WORKSHOP MANUAL NHR « NKR * NPR ENGINE 4H SERIES SECTION 6 ISU2UMEMONOTICE Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section 0A under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL”. All material contained in this Manual is based on latest product information available at the time of publication. All rights are reserved to make changes at any time without prior Applicable Model N Series NKR66 NPS66 NQR71 NPR66 NPS71 NPR70 NaR66 NPR71 NaR70 This manual is applicable to 1996 year model and later vehicles except those sold in the United States of America, and Canada.THIS MANUAL INCLUDES THE FOLLOWING SECTIONS: SECTION NO. CONTENTS 00 Service Information 6A Engine Mechanical 6A3 Engine (4HF1/4HF1-2/4HE1-T/4HE1-TC/4HG1/4HG1-T) 6B Engine Cooling 6c Fuel System 6D Engine Electrical 6E Emission and Electrical Diagnosis oF Exhaust 6G TurbochargerSERVICE INFORMATION 00-1 SECTION 00 SERVICE INFORMATION Troubleshooting. Main Data and Specification: Service Standard Servici Fixing Torque... Special Tools... Lubricating System... CONTENTS. PAGE 00- 2 00-19 00 - 28 00 - 42 00 - 59 00 - 70 00 - 7200-2 SERVICE INFORMATION TROUBLESHOOTING CONTENTS, Hard Starting... Starter Motor Inoperative.. Starter Motor Operates but Engine does not turn over. Engine turns over but does not start Fuel is not being delivered to the injection pump .. Fuel is being delivered to the injection pump... Quick-on Start System ... Unstable Idling. Insufficient Power.. Excessive Fuel Consumption Excessive Oil Consumption. Overheating. White Exhaust Smoke Dark Exhaust Smoke Oil Pressure Does Not Abnormal Engine Noise .. Engine Knocking .. Gas Leakage Noise.. Continuos Noise Slapping Noiss Engine Cooling Trouble Starter Motor Does Not Stop. PAGE 00 - 00 - 00 - 00 - 00- 00 - Rk RO ww oo- 5 00- 10 00-11 00 - 12 00 - 12 00 - 13 00 - 13 00-14 00-14 00 - 15 00-15 00 - 15 00 - 15 00-16 00-17 00-18SERVICE INFORMATION 00-3 1. HARD STARTING 4. STARTER MOTOR INOPERATIVE. Checkpoint Possible cause Correction Battery Loose battery cable terminal Clean andior retighten the battery Poor connections due to rusting cable terminal Battery discharged or weak Recharge or replace the battery Fan belt loose or broken ‘Adjust or replace the fan belt Fusible link Fusible link shorted Replace the fusible link Starter switch Defective starter switch or starter relay Replace the starter switch or the starter relay Starter motor Defective magnetic switch or starter relay | Repair or replace the magnetic switch Defective starter motor Repair or replace the starter motor 2. STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER Battery Loose battery cable terminal Clean andlor retighten the battery Poor connections due to rusting cable terminal Battery discharged or weak Recharge or replace the battery Fan belt loose or broken Adjust or replace the fan belt Starter motor Defective pinion gear Replace the pinion gear Defective magnetic switch Repair or replace the magnetic switch Brush wear, Weak brush spring | Replace the brush andlor the brush spring Engine Piston, crank bearing seizure, or other | Repair or replace the related parts damage00-4 SERVICE INFORMATION 3, ENGINE TURNS OVER BUT DOES NOT START Checkpoint Possible cause Correction Engine stop Defective fuel cut solenoid valve Replace the fuel cut solenoid valve mechanism FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP Fuel Fuel tank is empty Fill the fuel tank Fuel piping Clogged or damaged fuel lines. Loose fuel__| Repair or replace the fuel lines line connection Retighten the fuel line connection Fuel fiter Fuel fier overfiow valve does not close Repair or replace the fuel fiter overflow valve Clogged fuel fer element, Replace the fuel fier element or the fiter cartridge Fuel system Air in the fuel system Bleed the air from the fuel system Fuel feed pump Defective feed pump Repair or replace the feed pump FUEL IS BEING DELIVERED TO THE INJECTION PUMP Injection nozzle Injection pump Injection nozzle sticking Injection nozzle injection starting pressure too low Improper spray condition Defective fuel injection nozzle resulting in the fuel drippage after fuel injection Defective injection pump control rack ‘operation Injection pump plunger worn or stuck Injection pump drive shaft seizure or other damage Injection pump governor spring seizure Fuel Use of the wrong fuel Use the correct fuel ‘Water particles in the fuel Charge the fuel Fuel system Air in the injection pump Bleed the air from the fuel system Replace the injection nozzle Adjust or replace the injection nozzle Replace the delivery valve Repair or replace the injection pump control rack Replace the injection pump plunger assembly Replace the injection drive shat Replace the injection pump governor spring‘SERVICE INFORMATION 00-5 4, QUICK-ON START SYSTEM Check point Possible cause Correction Glow plug indicator. 1, Defective Fusible link wire Replace the fusible link wire light does not tum on. 2, Broken indicator light fuse. Replace the indicator light fuse 3. Defective indicator bulb Replace the indicator light bulb Preheating system 1,_Defective fusible link wire shorted Replace the fusible link wire dose not work 2. Defective glow plug relay connector Replace or Repair glow plug relay 3. Defective glow plug connector 4, Defective quick-on start timer connector Preheating time to 4. Defective thermo switch include long or to short defective wiring harness 2. Defective glow plug 3, Defective timer unit connector Replace or Repair glow plug connector Replace or Repair quick-on start timer connector Replace thermo switch Replace glow plug Replace timer unit00-6 SERVICE INFORMATION Check if battery is normal, then perform the following diagnosis. ‘STARTER DOES NOT RUN (CHECK BATTERY (CHARGING FAILURE OR UFE BATTERY IS NORMAL (CHECK BATTERY [CHECK TERMINAL CONNECTION ‘CONNECTION FAILURE ‘TERMINAL CONNECTION Is NORMAL CLEAN BATTERY TERMINALS, AND RECONNECT (CHECK STARTER OR STARTER SWITCH FAILURE REPAIR OR REPLACE, ‘TURN ON HEAD LAMP AND STARTER SWITCH HEAD LAMP DOES NOT COME ON HEAD