0.35 (0.00591 - 0.0138) 1.50 (0.0591) aaa ‘st Compression Ring 0.24 - 0.40 (0.0004 - 0.0157) 1.50 (0.0591) 4nie1-1 [2nd Compression Ring 0.56 - 0.71 (0.0220 - 0.0279) 1.50 (0.0591) mn ie) Oil Ring 0.20 - 0.40 (0.0078 - 0.0157) 1.50 (0.0591) ‘1st Compression Ring 0.24 - 0.40 (0.0094 - 0.0157) 1.50 (0.0591) “gnerere [24 Compression Ring 0.30 - 0.40 (0.0118 - 0.0157) 1.50 (0.0591) 3rd Compression Ring 0.30 - 0.40 (0.0118 - 0.0157) 1.50 (0.0591) Oil Ring 0.02 - 0.40 (0.0008 - 0.0157) 1.50 (0.0591) ‘Ist Compression Ring (0.062 - 0.092 (0.0024 - 0.0036) (0.2 (0.0078) Ane [2nd Compression Ring 0.04 - 0.08 (0.0015 - 0.0031) 0.15 (0.0059) OilRing 0.02 - 0.06 (0.0008 - 0.0024) 0.15 (0.0059) Piston ‘Ist Compression Ring (0.062 - 0.092 (0.0024 - 0.0036) (0.2 (0.0078) feos 4461 land Compression Ring | 004-008 (0.00%6-00031) 0.45 (0.0069) pon Oil Ring (0.02 - 0.06 (0.0008 - 0.0024) (0.45 (0.0059) Reo ‘st Compression ing [0.09 0.13 (0035 - 0.0061) 02 (00078) Clearance |4HE1-T [2nd Compression Ring 0.09 - 0.43 (0.0036 - 0.0051) 0.2 (0.0078) Oil Ring 0.03 - 0.07 (0.0012 - 0.0028) 0.15 (0.0069) me) “1st Compression Ring 0.09 - 0.13 (0.0035 - 0.0051) 0.2 (0.0078) “anette [24 Compression Ring 0.09 - 0.13 (0.0035 - 0.0051) (0.2 (0.0078) 3rd Compression Ring 0.09 - 0.13 (0.0035 - 0.0051) (0.2 (0.0078) Oil Ring 0.03 -0.07 (0.0012 - 0.0028) 0.15 (0.0059) ‘The direction of the piston ring connecting end ‘Alternately at 180°. Don't position the connecting end in the side pressure direction. Place the connecting end of the oil ring and that of the expander coil at 480° alternateSERVICE INFORMATION 00-35 Item Service Standard Service Limit CONNECTING ROD Connecting Rod Distortion 0.08 (0.002) or less 0.20 (0.008) ‘Alignment mm (in) | Parallelism 0.08 (0.002) or less 0.20 (0.008) ‘Connecting Rod Small End mm (in) | __0.0%2 - 0.027 (0.0008 - 0.0011) 10.08 (6.002) Bushing and Piston Pin ‘There must be clearance enough to rotate Clearance the piston pin while holding it lightly with its large end fixed. Connecting Rod Bearing Spread mm (in) 70 (2.77) or more ‘Connecting Rod Bearing and ———mmi(in)|__-0.036- 0.077 (0.0014 - 0.0030) (0.10 (0.004) Crankpin Clearance ‘Connecting Rod Bearing Selection +4HFt + 4HF1-2 + 4HG1 + 4HG1-T mm (in) |" Connecting Rod Big End Crankpin [Big End Grade | (Reference) (Reference) | Bearing Color Remarks: Mark _| Inside Diameter | Outside Diameter |Code The connecting rod big end inside 69.985 - 69.092 | 65,002 - 65.922 aie grace marks (Aor B) ate A | (2.7553-2.7556) | (2.5946-2.5954) | __Sreen stamped on 1 cylinder nu Sec aicr ea nace p | 69.993-70.000 | 65.902-65.922 | Venay (2.7556 - 2.7559) | (2.5946 - 2.5954) + 4HEI-T + 4HE1-TC 77.985 - 77.992 | 72.902 - 72.922 Green| 4 _| a.0702-3.0708) | (2.8702 - 2.8709) 77.983 - 78.000 | 72,902- 72.922 B | (g.6706-3.0709) | (28702-28709) | __Yelow The difference in weight between the 02 (2070.28) connecting rod and the piston when assembled. Nige/ FLYWHEEL Flywheel Thickness. mm (in) 31.4 31.6 (1.236 - 1.244) 31.0 (1.22) (Flywheel friction surface - crankshaft setting face) Friction Surface Run-Out mm (in) 0.2 (0.008) Friction Surface Roughness mm Gin) 0.006 (0.0002) or less Ring Gear ‘The tooth face burr must be chamfered Replace ones when damaged excessively.00 - 36 SERVICE INFORMATION tem Service Standard Service GEAR TRAIN Timing Gear Backlash Gear to Gear {In the direction of a normal ine) (0.10 - 0.17 (0.0038 - 0.0067) Hold both the gear to be checked and the 0.30 (0.012) mm (iP) | adjoining gear stationaly. Crankshaft Gear and Crankshaft (0.03 - 0,098 (0.0012 - 0.0037) Interference mm (in) ‘Camshaft Gear and Camshaft 0.016 - 0.023 (0.0006 - 0.0009) Interference mm (in) Idle Gear Shaft Wear mm (in) | 28,959 - 