SECTION 6A

ENGINE MECHANICAL (4JK1/4JJ1)

TABLE OF CONTENTS

ISUZU DIESEL ENGINE (4JK1/4JJ1)................ 6A-3 Inspection........................................................ 6A-47

Service Precautions ........................................ 6A-3 Installation ....................................................... 6A-47
Trouble Shooting ............................................. 6A-8 Torque Specifications...................................... 6A-49
Main Data and Specifications.......................... 6A-13 Timing Gear Train .............................................. 6A-50
Special Tools................................................... 6A-14 Components.................................................... 6A-50
Engine Assembly................................................ 6A-15 Removal .......................................................... 6A-51
Removal .......................................................... 6A-15 Disassembly.................................................... 6A-53
Installation ....................................................... 6A-17 Reassembly .................................................... 6A-53
Special Tools................................................... 6A-19 Inspection........................................................ 6A-54
Engine Mount ..................................................... 6A-20 Installation ....................................................... 6A-55
Components.................................................... 6A-20 Torque Specifications...................................... 6A-58
Removal .......................................................... 6A-21 Camshaft Assembly ........................................... 6A-59
Installation ....................................................... 6A-21 Components.................................................... 6A-59
Torque Specifications...................................... 6A-22 Removal .......................................................... 6A-60
Special Tools................................................... 6A-22 Disassembly.................................................... 6A-61
Cylinder Head Cover .......................................... 6A-23 Reassembly .................................................... 6A-63
Components.................................................... 6A-23 Installation ....................................................... 6A-64
Removal .......................................................... 6A-24 Torque Specifications...................................... 6A-66
Installation ....................................................... 6A-25 Special Tools................................................... 6A-66
Intake Manifold ................................................... 6A-27 Valve Stem Seal and Valve Spring .................... 6A-67
Components (Standard Output) ...................... 6A-27 Components.................................................... 6A-67
Components (High Output) ............................. 6A-28 Removal .......................................................... 6A-68
Removal .......................................................... 6A-29 Inspection........................................................ 6A-69
Installation ....................................................... 6A-31 Installation ....................................................... 6A-70
Torque Specifications...................................... 6A-32 Special Tools................................................... 6A-71
Turbocharger and Exhaust Manifold Cylinder Head..................................................... 6A-72
(Standard Output) ........................................... 6A-33 Components.................................................... 6A-72
Components.................................................... 6A-33 Removal .......................................................... 6A-72
Removal .......................................................... 6A-34 Disassembly.................................................... 6A-81
Inspection ........................................................ 6A-36 Inspection........................................................ 6A-83
Installation ....................................................... 6A-37 Reassembly .................................................... 6A-87
Torque Specifications...................................... 6A-40 Installation ....................................................... 6A-89
Turbocharger (High Output) ............................... 6A-41 Torque Specifications......................................6A-100
Components.................................................... 6A-41 Special Tools...................................................6A-100
Removal .......................................................... 6A-42 Piston and Connecting Rod................................6A-101
Inspection ........................................................ 6A-43 Components....................................................6A-101
Installation ....................................................... 6A-44 Removal ..........................................................6A-101
Torque Specifications...................................... 6A-45 Disassembly....................................................6A-102
Exhaust Manifold (High Output) ......................... 6A-46 Reassembly ....................................................6A-107
Components.................................................... 6A-46 Installation .......................................................6A-108
Removal .......................................................... 6A-47 Torque Specifications......................................6A-110
 Special Tools...................................................6A-110 Installation .......................................................6A-147
Flywheel .............................................................6A-111 Crank Case and Oil Pan ....................................6A-150
Components....................................................6A-111 Components....................................................6A-150
Removal ..........................................................6A-111 Removal ..........................................................6A-151
Inspection ........................................................6A-113 Disassembly....................................................6A-152
Installation .......................................................6A-113 Reassembly ....................................................6A-152
Torque Specifications......................................6A-115 Installation .......................................................6A-153
Special Tools...................................................6A-115 Torque Specifications......................................6A-155
Gear Case Assembly .........................................6A-116 Oil Pump ............................................................6A-156
Components....................................................6A-116 Components....................................................6A-156
Removal ..........................................................6A-117 Removal ..........................................................6A-156
Installation .......................................................6A-118 Disassembly....................................................6A-157
Torque Specifications......................................6A-119 Reassembly ....................................................6A-158
Crankshaft Front Oil Seal...................................6A-120 Inspection........................................................6A-158
Components....................................................6A-120 Installation .......................................................6A-159
Removal ..........................................................6A-120 Oil Pressure SW ................................................6A-161
Installation .......................................................6A-121 Components....................................................6A-161
Torque Specifications......................................6A-122 Removal ..........................................................6A-162
Special Tools...................................................6A-122 Inspection........................................................6A-162
Crankshaft Rear Oil Seal ...................................6A-123 Installation .......................................................6A-162
Components....................................................6A-123 Circuit check....................................................6A-162
Removal ..........................................................6A-124 Air Cleaner Element ...........................................6A-163
Installation .......................................................6A-124 Removal ..........................................................6A-163
Special Tools...................................................6A-125 Cleaning ..........................................................6A-163
Crankshaft..........................................................6A-126 Installation .......................................................6A-163
Components....................................................6A-126
Removal ..........................................................6A-127
Disassembly....................................................6A-127
Reassembly.....................................................6A-128
Inspection ........................................................6A-128
Installation .......................................................6A-132
Torque Specifications......................................6A-135
Cylinder Block ....................................................6A-136
Components....................................................6A-136
Removal ..........................................................6A-136
Inspection ........................................................6A-137
Installation .......................................................6A-139
Lubrication System .............................................6A-140
Service Precautions ........................................6A-140
Functional Check ............................................6A-141
Oil Filter Cartridge ..............................................6A-143
Components....................................................6A-143
Removal ..........................................................6A-143
Installation .......................................................6A-143
Special Tools...................................................6A-144
Oil Filter Assembly and Oil Cooler .....................6A-145
Components....................................................6A-145
Removal ..........................................................6A-145
Disassembly....................................................6A-146
Reassembly.....................................................6A-147
 ISUZU DIESEL ENGINE (4JK1/4JJ1)
• Surfaces covered with liquid gasket must be
Service Precautions assembled within 5 minutes of gasket application.
Matters that require attention in terms of If more than 5 minutes has elapsed, remove the
maintenance existing liquid gasket and apply a new liquid
To prevent damage to the engine and ensure reliability gasket.
of its performance, pay attention to the following in
• When assembling or installing parts, fasten them
maintaining the engine:
with the prescribed tightening torque so that they
• When lifting up or supporting the engine, do not
are installed properly.
apply a jack on the oil pan.
When taking down the engine on the ground, do Matters that require attention in specifically dealing
not make the bearing surface of the oil pan touch with this engine.
the ground directly. Use a wooden frame, for Holes or clearances in the fuel system, which serve as
example, to support the engine with the engine a passage of fuel, including the inside of the injector,
foot and the flywheel housing. are made with extreme precision. For this reason, they
are highly sensitive to foreign matter and, if it gets in, it
Because there is only a small clearance between
can lead to an accident on the road, for instance; thus,
the oil pan and the oil pump strainer, it can make sure that foreign matter is prevented from getting
damage the oil pan and the oil strainer. in.
• When the air duct or air cleaner is removed, cover
the air intake opening to prevent foreign matter When servicing the fuel system, every precaution must
from getting into the cylinder. If it gets be taken to prevent the entry of foreign material into the
contaminated, it can considerably damage the system.
cylinder and others while the engine is operating. • Before beginning the service procedure, wash the
• When maintaining the engine, never fail to remove fuel line and the surrounding area.
the battery earth cable. If not, it may damage the • Perform the service procedures with clean hands.
wire harness or electrical parts. If you need Do not wear work gloves.
electricity on for the purpose of inspection, for • Immediately after removing the fuel hose and/or
instance, watch out for short circuits and others. fuel pipe, carefully tape vinyl bags over the
• Apply engine oil to the sliding contact surfaces of exposed ends of the hose or pipe.
the engine before reassembling it. This ensures • If parts are to be replaced (fuel hose, fuel pipe,
adequate lubrication when the engine is first etc.) do not open the new part packaging until
started. installation.
• When valve train parts, pistons, piston rings,
connecting rods, connecting rod bearings or Work procedure
crankshaft journal bearings are removed, put them
• The fuel opening must be quickly sealed when
in order and keep them.
removing the fuel pipe, injection pipe, fuel injector,
• When installing them, put them back in the same
fuel supply pump, and fuel rail.
location they were removed from.
• The eyebolts and gasket must be stored in a clean
• Gaskets, oil seals, O-rings, etc. must be replaced
parts box with a lid to prevent adhesion of foreign
with new ones when the engine is reassembled.
matter.
• As for parts where a liquid gasket is used, remove
• Fuel leakage could cause fires. Therefore, after
an old liquid gasket completely and clean it up
finishing the work, wipe off the fuel that has leaked
thoroughly so that no oil, water or dust is clinging
out and make sure there is no fuel leakage after
to them. Then, apply the designated liquid gasket
starting the engine.
to each place anew before assembly.
How to read the model (This illustration is 4JK1 engine)

RTW56ALF004701

Legend
1. Engine Model (Stamped) 3. Front
2. Engine Number (Stamped)

Explanation of functions and operations Cylinder head

Electronic engine control The cylinder head is aluminum-alloy and there are 4
With the control unit, the range from injection to air valves per cylinder. The angular tightening method of
intake/exhaust, including fuel injection quantity, injection the cylinder head bolt further increases reliability and
timing, intake air restriction, EGR, and idling rpm, is durability.
controlled.
Piston
The piston is aluminum-alloy and a thermal flow piston
with a strut cast, while the combustion chamber is a
round reentrant type.
EGR system Fuel filter with sedimenter
Based upon data, including water temperature, engine It is a fuel filter with sedimenter that gets rid of water by
speeds or engine loads, it is controlled via Engine making use of the difference in specific gravity between
Control Module (ECM) to purify exhaust by recycling light oil and water, which comes with an indicator that
part of it. notifies you that it is filled with water.
Its main components include an EGR valve, an EGR
cooler and various sensors. Preheating system
The preheating system consists of the ECM, the glow
Connecting rod cap bolt relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
The angular tightening method of the connecting rod
temperature is low, and makes the engine easy to start.
cap bolt further increases reliability and durability.
Lubrication system
Fuel rail-type electronic control injection system It is an oil filter with full-flow bypass, which uses a
The fuel rail-type electronic control injection system is water-cool oil cooler and oil jet to cool the piston.
composed of a fuel supply pump that sets the target
pressure of high-pressure fuel and supply it, a fuel rail Functional inspection
that measures such high-pressure fuel and a fuel Inspection/adjustment of valve clearance
injector that turns it into a fine spray and injects it. Each
1. Inspection of valve clearance
is controlled via ECM based upon various signals, while
injection timing or fuel injection quantity is controlled • Remove the fuel injector harness assembly.
under every possible driving condition. • Remove the leak off hose.
• Remove the cylinder head cover.
Fuel injector • Rotate the crankshaft to make the No.1
The fuel injector is a 6-hole nozzle that adjusts fuel cylinder meet the compression top dead center
injection quantity or injection timing by opening or (TDC).
closing an electromagnetic valve on the head of the fuel
injector.
ECM corrects the dispersion of fuel injection quantity
between fuel injector according to ID code data in
memory. At the replacement of fuel injector, ID code
data should be stored in ECM.

RTW76ASH001301

Legend
1. TDC
 • Insert a 0.15 mm (0.006 in) thickness gauge
between the roller of the rocker arm and the
camshaft to tighten up the adjusting screw of
the rocker arm. When the movement of the
thickness gauge becomes tight, fasten the
adjusting screw nut of the rocker arm.

Valve clearance mm (in)

Intake valve 0.15 (0.006)
Exhaust valve 0.15 (0.006)

Note:
Adjust while cold.
2. Adjustment of valve clearance
• Loosen each adjusting screw of the rocker arm LHW71BSH001201

completely. Legend
1. Cam; Exhaust
2. Cam; Intake
3. Roller; Intake
4. Roller; Exhaust

Tightening torque:

Rocker arm adjustment screw nut

18 N⋅⋅m (1.8 kg⋅⋅m/ 13 lb ft)

Adjustment table

Cylinder No. 1 2 3 4
Valve
IN EX IN EX IN EX IN EX
arrangement
No. 1 cylinder
RTW56ASH003701 Compression
Legend TDC
1. Screwdriver No. 4 cylinder
2. Ring Spanner Compression × × × ×
3. Valve Clearance Adjust Nut Wrench TDC

Special tool
• If the No.1 cylinder is the compression TDC, adjust
Valve clearance adjust nut wrench: 5-8840-2822-0
a valve clearance with mark given on the table
• Insert a 0.15 mm (0.006 in) thickness gauge
and if the No. 4 cylinder is the compression TDC,
between the roller of the rocker arm and the
adjust that with × mark.
camshaft to tighten up the adjusting screw of
• Install the cylinder head cover.
the rocker arm. When the movement of the
Refer to "Cylinder Head Cover."
thickness gauge becomes tight, fasten the
• Install the leak off hose.
adjusting screw nut of the rocker arm.
• Install the fuel injector harness assembly.

Compression pressure inspection

• Warm up the engine.
• Disconnect the negative battery cable.
 • Remove the all glow plugs. A list of defective phenomena
• Engine does not turn over.
Note: • Engine turns over but does not start.
When the harness connector is removed, ECM judges • Excessive black exhaust smoke.
that it broke down and DTC is recorded. Upon • Excessive white exhaust smoke.
completion of measurement, never fail to clear the
• Engine knocking.
memory of the ECM.
(For how to clear the memory of the ECM, refer to • Abnormal engine rotation.
“ENGINE CONTROL SYSTEM” Section) • Abnormal battery charging.
• Connect the negative battery cable. • Turbocharger trouble shooting.
• Turn on the starter to emit foreign matter within the
cylinders.
• Install an adapter and a gauge of a compression
gauge of the special tool.

RTW56ASH003801

Compression gauge: 5-8840-2675-0

Gauge adapter: 5-8840-2815-0
• Turn on the starter to inspect compression
pressure.
Compression pressure MPa(psi)/200rpm
Standard 2.84 − 3.24 (412 − 469)
Limit 1.96 (284)
Differences among
294 kPa (43)
the cylinders

• Measure each cylinder one by one.

Note:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
• Remove a compression gauge of the special tool.
• Disconnect the negative battery cable.
• Install the glow plugs.
• Connect the negative battery cable.
Trouble Shooting
Engine does not turn over
Condition Possible Cause Correction
Starter motor does not rotate Dead or weak battery Charge battery
Replace battery
Incomplete circuit Connect
Repair
Starter motor brushes stuck, worn, Replace brushes
or broken
Starter motor internal damage Repair motor
Starter motor not meshed with Ring gear abrasion Replace ring gear
flywheel
Magnetic switch (starter motor) not Adjust
properly adjusted
Starter motor pinion meshed with Dead or weak battery Charge battery
ring gear but does not rotate Replace battery
Insufficient contact pressure Adjust pressure
between starter motor brushes and
commutator
Armature (starter motor) stuck Repair armature
Engine internal damage (Seizure) Repair engine

Engine turns over but does not start

Condition Possible Cause Correction
Fuel is not delivered to fuel supply Air in fuel system Bleed air from fuel system
pump
Air entering fuel pipe Replace pipe and bleed air from
fuel system
Empty fuel tank Replenish fuel
Clogged strainer (fuel suction) Clean or replace strainer
Clogged fuel pipe Clean or replace pipe
Feed pump malfunction Replace pump
Use of wrong fuel for prevailing Drain existing fuel and replace with
temperatures appropriate fuel
Clogged fuel filter Replace filter
Fuel is delivered to fuel supply Loose injection pipe connections Tighten connections
pump
Loose or broken electrical Tighten and/or replace connectors
connectors
Bad rotational sensor Replace sensor
Engine control system malfunction System diagnosis
Insufficient or unstable fuel delivery Air in fuel system Bleed air from fuel system
volume
Feed pump malfunction Repair pump
Loose or broken electrical Tighten and/or replace connectors
connectors
Clogged fuel filter Replace filter
Engine control system malfunction System diagnosis
Excessive black exhaust smoke
Condition Possible Cause Correction
Bad injection timing Engine control system malfunction System diagnosis
Bad fuel injector condition Carbon deposit at nozzle tip Clean fuel injector assembly
Sticking nozzle Replace fuel injector assembly
Engine control system malfunction System diagnosis
Insufficient compression pressure Excessive valve clearance Adjust clearance
Sticking valve stem (valve open) Repair or replace valve
Damaged valve spring Replace spring
Valve seat abrasion Repair valve seat
Compression leakage due to Replace piston ring
damaged piston ring
Damaged gasket Replace gasket
Piston scoring Replace piston
Fuel condition Water in fuel Drain existing fuel and replace with
new fuel
Poor fuel quality Drain existing fuel and replace with
new fuel
Poor engine aspiration Clogged intake pipes Clean or replace pipes
Clogged air cleaner element Clean or replace element
Malfunction detected by engine Defective sensor Replace sensor
control system
Engine control system malfunction System diagnosis
EGR valve and/or intake throttle Intake throttle valve sticking Repair or replace valve
valve malfunction
EGR valve sticking Repair or replace valve
Engine control system malfunction System diagnosis
Turbocharger malfunction Damaged turbocharger blade Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Oil leakage from oil seal Replace turbocharger
Broken actuator Replace turbocharger
Excessive white exhaust smoke
Condition Possible Cause Correction
Bad injection timing Engine control system malfunction System diagnosis
Malfunction detected by engine Defective sensor Replace sensor
control system
Control unit malfunction Replace unit
Engine control system malfunction System diagnosis
Insufficient compression pressure Excessive valve clearance Adjust clearance
Sticking valve stem (valve open) Repair or replace valve
Damaged valve spring Replace spring
Valve seat abrasion Repair valve seat
Compression leakage due to Replace piston ring
damaged piston ring
Damaged gasket Replace gasket
Piston scoring Replace piston
Fuel condition Water in fuel Drain existing fuel and replace with
new fuel
Excessive oil consumption Worn or damaged piston ring(s) Replace ring(s)
Defective valve stem oil seal Replace oil seal
Defective turbocharger oil seal Replace turbocharger
Clogged turbocharger oil return Repair pipe
pipe