LAMP ILLUMINATES, ‘OR ITS EXTREMELY DARK 2) DISCONNECT STARTER CIRCUIT 2) LACK OF BATTERY CHARGING b) DISCONNECT STARTER COIL b) SHORT-CIRCUIT IN STARTER COIL /¢)_ FAULTY STARTER SWITCH (©) FAULTY STARTER PARTSSERVICE INFORMATION 00-7 FAULTY MESHING OF PINION AND RING GEAR (CHECK IF BATTERY VOLTAGE IS PRESENT AT MAGNETIC SWITCH TERMINAL "S’ WHEN, 'STARTER SWITCH IS TURNED TO "START (ST)" = ie Si aoa eoarer seer ee racereeten en orate owner pierre oey omen | |amrmanee aaa ee Bae = [eo] rermnovrenac| —_|fepan cnnenace pee pecowecrouen | [aecerwneae Pec ere te |oecce commen ewwacsomeres” | [eomacronsew sy Srecvcweenc | |Somromtece a ny REPAIR ves | [no } FAULTY CONNECTIONOF | [DISCONNECTION OR STARTER SWITCH FAULTY CONNECTION BETWEEN STARTER SWITCH AND BATTERY REPLACE STARTER SWITCH a00-8 SERVICE INFORMATION MAGNETIC SWITCH DOES NOT OPERATE THOUGH [STARTER SWITCH IS TURNED TO START (ST" ‘CHECK IF VOLTAGE IS PRESENT AT MAGNETIC. ‘SWITCH TERMINAL °S" WHEN STARTER SWITCH IS ‘TURNED TO"START (ST)" ‘CHECK GROUND CABLE Yes No REPAIR oR PINION MAGNETIC SWITCH 'SUDING ‘OR COIL IS PART DOES DISCONNECTED OR NOTMOVE BURNED CUT REPAIR OR REPLACE STARTER, (CHECK IF INDICATOR LAMP ON teeny ae pases! Eecerrge parece fee Peres ae excocsranre] [Fase comecron Ere anna CHECK CLUTCH /START SWITCH REPLACE STARTER SWITCHSERVICE INFORMATION 00-9 PINION MESHES WITH RING GEAR BUT [ENGINE DOES NOT RUN (CHECK GROUND CABLE YES NO REPAIR OR REPLACE. GROUND CABLE FAULTY CONNECTION BURNED-OUT DISCONNECTION DISCONNECTION SLIP OF ‘OF BRUSH AND MAGNETIC OR DAMAGE OF OR DAMAGE OF PINION, ‘COMMUTATOR [STARTER SWITCH FIELD COIL ARMATURE COIL, JCLUTCH REPAIR OR REPLACE STARTER00-10 SERVICE INFORMATION 2. UNSTABLE IDLING Piston ring sticking between the valve and the valve seat Check point Possible cause Correction Idling system Idling improperly adjusted Adjust the idling Fast idling speed Defective fast idling speed control device —_| Repair or replace the fast idiing speed control device control device ‘Accelerator control Accelerator control system improperly Adjust the accelerator control system system adjusted Fuel system Fuel system leakage or blockage Repair or replace the fuel system Air in the fuel system Bleed the air from the fuel system Water particles in the fuel system ‘Change the fuel Fuel fiter Clogged fuel fer element Replace the fuel fier element or the fuel fter cartridge Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump Injection nozzle Injection nozzle sticking Replace the injection nozzle Injection nozzle injection starting pressure | Adjust or replace the injection nozzle teponer spray condition Injection pump Defective delivery valve resulting in fuel Replace the delivery valve drippage after fuel injection Injection pump Injection timing improperly adjusted ‘Adjust the injection timing (cone) Insufficient injection volume ‘Adjust the injection volume Defective idle spring Replace the idle spring Defective governor lever operation Repair or replace the governor lever Regulator valve improperly adjustment ‘Adjust or replace the regulator valve Broken plunger spring Replace the plunger spring ‘Wom plunger Replace the plunger assembly Wom cam disc Replace the cam disc Valve clearance Valve clearance improperly adjusted Adjust the valve clearance ‘Compression pressure Blown out cylinder head gasket Replace the related parts Wom oyinder linerSERVICE INFORMATION 00-11 3. INSUFFICIENT POWER Check point Possible cause Correction Air cleaner (Clogged air cleaner element Clean or replace the air cleaner element Fuel Water particle in the fuel Replace fuel Fuel filter ‘Clogged fuel fter element Replace the fuel fiter element or the fuel fiter cartridge Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump Injection nozzle Injection nozzle sticking Replace the injection nozzle Injection nozzle injection starting pressure too low Improper spray condition Adjust or replace the injection nozzle Fuel injection pipes Fuel injection pipes damaged or obstructed Replace the fuel injection pipes Injection pump Defective regulating valve Repair or replace the regulating valve Defective delivery valve Defective timer Repair or replace the timer ‘Wor cam disk Improper control lever operation Adjust or replace the control lever Defective injection timing Replace the govemnor spring Weak governor spring Wom plunger Replace the delivery valve Replace the cam disk ‘Adjust the injection timing Repair or replace the injection pump timer Replace the plunger assembly Compression pressure Blown out cylinder head gasket ‘Wom cytinder liner Piston ring sticking Replace the related parts Valve clearance Valve clearance improperly adjusted ‘Adjust the valve clearance Valve spring Valve spring weak or broken Replace the valve spring Exhaust system Exhaust pipe clogged Clean the exhaust pipe Full load adjusting screw seal ‘Open and improperly set adjusting screw seal Adjust and reseal the adjusting screw00 - 12 SERVICE INFORMATION 4. EXCESSIVE FUEL CONSUMPTION too low Improper spray condition Check point Possible cause Correction Fuel system Fuel leakage Repair or replace the fuel system related parts Air cleaner (Clogged air cleaner element Clean or replace the air cleaner element Idling speed Poorly adjusted idling speed Adjust the idling speed Injection nozzle Injection nozzle injection starting pressure __| Adjust or replace the injection nozzle Fuel injection timing Fuel injection timing improperly Adjust the fuel injection timing Injection pump Defective delivery valve resulting is fuel drippage after fuel injection Replace the delivery valve Valve clearance Valve clearance improperly adjusted Adjust the valve clearance Compression pressure Blown out cylinder head gasket Wom eylinder liner Piston ring sticking Replace the related parts, Oil seal and gasket Too much engine cil Oil leakage from the oilseal and/or the gasket Valve spring Valve spring weak or broken Replace the valve spring 5. EXCESSIVE OIL CONSUMPTION Check point Possible cause Correction Engine oil Engine oil unsuitable Replace