29.980 (1.1795 - 1.1803) 29,80 (1.1732) Idle Gear Bushing Wear mm (in) | 30.000 - 30.021 (1.1811 - 1.1819) 30.1 (1.185) Idle Gear Bushing and Idle Gear 0.020 - 0.062 (0.0008 - 0.0024) 0.2 (0.008) Shaft Clearance mm (in) Idle Gear End Play mm (in) (01058 - 0.116 (0.0002 - 0.005) 0.2 (0.008) LUBRICATION SYSTEM il Pump [Gear Teeth and Inner Wencesae Eee 0.125 - 0.220 (0.0049 - 0.0087) 0.3 (0.012) Gear and Pump Cover ae aa 0.064 - 0.109 (0.0018 - 0.0043) 0.2 (0.008) Gear ShaftWear __mm{(in)|__ 15.989 - 16.000 (0.6295 - 0.6299) 15.9 (0.626) Gear Shaft and Bushing —— an 0.04 - 0.07 (0.0016 - 0.0028) 0.2(0.012) Delivery Volume 16.54 (1.0) cc (curin)rev | Delivery Pressure: 302kPa 4 kglem? / 56.9 psi) Oil Temperature: 502°C (1222 36°F) Oil viscosity SAE 30 Relief Valve Opening [oi Gallery 441.3 (45/640) (Reference) Pressure kPa (kglem? /psiy [Oil Pump 784.5 (8.0 /113.8) (Reference)‘SERVICE INFORMATION 00 - 37 Item Service Standard Service Limit COOLING SYSTEM Water | External appearance Check the following: Pump + Cracks and damages of the pump body + Cracks and corrosion of the impeller + Water leak from the seal unit When an abnormal condition is found, replace the water pump as an assembly. Seal Unit Push the fan center in the radial direction while rotating it and check the seal unit for any excessive play or abnormal sound. When there is any abnormal condition found, replace the water pump as an assembly. Delivery Volume 200 or more lt (US/UK gal) min | Water Pump Speed: 3,300 rpm Water Temperature: 80 42°C (176 + 3.6°F) Fan Drive Belt Tension mm (in) 8-12 (0.31 - 0.47) ... New belt 10 - 14 (0.39 - 0.55) ... Reuse belt Depress the drive belt mid-portion with a SBN (10k /22Ib) force Thermostat | Valve initial Opening 8541.5 (185+ 27) With Jiggle | Temperature “CCF Valve Fi Valve Lit At 100°C 8 (0.31) or more @12F) mm (in Thermostat | Valve initial Opening Primary. 8522185 +36) With-Out” | Temperature °CUCF)| Secondary: 8221786 + 36) age Valve Lift At 95°C (0.31) or more (203°F) mm (in) Radiator _|External appearance + Check the radiator for any corrosion, water leak, fin damage, or clogging. When there is any abnormal condition found, correct the radiator or replace it + When deterioration, cracking or water leak is found in the rubber hose, replace the rubber hose. Pressure Valve Opening 103.0 + 14.7 (1.05 + 0.15 / 14.9 2.1) Pressure kPa (kg /om? / psi) ‘Vacuum Valve Opening MIT: 4.0- 4.9 (0.01 - 0.05 /0.14- 0.71) Pressure AMT: 20 - 4.9 (0.02 - 0.05 /0.28 -0.71) kPa (kg em? / psi)00 - 38 SERVICE INFORMATION higher than 70°C (158°F) AIT: 3,450 + 150 ttem Service Standard COOLING SYSTEM (CONT.) Coating Fan | Cooling Fan Pulley Mm: 3,900 Rotate the fan by Speed AIT 3.860 hand, and when ‘pm itdoesn't rotate Cold Condition (Bi-metal MT: 900 or lower ee lower than 40° (104°F) AT 4200 lower Sec fem replace the fan Hot Condition (Bimetal MIT: 3,300: 160 clutch Time required for the pressure to fall from 16,180 kPa (165 kg /om® 12,346 psi) to 14,220 kPa (145 kPa (kg fom? / 2,082 psi) Spray Condition + The spray must be fine and uniform. + The injection must be directed in the center direction with no stray spray. + The spray from each nozzle hole must be uniform ‘pm Pulley Reto WET184 (Crankshaft/Fan) FUEL SYSTEM Fuel Feed | Suction capacity The suction must be completed in 25 times or less. Pump Priming Pump Speed —_: 60 - 100 times/minute_ Pipe Inside Diameter: 8mm (0.31in) Suction Pipe Length: 2.000mm (78.7 in) Suction Height 4, 000mm (38-4) injection | Nestle Valve Seat Nozzle Portion Oil Tight sec 5 or more.SERVICE INFORMATION 00-39 tem Service Standard Service ENGINE ELECTRICAL Generator | Ball bearing When it doesn't rotate smoothly or is giving out an abnormal