Engine knocking
Condition Possible Cause Correction
Bad timing Engine control system malfunction System diagnosis
Malfunction detected by engine Defective sensor Replace sensor
control system
Control unit malfunction Replace unit
Engine control system malfunction System diagnosis
Fuel condition Poor quality fuel Drain existing fuel and replace with
new fuel
Poor engine aspiration Clogged air cleaner element Clean or replace element
Clogged intake pipes Clean or replace pipes
Engine control system malfunction System diagnosis
Engine break-down Foreign material in cylinders Engine overhaul
Scored pistons and/or bearings Replace pistons and/or bearings
Abnormal engine rotation
Condition Possible Cause Correction
Engine speed cannot be increased Defective control unit Replace unit
Engine control system malfunction System diagnosis
Engine speed unstable Defective control unit Replace unit
Engine control system malfunction System diagnosis
Clogged fuel filter element Replace element
Defective fuel injector(s) Replace fuel injector assembly
Water in fuel Drain existing fuel and replace with
new fuel
Air in fuel system Bleed air from fuel system
Turbocharger malfunction Damaged turbocharger fan Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Broken actuator Replace turbocharger

Abnormal battery charging

Condition Possible Cause Correction
No charging Open or shorted wiring and/or Repair or replace wiring and/or
connectors connectors
Defective generator Repair or replace generator
Defective battery Replace battery
Insufficient charging Open or shorted wiring and/or Repair or replace wiring and/or
connectors connectors
Defective generator Repair or replace generator
Loose generator drive belt Adjust belt tension or replace belt
Defective battery Replace battery
Excessive charging Shorted wiring Repair or replace wiring
Defective generator Repair or replace generator
Defective battery Replace battery
Turbocharger Troubleshooting
Condition Possible Cause Correction
Engine has less than normal power Air leakage from intake pipe rubber Repair
hose
Air leakage from intake cover Repair
Clogged intercooler cooling section Clean
Clogged air cleaner element Clean or replace
Intake throttle valve stuck Repair or replace
Turbine and housing contact Replace
(Interference)
Excessive carbon deposit near Clean or repair
turbine exhaust port that interferes
with turbine
Rough turbine shaft rotation Repair or replace
Damaged turbine blade Repair or replace
Blue exhaust smoke Oil leakage from turbocharger oil Repair or replace
seal
Clogged turbocharger oil return Repair
pipe
Clogged center housing oil Repair or replace
passages
Engine oil deterioration Change engine oil
Noisy turbocharger operation Gas leakage from intake or Repair
exhaust system
Turbine and housing contact Repair or replace
(Interference)
Damaged turbine blade Replace
Turbine shaft bearing abrasion or Repair or replace
scoring
Excessive rotating part wear Engine oil deterioration Change engine oil
Clogged turbocharger oil feed pipe Repair
Low engine oil pressure Repair
Main Data and specifications
Item Engine model 4JK1 Engine model 4JJ1
Type Diesel/4-cycle/water cooling-type in-line DOHC
Combustion chamber type Direct injection type
Cylinder liner type Liner less
Number of cylinders -cylinder mm (in) 4-95.4 (3.76) × 87.4 (3.44) 4-95.4(3.76) × 104.9(4.13)
bore × strokes
Displacement cc (cu.in) 2499 (152) 2999 (183)
Compression ratio 18.3 17.5
Compression pressure MPa (psi)/rpm 3 (435)/200
Idling speed rpm 700 ± 25
Valve clearance Intake 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 delivery type
Oil pump type Gear type
Volume of lubricating oil L (qts) 8.0 (8.5)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in-type, water cooling
Cooling system
Cooling type Water cooling type
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt drive type
Thermostat type Wax-type units
Thermostat valve-opening temperature °C (°F) 85 (185)
Volume of coolant L (qts) M/T8.7 (9.2) A/T 8.6 (9.1) (incl. radiator)
Fuel system
Injection pump type Fuel supply pump fuel rail type
Fuel injector type Electronic control injector
6-hole
Fuel pump type Into the fuel tank type
Charging system
Generator type AC type
Power output V-A 12 - 90
 Item Engine model 4JK1 Engine model 4JJ1
Regulator type IC
Starting system Engage magnet type
Starter type Reduction type
Power output V-kW 12 – 2.3
Preheat system type Glow plug
Glow plug standard voltage/electric current V-A 12 - 3.5

Special Tools
PART NO.
ILLUSTRATION
PART NAME

5-8840-2822-0
Valve clearance
adjust nut wrench

5-8840-2675-0
Compression gauge

5-8840-2815-0
Compression gauge
adapter
 Engine Assembly

Removal
1. Disconnect the negative battery cable.
2. Remove the engine hood.
3. Drain the coolant.
4. Remove the starter motor.
5. Remove the transmission assembly.
Refer to removal procedure for “TRANSMISSION”
in this manual.
6. Disconnect the ECM harness connector.
7. Remove the ECM.
8. Remove the air cleaner.
• Disconnect the MAF sensor harness connector.
• Remove the intake pipe with the lid of air
cleaner box.
• Remove the air cleaner box. RTW56ASH004001

Legend
1. Intake Hose (intercooler - intake throttle)
2. Intake Hose (turbocharger - intercooler)

11. Remove the intercooler (High output).

• Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).

RTW76ASH000401

Legend
1. ECM Harness Connector
2. ECM
3. Air Cleaner Box
4. MAF Sensor Harness Connector

9. Remove the intake hose (intercooler - intake

throttle) (Standard output).
10. Remove the intake hose (turbocharger - RTW76ASH000501

intercooler) (Standard output). 12. Remove the radiator upper hose.

Remove the harness connector. 13. Remove the engine harness clip (1).
 20.Remove the power steering pump.
• Remove the bracket of power steering oil hose
(1).

RTW76ASH001401

14. Remove the breather hose and lower hose of the

radiator.
15. Remove the fan guide. LTW56ASH000101

16. Remove the drive belt. 21.Remove the harness of engine, battery and earth
17. Remove the fan assembly. from the body side.
18.Remove the radiator. 22.Remove the connector of the shift on the fly (4×4).
19.Remove the A/C compressor. 23.Remove the vacuum hose of brake master-vac.
24.Remove the front exhaust pipe.
25.Disconnect the fuel hose on the feed and return
sides.
26.Install the engine hanger (special tool 5-8840-
2823-0).

RTW76ASH000701

Legend
1. A/C Compressor Bracket
2. A/C Compressor

• Disconnect the connector.

RTW56ASH004301
• Disconnect the A/C generator harness. Legend
• Disconnect the terminal B cable and harness
1. Engine Hanger (Front Side)
connector from the generator.
 7. Install the vacuum hose of brake master-vac.
8. Install the connector of the shift on the fly (4×4).
9. Install the harness of engine, battery and earth to
the body side.
10.Install the power steering pump.
Tightening torque: 25 N⋅⋅m (2.5kg⋅⋅m / 18 lb ft)
• Install the bracket of power steering oil hose.
11.Install the A/C compressor.
Tightening torque: 25 N⋅⋅m (2.5kg⋅⋅m / 18 lb ft)
• Install the connector.
12.Install the A/C generator harness.
• Install the terminal B cable and the harness
connector to the generator.
13.Install the radiator.
RTW56ASH004401 Tightening torque: 25 N⋅⋅m (2.5kg⋅⋅m / 18 lb ft)
Legend 14.Install the fan assembly.
1. Engine Hanger (Rear Side)
Tightening torque: 8 N⋅⋅m (0.8kg⋅⋅m / 69 lb in)
27.Hang wire on the engine hanger and hoist to lift up 15.Install the drive belt.
the engine slightly. Refer to removal procedure for drive belt in this
28.Remove the engine mount. manual.
• Remove the fastening bolts for the engine mount 16.Install the fan guide.
on the engine side. 17.Install the breather hose and lower hose of the
29.Remove the engine assembly. radiator.
• Hoist the engine slightly to provide space to 18.Install the engine harness clip (1).
remove the catalytic converter.

Installation
Notice:
Be absolutely sure that each harness is reconnected to
its original position.
1. Install the engine assembly.
• Hang wire on the engine hanger and hoist to lift up
the engine.
• Operate a hoist slowly to move the engine to the
place where it is to be installed.
• Make the transmission side lower and operate a
hoist slowly, pulling it backward to the engine.
2. Install the engine mount.
Tightening torque: 48 N⋅⋅m (4.9kg⋅⋅m / 35 lb ft)
3. Remove the engine hanger. RTW76ASH001401

4. Install the catalytic converter. 19.Install the radiator upper hose.

20.Install the intake hose (turbocharger -intercooler)
Tightening torque: 27 N⋅⋅m (2.8kg⋅⋅m /20 lb ft)
(Standard output).
5. Install the front exhaust pipe. • Install the harness connector.
Tightening torque: 67 N⋅⋅m (6.8kg⋅⋅m / 49 lb ft)
6. Install the fuel hose on the feed and return sides.
21.Install the intake hose (intercooler - intake throttle)
(Standard output).

RTW56ASH004001

22.Install the intercooler (High output).

• Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
23.Install the air cleaner.
• Install the intake pipe with the lid of air cleaner
box.
• Install the air cleaner box.
• Connect the MAF sensor harness connector.
24.Install the ECM.
25.Connect the ECM harness connector.
26.Install the transmission assembly.
Refer to installation procedure for
“TRANSMISSION”.
27.Install the starter motor.
Tightening torque: 94 N⋅⋅m (9.6kg⋅⋅m / 69 lb ft)
28.Replenish the coolant.
29.Install the engine hood.
Tightening torque: 10 N⋅⋅m (1.0kg⋅⋅m / 87 lb in)
30.Connect the negative battery cable.
Special Tools
PART NO.
ILLUSTRATION
PART NAME

5-8840-2823-0
Engine hanger
 Engine Mount

Components

RTW56ALF001801

Legend
1. Nut 8. Bolt (L = 45 mm / 1.77 in)
2. Bolt (L = 80 mm / 3.15 in) 9. Bolt (L = 30 mm / 1.18 in)
3. Bolt (L = 30 mm / 1.18 in) 10. Bolt (L = 40 mm / 1.57 in)
4. Bolt (L = 30 mm / 1.18 in) 11. Bolt (L = 20 mm / 0.78 in)
5. Engine Foot RH 12. Bolt (L = 100 mm / 3.94 in)
6. Engine Mount RH 13. Engine Foot LH
7. Bolt (L = 25 mm / 0.98 in) 14. Engine Mount LH
Removal Installation
1. Remove the engine hood. 1. Install the engine mount and tighten up with the
2. Remove the engine cover. specified torque.
3. Set the hoist and the engine hanger of the special Tightening torque: 52 N⋅⋅m (5.3 kg⋅⋅m / 38 lb ft)
tool (special tool 5-8840-2823-0).
2. Install the engine cover.
4. Remove the engine mount.
3. Install the engine hood.
• Before removing the engine mount, hang the
• Check if nothing is wrong with the engine
engine with a hoist.
mount by starting the engine.
• Remove the bolts of the engine mount.
• Hoist the engine assembly slightly to remove the
engine mount.

RTW56ASH004501
Torque Specifications

RTW56ALF003801

Special Tools
PART NO.
ILLUSTRATION
PART NAME

5-8840-2823-0
Engine hanger
 Cylinder Head Cover

Components

RTW76ALF000101

Legend
1. Oil Filler Cap 5. Head Cover Mounting Rubber
2. Oil Filler Cap Gasket 6. Nozzle Seal Cover
3. Cylinder Head Cover 7. Head Cover Gasket
4. Bolt 8. Nut
 5. Disconnect the fuel injector connector (2).
Removal 6. Remove the fuel leak off hose (1).
1. Remove the engine cover.
2. Remove the intake air duct (3) (Standard output).
3. Remove the harness bracket (6).

RTW76ASH000101

Note: Do not reuse the clips (1).

RTW56ASH025001

Legend
1. Blow-by Hose
2. Leak-off Hose
3. Intake Air Duct
4. Fuel Injector Connector
5. Leak-off Hose
6. Harness Bracket

4. Remove the intercooler (High output).

• Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).

LNW76ASH002101

7. Disconnect the blow-by hose.

RTW76ASH000501
8. Remove the cylinder head cover.
Installation
1. Install the nozzle seal cover.
• Insert from the lower side of cylinder head
cover.
• Apply soapy water or engine oil to the surface
of cylinder head cover side.
• Insert the nozzle seal cover as far as it will go.
2. Install the cam end gasket.
• Apply the liquid gasket (ThreeBond TB-1207B
or equivalent) and mount.

LNW71BSH000401

9. Remove the nozzle seal cover from the cylinder

head cover.
• Remove from the lower side of cylinder head
cover.
10. Remove the cam end gasket (1).
• Remove the liquid gasket that has adhered to
cylinder head completely.

RTW56ASH020601

Legend
1. Cam End Gasket
2. Apply The Liquid Gasket
3. 2.0 - 3.0 mm (0.079 - 0.118 in)

• Apply attaching cam end gasket.

Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).

RTW56ASH020501
 8. Install the intake air duct.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb in)
9. Install the engine cover.

RTW56ASH022701

Legend
1. 3.0 - 5.0 mm (0.118 - 0.197 in)
2. 3.0 - 5.0 mm (0.118 - 0.197 in)

3. Install the cylinder head cover.

Tightening torque: 10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in)
• Tighten the nut and bolts in order shown in the
illustration.

RTW56ASH004801

4. Install the blow-by hose.

5. Install the leak-off hose and the fuel injector
connector.
6. Install the harness bracket to the cylinder head
cover.
7. Install the intercooler (High output).
• Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
 Intake Manifold

Components (Standard Output)

RTW76ALF000201

Legend
1. Intake Duct 4. Intake Manifold
2. Throttle Assembly 5. EGR Valve Assembly Gasket
3. Intake Manifold Gasket 6. EGR Valve Assembly
Components (High Output)

RTW76ALF000301

Legend
1. Intake Duct 5. Intake Manifold
2. Intake Throttle 6. EGR Valve Assembly Gasket
3. Intake Throttle Gasket 7. EGR Valve Assembly
4. Intake Manifold Gasket 8. Bracket
Removal
1. Remove the engine cover.
2. Disconnect the connectors.
• Fuel Injector
• Throttle Assembly
• EGR Valve
• Glow Plug
• Barometric Sensor
• A/C Compressor Connector
3. Remove the A/C belt
4. Remove the A/C compressor.
5. Remove the A/C compressor bracket.
6. Remove the intake air duct (Standard output).

RTW76ASH000501

8. Remove the injector leak-off hose (1).

RTW56ASH024801

Legend
1. A/C Compressor Bracket
2. Intake Air Duct RTW56ASH024301

3. A/C Compressor 9. Remove the engine oil level gauge guide tube.
10. Remove the EGR valve.
7. Remove the intercooler (High output).
• Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).
 RTW66ASH003001 RTW56ASH005201

11. Remove the injection pipes. Legend

• Remove sequentially from No.1 cylinder. 1. Throttle Assembly
12. Disconnect the vacuum hose of swirl control valve 2. Intake Manifold
(1).
14. Remove the intake manifold.

RTW66ASH003101
RTW56ASH018001
13. Remove the throttle assembly and gasket.
15. Remove the intake manifold gasket.
Installation
1. Install the intake manifold gasket.
2. Install the intake manifold.
• Tighten the nuts and bolts in the order
described in the drawing.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)

RTW56ASH024301

Legend
1. Injector Leek-off Hose

11. Install the intake air duct.

Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
12.Install the A/C compressor bracket.

RTW56ASH018001
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
3. Install the throttle assembly and gasket. 13.Install the A/C compressor and A/C compressor
• Tighten the bolts to the specified torque. connector.
Tightening torque: 10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in) Tightening torque: 44 N⋅⋅m (4.5 kg⋅⋅m / 33 lb ft)
4. Install the vacuum hose of swirl control valve. 14.Install the A/C belt.
5. Install the injection pipe (fuel rail - fuel injector). Check the A/C belt tension.
• It installs sequentially from No. 4 cylinder. Depress the A/C belt mid-portion with 98 N (10 kg /
Tightening torque: 29 N⋅⋅m (3.0 kg⋅⋅m / 22 lb ft) 22 lb) force.