the engine oil Correct the engine oil level Replace the oil seal andlor the gasket Air breather (Clogged air breather Clean the air breather Intake and exhaust valve ‘Wom valve stems and valve guides Replace the intake and exhaust valves and the valve guidesSERVICE INFORMATION 00-43 6. OVERHEATING Check point Possible cause Correction Cooling water Insufficient cooling water Replenish the cooling water Fan clutch Oil leakage from the fan clutch Replace the fan clutch Fan belt Fan belt loose or cracked causing slippage _| Replace the fan belt Radiator Defective radiator cap or clogged radiator | Replace the radiator cap or clean the core radiator core Water pump Defective water pump Repair or replace the water pump Cylinder head and cylinder body sealing cap Defective sealing cap resulting in water leakage Replace the sealing cap Thermostat Coating system Fuel injection timing Defective thermostat Cooling system clogged by foreign material Fuel injection timing improperly adjusted Replace the thermostat Clean the foreign material from the. cooling system Adjust the fuel injection timing 7. WHITE EXHAUST SMOKE Check point Possible cause Correction Fuel Water particles in the fuel Replace the fue! Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing Compression pressure Blown out cylinder head gasket Wom cylinder liner Piston ring sticking Replace the related parts, Inlet and exhaust valves Valves seals Defective valve seales Wom valves stems and valve guides Replace the valve seales, the valves, and the valve guides00-14 SERVICE INFORMATION 8. DARK EXHAUST SMOKE too low Improper spray condition Check point Possible cause Correction Air cleaner (Clogged air cleaner element Clean or replace the air cleaner element Injection nozzle Injection nozzle injection starting pressure __| Adjust or replace the injection nozzle Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing Injection pump Defective delivery valve resulting in fuel Replace the delivery valve drippage after fuel injection Excessive injection volume Adjust the injection volume 9. OIL PRESSURE DOES NOT RISE Check point Possible cause Correction Engine oil Improper viscosity engine oil Replace the engine oil Insufficient engine oil Correct the engine oil volume Oil pressure gauge or unit Oil pressure indicator light Ol fiter Relief valve and by-pass valve il pump Rocker arm shaft Camshaft Crankshaft and bearings Defective oil pressure gauge or unit Defective indicator light Clogged oil fter element Relief valve sticking and/or weak by-pass valve spring Clogged oil pump strainer Wor oil pump related parts Wom rocker arm bushing ‘Wom camshaft and camshaft bearing Worn crankshaft and bearings Repair or replace the oil pressure gauge or unit Replace the indicator light Replace the oil filter element or the oil filter cartridge Replace the relief valve andlor the by- pass valve spring Clean the oil pump strainer Replace the oil pump related parts Replace the rocker arm bushing Replace the camshaft and the camshaft bearing Replace the crankshaft and/or the bearingsSERVICE INFORMATION 00-15 10. ABNORMAL ENGINE NOISE 41. ENGINE KNOCKING Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure. Check point Possible cause Correction Fuel Fuel injection timing Injection nozzle Fuel unsuitable Fuel injection timing improperly adjusted Improper injection nozzle starting pressure ‘and spray condition Compression pressure Blown out head gasket Replace the fue! ‘Adjust the fuel injection timing Broken piston ring Adjust or replace the injection nozzle Replace the head gasket or the piston ring 2. GAS LEAKAGE NOISE Exhaust pipes Loosely connected exhaust pipes Broken exhaust pipes Tighten the exhaust pipe connections Replace the exhaust pipes Injection nozzles Loose injection nozzles and /or glow plugs Replace the washers ‘and/or glow plugs Tighten the injection nozzles andor the glow plugs, Exhaust manifold Loosely connected exhaust manifold andior | Tighten the exhaust manifold glow plugs connections Cylinder head gasket Damaged cylinder head gasket 3, CONTINUOUS NOISE. Replace the cylinder head gasket Fan belt Cooling fan Loose fan belt Loose cooling fan Readjust the fan belt tension Retighten the cooling fan ‘Water pump bearing Altemator or vacuum pump Valve clearance Wom or damaged water pump bearing Defective alternator or vacuum pump Clearance improperly adjust Replace the water pump bearing vacuum pump Repair or replace the alternator or the Adjust the valve clearance00-16 SERVICE INFORMATION 4. SLAPPING NOISE Check point Possible cause Correction Valve clearance Valve clearance improperly adjusted Adjust the valve clearance Rocker arm Damaged rocker arm Replace the rocker arm Flywheel Loose flywheel botts Retighten the flywheel bolts Crankshaft and thrust Worn or damaged crankshaft andior thrust | Replace the crankshaft and/or the bearings bearings thrust bearings Crankshaft and Wom or damaged crankshaft andor Replace the crankshaft and/or the ‘connecting rod connecting rod bearings connecting rod bearings bearings Connecting rod ‘Wom or damaged connecting rod bushing | Replace the connecting rod bushing bushing and piston pin and piston pin and/or the piston pin Piston and cylinder liner ‘Wom or damaged piston and cylinder liner Foreign material in the cylinder Replace the piston and the cylinder linerSERVICE INFORMATION 00-17 11. ENGINE COOLING TROUBLE Condition Possible cause Correction Engine overheating Low coolant level Replenish ‘Thermo unit faulty Replace Faulty thermostat Replace Faulty coolant unit Repair or replace Clogged radiator Clean or replace Faulty radiator cap Replace Low engine oil level or use of improper Replenish or change oil engine ol Replenish Damaged cylinder head gasket Replace ‘Clogged exhaust system Clean exhaust system or replace faulty parts Loose fan belt Adjust Excessive fuel injected Adjust Improper injection timing Adjust Engine overcooling _Fauity thermostat Replace “Too long engine Faulty thermostat Replace warm-up time ‘Thermo unit faulty Replace00 - 18 SERVICE