sound, or when there is an oll leak from the seal, replace it Slip Ring Diameter mm (in Nominal size 31.6 (1.244) 30.6 Rotor | Coil Resistance | Nominal resistance 12.6 When the resistance differs largely from Coil Insulation 1 or more the standard value, Resistance MO (500 volt megger tester) DRuren= ho Stator | Coil Resistance Nominal resistance 0.17 insulation is found, (Between coil end and each coil end) _| replace it Coil Insulation 1 or more Resistance MQ (600 volt megger tester) Brush Length mm (in Nominal size 20 (0.79) 6 (0.24) ICVoltage | Rectifier The rectifier is normal when there is ‘When there is Regulator ‘continuity with the tester © terminal ‘continuity in both ‘connected to "B” (battery) terminal and the | directions, or when '@ terminal to the rectifier holder, and when | there is no continuity in there is no continuity with their connections. | both directions, replace reversed. the rectifier. Battery Power V | <4HF4 | 4H 1-2 | 4HG1/4HG1-1> LR 250-504 (24\-60A) eee 28-29 LR 250-5088 (24V-50A) c DENSO(12V-36A) eae LR 250-510 (24V-50A) bara LR 180-510 _(12V-80A) I Output Current ry 4300rpm 2000rpm 4000rpm <4HF1 | 4HF1-2 / 4HG1 / 4HG1-T> LR 250-504 18 3583. LR 250-5088 153246 DENSO 12 (18 a LR250-510 15 32 © 43 LR 180-510 25 58 82 Pulley Ratio (CrankshafvGenerator) ua00-40 SERVICE INFORMATION Item Service Standard Service Limit ENGINE ELECTRICAL (CONT.) Vacuum | Pump Housing Inside (GHET-aHiF 1-2) Pump Diameter fren) ecard aa GHG HaHGi-1) (Reference) econ mit) 142-152 (0.559-0.508) CHENEY 2) (Reference) Performances 11900 rp 13 see or ess +1000 rpm 35 sec or less Mile ated (LR 180-510 only) Pressure to get to 5,000 rpm 4 sec or less: -66.7kPa 5,000 rpm 10 sec or less (-500mmHg /-8.7psi (UR 180-510 only) Oil Viscosity SAE 30 Oil Temperature : 70 5°C (158 + 9°F) Oil Pressure |: 447kPa (4.5 kg/cm /64psi) “Tank Capac : 7,000ce (427 cuvn) ‘Check Valve * Apply 98 — 490 kPa (1-5 kg/om? 14-71 psi) compressd ar to pump side of the check valve. + Check for air leakage from the check valve. -lf there is air leakage, the check valve must be replaced. Starter ‘Commutator Run-Out ‘mm (in) 0.08 (0.002 ) or less 0.2 (0.008) ‘Commutator wT 36.5 (1.437) 36.5 (1.398) Outside Diameter mm (in) AT 38.0 (1.496) 96.6 (1.441) Mica Segment Depth ‘mm (in 0.5 -0.8 (0.020 -0.031) 0.2 (0.008) Brush Length MT 15.0 (0.591) 10.5 (0.413) mm (in) | ArT 48.0 (0.709) 11.0 (80.443) Brush Spring wT 24.5 - 34.3 (25-36/55-7.7) Tension Nikg/b) | AT 28.4-35.3 (2.9-3.6/6.4-7.9) Load Characteristics, Terminal Voltage v MT: 18.55 AT: 14.30 Load Current A MT: 250 AT: 400 Torque MIT: 14.2 (1.45/ 10.5) or more Nem (kgem /Ibeft ) AT eee Speed tpm 1 m MT: 860 Terminal acc| B | on| st | 8: | Pr | Pe | w | w Lock Acc ON STARTSERVICE INFORMATION 00-41 ttem ‘Service Standard Service Limit ENGINE ELECTRICAL (CONT.) Preheating | Time required for the 35 system glow indicator to light up After the key switch is turned to (@osil) sec | "ON" position without engine turned. Time required for the 5 source voltage to be After the key switch is turned to supplied tothe glow plug “ON” posiion without engine tured Glow Relay Coil Rsseaaree a Nominal resistance 61.5, ‘Thermo Switch Operating | OFF -> ON: 7 - 13 (44.8 - 55.4) Temperature CPF) | ON-> OFF: Less 3 (37.4) Glow Plug Continuity fno continuity exists, must be replaced,00 - 42 SERVICE INFORMATION SERVICING ‘Servicing refers to general maintenance procedures to be performed by qualified service personnel. MODEL IDENTIFICATION Engine Serial Number ‘The engine number is stamped on the front left hand side of the oylinder body. = ‘Engine number AIR CLEANER Dry Type Washable Paper Element Element cleaning procedures will vary according to the condition of the element. Dust Fouled Element Rotate the element with your hand while apolying compressed air to the inside of the element. This will blow the dust free Compressed air pressure must not exceed 7 kg/om” (88.6 psl686 kPa) Carbon and Dust Fouled Element 1. Prepare a cleaning solution of Isuzu Genuine Element Cleaner (Donaldson D140) diluted with water. 