6. Install the EGR valve. Standard deflection: 7.6 - 9.2 mm (0.29 - 0.36 in)
• Tighten the nuts to the specified torque.
Tightening torque: 27 N⋅⋅m (2.8 kg⋅⋅m / 20 lb ft)
7. Install the engine oil level guide tube.
Tighten the nuts to the specified torque.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
8. Install the intercooler (High output).
9. Connect the connector of other parts.
• Fuel Injector
• Throttle Assembly
• EGR Valve
• Glow Plug
• Barometric Sensor
• A/C Compressor Connector
10. Install the leak-off hose.
RTW510SH000201

15. Install the engine cover.

Torque Specifications

RTW76AMF000101
 Turbocharger and Exhaust Manifold (Standard Output)

Components

RTW56ALF002101

Legend
1. Turbocharger Assembly 6. Oil Return Pipe
2. Exhaust Manifold 7. Intake Hose for Intercooler and Intake Throttle
3. Heat Protector 8. Intake Duct for Turbocharger and Air Cleaner
4. Catalyst Converter 9. Intake Hose for Turbocharger and Intercooler
5. Oil Feed Pipe
 Legend
Removal 1. Oil Feed Pipe
1. Loosen the radiator drain plug to drain coolant. 2. EGR Cooler
2. Remove the engine cover. 3. Water Feed Pipe
3. Remove the intake hose from the intercooler and 4. Water Return Pipe
intake throttle. 5. Oil Return Pipe
4. Remove the intake hose from the turbocharger
10. Remove the front exhaust pipe.
and the intercooler.
5. Remove the air intake duct from the turbocharger
and the air cleaner.
6. Remove the EGR cooler.
Refer to “EGR Cooler” in EXHAUST SYSTEM
Section.
7. Remove the oil feed pipe.
8. Remove the oil return pipe.
• Loosen clamp (1) of A/T oil cooler pipe.

RTW56ASH018301

Legend
1. Gasket
2. Front Exhaust Pipe (4×2 High Ride Suspention,
4×4)
3. Gasket
4. Front Exhaust Pipe (4×2 Except High Ride
Suspention)

RTW56ASH025101 11. Disconnect the front propeller shaft flange (1)

9. Remove the water feed and return pipe. (Front Diff Side, 4×4 only).

RTW56ASH005401 RTW76ASH002301
 12. Remove the catalyst converter. 14. Remove the exhaust manifold.
• Remove the 8 nuts from the exhaust manifold.

RTW56ASH005601

RTW56ALH000201

13. Remove the turbocharger from the exhaust

manifold.

RTW56ASH005501

Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger
Inspection
• Inspection of the exhaust manifold. Inspect the
plane surface of the plane on which the
manifold and the cylinder head are to be
installed.

Manifold installation plane surface mm (in)

Standard 0.3 (0.01) or lower
Limit 0.5 (0.02)

Note:
If the plane surface exceeds the limit, replace it.

LNW21BSH022201

Wheel shaft and bearing clearance

Use a dial gauge to measure the clearance between the
wheel shaft and the bearing.

Clearance mm (in)
Standard 0.056 − 0.127 (0.0022 − 0.0050)
Limit 0.14 (0.0055)

LNW21BSH022301

• 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.

Wheel shaft axial play

Use a dial gauge to measure the wheel axle shaft play
when a force of 12 N (1.2 kg / 2.6 lb) is alternately
applied to both sides of the compressor wheel.

Axial play mm (in)

Standard 0.03 − 0.06 (0.0012 − 0.0024)
LNW21BSH022301
Limit 0.09 (0.0035)
Legend
1. Oil Outlet
2. Oil Intake
Waste gate operation
1. Remove the hose from the waste gate actuator. Installation
2. Install the pressure gauge (general tool). Refer to 1. Put the gasket in to install the exhaust manifold.
the illustration. • Tighten up with the 8 nuts according to the
order given in the figure.
Tightening torque: 52 N⋅⋅m (5.3 kg⋅⋅m / 38 lb ft)
Note:
Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
manifold.

RTW56ASH005701

Legend
1. Waste Gate Actuator
2. Waste Gate Hose
3. Pressure Gauge (General Tool)

3. Use the pressure gauge pump to apply pressure

(load) to the waste gate actuator (the engine must RTW56ASH005801

be off). 2. Install the gasket and turbocharger to the exhaust

4. Note the pressure at which the control rod moves manifold. Tighten the nuts to the specified torque.
2 mm (0.078 in). This pressure must be within the Tightening torque: 27 N⋅⋅m (2.8 kg⋅⋅m / 20 lb ft)
specified limit.

Control rod pressure range: kPa (mmHg / psi)

109 − 118 (818 − 885 / 16 − 17)

5. Inspect the hose for cracks and other damage.

Replace the hose if necessary.
6. Do not apply a pressure of more than 120 kPa
(900 mmHg) to the waste gate actuator.

RTW56ASH005501

Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger
3. Install the catalyst converter.
Tighten the nuts to the specified torque.
Tightening torque: 27 N⋅⋅m (2.8 kg⋅⋅m / 20 lb ft)
4. Connect the front propeller shaft flange (Front Diff
Side, 4×4 only).
5. Install the front exhaust pipe.
Tighten the nuts to the specified torque.
Tightening torque

Exhaust Manifold Side: 67 N⋅⋅m (6.8 kg⋅⋅m / 49 lb ft)

Exhaust Pipe Side: 43 N⋅⋅m (4.4 kg⋅⋅m / 32lb ft)

6. Install the water feed pipe to the turbocharger (1).
• Tighten the joint bolts to the specified torque.
Tightening torque: 54 N⋅⋅m (5.5 kg⋅⋅m / 40 lb ft)
• Install the pipe bracket and tighten the bolts to RTW56ASH019001

the specified torque. 8. Install the turbocharger oil feed pipe to the top of
Tightening torque: 10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in) the turbocharger. Tighten the joint bolts to the
specified torque.
• Install the rubber hose between the water
return pipe and the thermostat housing. Tightening torque (Turbo charger side):
23 N⋅⋅m (2.3 kg⋅⋅m / 17 lb ft)

Tightening torque (Oil cooler side):

23 N⋅⋅m (2.3 kg⋅⋅m / 17 lb ft)
• Install the pipe bracket and tighten the bolts to
the specified torque.
Tightening torque: (Clip)
10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in)

RTW56ASH019101

7. Install the water return pipe. Tighten the joint bolt

to the specified torque.
Tightening torque: 54 N⋅⋅m (5.5 kg⋅⋅m / 40 lb ft)

RTW56ASH00610

Legend
1. Oil Feed Pipe
2. Clip
3. Oil Return Pipe
9. Tighten the oil return pipe bolts and nuts to the
specified torque.
Tightening torque (Turbocharger side):
10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in)

Tightening torque (Crank case side):

25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
10.Install the EGR cooler.
• Refer to “EGR Cooler” in EXHAUST SYSTEM
section.
11. Install the heat protector.
• Refer to “EGR Cooler” in EXHAUST SYSTEM
section.
12. Install the intake hose between the intercooler and
the intake throttle (7).
13. Install the intake hose between the turbocharger
and the intercooler (9).
14. Install the intake duct between the turbocharger
and the air cleaner (8).
Tightening torque: 6 N⋅⋅m (0.6 kg⋅⋅m / 52 lb in)
15.Replenish the coolant.
Torque Specifications

RTW76ALF000901
 Turbocharger (High Output)

Components

RTW76ALF000401

Legend
1. Turbocharger Assembly Gasket 6. Oil Feed and Return Pipe Gasket
2. Turbocharger Assembly 7. Oil Feed and Return Pipe
3. Turbocharger Heat Protecter 8. Catalyst Converter Gasket
4. Water Feed and Return Pipe Gasket 9. Catalyst Converter
5. Water Feed and Return Pipe
 Legend
Removal 1. Gasket
1. Drain the engine coolant. 2. Front Exhaust Pipe (4×2 High Ride Suspention,
2. Remove the engine cover. 4×4)
3. Remove the intercooler. 3. Gasket
• Disconnect the BARO sensor harness 4. Front Exhaust Pipe (4×2 Except High Ride
connector (2). Suspention)
• Remove the two intake hoses.
7. Remove the heat protector of the turbocharger.
• Remove the intercooler (1).
• Remove the mud cover of front RH fender skirt
(4×4 only).
• Loosen the bolt of Turbocharger bracket.
8. Remove the catalyst converter.
9. Remove the turbocharger bracket.
10. Remove the oil feed and return pipe.
11. Remove the water feed and return pipe from the
turbocharger.

RTW76ASH000501

4. Disconnect the vacuum hose from the

turbocharger actuator.
5. Remove the air intake duct from the turbocharger
and the air cleaner.
6. Remove the front exhaust pipe.

RTW76ASH001001

12. Remove the turbocharger from the exhaust

manifold.

RTW56ASH018301
Inspection
Wheel shaft axial play
Use a dial gauge to measure the wheel axle shaft play
when a force of 12 N (1.2kg / 2.6 lb) is alternately
applied to both sides of the compressor wheel.

Axial play mm (in)

Standard 0.03 − 0.06 (0.0012 − 0.0024)
Limit 0.09 (0.0035)

LNW21BSH022301

Legend
1. Oil Outlet
2. Oil Intake

Actuator operation
1. Install a vacuum pump (2) to the actuator (1).

LNW21BSH022201

Wheel shaft and bearing clearance

Use a dial gauge to measure the clearance between the
wheel shaft and the bearing.

Clearance mm (in)
Standard 0.056 − 0.127 (0.0022 − 0.0050)
Limit 0.14 (0.0055)

LNW71JSH000201

2. Operate the vacuum pump and apply vacuum

pressure to the actuator.

Working vacuum pressure kPa (mmHg / psi)

52.8 (396 / 7.66)
 3. Place a vernier caliper on the end of the control 12. Install the intake duct between the turbocharger
rod of actuator. Release the vacuum pressure and and the air cleaner.
check the control rod moves. Measure the length Tightening torque: 6 N⋅⋅m (0.6 kg⋅⋅m / 52 lb in)
of the control rod moving.
13.Replenish the coolant.

Standard length mm (in)

12 (0.48)

Installation
1. Install the gasket and the turbocharger to the
exhaust manifold. Temporarily tighten nuts.
2. Install the oil feed and return pipe and temporarily
tighten.
3. Tighten the turbocharger nuts to the specified
torque.
Tightening torque: 27 N⋅⋅m (2.8 kg⋅⋅m / 20 lb ft)
4. Tighten the oil feed and return pipe bolts and nuts
to the specified torque.
Tightening torque (Turbocharger side):
10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in)

Tightening torque (Crank case side):

25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
5. Install the water feed and return pipe to the
turbocharger.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
6. Install the heat protector to the turbocharger.
Tightening torque: 10 N⋅⋅m (1.0 kg⋅⋅m / 18 lb ft)
7. Install the turbocharger bracket.
8. Install the catalyst converter.
Tighten the nuts to the specified torque.
Tightening torque: 27 N⋅⋅m (2.8 kg⋅⋅m / 20 lb ft)
9. Install the mud cover of front RH fender skirt (4×4
only).
10. Install the front exhaust pipe.
Tighten the nuts to the specified torque.
Tightening torque

Exhaust Manifold Side: 67 N⋅⋅m (6.8 kg⋅⋅m / 49 lb ft)

Exhaust Pipe Side: 43 N⋅⋅m (4.4 kg⋅⋅m / 32lb ft)

11. Install the intercooler.
• Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
Torque Specifications

RTW76ALF000501
 Exhaust Manifold (High Output)

Components

RTW76FMF000101

Legend
1. EGR Cooler 5. Heat Protector
2. EGR Cooler Gasket 6. Exhaust Manifold
3. EGR Cooler Gasket
 Caution:
Removal
If the plane surface exceeds the limit, replace it.
1. Drain the engine coolant.
2. Remove the turbocharger.
• Refer to “Turbocharger”.
3. Remove the EGR cooler heat protector.
4. Disconnect the water hoses from the EGR cooler
water pipes.
5. Remove the EGR cooler.
6. Remove the exhaust manifold.

LNW21BSH022301

• 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.

Installation
1. Put the gasket in to install the exhaust manifold.
RTW76ASH002101 • Tighten up with the 8 nuts according to the
order given in the illustration.
Inspection
Tightening torque: 52 N⋅⋅m (5.3 kg⋅⋅m / 38 lb ft)
• Inspection of the exhaust manifold. Inspect the
plane surface of the plane on which the Caution:
manifold and the cylinder head are to be Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
installed.
manifold.

Manifold installation plane surface mm (in)

Standard 0.3 (0.01) or lower
Limit 0.5 (0.02)

RTW76ASH002201
2. Install the EGR cooler.
• Install the gaskets.
• Install the EGR cooler.
• Temporary tightening order.
1→2→3→4→5→6
• Fully tightening order.
3→4→5→1→2→6
Tighten the nut and bolts to the specified torque.
Tightening torque:
Nuts and bots 1-5: 27 N·m (2.8 kg·m / 20 lb ft)
Bolt 6: 52 N·m (5.3 kg·m / 38 lb ft)

RTW76FSH000101

5. Install the turbocharger.

• Refer to “Turbocharger”.
6. Replenish the engine coolant.

RTW76FSH000201

3. Install the water hoses to the EGR cooler water

pipes.
4. Heat protector.
Tighten the bolts to the specified torque.
Tightening torque: 25 N·m (2.5 kg·m / 18 lb ft)
Torque Specifications

RTW76AMF000701
 Timing Gear Train

Components

RTW56ALF001101

Legend
1. Oil Pump Gear 8. Injection Pump Sprocket
2. Crankshaft Gear 9. Injection Pump Gear
3. Idle Gear D 10. Idle Gear A
4. Exhaust Camshaft Gear 11. Vacuum Pump Gear
5. Intake Camshaft Gear 12. Power Steering Oil Pump Gear
6. Idle Gear D Sprocket 13. Idle Gear C
7. Timing Chain
 4. Remove the cooling fan and fan pulley.
Removal
1. Partially drain the engine coolant.
2. Remove the radiator upper hose.

RTW56ASH025401

5. Remove the A/C compressor drive belt and fan

belt.
RTW56FSH000101 6. Remove the crank pulley.
3. Remove the fan guide. 7. Remove the power steering pump with hose.

RTW46BSH000101 RTW56ASH021101

Legend Legend
1. Fan Guide 1. Power Steering Pump
2. Clips 2. Nut
3. Lower Fan Guide
• Disconnect the bracket (1) of power steering oil
4. Fan Shroud
hose.
 9. Remove the front cover.

LTW56ASH000101

8. Remove the vacuum pump. RTW56ASH019701

• Remove the vacuum pipe bracket and vacuum 10. Install the M6 bolt to the idle gear A.
pipe. 11. Remove the idle gear A and idle gear A flange, idle
• Remove the oil pipe (feed side and return side) gear A shaft.
of vacuum pump.

RTW56ASH011301

RTW76ASH000201
12. Remove the idle gear C and idle gear C shaft.
Disassembly
1. Remove the scissor gear assembly.
• Clamp the vise. Insert soft metal protectors
(aluminum) between the vise and component.
Use a pair of snap ring pliers to remove the
scissor gear assembly.

RTW56ASH011401

13. Remove the crankshaft gear.

RTW56ASH022001

Legend
1. Snap Ring
2. Sub-gear
3. Spring
4. Idle Gear A

Reassembly
1. Install the scissor gear assembly.
• Clamp the vise. Insert soft metal protectors
(aluminum) between the vise and component.
RTW56ASH021501
Press against the pin on the left side of the idle
gear A spring to make a gap on the right side of
the spring. Push the spring into place.
 • Align the sub gear pin with the hole in the right • If the measurement exceeds the limit, replace
side of the idle gear A spring. Press the sub- either the idle gear or the thrust collar.
gear into place. End clearance of the idle gear mm (in)
Standard 0.080 − 0.155 (0.003 − 0.006)
Limit 0.20 (0.008)
• Measure an end clearance of the idle gear
before removing the idle gear B.
3. External diameter of the idle gear shaft.
• Use a micrometer to measure an external
diameter of each idle gear shaft.
• If the measurement exceeds the limit, replace
the shaft.
External diameter of the idle gear A shaft mm (in)
Standard 44.950 − 44.957 (1.7697 − 1.7700)
Limit 44.80 (1.764)

RTW56ASH022001
External diameter of the idle gear C shaft mm (in)
Legend
Standard 24.959 − 24.980 (0.9826 − 0.9835)
1. Snap Ring
2. Sub-gear Limit 24.80 (0.976)
3. Spring
4. Idle Gear A

• Use a pair of snap ring pliers to snuggly install

the snap ring.