INFORMATION 12. STARTER MOTOR DOES NOT STOP [STARTER DOES NOT STOP THOUGH STARTER [SWITCH IS RETURNED TO “ON” a DISCONNECTED STARTER SWITCH WIRING CONNECTOR, AND CHECK STARTER SWITCH OPERATION. starrer 1[2[s[4l+[z[«[s][e eee mon eel ace e [ow [er [|e [|e | w | w OFF Lock Ce ace | 0-0 oN on | o+0-+o ot—o START ‘THERE MUST BE NO CONTINUITY EXCEPT ABOVE LINES. ra] sol) MAGNETIC SWITCH CONTACTS ARE FUSED AND NOT MOVED. OR A RETURN SPRING IS BROKEN OR DETERIORATED REPLACE MAGNETIC SWITCHSERVICE INFORMATION 00-19 MAIN DATA AND SPECIFICATIONS MAIN DATA AND SPECIFICATIONS Engine Model Item Engine type Combustion chamber type Cylinder liner type Timing drive system No, of cylinders - Bore x stroke mm (in) No. of piston rings Total piston displacement om? (in?) Compression ratio to: Compression pressure kPa (kg/m? / psi) - rpm Fuel injection order Fel injection timing (BTDC) deg Specified fuel type Idling speed rpm Valve system Valve clearances (At cold): Intake mm (in) Exhaust mm (in) Valve timing (At valve clearances 0.4 mm (0.016 in)) Intake valves Open at (BTDC) deg Close at (ABDC) deg Exhaust valves Open at (BBDC) deg Close at (ATDC) deg Fuel system Injection pump type Plunger outside diameter mm (in) Plunger lift mm (in) Governor type Automatic timer type Fuel feed pump type Injection nozzle type Injection nazzle type Pressure MPa (kg / cm? / psi) Pressure adjustment Main fuel fter type 4HF1 HF 1-2 Four-cycle, overhead camshaft, water cooled Direct injection Dry liner, special compound metal Gear drive 4-112 110 (4-441 x 4.33) Compression rings: 2, Oring: 4 4334 (284.5) 19.0 3,040 (31/441)-200 | 3,226 (32.9/468) -200 1-3-4-2 8 12 7° (Taiwan only) SAE No. 2 diesel fuel 550 ~ 600 (W/T) 575 ~ 625 (MIT) 0.4 (0.016) 0.4 (0.016) 18 50 51 7 Bosch inne type with | Bosch “VE" distributor ‘automatic timer with automatic timer 9.5 (0.374) 12 (0.472) 11.0 (0.433) 2.8 (0.110) RLD-F mechanical Half all speed governor (Variable speed) SCDM, centrifugal, Hydraulic speed flyweight sensing type Piston Vane Hole type (with 5 orifices) 18.1 (185 / 2,631) ‘Shim adjusted Disposal spin-on cartridge and remote mounted water separator00 - 20 SERVICE INFORMATION Engine Model HFA HF 1-2 Item Lubricating system Lubrication method Full flow pressure circulation ‘Specified engine oil (API grade) CD or above Oil pressure kPa (kg /em? / psi) - 1pm 447 (1.5 / 21-700 (we 40W-30 API CD grade engine oll at 80°C (176°F) oll pump type Gear type il fiter type Spin-on cartridge Oil capacity lit (US/UK gal) 10.5 (2.77 /2.31) Oil cooler type Weater cooled Cooling system Radiator type Corrugated fin with reserve tank Coolant capacity lit(US/ UK gal) 12 (3.17 2.64) Water pump type Centrifugal impeller, V-belt drive Pump to crankshaft speed ratio to:1 Delivery volume lit (US / UK galyimin Pump bearing type ‘Thermostat type Valve initial opening temperature °C("F) Valve lift mm (in) Air cleaner type Battery type Volt-amp.hr. Generator Type Voltage v Drive and rotation Ground polarity Maximum output A Maximum speed rpm 4.46 (175 / 151) 200 (52.8 / 44.0) Pump speed at 3,300 rpm Water temperature at 82°C (180°F) Double row shaft Wax pellet ‘With jiggle valve Primary : 8581.6 (182 - 188) Without jiggle valve (Heaterless) Primary : 8541.5 (182 - 188) Secondary: 821.5 (177 - 182) 8 (0.3) or more at 95°C (203°F) Dry paper element 85D23R / 12-60 : 2 pos AC brush with IC regulator and vacuum pump 24 V-belt, clockwise viewed from the drive pulley Negative 36 at 5,000 rpm (For Thailand and Indonesian) {60 at 5,000 rpm 80 at 5,000 rpm 7,500 ~ 10,000 0 at 6,000 rpmSERVICE INFORMATION 00-21 Engine Model i 4H 412 Regulator Type Ic Regulating voltage v 28-29 Vacuum pump -500 mmHg (-9.67 psi /-66.7 KPa) build-up time Maximum vacuum Starter motor Type Model Rated voltage v Rated output kW. Load characteristics Terminal voltage v Load current. A Torque Nem (kgem/ Ibs) Preheating system Exhaust system Pipe outside diameter X thickness Front pipe mm (in) Middle pipe mm (in) Rear pipe mm (in) Silencer Type Inside diameter mm (in) 13 seconds or less at 1,000 rpm 4 seconds or less at 5,000 rpm 680 mmbig (-13.1 psi! -90.7 kPa) ‘or more at §,000 rpm Magnetic solenoid-controlled $25-168, 24 40 18.55 250 14,22 (1.45 / 10.49) at 1,500 rpm or more Quick-On- Start System It 60.5 x 2.0 (2.38 x 0.079) 60.5 x 2.0 (2.38 x 0.079) 60.5 x 1.6 (2.38 x 0.063) Circular section-shell construction of triple ‘skin and end plates, internal construction of baffles and perforated tubes Approximately 200 (7.87)00 - 22 SERVICE INFORMATION MAIN DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Engine Model Item Engine type Combustion chamber type Cylinder liner type Timing drive system No, of cylinders - Bore « stroke mm (in) No, of piston rings Total piston displacement em? (in?) Compression ratio to: Compression pressure kPa (kg / cm? / psi) - rpm Fuel injection order Fuel injaction timing (BTDC) deg Specified fuel type Idling speed rpm Valve system Valve clearances (At cold): Intake mm (in) Exhaust mm (in) Valve timing (At valve clearances 0.4 mm (0.016 in)) Intake valves Open at (BTDC) deg Close at (ABDC) deg Exhaust valves Open at (BBDC) deg Close at (ATDC) deg Fuel system Injection pump type Plunger outside diameter mm (in) Plunger lift mm (in) Govemor type ‘Automatic timer type Fuel feed pump type Injection nozzle opening Injection nazzle type Pressure MPa (kg / cm? / psi) Pressure adjustment Main fuel fiter type 4HGt 4HG1-T Four-cycle, overhead camshaft, water cooled Direct injection Dry liner, special compound metal Gear drive 4-115 110 (4-453 + 4.33) Compression rings: 2, Oil ring: + 4570 (278.9) 19.0 3,226 (32.9/468) - 200 1-3-4-2 9 7 (Except Colombia) ‘9 (For Colombia) SAE No. 2 diesel fuel 550 ~ 600 (WIT) 600 ~ 650 (MT) 0.4 (0.016) 0.4 (0.016) 18 50 51 v7 Bosch in-line type with automatic timer 9.5 (0.374) 10.5 (0.413) 11.0 (0.433) RLD-F mechanical (Variable speed) ‘SCDM, centrifugal, flyweight Piston Hole type (with 5 orifices) 18.1 (185 /2,631) Ast 18.1 (185 /2,631) 2nd 21.4 (218 /3,087) ‘Shim adjusted Disposal spin-on cartridge and remote mounted water separatorSERVICE INFORMATION 00 - 23 Engine Model tem 4HG1 4HG1-T Lubricating system Lubrication method Specified engine oil (API grade) Oil pressure kPa (kg /om? / psi) - rpm oll pump type il iter type Oil capacity Oil cooler type Cooling system Radiator type Coolant capacity Water pump type Pump to crankshatt speed ratio. to:1 Delivery volume lit (US / UK gayi lit(US/ UK gal lit (US / UK gal) Pump bearing type ‘Thermostat type Valve initial opening temperature °C("F) Valve lift mm (in) Air cleaner type Battery type Volt-amp.hr. Generator Type Voltage v Drive and rotation Ground polarity Maximum output A Maximum speed rpm Full flow pressure circulation CD or above 447 (1.51 21-700 ‘SAE 10W-30 APICD gate) engine oll at 80°C (176°F) Gear ype Spin-on cartridge 10.5 (277/231) Weater cooled Corrugated fin with reserve tank 12.