2. Immerse the element in the solution for twenty minutes.SERVICE INFORMATION 00 - 43 3, Remove the element from the solution and rinse it well with running water. Water pressure must not exceed 2.8 kg/cm? (39.8 psil274KPa). 4, Dry the element in a well ventilated area. An electric fan will hasten drying. cAUTIO! Do not use compressed air or an open flame to dry the int quickly. Damage to the element will result. usually take two or three days for the element to dry completely. Therefore, it is a good idea to have a ‘spare on hand to use in the interi LUBRICATING SYSTEM Main Oil Filter (Disposable Spin-On Cartridge Element) Replacement Procedure 1. Loosen the used ol fiter by turning it counterclockwise with the filter wrench Fitter Wrench: 1-85221-097-0 2. Clean the ol iter fitting face This will allow the new oil filter to seat property, Apply alight coat of engine oil to the O-ring 4, Turin the new oil fiter until the filter O-ring is fitted against the sealing face. 5. Use the fitter wrench to turn in the fiter an additional, one full tur. 6. Check the engine oil level and replenish to the specified level if required Engine Oil Replenishment 0.7 (0.190.415) 7. Start the engine and check for oll leakage from the ‘main oll filter. lit (US/UK gal)00 - 44 SERVICE INFORMATION Engine Oil Replacement Draining 1. Remove the drain plug to completely drain the engine ol at Do this while the engine is hot [a=] 2. Replace the drain plug — 3. Tighten the drain plug to the specified torque. \) Drain Plug Torque Nem (kgerbet) 78 (8.0158) Replenishment 4, Remove the filer cap. 2. Pour the specified engine oil into the crankcase through the oil filer. 3. Replace the filer cap. Crankcase and Filter Oil Capacity lit (USIUK gal) 10.5 (2.8/2.3) 4. Start the engine and allow it to ide for a few minutes, 5. Stop the engine, 6. Use the dipstick to check the ol level. If the oil level is below the “MIN” line, add oll through the ol filer. If the ol level is above the "MAX’ ne, drain off the excess ol through the drain plug. FUEL SYSTEM Fuel Filter Replacement Procedure 1. Loosen the used fuel fiter by turning it counterclockwise with the universal filter wrench, 2. Clean the upper cover fiting fave. This will allow the new fuel filter to seat properly.SERVICE INFORMATION 00 - 45 3. Apply a light coat of engine oil to the O-ring, ‘Supply fuel to the new fuel iter to facitate bleeding 5. Tum in the new fuel fter until the filter O-ring is fitted against the sealing face. Be very careful to avoid fuel spillage. Use the fier wrench to turnin the fue! fiter an additional 1/3 to 2/3 of a tur. » 3 7. Operate the priming pump to bleed the air from the fuel line, Bleeding the Fuel System + Loosen the priming pump cap @. + Loosen the air bleeding plug: @. (4HG1-T model only) + Operate the priming pump. Pump the primer pump until fuel flow is free of air bubbles. (Except 4HG1-T model) + Tighten the air bleeding plug ®. oe (4HG1-T model only) + Loosen the bleeding plug ©. + Operate the priming pur. Pump the primer pump until fuel flow is free of air bubbles. + Tighten the bleeder plug ©. + Operate the priming pump. Pump the primer pump until fuel flow is free of air bubbles. (Except 4HE1-TC model) + Loosen the bleeding plug on the injection pump ®. (4HE1-TC model only) + Operate the priming pump. Pump the primer pump until fuel flow is free