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 idle gear mm (in)
Standard 0.10 − 0.17 (0.004 − 0.006)
Limit 0.30 (0.01) RTW56ASH021601

4. Clearance between the idle gear and the idle gear

• Measure backlash of the idle gear before
shaft
removing the idle gear A.
• Measure an inside diameter of the idle gear
2. Measurement of end clearance of the idle gear.
bush to calculate a clearance between the idle
• Insert a thickness gauge between the idle gear
gear and the idle gear shaft.
and the thrust collar to measure a clearance.
 • If the measurement exceeds the limit, replace • Apply engine oil to the bolt screw thread and
either the idle gear or the shaft. seat, and temporarily tighten together with the
Clearance between the idle gear A and the shaft flange (tighten fully in later process).
mm (in)
Standard 0.020 − 0.062 (0.0007 − 0.0024)
Limit 0.200 (0.0079)

Clearance between the idle gear C and the shaft

mm (in)
Standard 0.025 − 0.075 (0.0010 − 0.0030)
Limit 0.200 (0.0079)

RTW56ASH011401

3. Install the idle gear A.

4. Tighten sub gear setting bolt.
• Use the M6 bolts and lever to turn sub gear to
right direction until it aligns with the M6 bolt
hole between idle gear A and sub gear.
• Tighten the M6 bolt to a suitable torque to
prevent the sub gear from moving.

LNW21BSH003601

Installation
1. Install the crankshaft gear.
2. Install the idle gear C.
• Apply engine oil over the part where the gear of
the idle gear shaft is to be put together.

RTW56ASH011501
• Align the oil hole of the cylinder body (2) with • Attach, aligning with the gear crank: idle A and
the oil hole of the idle gear A shaft (3). timing mark.
• Install the flange so that the front mark (1) face
toward the front.
• Install the idle gear A and idle gear A flange,
idle gear A shaft at the position shown in the
figure.
• Apply engine oil over the part where the gear of
the idle gear shaft is to be put together.
• Apply engine oil to the bolt screw thread and
seat, and temporarily tighten together with the
flange (tighten fully in later process).

RTW56ALH000301

5. Tighten the bolts of idle gear A and idle gear C to

the specified torque.

LNW71BSH000501
Tightening torque:
idle gear A 32 N⋅⋅m (3.3 kg⋅⋅m / 24 lb ft)
idle gear C 59 N⋅⋅m (6.0 kg⋅⋅m / 43 lb ft)

RTW56ASH011701

Legend
1. Idle Gear A Bolt
2. Idle Gear C Bolt
 6. Remove the M6 bolt from the idle gear A. 8. Install the vacuum pump.
7. Install the gear case cover. Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
• Apply the liquid gasket (ThreeBond TB-1207B
• Install the oil pipe (feed side and return side) of
or equivalent).
vacuum pump.
• Install the vacuum pipe bracket and vacuum
pipe.
9. Install the power steering pump.
• Tighten the nuts to the specified torque.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
• Connect the bracket (1) of power steering oil
hose.

RTW56ASH020101

Legend
1. Apply the liquid gasket

• Install the gasket in slot of the gear case cover.

• Tighten the bolts to the specified torque.
Tightening torque: 8 N⋅⋅m (0.8 kg⋅⋅m / 69 lb in)

LTW56ASH000101

10. Install the crank pulley.

Tightening torque: 294 N⋅⋅m (30.0 kg⋅⋅m / 217 lb ft)
11. Install the A/C compressor drive belt and fan belt.
Refer to drive belt tension check procedure for
Heating and air conditioning and Engine cooling in
this manual.
12. Install the cooling fan.
13. Install the fan guide.
14. Install the radiator upper hose.
15. Replenish the engine coolant.

RTW56ASH012101
Torque Specifications

LNW76ALF000601
 Camshaft Assembly

Components

RTW56ALF000901

Legend
1. Snap Ring 5. Camshaft Gear and Camshaft
2. Sub Gear 6. Camshaft Bearing Cap
3. Knock Pin 7. Bolt
4. Damper Spring
 5. Remove the baffle plate (1).
Removal
1. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.

RTW56ASH006301

6. Remove the camshaft bearing cap and camshaft.

• Check the engraved making on the camshaft
RTW76ASH001301 bearing caps.
Legend
1. TDC

2. Remove the engine cover.

3. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
4. Install the M5 lock bolt of fixing sub gear.

RTW56ASH018401

RTW56ASH007101
 • Use a pair of snap ring pliers to remove the
scissor gear assembly.
Note:
Take care not to damage the camshaft cams and
journals.

RTW56ASH013801

Disassembly
1. Remove the sub gear assembly.
• Clamp the camshaft in a vise. Insert soft metal
protectors (aluminum) between the vise RTW56ASH006401

surfaces and the camshaft. 2. Remove the camshaft gear.

• Use 5-8840-2591-0 to turn sub gear to right • Use a press (1) and socket (2) to remove the
direction to remove the M5 bolt. camshaft gear (3).

RTW56ASH006801
RTW56ASH006501
 3. Remove the dowel pin. 6. Check if the cam lobe is worn.
4. Inspect the camshaft visually. • Use a micrometer to measure the height of the
• Check if the journal and cam parts of the cam lobe.
camshaft are worn or damaged, if so, replace • If the height of the cam lobe is at the limit or
it. less, replace the camshaft.
Height of the cam lobe mm (in)
Inlet Exhaust
Standard 40.6 (1.60) 40.6 (1.60)
Limit 39.6 (1.56) 39.6 (1.56)

LNW21BSH020201

5. Inspect an end clearance 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. LNW21BSH020401

7. Check if the camshaft journal is worn.

End clearance of the camshaft mm (in)
• Use a micrometer to measure wear which is
Standard 0.085 − 0.205 (0.003 − 0.008) not even with a diameter of the camshaft
Limit 0.25 (0.010) journal.
• If the measured uneven wear exceeds the limit,
Note: replace the camshaft.
Measure an end clearance of the camshaft before
disassembling.
External diameter of the camshaft journal part
mm (in)
Standard 29.909 − 29.930
(1.1775 − 1.1783)
Limit 29.809 (1.1736)

Partial wear of the camshaft journal part mm (in)

Limit 0.05 (0.0020)

RTW56ASH013901
 Clearance of the journal part mm (in)
0.025 − 0.087
Standard
(0.0010 − 0.0034)
Limit 0.15 (0.0059)

LNW21BSH020501

8. Check if the camshaft is runout.

• Place the camshaft on a V block to measure a
runout with a dial gauge.
• Rotate the camshaft slowly to measure how
much the dial indicator shook. If it exceeds the
limit, replace the camshaft. LNW21BSH054601

Runout of the camshaft mm (in) Reassembly

1. Install the dowel pin.
Limit 0.05 (0.0020)
2. Install the camshaft gear.
• Align the knock pin with the slot in the camshaft
gear. Use a press to install the camshaft gear
to the camshaft.

LNW21BSH020601

9. Measure a camshaft journal oil clearance.

a. Measure an inside diameter of the camshaft
bearing with a dial gauge. RTW56ASH006601

b. Read the difference between the inside Legend

diameter of the camshaft bearing and the 1. Camshaft
diameter of the camshaft journal. 2. Dowel Pin
If the measured oil clearance exceeds the limit, 3. Camshaft Gear
replace the camshaft bearing.
 3. Install the sub gear assembly. 4. Tighten sub gear setting bolt.
• Clamp the camshaft in a vise. Insert soft metal • Use 5-8840-2591-0 to turn sub gear to right
protectors (aluminum) between the vise direction until it aligns with the M5 bolt hole
surfaces and the camshaft. Press against the between camshaft driven gear and sub gear.
pin on the left side of the camshaft gear spring • Tighten the M5 bolt to a suitable torque to
(3) to make a gap on the right side of the prevent the sub-gear from moving.
spring. Push the spring into place.
• Align the sub gear pin (2) with the hole in the
right side of the camshaft gear damper spring
(3). Press the sub-gear into place.

RTW56ASH006801

Installation
RTW56ASH006701
1. Check the crankshaft to make the No. 1 cylinder
Legend meet the compression TDC.
1. Snap Ring
2. Sub-gear
3. Damper Spring
4. Camshaft Gear

• Use a pair of snap ring pliers to snuggly install

the snap ring.

RTW76ASH001301

Legend
1. TDC
 2. Install the camshaft assembly. 4. Check that the alignment marks (camshaft bearing
• Align timing mark on intake camshaft and cap and camshaft) are aligned.
exhaust camshaft to idle gear D.

RTW56ASH006901

RTW56ASH007001
Legend
Legend 1. Align mark on intake camshaft and exhaust
1. Exhaust Camshaft Gear camshaft to mark of bearing cap
2. Intake Camshaft Gear
• Apply engine oil over the screw part and tighten
3. Idle Gear D
up the bearing cap with the prescribed torque.
3. Camshaft bearing caps, tighten ten bolts on one Tightening torque: 18 N⋅⋅m (1.8kg⋅⋅m / 13 lb ft)
side bank to the specified torque. 5. Remove the M5 lock bolt of fixing sub gear.
• Apply engine oil to camshaft journal and 6. Adjustment of valve clearance.
bearing surface of camshaft bearing caps. • Refer to installation procedure for inspection /
adjustment of valve clearance in this manual.
7. Install the baffle plate. Tighten the bolts to the
specified torque.
Tightening torque: 10 N⋅⋅m (1.0 kg⋅⋅m/87 lb in)
8. Install the cylinder head cover.
Refer to "Cylinder Head Cover".
9. Install the engine cover.

RTW56ASH018401
Torque Specifications

RTW56AMF001701

Special Tools
PART NO.
ILLUSTRATION
PART NAME

5-8840-2591-0
Camshaft gear tool
 Valve Stem Seal and Valve Spring

Components

RTW56ALF001301

Legend
1. Exhaust Rocker Arm Shaft Assembly 8. Pin
2. Bolt (Long) 9. Spring Lower Seat
3. Bolt (Short) 10. Valve Stem Oil Seal
4. Intake Rocker Arm Shaft Assembly 11. Valve Spring
5. Fuel Injector Assembly 12. Spring Upper Seat
6. Bolt 13. Split Collar
7. Fuel Injector Clamp 14. Valve Stem End Cap
 Note:
Removal Do not use the removed oil seal again.
1. Remove the cylinder head. 6. Remove the spring lower seat.
Refer to “Cylinder Head”.
2. Remove the split collar.
• Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Valve spring replacer: 5-8840-2818-0 (1)
Pivot assembly: 5-8840-2819-0 (2)

RTW56ASH012301

3. Remove the spring upper seat.

• Remove the special tool to remove the upper
seat.
4. Remove the valve spring.
Put the removed valve springs in order by
cylinder number.
5. Remove the valve stem oil seal.
• Use pliers to remove the oil seal.

RTW56ASH012401
Inspection
Inspect the valve spring
Note:
Check the valve spring visually and if there is clear
damage or wear, replace it.
1. Free length
• Measure free length of the spring and if it is
shorter than the prescribed limit, replace the
spring.
Free length of the valve spring mm (in)
Inlet / Exhaust
Standard 49.04 (1.93)
Limit 48.15 (1.89) LNW21BSH017101

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.
Tension of the valve spring N (kg / lb)
Inlet / Exhaust
Installation length mm (in) 37.80 (1.488)
Standard 213 (21.7 / 47.8)
Limit 188 (19.2 / 42.3)

LNW21BSH017001

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 mm (in)
Limit 2.1 (0.083)

LNW21BSH056701
 • Use a replacer to compress the valve spring
Installation and install the split collar.
1. Install the spring lower seat.
2. Install the valve stem oil seal. Special tool
• Apply engine oil over the peripheral part of the Valve spring replacer: 5-8840-2818-0 (1)
valve guide and install the oil seal by using a Pivot assembly: 5-8840-2819-0 (2)
valve stem seal installer.
Note:
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.
Special tool
Valve stem seal installer: 5-8840-2817-0

RTW56ASH012301

Note:
Move it up and down to check if it moves smoothly.
6. Install the cylinder head.
Refer to “Cylinder Head”.

RTW56ASH013701

3. Install the valve spring.

4. Install the spring upper seat.
5. Install the split collar.
Special Tools
PART NO.
ILLUSTRATION
PART NAME

5-8840-2818-0
Valve spring replacer

5-8840-2819-0
Pivot assembly

5-8840-2817-0
Valve stem seal installer
 Cylinder Head

Components

RTW56ALF001001

Legend
1. Fuel Injector Clamp 5. Cylinder Head
2. Fuel Injector Assembly 6. Timing Chain Tension Lever
3. Glow Plug 7. Timing Chain Guide
4. Intake and Exhaust Valves 8. Timing Chain Tensioner

Note:
To avoid electric shock;
Removal
Set the switch to the 'OFF' position and disconnect the 1. Remove the engine head cover.
negative battery cable before checking or repairing the 2. Drain the engine coolant.
fuel injector, wiring or/and connectors.
 3. Remove the radiator upper hose. 5. Remove the cooling Fan.

RTW56FSH000101 RTW56ASH025401

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

RTW46BSH000101

Legend RTW76ASH001301

1. Fan Guide Legend

2. Clips 1. TDC
3. Lower Fan guide
7. Remove the A/C compressor drive belt.
4. Fan Shroud
 8. Remove the A/C compressor adjust pulley. 12. Remove the intercooler (High output).
• Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).

RTW56ASH010601

Legend
1. Bolt
2. Nut
RTW76ASH000501

9. Remove the battery. 13. Remove the intake hose and duct (Standard
10. Disconnect the A/C compressor connector and output).
A/C compressor with hose.
11. Remove the A/C compressor bracket.

RTW56ASH022501

Legend
RTW56ASH024201 1. Intake Hose for Intercooler and Intake Throttle
Legend 2. Intake Duct for Turbocharger and Air Cleaner
1. A/C Compressor Bracket 3. Intake Hose for Turbocharger and Intercooler
2. Intake Duct
3. A/C Compressor
 14. Disconnect the fuel injector connector (2). 22. Loosen the nuts of catalyst converter and
15. Remove the fuel leak off hose (1). turbocharger.

RTW76ASH000101 RTW56ASH006201

Note: Legend
Do not reuse the fuel leak off hose clips. 1. Catalyst Converter
16. Disconnect each connector. 2. Turbocharger
• Glow Plug
23. Remove the exhaust front pipe.
• EGR Valve
• Throttle Assembly
• Barometric Sensor
• Water temperature sensor
• Camshaft Position sensor
17. Remove the harness bracket.
18. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
19. Remove the EGR cooler heat protector.
20. Remove the EGR cooler water pipe.
21. Remove the EGR cooler.

RTW56ASH007701

Legend
1. Exhaust Front Pipe (4×2 High Ride Suspension,
4×4)
2. Exhaust Front Pipe (4×2 Except High Ride
Suspension)
24. Disconnect the Front drive shaft (1). (4×4) 26. Remove the A/T oil cooler pipe bracket (A/T).

RTW76ASH002301 RTW56ASH025101

25. Remove the catalyst converter. Legend

1. A/T Oil Cooler Pipe Bracket

27. Remove the turbocharger water return pipe and

hose.

RTW56ASH019001

RTW56ALH000201
28. Remove the turbocharger water feed pipe (1) and 32. Remove the fuel injection pipe clip.
hose. 33. Remove the fuel injection pipe.
34. Remove the vacuum hose (1).

RTW56ASH019101

29. Remove the turbocharger engine oil feed pipe. RTW66ASH003101

30. Remove the engine oil level gauge guide tube. 35. Remove the noise cover (1).
31. Remove the fuel return pipe and hose (1).

RTW56CSH001401

RTW56ASH019201
 36. Remove the timing chain cover lower. 39. Remove the glow plug (1).
37. Remove the timing chain cover upper.

RTW56ASH019301

RTW56CSH001501 40. Remove the cylinder head cover.

Legend Refer to “Cylinder Head Cover”.
1. Timing Chain Cover Upper 41. Install the lock bolt for camshaft scissor gear.
2. Timing Chain Cover Lower

38. Remove the water by pass pipe (1).

RTW56ASH007101

42. Remove the fuel injector assembly.

43. Remove the baffle plate.
RTW56ASH008401
 44. Remove the camshaft bearing cap. Note:
Pay full attention so as not to drop the parts in the gear
case of the front part of the cylinder head or a hole into
which oil pours back in the front.
Note:
Remember the original position.
47. Remove the timing chain tensioner.

RTW56ASH018401

45. Remove the camshaft.

46. Remove the rocker arm shaft assembly.
Note:
Keep the removed rocker arm shaft assembly properly
so that they may be put back to the original place.
RTW56CSH003701

Legend
1. Timing Chain Tensioner
2. Gasket
3. Nut

48. Remove the idle gear D.

• Timing chain is dropped behind.

RTW56ASH012201

Legend
1. Exhaust Rocker Arm Shaft Assembly
2. Bolt (Long)
3. Bolt (Short)
4. Intake Rocker Arm Shaft Assembly
5. Front

RTW56ASH022101
49. Remove the timing chain tension lever pivot. 52. Remove the cylinder head gear case nuts (1) and
bolts (2).

RTW56ASH019401

50. Remove the timing chain from supply pump RTW56ASH020801

sprocket. 53. Remove the cylinder head bolt (1).