(3.17/2.64) Centrifugal impeller, V-belt drive 1.19 (1751 147) 200 (52.8 / 44.0) ( Pump speed at 3,200 rpm ) Water temperature at 82°C (180°F), Double row shaft Wax pellet With jiggle valve Primary : 8521.5 (182 - 188) ‘Without jiggle valve (Heaterless) Primary : 85#1.5 (182 - 188) Secondary: 82:H1.5 (177 - 182) 8 (0.3) or more at 95°C (203°F) Dry paper element or cil bath 7SD23R / 12-65 : 2 pos ‘AC brush with IC regulator and vacuum pump 24 | 120024 V-belt, clockwise viewed from the drive pulley Negative 35 at 6,000 rpm 50 at 6,000 rpm {60 at 5,000 rpm 80 (12V) at 5,000 rpm 7,800 ~ 10,00000 - 24 SERVICE INFORMATION Engine Model Exhaust system Pipe outside diameter x thickness Front pipe mm (in) Middle pipe mm (in) Rear pipe mm (in) Silencer type Inside diameter mm (in) i 4HG1 4HG1-T Regulator Type Ic Regulating voltage vi) 28-29 144e03 | 28-29 Vacuum pump -66.7kPa (-500 mmHg /-9.67 psi) build-up time 13 seconds or less at 1,000 rpm 4 seconds or less at 5,000 rpm Maximum vacuum -90.7 kPa (-680 mmHg /-13.1 psi) ‘or more at 5,000 rpm Starter motor Type Magnetic solenoid-controlled Model 825-168 R30 $25 - 168, Rated voltage v 24 2 24 Rated output KW 40 3.0 40 Load characteristics ‘Terminal voltage v 18.55 14.0 18.55 Load current A 250 890 (MAX) 250 Torque Nem ¢kgem / Ibe) 14.22 204 14.22 (1.45/10.49) | (2.99/21.63) | (1.45/ 10.49) at 1,500 rpm at 860 rpm. at 1,500 rpm or more or more or more Preheating system ‘Quick-On-Start System Il 60.5 x 2.0 (2.38 x 0.078) 60.5 x 2.0 (2.38 x 0.078) 60.5 x 1.6 (2.38 x 0.063) Circular section-shell construction of triple skin and end plates, internal construction of baffles and perforated tubes Approximately 200 (7.87)SERVICE INFORMATION 00 - 25 MAIN DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Engine Model tem Engine type Combustion chamber type Cylinder liner type Timing drive system No. of cylinders - Bore « stroke No. of piston rings mm (in) com* in’) to: kPa (kg / cm? / psi) - rpm Total piston displacement Compression ratio Compression pressure Fuel injection order Fuel injection timing (BTDC) deg Specified fuel type Idling speed rpm Valve system Valve clearances (At cold): Intake mm (in) Exhaust mm (in) Valve timing (At valve clearances 0.4 mm (0.016 in)) Intake valves Open at (BTDC) deg Close at (ABDC) deg Exhaust valves Open at (BEDC) deg Close at (ATDC) deg Fuel system Injection pump type Plunger outside diameter mm (in) Plunger lift mm (in) ‘Governor type ‘Automatic timer type Fuel feed pump type Injection nozzle opening Injection nozzle type Pressure MPa (kg / cm? / psi) Pressure adjustment Main fuel fiter type HET 4HE1-1C Four-cycle, overhead camshaft, water cooled Direct injection Dry liner, special compound metal Gear drive 4-110» 125 (44.33 x 4.92) ‘Compression rings 2, oil | Compression rings 3, oil ring 1 ring 1 4751(289.3) 18 173 3,040 (31/441) - 200 1+3-4-2 7 8 SAE No. 2 diesel fuel 550 ~ 600 (WIT) 775 ~ 825 (MIT) 640 ~ 690 (NT) 775 ~ 825 (AT) 0.4 (0.016) 0.4 (0.016) 14 51 49 6 Bosch in-line type with automatic timer 10 (0.394) 11 (0.433) 9.0 (0.354) 12 (0.472) RLD-F mechanical RLD-M mechanical (Variable speed) (Variable speed) SCDM, centrifugal, flyweight Piston Hole type Hole type (with § orifices) (with 6 orifices) 4st 17.5 (180 / 2,560) 21.87 (2201 3,128) 2nd 21.87 (220/ 3,128) ‘Shim adjusted Disposal spin-on cartridge and remote mounted water separator00 - 26 SERVICE INFORMATION Engine Model tem HEAT 4HE1-TC Lubricating system Lubrication method Specified engine oil (API grade) Oil pressure kPa (kg /om? / psi) - rpm oll pump type il iter type il capacity Oil cooler type Cooling system Radiator type Coolant capacity Water pump type Pump to crankshatt speed ratio. to:1 Delivery volume lit (US / UK gayi lit(US/ UK gal lit (US / UK gal) Pump bearing type Thermostat type Valve initial opening temperature °C CF) Valve lift mm (in) Air cleaner type Battery type Model / Vott-amp.lr. Generator Type Voltage v Drive and rotation Ground polarity Maximum output VAI pm Maximum speed fom Full flow pressure circulation CD or above 447 (1.51 21-700 ‘SAE 10W-30 API CD grade engine oil at 80°C (176°F) Gear ype ‘Spin-on cartridge 13 (3.43 / 2.88) Water cooled Corrugated fin with reserve tank 14 (3.70/ 3.08) Centrifugal impeller, V-belt drive 1.16 200 (52.8 / 44.0) Pump speed at 3,300 rpm 1 Water temperature at 82°C (180°F). Double row shaft Wax pellet Without jiggle valve With jiggle valve Primary : 80 - 184 835-865 (176- 183) (182 - 188) Secondary: 83 - 87 - (181 - 189) 8 (0.3) or more 8 (0.3) oF more at 95°C (203°F) at 100°C (212°F) Dry paper element or wet paper element ‘75D23R / 12-65 : 2 pes B80D26R / 12-65 : 2 pes ‘AC brush with IC regulator and vacuum pump 24 120124 \V-belt, clockwise viewed from the drive pulley Negative 241 35 at 5,000 (Denso) | 24/50 at 5,000 (Hitachi) 241.60 at 6,000 (Hitachi) | 12 / 80 at 6,000 (Hitachi) 7,500 ~ 10,000‘SERVICE INFORMATION 00 - 27 Engine Model 4HEAT 4HEI-TC, Item Regulator Type Ic Regulating voltage vi) 28-29 144203 | 28-29 Vacuum pump -800 mmHg (-9.67 psi /-66.7 kPa) build-up time Maximum vacuum mmbg (psi / kPa) Starter motor Type Model Rated voltage v Rated output kw Load characteristics Terminal voltage v Load current