of air bubbles. (4HE1-TC model only) + Tighten the bleeding plug on the injection pump ©. (4HE1-TC model only) + Lock the priming pump cap ®. NOTE: Check for fuel leakage from around the injection pump, and the fuel filter.00-46 SERVICE INFORMATION Bi [ie] Pre-fuel Filter Water Draii Sub Fuel 8. Start the engine Crank the engine for ten seconds or unt it starts Ifthe engine does not start after ten seconds, repeat Step 7. fer (Dual Type) Replacement Procedure 1. Loosen the fuel fiters by turning them counterclockwise with the universal fiter wrench, 2. Clean the upper cover fiting faces, This will allow the new fuel filters to seat property. ‘Apply a thin coat of engine oil to the O-rings. 4, Install the fier assemblies. Carefully tum each assembly clockwise until the O-ring is fitted against the fier cover sealing face 5. Use the fiter wrench to turn in each fitter assembly an additional 1/3 to 2/3 of turn. 6. Operate the priming pump on the fuel fier to bleed the fuel system Refer to “AIR BLEEDING’ for more detailed information, 19 Procedure ‘The indicator light will come on when the water level in the water separator exceeds the specified level. Drain the water and foreign material from the water separator with the following procedure. 1. Place the end of a vinyl hose (beneath the drain plug) in a container. 2. Loosen the air intake plug and drain plug, then drain Water. 3. After draining, securely tighten the drain plug and air intake plug. 4, Then, operate the priming pump on the injection pump to bleed the fuel system, 5. After starting the engine, check to see that no fuel leaks from the drain plug.‘SERVICE INFORMATION 00 - 47 Injection Nozzle Pressure and Spray Condition Check 1. Use a nozzle tester to check the injection nozzle opening pressure. Ifthe opening pressure is above or below the specified value, the injection nazzle must be replaced or adjusted. Refer to “Adjustment. ae Injection Nozzle Opening Pressure Mpa (kg/em*ipsi) 4HFGHF1-2/4HG1 18.14 (1852,631) 4HE1-TC 21.57 (220/3,128) - jst 18.1 (185/2,631) paca 2nd 21.1 (215/3,057) jst 17.65 (180/2,560) aca 2nd_21.57 (220/3,128) 2. Check the spray coneiition, Refer to the illustration. Spray Condition © Correct @ Incorrect (Restrictions in orifice) @ Incorrect (Dripping) Ifthe spray condition is bad, the injection nazzle must be replaced or adjusted. Refer to “6C FUEL SYSTEM” [:-| Adjustment 1. Clamp the injection nozzle holder @ in a vise @, 2. Use a wrench to remove the injection nozzle retaining rut ©,00 - 48 SERVICE INFORMATION 3. Remove the injection nozzle holder from the vise. 4, Remove the injection nozzle @, the spacer ©, the spring seat © the spring @ and the adjusting shim ® 5. Install the new adjusting shim, the spring, the spring seat, the spacer, the injection nazzle, and the retaining rut 6. Clamp the injection nozzle holder in the vise. 7. Tighten the injection nozzle holder retaining nut to the specified torque. Injection Nozzle Hokler Retaining Nut Torque 7m (kgernibeft) 34 (3.5/25) 8. Remove the injection nozzle holder from the vise. 9. Attach the injection nozzle holder to the injection nozzle tester. 40. Apply pressure to the nozzle tester to check that the injection nozzle opens at the specified pressure. If the injection nozzle does not open at the specified pressure, instal or remove the appropriate number or adjusting shims to adjust it. Removing or installing one shim will increase or decrease the nazzle opening pressure approximately 3.77 kglem* (53.6 psi/370kPa). Adjusting Shim Availability mm (in) Range [0.51.5 (0.02 - 0.08) Increment 0.026 (0.001) Total Number of Shims 41 Air Bleeding (Except 4HF1-2 model onty) ‘Above works refer to "FUEL SYSTEM" in this section.