51. Remove the chain guide bolt from cylinder head.

RTW56ASH008501

RTW56ASH019501 Note:
Do not reuse the cylinder head bolt.
 54. Remove the cylinder head assembly.
• Loosen the cylinder head bolts in the order Disassembly
described in the drawing. 1. Remove the throttle assembly.
• Remove the cylinder head gasket. • Refer to procedure for Intake Manifold in this
Note: manual.
Replace the head gasket with a new one once it is 2. Remove the intake manifold assembly.
removed. • Refer to procedure for Intake Manifold in this
manual.
3. Remove the turbocharger.
• Refer to “Turbocharger and Exhaust Manifold”.
4. Remove the exhaust manifold assembly.
• Refer to procedure for Turbocharger and
Exhaust Manifold in this manual.
5. Remove the water outlet pipe.
6. Remove the valve stem cap.
Refer to procedure for valve stem and valve in this
manual.
7. Remove the split collar.
• Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Valve spring replacer: 5-8840-2818-0 (1)
RTW56ASH008601
Pivot assembly: 5-8840-2819-0 (2)

RTW56ASH012301

8. Remove the spring upper seat.

• Remove the special tool to remove the upper
seat.
9. Remove the valve spring.
• Put the removed valve springs in order by
cylinder number.
10. Remove the intake and exhaust valve. 14. Remove the cam end gasket (1).
• Sort the removed valves according to cylinders
by using tags others.

RTW56ASH020501

15. Remove the oil seal.

LNW21BSH016801

11. Remove the valve stem oil seal.

• Refer to procedure for valve stem and valve in
this manual.
12. Remove the spring lower seat.
13. Remove the valve guide.
• Use the valve guide replacer to press out the
valve guides from the bottom side of the
cylinder head.
Special tool
Valve guide remover and installer:
5-8840-2816-0

RTW56ASH008801

RTW56ASH008701
Inspection
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.

Cylinder Head Lower Face Warpage

1. Use a straight edge and a thickness gauge to
measure the four sides and the two diagonals of
the cylinder head lower face.
2. The cylinder head lower surface warpage is more
than the limit, it should be replaced.

011RY00013

Cylinder Head Height (H) (Reference) mm (in)

Standard 143.4 (5.646)

RTW56ASH008901

Cylinder Head Lower Face Warpage mm (in)

Standard 0.05 (0.002) or less
Limit 0.20 (0.0079)

NOTE:
The cylinder head lower face cannot be regrind.

RTW56ASH017401

Manifold Fitting Face Warpage

Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
Regrind the manifold cylinder head fitting surfaces if the
measured values are greater than the specified limit but
less than the maximum grinding allowance.
If the measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.
 Manifold Fitting Face Warpage mm (in)
Valve Stem Cap
Standard 0.05 (0.002) or less Make the necessary part replacements.
Limit 0.20 (0.008) If excessive wear or damage is discovered during
inspection.
Maximum Grinding Allowance 0.40 (0.016)
Valve Stem Outside Diameter
Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Valve Stem Outside Diameter mm (in)
Intake Valve Exhaust Valve
6.955 – 6.970 6.939 – 6.949
Standard
(0.2738 – 0.2744) (0.2732 – 0.2736)
6.935 6.920
Limit
(0.2730) (0.2724)

RTW56ASH017501

Exhaust Manifold Warpage

Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
If the measured values exceed the specified limit, the
manifold must be replaced.
Exhasut Manifold Warpage mm (in)
Standard 0.05 (0.002) or less
Limit 0.20 (0.008)
011LX027

Valve Stem and Valve Guide Clearance

1. Measure the valve stem outside diameter.
Refer to the item “Valve Stem Outside Diameter”.
2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.
If the measured values exceed the specified limit,
the valve and the valve guide must be replaced as
a set.
Valve Stem Clearance mm (in)
Intake Valve Exhaust Valve
0.039 – 0.071 0.064 – 0.096
Standard
(0.0015 – 0.0028) (0.0025 – 0.0038)
0.200 0.250
Limit
(0.008) (0.0098)
027RY00002
 Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel
rule to measure the valve depression from the
cylinder head lower surface.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
Valve Depression mm (in)
Standard 1.8 (0.07)
Limit 2.5 (0.098)

011RY00023

Valve Thickness
Measure the valve thickness.
If the measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Intake and Exhasut Valve Thickness mm (in)
Standard 1.32 (0.052)
Limit 1.1 (0.043)

014RY00021

Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact
surfaces.
2. Measure the valve contact width.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
Valve Contact Width mm (in)
Intake Exhaust
Standard 1.7 (0.067) 2.0 (0.079)
014RY00020 Limit 2.2 (0.087) 2.5 (0.098)
 014RY00027 LNW21BSH056101

• Attach compound in the valve insert seat.

Repair of the seat surface • Insert the valve into the valve guide.
• Remove carbon from the surface of the valve • Attach compound on the valve seat surface, rotate
insert seat. the valve and hit it lightly to grind it, and confirm
• Use a seat cutter to minimize the scratch and that it has even contact all round.
other roughness (15/45/75 degree-blade), thereby Note:
returning the contact width to the standard value. Remove compound completely after grinding.

LNW21BSH018201

Note: LNW21BSH031801
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.

Valve Seat Angle Degree

45
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.
Contraction due to cooling makes it easier to
remove the valve seat insert.
• Remove the valve seat insert, using a screw
driver . Be sure not to harm the cylinder head.

LNW21BSH018601

Legend
1. Attach Compound
2. Valve Seat
3. Press

Reassembly
1. Install the oil seal.
• Install on the surface of the injection pipe insert.
LNW21BSH056001

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

1. Arc-Weld Note:
Be sure not to harm the lip.
2. Valve Seat Insert
3. Screw Driver Special tool
Injection pipe oil seal installer: 5-8840-2820-0
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.
Note:
Do not apply too much pressure with the press. Attach
compound on the valve seat surface, rotate the valve
and hit it lightly to grind it, and confirm that it has even
contact all round.

RTW56ASH008801
 RTW56ASH009101 RTW56ASH023001

Legend Legend
1. Cylinder Head 1. 12.6 ± 0.1 mm (0.50 ± 0.0039 in)
2. Oil Seal Installer 2. Cylinder Head

2. Install the valve guide. 3. Install the valve spring lower seat.
• Hammer in the valve guide from the upper 4. Install the valve stem oil seal.
surface of the cylinder head, using the valve • Refer to procedure for valve stem and valve in
guide installer. this manual.
Special tool 5. Install the intake and exhaust valve.
Valve guide remover and installer: • Apply engine oil on the valve stem part and
5-8840-2816-0 install the valve.
Note: 6. Install the valve spring, the valve spring upper seat
When replacing the valve guide, it must be replaced and the split collar.
together with the valve. • Refer to procedure for valve stem and valve in
this manual.
7. Install the rocker arm and shaft assembly.
• Refer to procedure for valve stem and valve in
this manual.
8. Install the exhaust manifold assembly.
• Refer to procedure for Turbocharger and
Exhaust Manifold in this manual.
9. Install the turbocharger.
• Refer to procedure for Turbocharger and
Exhaust Manifold in this manual.
10. Install the intake manifold assembly.
• Refer to procedure for Intake Manifold in this
manual.
11. Install the throttle assembly.
• Refer to procedure for Intake Manifold in this
RTW56ASH009001 manual.
• Height from the upper surface of the cylinder
head to the edge surface of the valve guide
Installation
1. Select the cylinder head gasket.

Cylinder Head Gasket Selection

Cylinder head gasket is determined by the piston head
projection from the cylinder body upper surface, in order
to improve engine performance.
Three types of gasket are provided with difference of
thickness. Select the appropriate one out of three
grades of
gasket, according to the following procedure.
Before measurement, clear off carbon from the piston
head and cylinder body surface and also clean the
place where the gasket was installed.

RTW36ASH001701

3. Measure the points 1, 2, 3, 4 and obtain two

differences 1-2 and 3-4 on each cylinder. Calculate
the average value of the piston head projection on
each cylinder.
4. Obtain the maximum value in the four cylinders.
5. Determine the gasket grade required to the
maximum value described above in accordance
with the following table.

011LX011

1. Use a dial indicator to measure the piston

projection amount.
2. Refer to the illustration for the piston head
projection measuring positions. All measuring
positions should be as close as possible to the
cylinder block.

011RY00027
Cylinder Head Gasket Combination mm (in) 8. Apply liquid gasket (ThreeBond 1207B or
equivalent) at the two locations.

RTW76ASH000301

RTW56ASH020901

Legend
1. 2 - 3 mm (0.079 - 0.118 in)
2. 3 - 4 mm (0.118 - 0.157 in)

9. Install the cylinder head within 5 minutes

application of the liquid gasket.
10. Install the cylinder head.
• Wipe the cylinder head lower face.
• Install the cylinder head, adjusting the dowel of
the cylinder block.
11. Install the cylinder head bolt.
• Please use new cylinder head bolt.
• Use a torque wrench and angle gauge to
tighten the head bolts in the order described in
RTW56ASH009501
the drawing.
Note:
Tightening torque:
Difference of each piston projection must be equal or
within 0.05 mm (0.002 in). 1st step = 70 N⋅⋅m (7.1 kg⋅⋅m / 51 lb ft)
7. Select the gear case gasket. 2nd step = 70 N⋅⋅m (7.1 kg⋅⋅m / 51 lb ft)
• This should be of the same grade as the 3rd step = 60° (degrees)
cylinder gasket. 4th step = 60° (degrees)
 14. Install the vacuum hose (1).

RTW56ASH009701

Special tool RTW66ASH003101

Angle gauge: 5-8840-0266-0 15. Install the rocker arm shaft assembly.
• Apply the engine oil.
• Attach the rocker arm shaft assembly in
12. Install the cylinder head gear case bolt and nut. sequence from No.1 to No.4.
• Tighten the nuts (1) and bolts (2) to the
Tightening torque: 21 N⋅⋅m (2.1 kg⋅⋅m / 15 lb ft)
specified torque.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)

RTW56ASH012201

Legend
RTW56ASH020801
1. Exhaust Rocker Arm Shaft Assembly
13. Install the water by pass pipe. 2. Bolt (Long)
Apply soapy water to the O-ring. 3. Bolt (Short)
Tighten the bolt to the specified torque. 4. Intake Rocker Arm Shaft Assembly
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft) 5. Front
 16. Install the chain guide bolt from cylinder head. 19. Install the timing chain with idle gear D.
Tighten the bolt to the specified torque. • Apply the engine oil bolt thread and seat.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m/18 lb ft) Tightening torque : 59 N⋅⋅m (6.0 kg⋅⋅m/43 lb ft)

RTW56ASH019501
RTW56ASH021801
17. Install the tension lever. • Align the timing marks at two locations as
18. Rotate the crankshaft to make the No.1 cylinder shown.
meet the compression top dead center (TDC).

RTW56ASH020301
RTW76ASH001301 Legend
Legend
1. Timing Chain
1. TDC 2. Timing Mark
3. Blue Link
4. Yellow Link
20. Install the timing chain tension lever pivot.
Tighten the bolt to the specified torque.
Tightening torque: 27 N⋅⋅m (2.8 kg⋅⋅m / 20 lb ft)

RTW56CSH001701

23. Unlock the tensioner hook.

• Press the place of the arrow in the figure.
• The hook is opened. The plunger pushes the
RTW56ASH019401
tension lever.
21. Attach the hook of the timing chain tensioner.
• Hold the latch (3) depressed. Insert the plunger
(2). Attach the hook (5) to the pin (1) to hold the
plunger in place.

RTW56ASH020401

RTW56CSH004401

22. Install the timing chain tensioner (1) and the

gasket (2).
Tighten the nuts (3) to the specified torque.
Tightening torque: 10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in)
 24. Install the camshaft assembly. 26. Align mark on camshaft to mark on camshaft
• Align timing mark on intake camshaft and bearing cap.
exhaust camshaft to idle gear D. • Align mark (1) on intake camshaft and exhaust
camshaft to mark of bearing cap.

RTW56ASH007001

Legend RTW56ASH006901

1. Exhaust Camshaft Gear 27. Remove the lock bolt from the camshaft gear.
2. Intake Camshaft Gear 28. Turn the crank pulley two rotation (720°CA).
3. Idle Gear D • Align mark on camshaft to mark on camshaft
bearing cap.
25. Install the camshaft bearing cap.
• Apply engine oil to all of the cylinder head
journals.

RTW56ASH020701

Legend
1. Exhaust Camshaft Gear
RTW56ASH013801 2. Intake Camshaft Gear
Tightening torque: 18 N⋅⋅m (1.8 kg⋅⋅m / 13 lb ft) 3. Idle Gear D
 30. Install the timing chain cover upper (1).
Tighten the bolt to the specified torque.
• Apply loctite #262 or equivalent to the bolt and
stud threads of cylinder side head side (2).
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)

RTW56ASH020301

Legend
1. Timing Chain
2. Timing Mark
3. Blue Link
4. Yellow Link
RTW76CSH001201

29. Apply liquid gasket (ThreeBond TB-1207C or 31. Apply liquid gasket (ThreeBond TB-1207C or
equivalent) to timing chain cover upper (1). equivalent) to the timing chain cover lower (1).
• Attach cover within 5minutes after the • Attach the cover within 5 minutes of applying
application of gasket. the liquid gasket.

RTW56CSH002101 RTW56CSH002301

32. Install the timing chain cover lower.

Tighten the bolts and nuts to the specified torque.
Tightening torque: 10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in)
33. Install the noise cover to the timing chain cover
lower.
Tighten the bolts to the specified torque.
Tightening torque: 10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in)
 34. Inspection / adjustment of valve clearance. 39. Install the glow plug .
• Refer to procedure for Service Precautions in Tighten the glow plug to the specified torque.
this manual. Tightening torque: 18 N⋅⋅m (1.8 kg⋅⋅m / 13 lb ft)
35. Install the fuel injector.
40. Install the glow plug connector.
• Refer to procedure for Fuel System in this
Tighten the nut to the specified torque.
manual.
36. Install the baffle cover. Tightening torque: 2 N⋅⋅m (0.2 kg⋅⋅m / 17 lb in)
• Refer to procedure for Camshaft Assembly in
this manual.
37. Install the cam end gasket.
• Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).

RTW56ASH010201

Legend
1. Glow Plug Connector
2. Nut

RTW56ASH020601

Legend
1. Cam End Gasket
2. 2.0 - 3.0 mm (0.078 - 0.118 in)

38. Install the cylinder head cover.

Refer to procedure for Cylinder Head Cover in this
manual.
 47. Install the A/C compressor adjust pulley. 50. Install the turbocharger engine oil return pipe (1).
Tighten the bolt and nut to the specified torque. Tighten the bolt and nut to the specified torque.
Tightening torque: bolt 25 N⋅⋅m (2.6 kg⋅⋅m/19 lb ft) Tightening torque:
nut: 25 N⋅⋅m (2.6 kg⋅⋅m/19 lb ft)
Tightening torque: nut 25 N⋅⋅m (2.6 kg⋅⋅m/19 lb ft)
bolt: 10 N⋅⋅m (1.0 kg⋅⋅m/87 lb in)

RTW56ASH010601

Legend RTW56ASH010701

1. Bolt 51. Install the turbocharger engine oil feed pipe (1).
2. Nut Tighten the bolt to the specified torque.
Tightening torque: bolt 23 N⋅⋅m (2.3 kg⋅⋅m/17 lb ft)
48. Install the A/C compressor and connector.
Tighten the bolt to the specified torque.
Tightening torque: 44 N⋅⋅m (4.5 kg⋅⋅m / 33 lb ft)
49. Connect each connector.
• Barometric Sensor
• EGR Valve
• Glow plug
• Water temperature sensor
• Camshaft Position sensor
• Throttle Assembly

RTW56ASH010801
 52. Install the turbocharger water feed pipe. 57. Install the exhaust front pipe.
• Refer to procedure for “Exhaust System” in this
manual.
58. Install the EGR cooler.
• Refer to procedure for “Exhaust System” in this
manual.
59. Install the EGR cooler water pipe.
• Refer to procedure for “Exhaust System” in this
manual.
60. Install the EGR cooler heat protector.
• Refer to procedure for “Exhaust System” in this
manual.
61. Install the cooling fan.
• Refer to procedure for “Engine Cooling” in this
manual.
62.Install the A/C drive belt.
RTW56ASH019101
• Refer to procedure for “Intake Manifold” in this
Legend manual.
1. Turbocharger Water Feed Pipe 63. Install the radiator fan shroud. Upper and lower.
64. Install the radiator upper hose.
53. Install the turbocharger water return pipe. • Refer to procedure for engine cooling in this
manual.
65. Install the harness bracket.
66. Install the fuel leak off hose (1), and the fuel
injector connector (2).

RTW56ASH019001

Legend
1. Turbocharger Water Return Pipe

54 Install the A/T oil cooler pipe bracket.

RTW76ASH000101
Refer to procedure for automatic transmission in
this manual.
55. Install the catalyst converter.
Refer to procedure for Turbocharger and Exhaust
Manifold in this manual.
56. Connect the front drive shaft. (4×4)
Refer to procedure for front propeller shaft in this
manual.
 67.Install the intercooler (High output).
• Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
68. Install the intake hose.