A Torque Nem (kgem / bef) Preheating system Exhaust system Pipe outside diameter x thickness Front pipe mm Middle pipe mm Rear pipe mm Silencer type Inside diameter mm (in) (in) din) (in) 13 seconds or less at 1,000 rpm 4 seconds or less at 5,000 rpm 680 (-13.1 / -90.7) ‘or more at 5,000 rpm Magnetic solenoid-controlled S25-305A R30 S25-305A, 24 2 24 45 3.0 45 14.30 140 14.30 400 890 (MAX) 400 28.44 29.4 28.44 (2.90/2098) | (299/216) | (2.90/20.28) at1,500 rpm =| at 860 rpm | at 1,500 1pm. or more or more or more ‘Quick-On-Start System Il 60.5 x 2.0 (2.38 x 0.079) 60.5 x 2.0 (2.38 x 0.079) 60.5 x 1.6 (2.38 x 0.063) Circular section-shell construction of triple skin and end plates, internal construction of baffles and perforated tubes ‘Approximately 200 (7.87)00 - 28 SERVICE INFORMATION SERVICE STANDARD tem Service Standard Service Limit ENGINE ‘Compression Pressure KPa (kg om? / psi) / rpm 3040 (31/441) or more \Variance in pressure between the cylinders: less than 294 (3 / 43) / 200 2,187 (22/312) CYLINDER HEAD Inlet and Exhaust Valve Seat Depression : mm (in) 0.7 -1.2 (0.028 -0.047) 2.5 (0.098) all Measurement should be taken by {| using a new valve, Cylinder Head Lower Face Warpage mm (in) 0.05 (0.002) or less 0.2 (0.008) Do not regrind the cylinder head lower face. Manifold Fitting Face Warpage mm (in) 0.05 (0.002) or less 0.2 (0.008) Water Leak Test Repair or replace KPa (kg / om? psi) 490 (6/71) -3 minutes these having water Cylinder Head Gasket Selection mm (in) | 4HFAUGHFA-214HG1-T Fore Gyfinder Head Gasket Selection mm (in) otal sown by seme retches ace Timex | °*iRctence) Remeber | To | SEER, | ron 8 | o—~ _| ctzss-o0as1) | 175:0088) © [om at-288, [inca AHEA-TIMHEA-TC Cylinder Head Gasket Selection mm (in) Gasket Grade Timex | Reece A | O~ _| cobaoe eed) |_ 17210000) B | = _| cteao-doc6n|_ 17500958) © | or _|ecteer=aasmn | 189000708)SERVICE INFORMATION 00 - 29 tem ‘Service Standard ‘Service Limit CAMSHAFT ‘Cam Height mm (in) 52.75 - 62.91 (2.076 - 2.083) 51.8 (2.039) Camshaft Journal Uneven Wear mm (in) 0.016 (0.0006) or less. 0.05 (0.002) Camshaft Journal Wear mm (in) | 39.950 - 39.976 (1.5728 - 1.5738) 39.860 (1.569) ‘Camshaft Journal and Bearing Clearance mm (in) | 0.025 - 0.087 (0.00098 - 0.00343) 0.15 (0.0059) ‘Camshaft Run-Out mm (in) 0.04 (0.0016) or less 0.05 (0.002) against the adjacent journal ROCKER ARM AND ROCKER ARM SHAFT Rocker Arm Shaft Wear mm (in) | 21.979 ~ 22.000 (0.8653 ~ 0.8661) 24.85 (0.880) Rocker Arm Bushing Wear mm (in) | 22.010 22.036 (0.8665 ~ 0.8675) 22.18 (0.872) Rocker Arm and Rocker Arm 0.010 - 0.056 (0.0004 - 0.0022) 0.2 (0.008) Shaft Clearance mm (in) Rocker Arm Shaft Run-Out mm (in) 0.3 (0.012) Rocker Arm Roller and Pin Clearnace mm (in) 0.040 - 0.084 (0.0016 - 0.0033) 0.5 (0.020) Roller Surface ‘When there is an ‘excessive wear or ‘deformation found, replace it. ‘When it is damaged ‘only slightly, correct itwith an oll stone. VALVE Valve Stem Wear inlet 8.946 - 6.961 (0.3522 - 0.3528) 8.88 (0.35) mm (in) [Exhaust 8.921 - 6.926 (0.3512 - 0.3529) 8.80 (0.34) Wave Siem ard vane inlet 0.036 - 0.074 (0.0046 - 0.0028) 0.20 (0.0079) eee eaten nm Gin [Exhaust (0.064 - 0,096 (0.0025 - 0.0038) 0.25 (0.0098)00 - 30 SERVICE INFORMATION tem Service Standard Service Limit VALVE (CONT.) Valve Guide and Cylinder Head [0.005 - 0.040 (0.0020 - 0.0016) Interference Press itin with the valve guide applied mm (in) |with engine ol. Valve Thickness mm (in) Jinlet Nominal size 1.80 (0.071) 1.3 (0.051) j Exhaust ‘Nominal size 1.76 (0.069) 1.3 (0.051) ‘Valve Contact Width mm (in) J inlet Nominal size 2.5 (0.088) 3.0 (0.118) \ x4 zl ic > Exhaust Nominal size 2.0 (0.078) 25 (0.098) Valve Guide mm (in) 14,140.2 (0.555+0.008) Upper End Height Valve Stem Seal Lip Wear mm (in) 8.3 -8.7 (0.3268 - 0.3425) 8.8 (0.346) Valve Spring Tension N(kg/te)| 414477 (42.2 - 48.6 / 93 - 107) 40.9 (98 / 401) Set length 47.0 mm (1.85 in) Valve Spring Free Height mm (in) Nominal size 62.5 (2.46) 59.4 (2.34) Valve Spring Squareness mm (in) 1.0 (0.04) Valve Clearance (At cold) mm (in) 0.4 (0.016) Valve Stem Cap Wear mm (in) 05 (0.02) Replace it when worn lor deformed excessively ciSERVICE INFORMATION 00-34 Tem Savvice Standard ‘Service Limit CYLINDER BODY Cylinder Liner Bore Wear mm (in) pas ip, 112021- 112.050 (4.4103. 4.4114) 112.20 (4.417) ® AGT: 118.021 - 118.080 (4.6284 4.5205) | 115,20 (4.535) 4uGHT: 4HETT: 140,041 - 110,080 (4.3923 4.3938) | 118.20 (4.535) © 20mm (0.79 in) eee © 0mm (356 in) © 160 mm (6.30 in) ‘ylinder Liner Grade Selection AE VAHET2 Line ]Gylinder Bore Service Liner Outside Remarks: Grade [Diameter _mm(in)| Grade _|Diameter _ mm (in) Cylinder Bore Grade Mark Position + | 15001-115.010 | 4, | 114991- 115.000 The grade mark (1, 2 or 3) ofthe cylinder (4.5276 - 4.5279) (4.5272 - 45276) bore is stamped on the position just 2 | 118011-115.020 beside each cylinder on the upper let side 45280-45283) | 4, | 115001-115.010 {the upper portion ofthe oil cooler 315.021 - 115.030 (4.5276 - 4.5279) installation face) of the cylinder body. 3 | (45284-4.5287) 4HGT4HGT-T Cylinder Liner Grade Mark Postion 118.001- 118.010 | 1X | 117.991- 118.000 The outside diameter grade mark (1, 2 or 1 | (a64s7 - 4.6461) (4.6453 - 4.6457) 3) ofthe cylinder liner is stamped on the 418.011 118.020 position approximately 160mm from the a (4.6461 - 4.6464) 448.001 - 118,010 top face of the liner. 3 | ta02t-118030 | % | 6457-46464) (4.6465 - 4.6468) AEST 4HE1-1C 3 | "5001-115.010 [1X | 115.021- 116.030 (4.5276 - 4.5279) (4.5284 - 4.5287) > | 115011-115.020 (4.5280 - 4.5283) 3x__| 118031- 118.040 3 | 115.021 118.030 (4.5289 - 4.5291) (4.5284 - 4.5287) Cylinder Liner Projection mm (in) Cylinder Body Upper Face Warpage mm (in) Water Leak Test kPa (kg/cm? / psi) (0:10 - 0.14 (0.0038 - 0.0055) ‘The difference in the cylinder liner projection height between any two adjacent cylinders must not exceed 0.03 (0.0012) 0.05 (0.002) or less Do not regrind the cylinder body upper face. 490 (5/71) - 3 minutes There must be a projection on the oylinder liner. 