RTW56ASH022501

Legend
1. Intake Hose for Intercooler and Intake Throttle
2. Intake Duct for Turbocharger and Air Cleaner
3. Intake Hose for Turbocharger and Intercooler

69. Install the engine head cover.

70. Replenish the coolant.
Torque Specifications

RTW76AMF000201

Special Tools
PART NO. PART NO.
ILLUSTRATION ILLUSTRATION
PART NAME PART NAME

5-8840-2820-0 5-8840-0266-0
Injection pipe oil seal Angle gauge
installer

5-8840-2816-0
Valve guide remover and
installer
 Piston and Connecting Rod

Components

RTWA56ALF001601

Legend
1. Piston Pin Snap Ring 4. Piston
2. Piston Pin 5. Connecting Rod
3. Piston Ring 6. Bearing

4. Remove the cylinder head.

Removal Refer to “Cylinder Head”.
1. Demount the engine assembly. 5. Remove the gear case assembly.
Refer to “Engine Assembly”. Refer to “Gear Case Assembly”.
2. Remove the cylinder head cover. 6. Remove the oil pan.
Refer to “Cylinder Head Cover”. Refer to “Oil Pan” .
3. Remove the camshaft assembly. 7. Remove the connecting rod cap.
Refer to “Camshaft Assembly”.
Note:
Sort the removed bearings according to cylinders by
using tags.

LNW21BSH005101

2. Remove the snap ring.

3. Remove the piston pin.
LNW21BSH004901 Note:
8. Remove the piston and connecting rod. Sort the disassembled piston pins, pistons and
• Remove carbon on the upper side of the connecting rods together in the same order as the
cylinder block with a scraper. cylinders.
• Pull out the piston and connecting rod towards
the cylinder head.
Note:
Be sure not to damage the oil jet and cylinder block
when pushing out the connecting rod.
9. Remove the connecting rod bearing.
Note:
Sort the bearings in the order of cylinders when reusing
them so that they are not confused with the bearings of
other cylinders.

Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
Note:
Sort the piston rings in the same order as the cylinders LNW21BSH005201
when reusing them so that they are not confused with 4. Remove the connecting rods from the piston.
the pistons and piston rings of other cylinders.
5. Clean the piston.
• Carefully clean carbon that is adhered to the
head of the piston and the groove of the piston
ring.
Note:
Do not use a wire brush to clean the piston because it
scratches the piston.
Visually inspect the piston 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.
Inner diameter of the cylinder block.
• Use a cylinder bore dial indicator to measure
the cylinder block inner diameter both in the
thrust and radial directions in the designated
position.
• Measurement position (from the upper surface
of the cylinder block) 20 mm (0.79 in)
• Measure the cylinder block inner diameter
based on the average value of the actual
measurement values on 6 positions.
Cylinder block inner diameter mm (in)
95.421 – 95.450 (3.75673 – 3.75787)

RTW56ASH023101

Legend
1. 11 mm (0.43 in)

Gap between the piston and the inner

diameter of the cylinder block mm (in)
Standard 0.082 – 0.100 (0.0032 – 0.0039)

NOTE:
If the gap exceeds the standard value, replace the
piston or rebore the cylinder block.
7. Piston replacement
• The head of piston has a marking of grade A, B
or C.
• Refer to “Cylinder Block” if over size piston is
installed.

LNW61ASH006401

Legend Piston Grade (Service Part) mm (in)

1. 20 mm (0.79 in) A 95.330 – 95.339 (3.75314 – 3.75350)
2. Radial
B 95.340 – 95.349 (3.75354 – 3.75389)
3. Thrust
C 95.350 – 95.359 (3.75393 – 3.75428)
Piston outside diameter
• Use a micrometer to measure the outside
diameter of the piston in the right angle to the
piston pin in the designated position.
• Measurement position (from the bottom surface
of the piston) 11.00 mm (0.43 in).
4JK1

LNW21BSH009301

RTW56ASH025701 • Push the piston ring into the cylinder bore until
Legend it reaches the measuring point 1 or 2 where the
1. Grade cylinder block bore is the smallest.
2. Front Mark Cut Do not allow the piston ring to slant to one side
or the other. It must be perfectly horizontal.
4JJ1 Measuring Point 1 10 mm (0.4 in)
or
Measuring Point 2 120 mm (4.7 in).

LNW76ASH001401

Legend
1. Grade
2. Front Mark Cut LNW61ASH004401

8. Inspect the piston ring.

• Insert the piston ring horizontally (in the position
it would assume if it were installed to the
piston) into the cylinder block.
 Piston ring and piston ring groove clearance mm (in)
Standard Limit
1st compression ring —∗ —∗
2nd compression ring 0.05 - 0.09 1.50
(0.0020 - 0.0035) (0.059)
Oil ring 0.03 - 0.07 1.50
(0.0012- 0.0028) (0.059)
∗ Measurement is impossible

LNW61ASH004501

• Use a thickness gauge to measure the piston

ring gap.
If the measured value exceeds the specified
limit, the piston ring must be replaced.
Piston ring gap mm (in)
Standard Limit
1st compression ring 0.3 - 0.5 1.50
(0.0118 - 0.0197) (0.059)
2nd compression ring 0.3 - 0.5 1.50 LNW21BSH009501
(0.0118 - 0.0197) (0.059) 9. Inspect the piston pin.
Oil ring 0.25 - 0.45 1.50 • Visually inspect the piston pin for cracks,
(0.0098- 0.0177) (0.059) scratches and other damage, and replace it if
Measure the clearance between the piston ring necessary.
groove and the piston. • Use a micrometer to measure the outer
• Remove carbon in the piston ring groove. diameter of the piston pin. If the measured
• Put the piston ring in the piston ring groove, use value exceeds the limit, replace the piston pin.
a thickness gauge to measure the gap between Piston pin outer diameter mm (in)
them. Standard 33.995 – 34.000 (1.33838 – 1.33858)
• If the clearance between the piston ring groove Limit 33.970 (1.33740)
and the piston exceeds the limit, replace the
piston and the piston ring.
 LNW21BSH009601 LNW21BSH009801

• Inspect to make sure that there is a resistance 10. Measure the clearance between the piston and
to the extent which the piston can push the the piston pin.
piston pin lightly in normal temperatures. • Apply engine oil on the piston pin. Use your
• If it feels a large looseness or instability in finger to push it in the piston hole and rotate it.
normal temperatures, replace the piston or If the pin smoothly rotates without instability,
piston pin. the clearance is normal. If there is instability,
measure the clearance. If the clearance
exceeds the limit, replace the piston and the
piston pin.
Piston pin and piston pin hole clearance mm (in)
Standard 0.004 - 0.017 (0.0002 - 0.0007)
Limit 0.04 (0.0016)
11. Measure the connecting rod alignment.
• Use a connecting rod aligner to measure the
torsion and parallel level of the big end hole
and the small end hole. If the measured value
exceeds the limit, replace it.
Connecting rod alignment
(par length of 100 mm (3.94 in)) mm (in)
Standard Limit
LNW21BSH009701
Distortion 0.08 (0.003) or less 0.20 (0.008)
• Measure the bush of the small edge of the
connecting rod. If the clearance of the bush inner Parallelism 0.05 (0.002) or less 1.50 (0.060)
diameter and the pin diameter exceeds the limit,
replace the bush or connecting rod assembly, and
the pin.
Piston pin and connecting rod small end bushing
clearance mm (in)
Standard 0.008 - 0.020 (0.0003 - 0.0008)
Limit 0.05 (0.0020)
 LNW21BSH010401 LNW46ASH004601

12. Measure the bearing oil clearance. Legend

• Install the bearing to the connecting rod big 1. Front Mark
end. 2. Forging Mark (Projecting)
• Tighten the bearing cap to the two step of
4. Apply enough engine oil on the piston pin, push it
angular tightening method.
in the piston and the connecting rod small edge.
• Use an inside dial indicator to measure the
5. Use snap ring pliers to install the snap ring.
connecting rod bearing inside diameter.
Connecting rod bearing cap bolt torque: Note:
N⋅m (kg⋅m / lb ft) Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
1st step 29.4 (3.0 / 22)
moves smoothly.
2nd step 45 deg
If the clearance between the measured bearing
inside diameter and the crankpin exceeds the
specified limit, the bearing and/or the crankshaft
must be replaced.
Crankpin and bearing clearance mm (in)
Standard 0.029 - 0.083 (0.0011 - 0.0033)
Limit 0.10 (0.0039)

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, both face in
015R100001
the same direction.
6. Use ring pliers to install the piston ring.
• Install the snap ring of one side.
• Install the piston rings in the order shown in the
illustration.
• Install 2nd and 1st compression rings in this
order so that the marks “2N” and “N” face
upward.
 • Insert the expander coil into the oil ring groove
so that there is no gap on either side of the
expander coil before installing the oil ring.

015LX096

3. Install the connecting rod cap.

• Install the bearing on the connecting rod cap
RTW56ASH023201 and apply engine oil.
Legend • Install the cap, matching the numbers (1, 2, 3,
1. Compression Ring 1st and 4) of the caps and connecting rods.
2. Compression Ring 2nd
3. Oil Ring
4. Expander

Installation
1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, and
apply engine oil on the bearing.
2. Install the piston and connecting rod assembly.
• Apply enough engine oil on the piston ring, ring
groove and piston side surface.
• With the piston front mark cut facing forward,
use the piston ring compressor to insert the
piston in the cylinder block.
Note:
015R100007
• Be sure not to make the connecting rod touch • Apply engine oil disulfide on the screw part and
the oil jet when pushing in the piston. the setting face of the tightening bolt and
• Be sure not to harm the inside of the cylinder tighten it with the designated torque.
block when pushing in the piston.
Tightening torque:
Special tool
1st step = 29 N⋅⋅m (3.0 kg⋅⋅m / 22 lb ft)
Piston ring compressor: 5-8840-9018-0
2nd step = 45° (degrees)
Special tool
Angle gauge: 5-8840-0266-0
Note:
Make sure that the crankshaft smoothly rotates.
 015LX130

4. Install the oil pan.

Refer to “Oil Pan”.
5. Install the gear case assembly.
Refer to “Gear Case Assembly”.
6. Install the cylinder head.
Refer to “Cylinder Head”.
7. Install the camshaft assembly.
Refer to “Camshaft Assembly”.
8. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
Torque Specifications

RTW56AMF001801

Special Tools
PART NO.
ILLUSTRATION
PART NAME

5-8840-9018-0
Piston ring compressor

5-8840-0266-0
Angle gauge
 Flywheel

Components

RTW56ALF001701

Legend
1. Flywheel Assembly and Pilot Bearing 4. Release Bearing
2. Driven Plate 5. Shift Fork
3. Pressure Plate Assembly 6. Transmission Assembly

2. Remove the clutch pressure plate.

Removal • Remove the pressure plate installation bolts in
1. Remove the transmission assembly. the order shown in the drawing.
Refer to "transmission assembly removal and • Remove the pressure plate from the flywheel.
installation".
 5. Remove the flywheel.
• Gradually loosen the flywheel installation bolts
in the order shown in the drawing so that the
flywheel does not rotate.
• After loosening the bolts, remove the stopper
and remove the flywheel.
• In the case of A/T car, after loosening the
flywheel installation bolts, remove the washer,
flexible plate, flywheel and sleeve in this order.

RTW56ASH014201

3. Remove the driven plate.

• Remove the driven plate from the flywheel
along with the clutch aligner.
• Install the crankshaft stopper in the starter
installation part of the rear plate.
Note:
Make sure that the stopper is applied with the ring gear
and installed properly.
Special tool 015RY00001

Crankshaft stopper: 5-8840-0214-0 6. Remove the ring gear.

4. Remove the pilot bearing. • Put a bar on the ring gear and hit it with a
• Remove the pilot bearing from the flywheel. hammer to remove it.

015RY00018 LNW21BSH012001

Special tool
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0
Inspection Installation
1. Visual inspection 1. Install the ring gear.
• Inspect the flywheel friction surface for cracks • Heat the ring gear evenly with a gas burner to
and damages, and replace it if it has invite thermal expansion. Do not allow the
abnormality. temperature of the gas burner to exceed 200°C
• Inspect the tooth part of the ring gear, replace (392°F).
the ring gear if it has damage or serious wear. • Install the ring gear when it is sufficiently
2. Measurement of the friction surface heated. The ring gear must be installed with the
• Measure the depth of the friction surface of the chamfer facing the clutch.
flywheel. Note:
• Adjust it if the measured value is within the • Install the ring gear so that the side with a
standard value and the limit. pattern faces forward.
• If the measured value exceeds the limit, • Shrink fit the ring gear to the flywheel.
replace the flywheel. Make sure that flywheel and ring gear adhesion
Depth of the friction surface of the flywheel mm (in) is complete.
Standard 18 (0.7087)
Limit 19 (0.7480)
Depth = From the pressure installation surface
to the friction surface.

LNW21BSH01201

2. Install the pilot bearing.

• Place the crankshaft pilot bearing right angle
across the crankshaft bearing installation hole.
• Tap around the edges of the crankshaft pilot
LNW21BSH011901
bearing outer races with a brass hammer to
3. Flywheel installation bolts.
drive the bearing into the crankshaft bearing
• There is no damage in appearance.
installation hole.
• Exchange for a new part if damage is
Special tool
extensive.
Pilot Bearing Installer: 5-8522-0024-0
 015RY00010 LNW21BSH002601

3. Install the flywheel. Legend

• Install the flywheel of the crankshaft, tighten 1. Clutch Aligner
them in the order shown in the illustration.
5. Install the clutch pressure plate.
• Apply molybdenum disulfide on the screw part
• Install the pressure plate on the flywheel so that
and setting face of the bolt.
the installation hole of the pressure plate
• Install the crankshaft stopper on the starter
matches with the dowel pins of the flywheel.
installation part of the rear plate.
• Tighten the pressure plate in the order shown
Tightening torque: in the illustration.
1st step = 59 N⋅⋅m (6.0 kg⋅⋅m / 43 lb ft)
Tightening torque: 18 N⋅⋅m (1.8 kg⋅⋅m / 13 lb ft)
2nd step = 60° - 90° (degrees)
Special tool
Crankshaft stopper: 5-8840-0214-0

RTW56ASH023301

6. Install the transmission assembly.

Refer to removal procedure for “TRANSMISSION”.
015RY00001

4. Install the driven plate.

• Use a clutch aligner to install the driven plate
on the flywheel.
Torque Specifications

Special Tools
PART NO. PART NO.
ILLUSTRATION ILLUSTRATION
PART NAME PART NAME

5-8840-0214-0 5-8522-0024-0
Crankshaft stopper Pilot Bearing Installer

5-8840-2000-0
Pilot Bearing Remover

5-8840-0019-0
Sliding Hammer
 Gear Case Assembly

Components

RTW76ALF000601

Legend
1. Adjust Plate 3. Gasket
2. Generator 4. Gear Case Assembly
Removal
1. Remove the engine assembly.
Refer to removal procedure for “Engine Assembly”
in this manual.
2. Remove the cylinder head.
Refer to removal procedure for “Cylinder Head” in
this manual.
3. Remove the adjustment bracket of generator.
4. Remove the vacuum pump and pipe.
Refer to removal procedure for “Brake” in this
manual.
5. Remove the power steering pump.
Refer to removal procedure for “Power Steering” in
this manual.
6. Remove the water pump. RTW56ASH011301

Refer to removal procedure for “Water Pump” in 11. Remove the oil pump.
this manual. Refer to removal procedure for “Oil Pump” in this
7. Remove the fuel supply pump. manual.
Refer to removal procedure for “Fuel Supply 12. Remove the timing gear case (1) and gasket (2).
Pump” in this manual.
8. Remove the crankshaft pulley.
Refer to removal procedure for “Crankshaft Front
Oil Seal” in this manual.
9. Remove the gear case cover.
Refer to removal procedure for “Gear Case Cover”
in this manual.
10. Remove the idle gear A and idle gear A shaft, idle
gear C and idle gear C shaft.
Refer to removal procedure for “Timing Gear
Train” in this manual.

RTW76ASH001201

RTW56ASH011401
 Legend
Installation 1. Gear Case Assembly
1. Install the packing of the timing gear case. 2. Bolt L = 25 mm (0.98 in)
• Apply liquid gasket (ThreeBond 1207B or 3. Bolt L = 60 mm (2.36 in)
equivalent) on the joint (1) of the cylinder block 4. Bolt L = 45 mm (1.77 in)
and the crank case. 5. Bolt L = 35 mm (1.38 in)
6. Bolt L = 16 mm (0.63 in)
7. Bolt L = 20 mm (0.79 in)
8. Bolt L = 50 mm (1.97 in)
9. UP

• Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
• Tighten them in the order shown in the
illustration.
3. Install the oil pump.
Refer to installation procedure for “Oil Pump” in
this manual.
4. Install the idle gear C shaft and idle gear C, idle
gear A shaft and idle gear A.
Refer to installation procedure for “Timing Gear
RTW56ASH016301
Train” in this manual.
2. Install the timing gear case. 5. Install the gear case cover.
• Install the timing gear case to match with the Refer to removal procedure for “Gear Case Cover”
dowel pins, install bolts in the order shown in in this manual.
the illustration. 6. Install the crankshaft pulley.
Refer to removal procedure for “Crankshaft Front
Oil Seal” in this manual.
7. Install the fuel supply pump.
Refer to installation procedure for “Fuel Supply
Pump” in this manual.
8. Install the water pump.
Refer to installation procedure for “Water Pump” in
this manual.
9. Install the power steering pump.
Refer to removal procedure for “Power Steering” in
this manual.
10. Install the vacuum pump and pipe.
Refer to removal procedure for “Brake” in this
manual.
11. Install the adjustment bracket of generator.
RTW56ASH022601
Tighten the bolts to the specified torque.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
12. Install the cylinder head.
Refer to installation procedure for “Cylinder Head”
in this manual.
13. Install the engine assembly.
Refer to installation procedure for “Engine
Assembly” in this manual.
Torque Specifications

RTW76ALF000701
 Crankshaft Front Oil Seal

Components

RTW76AMF000501

Legend
1. Bolt 3. Crankshaft Damper Pulley
2. Washer 4. Crankshaft Front Oil Seal

Removal
1. Remove the fan assembly.
• Remove the fan assembly unscrewing four
mounting nuts.

RTW56ASH025401

2. Remove the fan belt.

 3. Remove the crankshaft pulley. • Apply engine oil to the lip of the oil seal.
Note: • With the seal pressed in check the dimension
Do not reuse the bolt and the washer. of the oil seal section.
Standard Dimension = 1.5 mm (0.06 in)

LNW61ASH005301

4. Remove the crankshaft front oil seal. RTW56ASH016601

• Remove only the oil seal with a screwdriver or 2. Install the crankshaft damper pulley.
the like, avoiding damage to the oil seal contact • Install the crankshaft pulley aligning with the
surface on the front cover and the shaft. key on the crankshaft.
• Hold the flywheel ring gear stationary to prevent
Installation the crankshaft from turning when tightening the
1. Install the crankshaft front oil seal. damper pulley bolt.
• Use the special tool to install the front oil seal. Tightening torque: 294 N⋅⋅m (30 kg⋅⋅m/217 lb ft)
Front Oil Seal • Take care not to damage the crankshaft
Installer: 5-8840-2821-0 (1) damper pulley boss.

RTW56ASH016501
014R100014

3. Install the fan belt.

• Refer to “Engine Cooling”
Torque Specifications

RTW76AMF000601

Special Tools
PART NO.
ILLUSTRATION
PART NAME

5-8840-2821-0
Oil seal installer
 Crankshaft Rear Oil Seal

Components

RTW56ALF002501

Legend
1. Crankshaft Rear Oil Seal 4. Clutch Pressure Plate
2. Flywheel 5. Transmission Assembly
3. Driven Plate
Removal
1. Remove the flywheel.
Refer to "Flywheel".
• With the oil seal pushed in deep, install the
special tool as shown in the illustration and
remove the oil seal.
Oil Seal Remover: 5-8840-2360-0

015LV002

Installation
1. Install the crankshaft rear oil seal.
• Use an oil seal install to install the crankshaft
rear oil seal.
Oil Seal Installer: 5-8840-2359-0

RTW56ASH022901

2. Install the flywheel.

Refer to "Flywheel".
Special Tools
PART NO.
ILLUSTRATION
PART NAME

5-8840-2359-0
Oil seal installer

5-8840-2360-0
Oil seal remover
 Crankshaft

Components

RTW56ALF002601

Legend
1. Upper Bearing 4. Crankshaft
2. Thrust Bearing 5. Lower Bearing
3. Gear 6. Bearing Cap
Removal
1. Demount the engine assembly.
Refer to "Engine Assembly".
2. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
3. Remove the camshaft.
Refer to "Camshaft Assembly".
4. Remove the cylinder head.
Refer to "Cylinder Head".
5. Remove the fuel supply pump and fuel rail.
Refer to "Fuel Supply Pump" and "Fuel Rail" in the
fuel system section.
6. Remove the front cover.
Refer to "Front Cover".
7. Remove the crankshaft rear oil seal. 015RY00003

Refer to "Crankshaft Rear Oil Seal". 16.Remove the lower crankshaft bearings.
8. Remove the water pump. 17.Remove the crankshaft assembly.
Refer to "Water Pump" in Cooling System Section. 18.Remove the thrust bearing.
9. Remove the timing gear train. 19.Remove the upper crankshaft bearings.
Refer to "Timing Gear Train".
10.Remove the oil pump. Disassembly
Refer to "Oil Pump". 1. Remove the crank angle sensor rotor (1).
11. Remove the gear case assembly. • Confirm that the pin (2) is not removed.
Refer to “Gear Case Assembly”.
12. Remove the crankshaft gear.

RTW76ASH001501

901R100008

13. Remove the crank case.

Refer to "Crank Case and Oil Pan".
14.Remove pistons and connecting rods.
Refer to "Piston and Connecting Rod".
15. Remove the bearing cap.
• Loosen the crankshaft bearing cap bolts in
numerical order a little at a time.
Reassembly
1. Install the crank angle sensor rotor.
• Attach by making a rotor tooth’s running out
side into a front side.
• Apply Loctite #262 or the equivalent to the bolt
threads (if a new bolt is used, Loctite
application is not required).
Tightening torque: 12 N⋅⋅m (1.2 kg⋅⋅m / 104 lb in)

015RY00002

2. Main bearing clearance

• Remove the crank case.
Set out disassembled main bearings in the
order of the numbers.
• Remove the crankshaft. Remove the main
bearings.
• Clean the crankshaft journal and upper and
lower bearings.
• Check the bearings for damage or excessive
RTW76ASH001601

Legend wear.
1. Crank Angle Sensor Rotor
If you find damage or excessive wear, replace
2. Pin
the bearings in pairs.

Inspection • Place the upper bearings and the crankshaft on

1. Thrust clearance the cylinder block. Install the crankshaft so that
• Measure the crankshaft end play at the center it is horizontal.
journal of the crankshaft. Note:
• Do this before removing the crankshaft bearing Turn the crankshaft about 30 degrees to allow the
caps. If the measured value exceeds the bearings to settle in.
specified limit, the crankshaft thrust bearing • Place plastigage on the crankshaft journal as
must be replaced. shown.
Axial play of the crankshaft mm (in) • Place the lower bearings at original positions on
Standard 0.10 (0.004) the bearing cap.
Limit 0.30 (0.012)

Note:
Measure the thrust clearance before dismounting.
 015RY00012 LNW21BSH024401

• Install the bearing cap and tighten bolts to the • If the journal oil clearance exceeds the limit,
specified tightening torque. replace the main bearings altogether or the
• Tighten the bearing cap in the sequence shown crankshaft.
using a torque wrench and an angle gauge. • Remove the Plastigage from the bearings and
the crankshaft.

Inspection of the 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 mm (in)
Standard 0.05 or less (0.0020 or less)
015LX129
Limit 0.08 (0.003)
Tightening torque: 166 N⋅⋅m (16.9 kg⋅⋅m / 122 lb ft)
Note:
Do not turn the crankshaft after you have tightened the
bearing cap.
• Loosen the bolts and gently remove the bearing
cap.
• Measure the widest part of the Plastigage
flattened by tightening the bearing cap to
determine the clearance.
Journal oil clearance mm (in)
Standard 0.032 - 0.077 (0.0013 - 0.0030)
Limit 0.11 (0.0043)
 Note:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
should not polish the surface of the crankshaft.

Crankshaft bearing selection

• Crankshaft bearing selection is based on the
measured diameters of the crankshaft journals
and the bearing inserts.
• Match the crankshaft bearing housing grade
marks and the crankshaft journal grade marks
in the table below to determine the correct
crankshaft bearing size.
• Crankshaft bearing housing grade marks 1, 2
or 3 are stamped on the rear right hand side of
the cylinder block.
015LX061

4. Measure the journal and the crankpin 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.

RTW56ASH017101

Legend
1. No.1
2. No.2
3. No.3
4. No.4
5. No.5

LNW21BSH024601 • The crankshaft journal grade marks (1 or -, 2 or

--, 3 or ---) are stamped on each crankshaft
Crankshaft outside diameter mm (in) journal web.
Standard Limit The crankshaft journal and bearing clearance
must be the same for each position after
Journal 69.917 – 69.932 69.91
installation of the crankshaft and the crankshaft
(2.7526 – 2.7532) (2.7524)
bearings.
Pin 52.915 – 52.930 52.9
(2.0833 – 2.0839) (2.083)
4JK1 4JJ1

RTW56ASH023901 RTW56ASH017201

Legend Legend
1. No.1 1. No.1
2. No.2 2. No.2
3. No.3 3. No.3
4. No.4 4. No.4
5. No.5 5. No.5

Note:
NOTE: Be careful about difference in the shape of the bearings
The crankshaft journal mark No. 4 is stamped on when installing them.
crankshaft No. 4 journal web front side or rear side.

RTW56ASH017301

Legend
1. Lot No.
2. Size Code
Bearing Selection Table
mm (in)
Crankshaft
Crankshaft Journal Crankshaft
Bearing Housing
Bearing
Grade Grade Size Code
Diamaeter Diamaeter
Mark Mark
1 or 69.927-69.932
- (2.7530-2.7532)
73.992- 4
74.000 2 or 69.922-69.927
1
(2.9131- -- (2.7528-2.7530)
2.9134)
3 or 69.917-69.922
5
--- (2.7526-2.7528)
1 or 69.927-69.932
2
- (2.7530-2.7532)
73.983-
73.991 2 or 69.922-69.927
2 3
(2.9127- -- (2.7528-2.7530)
2.9130)
3 or 69.917-69.922
4 015LX125
--- (2.7526-2.7528)
2. Install the crankshaft assembly.
1 or 69.927-69.932
1 Apply an ample coat of engine oil to the crankshaft
- (2.7530-2.7532)
73.975-
73.982 2 or 69.922-69.927 journals and the crankshaft bearing surfaces
3
(2.9124- -- (2.7528-2.7530) before installing the crankshaft.
2.9127) 2
3 or 69.917-69.922
--- (2.7526-2.7528)

Installation
1. Install the crankshaft upper bearing.
• The crankshaft upper bearings have an oil hole
and an oil groove. The lower bearings do not.
• Carefully wipe any foreign material from the
upper bearing.
• Locate the position mark applied at
disassembly if the removed upper bearings are
to be reused.
Note:
Do not apply engine oil to the bearing back faces and
the cylinder block bearing fitting surfaces.
015R100004

3. Install the thrust bearing.

• Apply an ample coat of engine oil to the thrust
bearings before installation. Install the thrust
bearings to the crankshaft center journal.
• The thrust bearing oil grooves must be facing
the sliding faces.
 5. Install the bearing cap.
• Install the bearing caps with the bearing cap
head arrow mark facing the front of the engine.
The bearing cap numbers must be facing up.

015LX115

4. Install the lower crankshaft bearing.

• Before the crankshaft bearing installation,
select the appropriate bearings in accordance
with the description in CRANK BEARING 015LX128

SELECTION of INSPECTION AND REPAIR. • Tighten the crankshaft bearing cap bolts to the
• Apply the recommended liquid gasket or its specified torque a little at time in the sequence
equivalent to the No. 5 crankshaft bearing cap shown in the illustration.
cylinder body fitting surfaces at the points Crankshaft Bearing Cap Torque N⋅m (kg⋅m / lb ft)
shown in the illustration. 166 (16.9 / 122)
Note:
Check to see the crankshaft turns smoothly by
Be sure that the bearing cap fitting surface is completely
free of oil before applying the liquid gasket. ThreeBond rotating it manually.
1207B Do not allow the liquid gasket to obstruct the Note:
cylinder thread holes and bearings. Confirm that the crankshaft turns smoothly.
ThreeBond 1207B is a fast-drying liquid gasket. Tighten
the bearing caps immediately after applying the gasket.

015LX129

6. Install pistons and connecting rods.

015LX127
Refer to "Piston and Connecting Rod".
7. Install the crank case.
Refer to "Crank Case and Oil Pan".
8. Install the crankshaft gear.

RTW56ASH017001

9. Install the gear case assembly.

Refer to "Gear Case Assembly".
10.Install the oil pump.
Refer to "Oil Pump".
11.Install the timing gear train.
Refer to "Timing Gear Train".
12.Install the water pump.
Refer to "Water Pump" in Cooling System Section.
13.Install the front cover.
Refer to "Timing Gear Train".
14.Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
15.Install the fuel supply pump and fuel rail.
Refer to "Fuel Supply Pump" and "Fuel Rail".
16.Install the cylinder head.
Refer to "Cylinder Head".
17.Install the camshaft assembly.
Refer to "Camshaft Assembly".
18.Install the cylinder head cover.
Refer to "Cylinder Head Cover".
19.Mount the engine assembly on the chassis.
Refer to "Engine Assembly".
Torque Specifications

RTW76AMF000301
 Cylinder Block
Components

RTW76ASF000101

Legend
1. Cylinder Block

8. Remove the crankshaft rear oil seal.

Removal Refer to "Crankshaft Rear Oil Seal".
1. Demount the engine assembly. 9. Remove the oil pan.
Refer to "Engine Assembly". Refer to "Oil Pan".
2. Remove the cylinder head cover. 10. Remove the water pump.
Refer to "Cylinder Head Cover". Refer to "Water Pump" in Cooling System Section.
3. Remove the camshaft assembly. 11. Remove the front cover.
Refer to "Camshaft Assembly". Refer to "Front Cover".
4. Remove the cylinder head. 12. Remove the timing gear train.
Refer to "Cylinder Head". Refer to "Timing Gear Train".
5. Remove the fuel supply pump and fuel rail 13. Remove the oil pump.
assembly. Refer to "Oil Pump".
Refer to "Fuel Supply Pump" and "Fuel Rail 14. Remove pistons and connecting rods.
Assembly" in FUEL SYSTEM Section. Refer to "Piston and Connecting Rod".
6. Remove the oil filter assembly and oil cooler. 15. Remove the crankshaft.
Refer to “Oil Filter Assembly and Oil Cooler”. Refer to "Crankshaft".
7. Remove the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal".
 16. Remove the piston cooling pipe. 5. Cylinder block wear measurement.
• Use a cylinder indicator to measure the cylinder
bore at measuring point (1) in the thrust (2-2)
and axial (3-3) directions of the crankshaft.
• Measuring Point (1): 20 mm (0.79 in)
If the measured value exceeds the specified
limit, the cylinder block must be replaced or
rebored.

RTW76ASH001101

Inspection
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. 012RY00010

3. Clean up the cylinder block.

4. Visually inspect the cylinder block. Cylinder block bore diameter mm (in)
• Conduct color check and hydraulic (or Standard 95.421 − 95.450 (3.7567 − 3.7579)
pneumatic) test and if you find a crack or other Limit 95.48 (3.7590)
damage, replace the cylinder block.

RTW76ASH000801
 6. Cylinder Reboring. • Bore and hone the individual cylinders as
• Select oversize pistons to fit the largest cylinder required.
bore (previously measured). • Once again, measure the individual cylinder
• At a point 11 mm (0.43 in) above the lower bores.
edge of the piston skirt, measure the piston Each cylinder bore remainder mm (in)
diameter at a right angle to the piston pin.
0.02 (0.0008) or less.
Calculate the additional cylinder boring required
for each cylinder.
7. Cylinder block upper face warpage.
• Use a straight edge (1) and a thickness gauge
(2) to measure the four sides and the two
diagonals of the cylinder block upper face.
• If the measured values exceeds the limit, the
cylinder block must be replaced.
Cylinder block upper face warpage mm (in)
Standard 0.05 or less (0.002 or less)
Limit 0.20 (0.0080)

RTW56ASH023101

Legend
1. 11mm (0.43in)

• Formula
Boring inside diameter = D + C - H ± E
D = Piston outside diameter
(Measured Oversize Piston)
C = Piston and cylinder bore clearance
0.082 - 0.100 mm (0.0032 - 0.0039 in)
H = Honing allowance
012R100001
0.03 mm (0.0012 in) or less
E = Boring machine error

Piston size mm (in)

Standard 95.330 - 95.359 (3.7531 - 3.7543)
Oversize (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)
 Cylinder block height (H) (Reference) mm (in) 2. Install the crankshaft.
Standard 259.945 – 260.055 (10.2340 – 10.2384) Refer to "Crankshaft".
3. Install pistons and connecting rods.
Refer to "Piston and Connecting Rod".
4. Install the oil pump.
Refer to "Oil Pump".
5. Install the timing gear train.
Refer to "Timing Gear Train".
6. Install the front cover.
Refer to "Front Cover".
7. Install the water pump.
Refer to "Water Pump" in Cooling System Section.
8. Install the oil pan.
Refer to "Oil Pan".
9. Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
10. Install the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal".
11. Install the oil filter assembly and oil cooler.
012R100009
Refer to "Oil Filter Assembly and Oil Cooler".
Installation 12. Install the fuel supply pump and fuel rail
assembly.
1. Install the piston cooling pipe.
Refer to "Fuel Supply Pump" and "Fuel Rail
• Align the dowel pin of the piston cooling pipe
Assembly " in Fuel System Section.
with the pin hole on the cylinder block and
13. Install the cylinder head.
tighten with the relief valve.
Refer to "Cylinder Head".
Tightening torque: 14. Install the camshaft assembly.
Relief valve 30 N⋅⋅m (3.1 kg⋅⋅m / 22 lb ft) Refer to "Camshaft Assembly".
bolts M8 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft) 15. Install the cylinder head cover.
bolts M6 8 N⋅⋅m (0.8 kg⋅⋅m / 69 lb in) Refer to "Cylinder Head Cover".
Note: 16. Mount the engine assembly on the chassis.
Be careful not to deform or damage the piston cooling Refer to "Engine Assembly".
pipe nozzle.