0.02 (0.008) Repair or replace those having water leak.00 - 32 SERVICE INFORMATION ttem Service Standard ‘Service Limit CRANKSHAFT ‘Crankshaft Jurnal and Crankpin Uneven Wear mom (in) 0.05 (0.002) ae Journal No. 1, 2,4 and 5 81.905 - 81.925 (3.2246 - 3.2254) 81.85 (3.2224) lear mm (in)_No.3 81.890 - 81.910 (3.2240 - 3.2248) 81.85 (3.2224) Crankshaft Journal No, 1, 2,4 and 0,037 - 0,072 (0.0015 - 0.0028) 0.11 (0.0043) and Bearing Clearance” _mm (in) No.3 0.051 - 0.086 (0.0020 - 0.0034) 0.11 (0.0043) pais euecen ‘Crankshaft Journal No. 1, 2, 4 and 5 mm (in) Bearing Housing Crankshaft Journal Crankshaft Remarks: Grade] (Reference) | Grade | (Reference) Bearing Crankshaft Bearing Housing | | Mark | Inside Diameter | Mark | Outside Diameter | Color Code Grade Mark Position 1 | 87.905-81.915 a The crankshaft bearing 4 | 87.000-87.009 (8.2246 - 3.2250) housing grade marks (1 or (34262-34255) |) | 81.916- 81.925 2) are stamped collectively (8.2250 - 3.2254) ES for all cylinders on the 1 81.905 - 81.915 Blue peer ie aoe 2 | 87.010-87.019 (3.2246 - 3.2250) i G (8.4286 -3.4259) 81.916 - 81.925 ee 2 | (2250-32254) Black Reacher sournal Grade | crankshaft Journal No. 3 “The crankshaft journal Bearing Housing ‘Crankshaft Journal Crankshaft grade marks (1 or 2) are Grade} —_ (Reference) Grade (Reference) Bearing ‘stamped collectively for ‘Mark | Inside Diameter_| Mark | Outside Diameter Color Code all cylinders on the front 1 | 81.890-87.900 a side of the crankshaft | 87.000-87.009 (8.2240 - 3.2244) No. 1 balancer (3.4282 - 3.4255) 81.901 -81.910 2 | 2244-32248) bal Crankshaft Bearing Grade isons e150 ‘Mark Position 1 : Blue The 87.010 -87.019 (3.2240 - 3.2244) identification color Ba ercee Barc code (black, brown or blue) ¢ a Ree Black of the crankshaft journal {3.2244 - 3.2248) bearing arade mark is applied on the side of each bearing.SERVICE INFORMATION 00-33 tem Service Standard ‘Service Limit CRANKSHAFT (CONT.) Crankpin Wear 4HF1, 4HG1, 4HGI-T: 165.902 - 65.992 (2.5946 - 2.5954) 66.85 (2.6925) HEAT, 4HE4-TC: 72.850 (2.8681) 72.920 - 72.922 (2.8709 - 2.8433) ‘Crankshaft Journal Bearing Spread mm) 87 (3.43) Crankshaft End Play mm(in)| 0.104 - 0.205 (0.0041 - 0.0081) 0.35 (0.014) Crankshaft Run-Out mm (in) 0.05 (0.002) or less 0.3 (0.012) Crankshaft Front and Rear Gil Seal and ‘Slinger Wear When there is an oil leak found, the oil seal and slinger must be replaced as a set. Insertit seourely with a spedal too PISTON Piston and Cylinder Liner Clearance (AHF: 0.08% - 0.17 (0.002 - 0.0044) rm (in) HG: 0.081 - 0.116 (0.0032 - 0.0044) 4HE1-T: 0,091 - 0.131 (0.0036 - 0.0062) AHE%-TC: 0,091 - 0.131 (0,0036 - 0.0052) Piston Grade Selection mm (in) [Piston Grade , ; Piston ; Engine | cyinder Liner Bore Piston Outside Remarks: model | ‘Diameter mm (in)| Swe? | Diameter mm (in) Piston Grade Mark Position ‘The piston grade marks (ie. A, B, C) anei | 112.041-112.060 | _——=«|117,947- 117.960 are stamped on the piston upper face. avez | (44111-44118) (4.4074 = 4.4079) 4HG1_| 118,040-116.050| ‘| 114.944- 114.959, Bilon Ouse Diameter Measuring avert | (45201-45299) (4.5253 - 4.5259) jon 109,944 - 109.959, ‘Take measurement ofthe Piston atthe ax : poston 82mm (2.23 in) from he top inthe | AWE. | 140086 - 007s = st direction ofthe longer dlameter. ox | Wage Te ers00 - 34 SERVICE INFORMATION tem Service Standard Service Limit PISTON PIN Piston Pin Wear mmo] EE sass souan 4HG1 (1.8171 = 1.4173) peer ey) 4HGIT 4HE‘-T 39,095 - 40.000, 4HEI-TC (1.8746 - 1.5748) Seeeeenee Piston and Piston Pin Clearance mm{(in)| 0.004 -0.017 (0.0002 - 0.0007) 0.04 (0.0016) Clearance should be wide enough for the piston pin to be inserted under the conaition where the piston is heated to the ‘When an abnormal striking sound is heard, replace the piston and temperature of 80°C to 100°C (176°F to | the piston pin. 22°F) PISTON RING “ist Compression Ring 0.24 0.30 (0.0084- 0.0153) 1.50 (0.0591) ree 2nd Compression Ring 0.35 - 0.50 (0.0138 - 0.0197) 1.50 (0.0591) Oil Ring 0.02 - 0.40 (0.0008 - 0.0157) 1.50 (0.0591) ‘1st Compression Ring 0.24 -0.39 (0.0004 - 0.0153) 1.50 (0.0591) risen |4HS1 and Compression Rng_| 0.36 0.50 (0.0738-0.0187) 7.500.581) ea il Ring (0.15 - 0.35 (0.00591 - 0.0138) 1.50 (0.0591) aaa ‘st Compression Ring 0.24 - 0.40 (0.0004 - 0.0157) 1.50 (0.0591) 4nie1-1 [2nd Compression Ring 0.56 - 0.71 (0.0220 - 0.0279) 1.50 (0.0591) mn ie) Oil Ring 0.20 - 0.40 (0.0078 - 0.0157) 1.50 (0.0591) ‘1st Compression Ring 0.24 - 0.40 (0.0094 - 0.0157) 1.50 (0.0591) “gnerere [24 Compression Ring 0.30 - 0.40 (0.0118 - 0.0157) 1.50 (0.0591) 3rd Compression Ring 0.30 - 0.40 (0.0118 - 0.0157) 1.50 (0.0591) Oil Ring 0.02 - 0.40 (0.0008 - 0.0157) 1.50 (0.0591) ‘Ist Compression Ring (0.062 - 0.092 (0.0024 - 0.0036) (0.2 (0.0078) Ane [2nd Compression Ring 0.04 - 0.08 (0.0015 - 0.0031) 0.15 (0.0059) OilRing 0.02 - 0.06 (0.0008 - 0.0024) 0.15 (0.0059) Piston ‘Ist Compression Ring (0.062 - 0.092 (0.0024 - 0.0036) (0.2 (0.0078) feos 4461 land Compression Ring | 004-008 (0.00%6-00031) 0.45 (0.0069) pon Oil Ring (0.02 - 0.06 (0.0008 - 0.0024) (0.45 (0.0059) Reo ‘st Compression ing [0.09 0.13 (0035 - 0.0061) 02 (00078) Clearance |4HE1-T [2nd Compression Ring 0.09 - 0.43 (0.0036 - 0.0051) 0.2 (0.0078) Oil Ring 0.03 - 0.07 (0.0012 - 0.0028) 0.15 (0.0069) me) “1st Compression Ring 0.09 - 0.13 (0.0035 - 0.0051) 0.2 (0.0078) “anette [24 Compression Ring 0.09 - 0.13 (0.0035 - 0.0051) (0.2 (0.0078) 3rd Compression Ring 0.09 - 0.13 (0.0035 - 0.0051) (0.2 (0.0078) Oil Ring 0.03 -0.07 (0.0012 - 0.0028) 0.15 (0.0059) ‘The direction of the piston ring connecting end ‘Alternately at 180°. Don't position the connecting end in the side pressure direction. Place the connecting end of the oil ring and that of the expander coil at 480° alternateSERVICE INFORMATION 00-35 Item Service Standard Service Limit CONNECTING ROD Connecting Rod Distortion 0.08 (0.002) or less 0.20 (0.008) ‘Alignment mm (in) | Parallelism 0.08 (0.002) or less 0.20 (0.008) ‘Connecting Rod Small End mm (in) | __0.0%2 - 0.027 (0.0008 - 0.0011) 10.08 (6.002) Bushing and Piston Pin ‘There must be