RTW76ASH001101
 Lubrication System
• Avoid excessive or insufficient coating volume.
Service Precautions Note that seizure may occur in case of excessive
• During each disassembly, remove the old gasket coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid is insufficient.
gasket is to be used, clean the traces of oil, • Always, the start and end of the application should
moisture, and dirt completely using waste cotton be overlapped.
and apply the specified new fluid gasket at each
location.
Explanations on functions and operation
The lubrication system uses the filter element combined
with a full flow bypass, water-cooled oil cooler, and oil
jet for piston cooling.

Lubricating system diagram

LNW76ALF000201

2
1. Oil Pump Relief Valve Operating Pressure: 490 – 686 kPa (5.0 – 7.0 kg/cm / 71 – 100 psi)
2
2. Oil Cooler Relief Valve Opening Pressure: 176 – 216 kPa (1.8 – 2.2 kg/cm / 26 – 31 psi)
2
3. Oil Filter Relief Valve Opening Pressure: 80 – 120 kPa (0.8 – 1.2 kg/cm / 11 – 17 psi)
4. Oil Pressure Switch Operating Pressure: 29.4 – 49.0 kPa (0.3 – 0.5 kg/cm 2 / 4.3 – 7.1 psi)
2
5. Regulating Valve: 176 – 216 kPa (1.8 – 2.2 kg/cm / 26 – 31 psi)
Functional Check Engine oil
• Ensure the car is on level ground. Before starting
Oil pressure check the engine or when 30 minutes or more have
1. Check whether the engine oil is contaminated with elapsed after stopping the engine, check the
dirt, light oil, or water. If contaminated with dirt, engine oil volume using the level gauge. The
light oil, or water (after examining the cause and volume is appropriate if the engine oil is between
taking the appropriate measures for light oil or the upper and lower limits of the level gauge.
water contamination), replace the oil. Replenish the engine oil, if level is below the lower
2. Check the engine oil level. The oil level should be limit. Also, check for contamination of the engine
between the two holes of the level gauge. If the oil oil.
level is insufficient, replenish it.
3. Remove the oil pressure switch on the nipple.
4. Install the oil pressure gauge on the nipple.

RTW56ASH015601

RTW56ASH015501

Legend
1. Oil Pressure Switch

5. Warm the engine.

6. Measure the oil pressure, to check whether it is
2
more than 400 kPa (4 kg/cm / 58 psi) at 3600
rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
10. Start the engine and check for oil leakage.

RTW56ASH015701

Legend
1. Lower Limit
2. Upper Limit
Engine oil leakage
• In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.
 Oil Filter Cartridge

Components

RTW56ASF000101

Legend
1. Oil Filter Cartridge

Removal Installation
1. Place a tray under the oil filter cartridge. 1. Install the oil filter cartridge.
2. Remove the oil filter cartridge using the oil filter • Apply grease or engine oil to the seal in the
wrench. cartridge and install it using the oil filter wrench.
• Tighten the cartridge using the specified torque.
Special tool
Tightening torque: 20 N·m (2.0 kg·m / 14 lb ft)
Oil filter wrench: 5-8840-0203-0 (1)
Or
After it comes in contact with the oil seal,
tighten it through an additional turn of 1 and
1/4.
Special tool
Oil filter wrench: 5-8840-0203-0

RTW56ASH012501
Special Tools
PART NO.
ILLUSTRATION
PART NAME

5-8840-0203-0
Oil filter wrench
 Oil Filter Assembly and Oil Cooler

Components

RTW56AMF000401

Legend
1. Exhaust Manifold 4. Water Bypass Pipe
2. Generator Bracket 5. Water Intake Pipe
3. Generator Adjustment Bracket 6. Oil Filter Assembly and Oil Cooler

Removal
1. Remove the exhaust manifold.
Refer to removal procedure for "Turbocharger and
Exhaust Manifold" in this manual.
2. Remove the generator.
Refer to removal procedure for generator in this
manual.
3. Remove the adjustment bracket of generator.
4. Remove the bracket of generator.
5. Remove the water bypass pipe (1).

RTW56ASH008401
 6. Remove the water intake pipe.
Disassembly
1. Remove the element mounting nut (1).

RTW56ASH012601

Legend
1. Water Intake Pipe RTW56ASH012901

2. Bracket 2. Remove the element (1).

3. Bracket 3. Remove the gasket (2).
4. Bolt

7. Remove the oil cooler.

RTW56ASH013001

RTW66ASH009101
Reassembly Installation
1. Install the gasket on the element. 1. Install the oil filter and cooler.
2. Install the element. • Install the O-ring on the oil filter and cooler,
3. Tighten the element fixing nut using the specified apply grease.
torque. • Apply the liquid gasket and mount within 5
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft) minutes. Apply liquid gasket (ThreeBond TB-
1207C or equivalent) to the flange surface
groove (cylinder block). Bead diameter must
be between 2 and 3 mm (0.079 and 0.118 in).
Refer to the illustration for the offset position
(no more than 1 mm (0.004 in)).

RTW56ASH013101

Legend
1. Liquid Gasket
2. O-ring

• Align the oil filter and cooler holes with the

cylinder block studs. Install the oil cooler to the
cylinder clock.
 2. Install the water intake pipe.
a. Temporarily tighten the bolt (6).
b. Install the O-ring (2) to the water intake pipe
(7).
c. Apply soapy water to the O-ring (2) and install
the water intake pipe (7).
• Take care not to twist the O-ring.
d. Temporarily tighten the bolts.
Temporary tightening order: 1→3→4→5
e. Tighten the bolts to the specified torque.
Fully tightening order: 3→4→1→5→6
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)

RTW56ASH013201

Legend
1. Bolt 45 mm (1.77 in)
2. Bolt 110 mm (4.33 in)
3. Bolt 70 mm (2.76 in)
4. Nut

• 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)

RTW76ASH001701

3. Install the water bypass pipe (1).

• After applying soapy water to O-ring, set it on
bypass pipe and insert into the cylinder head.
Tighten the bolts to the specified torque.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)

RTW56ASH013301
 RTW56ASH008401

4. Install the bracket of generator.

Tighten the bolts to the specified torque.
Tightening torque: 51 N⋅⋅m (5.2 kg⋅⋅m / 38 lb ft)
5. Install the adjustment bracket of generator.
Tighten the bolts to the specified torque.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
6. Install the generator.
Refer to Installation procedure for generator in this
manual.
7. Install the exhaust manifold.
Refer to Installation procedure for turbocharger
and exhaust manifold in this manual.
 Crank Case and Oil Pan

Components

RTW76ALF000801

Legend
1. Gasket 5. Rear Plate
2. Oil Strainer 6. Bolt
3. Bolt 7. Oil Pan
4. Crank Case 8. Bolt
 4. Disconnect the earth terminal (1) of crank case
Removal side.
1. Remove the engine assembly.
Refer to “Engine Assembly”.
2. Remove the oil level gage guide tube.

RTW76ASH001801

5. Remove the flywheel.

Refer to “Flywheel”.
RTW56ASH015601 6. Remove the rear plate.
3. Remove the oil pan.

RTW76ASH001901

RTW56ASH015001
Legend
1. Rear Plate
2. Bolt
 7. Remove the cylinder head.
Refer to “Cylinder Head”. Disassembly
8. Remove the timing gear case. 1. Remove the oil strainer.
Refer to “Timing Gear Case”.
9. Remove the retainer.

RTW66ASH009201

Legend
RTW76ASH002001 1. Gasket
Legend 2. Oil Strainer
1. Retainer 3. Bolt
2. Bolt 4. Crank Case

10. Remove the crank case.

Reassembly
Install the oil strainer.
• Install the gasket on the strainer.
• Tighten the bolts to the specified torque.
Tightening torque: 22 N⋅⋅m (2.2 kg⋅⋅m / 16 lb ft)

RTW56ASH021901

Legend
1. O-ring
2. Crank Case

Note:
Take care not to damage the O-ring.
 3. Install the retainer.
Installation • Apply the liquid gasket (ThreeBond TB-1207C
1. Install the crank case. or equivalent) and mount within 5 minutes.
• Apply the liquid gasket (ThreeBond TB-1207C Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
or equivalent) and mount within 5 minutes.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)

RTW56ASH017701

Legend
RTW56ASH015301 1. 2 - 2.5 mm (0.079 - 0.098 in)
Legend 2. 2 - 2.5 mm (0.079 - 0.098 in)
1. 2.0 - 3.0 mm (0.079 - 0.118 in)
2. 4.0 - 5.0 mm (0.157 - 0.197 in)

2. Install the oil pan.

• Apply the liquid gasket (ThreeBond TB-1207B
or equivalent)and mount within 5 minutes.
Tightening torque: 22 N⋅⋅m (2.2 kg⋅⋅m / 16 lb ft)

RTW76ASH002001

Legend
1. Retainer
2. Bolt

4. Install the timing gear case.

Refer to “Gear Case Assembly”.
RTW56ASH015201 5. Install the cylinder head.
Legend Refer to “Cylinder Head”.
1. 2.0 mm (0.079 in)
2. 3.0 mm (0.118 in)
 6. Install the rear plate.
• Tighten the bolts to the specified torque.
Tightening torque: 82 N⋅⋅m (8.4 kg⋅⋅m / 61 lb ft)
7. Install the flywheel.
Refer to “Flywheel”.
8. Connect the earth terminal of crank case side.
Note:
Do not allow the caulked portion of the terminal to
interfere with nearby parts.
9. Install the oil level gage guide tube.
• Apply the engine oil to the O-ring.
• Tighten the bolts to the specified torque.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
10. Install the engine assembly.
Refer to “Engine Assembly”.
Torque Specifications

RTW56AMF001901
 Oil Pump

Components

RTW66AMF000701

Legend
1. Bolt 2. Oil Pump Assembly

Removal
1. Drain the engine coolant.
2. Remove the radiator upper hose.
3. Remove the upper fan shroud.
4. Remove the fan and fan clutch.
• Loosen the fan clutch nuts.
• Remove the fan together with the fan clutch.
Take care not to damage the radiator core.
5. Remove the fan drive belt and pulley.
• Loosen the tension adjust bolt on the generator
and A/C.
• Remove the fan drive belt with the fan pulley.
6. Remove the lower fan shroud.
7. Disconnect the power steering pump.
• Disconnect the bracket of the power steering oil LTW56ASH000101

hose clip (1).

8. Remove the vacuum pump.
• Remove the vacuum pipe bracket and vacuum
pipe.
• Remove the oil pipe (feed side and return side)
of vacuum pump.
9. Remove the noise cover (1).

RTW56ASH020001

Disassembly
1. Remove the spring pin.
2. Remove the spring seat.
3. Remove the spring.
RTW56CSH001401 4. Remove the valve.
10. Remove the crank pulley.
11. Remove the front cover.

RTW56ASH019701

12. Remove the oil pump (1).

Reassembly
1. Install the valve.
2. Install the spring.
3. Install the spring seat.
4. Install the spring pin.

RTW56ASH025601

• Measure the inside diameter of the bushes of

the cylinder block using the dial gauge.
• If the clearance between the driven gear
shaft/drive gear shaft and bush exceeds the
limit, replace the oil pump assembly.
RTW56ASH015901 Clearance between the driven gear shaft/drive gear
Legend shaft and bush mm (in)
1. Spring Pin Standard 0.04 - 0.07 (0.0016 - 0.0028)
2. Spring Seat Limit 0.20 (0.0079)
3. Spring
4. Valve

Inspection
NOTE:
Think to match direction of ditch of gear when
assembling it.
1. Measure the clearance between the driven
gear/drive gear shaft and the bush.
• Measure the outside diameter of the driven
gear shaft using a micrometer.
Outside diameter of the driven gear shaft/drive
gear shaft mm (in)
Standard 15.989 - 16.000 (0.62949 - 0.62992)
Limit 15.900 (0.62598)

RTW56ASH014701

2. Measure the clearance between the gear side

surface and the gear side surface of the oil pump
housing.
• Measure the width size the driven gear/drive
gear.
Width size the driven gear/drive gear mm (in)
Standard 14.5 (0.5709)
 Installation
1. Install the oil pump.
• Apply engine oil to the oil pump attachment
gearbox.
• Tighten the bolts to the specified torque.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
• Installed pump gear should be smooth to
rotate.
2. Install the gear case cover.
• Apply the liquid gasket (Threebond TB-1207B
or equivalent) mount within 5 minutes.

RTW56ASH025501

• Measure the Depth size of the gear case

housing surface and the oil pump housing gear
case side.
Depth size the gear case housing surface and the oil
pump housing gear case side
mm (in)
Standard 14.500 - 14.527 (0.5709 - 0.5719)

RTW56ASH020101

Legend
1. Apply the liquid gasket in area

RTW56ASH014801

Clearance between the gear side surface and the

gear side surface of the oil pump housing mm (in)
Standard 0.063 - 0.027 (0.0025 - 0.0011)
Limit 0.20 (0.0079)
 • Install the gasket in the slot of the gear case
cover.
• Tighten the bolts to the specified torque.
Tightening torque: 8 N⋅⋅m (0.8 kg⋅⋅m / 69 lb in)

LTW56ASH000101

7. Install the lower fan shroud.

8. Install the fan drive belt and pulley.
• Install the fan drive belt with the fan pulley.
9. Install the fan and fan clutch.
RTW56ASH012101
• Tighten the bolts to the specified torque.
3. Install the crank pulley.
• Tighten the bolts to the specified torque. Tightening torque: 8 N⋅⋅m (0.8 kg⋅⋅m / 69 lb in)

Tightening torque: 294 N⋅⋅m (30.0 kg⋅⋅m / 217 lb ft) 10. Adjust the drive belt of generator and A/C
compressor.
4. Install the noise cover to the timing chain cover
• Apply tension to the fan drive belt by moving
lower.
the generator.
• Tighten the bolts to the specified torque.
• Apply a force of 98 N (10 kg / 22 lb) to the drive
Tightening torque: 10 N⋅⋅m (1.0 kg⋅⋅m / 87 lb in) belt mid portion to check the drive belt
5. Install the vacuum pump. deflection.
• Tighten the nuts to the specified torque. Generator drive belt deflection mm (in)
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft) New belt 5 - 6 (0.20 – 0.24)
• Install the oil pipe (feed side and return side) of Reuse belt 7 - 8 (0.28 – 0.31)
vacuum pump.
• Install the vacuum pipe bracket and vacuum A/C compressor drive belt deflection mm (in)
pipe.
New belt 6 - 7 (0.24 – 0.28)
6. Install the power steering pump.
• Tighten the nuts to the specified torque. Reuse belt 8 - 9 (0.31 – 0.35)
11. Install the upper fan shroud.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m / 18 lb ft)
12. Install the radiator upper hose.
• Install the bracket of power steering oil hose
13. Replenish the engine coolant.
clip (1).
 Oil Pressure SW

Components

RTW76AMF000401

Legend
1. Cylinder Block 4. Oil Pressure SW
2. Gasket 5. Nipple; Oil Gallery
3. Nipple; Oil Pressure Warning SW
Removal Circuit check
1. Remove the oil pressure SW. 1. Turn the starter switch to ON.
2. Remove the nipple; oil gallery. 2. Disconnect the oil pressure switch connector, and
3. Remove the nipple; oil pressure warning SW and confirm that the oil pressure-warning lamp lights
gasket. when the connector on the harness side is
grounded.
Inspection If the warning lamp does not light up, check the
Check the continuity between the switch terminal and circuit between the meter and the oil pressure
the body grounding in a no-load condition. switch, and repair the disconnected locations.
If there is no connectivity, replace with normal parts.

LNW21HSH003401
LNW21HSH003301

Installation
1. Install the nipple; oil gallery, oil pressure warning
SW and gasket.
Tightening torque: 25 N⋅⋅m (2.5 kg⋅⋅m/18 lb ft)
2. Install the Nipple.
Tightening torque: 15 N⋅⋅m (1.5 kg⋅⋅m/11 lb ft)
3. Install the oil pressure SW.
Tightening torque: 15 N⋅⋅m (1.5 kg⋅⋅m/11 lb ft)
 Air Cleaner Element
High Output
Removal
1. Remove the air cleaner cover fixing clip.
2. Remove the air cleaner element assembly.

Cleaning
Dry type element
• Rotate the element with your hand while applying
compressed air to the inside of the element. This
will blow the dust free.
2
Compressed air pressure kPa (kg/cm /psi)
392 − 490 (4 − 5/57 − 71)

Standard Output

LNW71BSH000201

Installation
1. Install the air cleaner element assembly.
2. Install the air cleaner cover.

LNW46ASH003201