clearance enough to rotate Clearance the piston pin while holding it lightly with its large end fixed. Connecting Rod Bearing Spread mm (in) 70 (2.77) or more ‘Connecting Rod Bearing and ———mmi(in)|__-0.036- 0.077 (0.0014 - 0.0030) (0.10 (0.004) Crankpin Clearance ‘Connecting Rod Bearing Selection +4HFt + 4HF1-2 + 4HG1 + 4HG1-T mm (in) |" Connecting Rod Big End Crankpin [Big End Grade | (Reference) (Reference) | Bearing Color Remarks: Mark _| Inside Diameter | Outside Diameter |Code The connecting rod big end inside 69.985 - 69.092 | 65,002 - 65.922 aie grace marks (Aor B) ate A | (2.7553-2.7556) | (2.5946-2.5954) | __Sreen stamped on 1 cylinder nu Sec aicr ea nace p | 69.993-70.000 | 65.902-65.922 | Venay (2.7556 - 2.7559) | (2.5946 - 2.5954) + 4HEI-T + 4HE1-TC 77.985 - 77.992 | 72.902 - 72.922 Green| 4 _| a.0702-3.0708) | (2.8702 - 2.8709) 77.983 - 78.000 | 72,902- 72.922 B | (g.6706-3.0709) | (28702-28709) | __Yelow The difference in weight between the 02 (2070.28) connecting rod and the piston when assembled. Nige/ FLYWHEEL Flywheel Thickness. mm (in) 31.4 31.6 (1.236 - 1.244) 31.0 (1.22) (Flywheel friction surface - crankshaft setting face) Friction Surface Run-Out mm (in) 0.2 (0.008) Friction Surface Roughness mm Gin) 0.006 (0.0002) or less Ring Gear ‘The tooth face burr must be chamfered Replace ones when damaged excessively.00 - 36 SERVICE INFORMATION tem Service Standard Service GEAR TRAIN Timing Gear Backlash Gear to Gear {In the direction of a normal ine) (0.10 - 0.17 (0.0038 - 0.0067) Hold both the gear to be checked and the 0.30 (0.012) mm (iP) | adjoining gear stationaly. Crankshaft Gear and Crankshaft (0.03 - 0,098 (0.0012 - 0.0037) Interference mm (in) ‘Camshaft Gear and Camshaft 0.016 - 0.023 (0.0006 - 0.0009) Interference mm (in) Idle Gear Shaft Wear mm (in) | 28,959 - 29.980 (1.1795 - 1.1803) 29,80 (1.1732) Idle Gear Bushing Wear mm (in) | 30.000 - 30.021 (1.1811 - 1.1819) 30.1 (1.185) Idle Gear Bushing and Idle Gear 0.020 - 0.062 (0.0008 - 0.0024) 0.2 (0.008) Shaft Clearance mm (in) Idle Gear End Play mm (in) (01058 - 0.116 (0.0002 - 0.005) 0.2 (0.008) LUBRICATION SYSTEM il Pump [Gear Teeth and Inner Wencesae Eee 0.125 - 0.220 (0.0049 - 0.0087) 0.3 (0.012) Gear and Pump Cover ae aa 0.064 - 0.109 (0.0018 - 0.0043) 0.2 (0.008) Gear ShaftWear __mm{(in)|__ 15.989 - 16.000 (0.6295 - 0.6299) 15.9 (0.626) Gear Shaft and Bushing —— an 0.04 - 0.07 (0.0016 - 0.0028) 0.2(0.012) Delivery Volume 16.54 (1.0) cc (curin)rev | Delivery Pressure: 302kPa 4 kglem? / 56.9 psi) Oil Temperature: 502°C (1222 36°F) Oil viscosity SAE 30 Relief Valve Opening [oi Gallery 441.3 (45/640) (Reference) Pressure kPa (kglem? /psiy [Oil Pump 784.5 (8.0 /113.8) (Reference)‘SERVICE INFORMATION 00 - 37 Item Service Standard Service Limit COOLING SYSTEM Water | External appearance Check the following: Pump + Cracks and damages of the pump body + Cracks and corrosion of the impeller + Water leak from the seal unit When an abnormal condition is found, replace the water pump as an assembly. Seal Unit Push the fan center in the radial direction while rotating it and check the seal unit for any excessive play or abnormal sound. When there is any abnormal condition found, replace the water pump as an assembly. Delivery Volume 200 or more lt (US/UK gal) min | Water Pump Speed: 3,300 rpm Water Temperature: 80 42°C (176 + 3.6°F) Fan Drive Belt Tension mm (in) 8-12 (0.31 - 0.47) ... New belt 10 - 14 (0.39 - 0.55) ... Reuse belt Depress the drive belt mid-portion with a SBN (10k /22Ib) force Thermostat | Valve initial Opening 8541.5 (185+ 27) With Jiggle | Temperature “CCF Valve Fi Valve Lit At 100°C 8 (0.31) or more @12F) mm (in Thermostat | Valve initial Opening Primary. 8522185 +36) With-Out” | Temperature °CUCF)| Secondary: 8221786 + 36) age Valve Lift At 95°C (0.31) or more (203°F) mm (in) Radiator _|External appearance + Check the radiator for any corrosion, water leak, fin damage, or clogging. When there is any abnormal condition found, correct the radiator or replace it + When deterioration, cracking or water leak is found in the rubber hose, replace the rubber hose. Pressure Valve Opening 103.0 + 14.7 (1.05 + 0.15 / 14.9 2.1) Pressure kPa (kg /om? / psi) ‘Vacuum Valve Opening MIT: 4.0- 4.9 (0.01 - 0.05 /0.14- 0.71) Pressure AMT: 20 - 4.9 (0.02 - 0.05 /0.28 -0.71) kPa (kg em? / psi)00 - 38 SERVICE INFORMATION higher than 70°C (158°F) AIT: 3,450 + 150 ttem Service Standard COOLING SYSTEM (CONT.) Coating Fan | Cooling Fan Pulley Mm: 3,900 Rotate the fan by Speed AIT 3.860 hand, and when ‘pm itdoesn't rotate Cold Condition (Bi-metal MT: 900 or lower ee lower than 40° (104°F) AT 4200 lower Sec fem replace the fan Hot Condition (Bimetal MIT: 3,300: 160 clutch Time required for the pressure to fall from 16,180 kPa (165 kg /om® 12,346 psi) to 14,220 kPa (145 kPa (kg fom? / 2,082 psi) Spray Condition + The spray must be fine and uniform. + The injection must be directed in the center direction with no stray spray. + The spray from each nozzle hole must be uniform ‘pm Pulley Reto WET184 (Crankshaft/Fan) FUEL SYSTEM Fuel Feed | Suction capacity The suction must be completed in 25 times or less. Pump Priming Pump Speed —_: 60 - 100 times/minute_ Pipe Inside Diameter: 8mm (0.31in) Suction Pipe Length: 2.000mm (78.7 in) Suction Height 4, 000mm (38-4) injection | Nestle Valve Seat Nozzle Portion Oil Tight sec 5 or more.SERVICE INFORMATION 00-39 tem Service Standard Service ENGINE ELECTRICAL Generator | Ball bearing When it doesn't rotate smoothly or is giving out an abnormal sound, or when there is an oll leak from the seal, replace it Slip Ring Diameter mm (in Nominal size 31.6 (1.244) 30.6 Rotor | Coil Resistance | Nominal resistance 12.6 When the resistance differs largely from Coil Insulation 1 or more the standard value, Resistance MO (500 volt megger tester) DRuren= ho Stator | Coil Resistance Nominal resistance 0.17 insulation is found, (Between coil end and each coil end) _| replace it Coil Insulation 1 or more Resistance MQ (600 volt megger tester) Brush Length mm (in Nominal size 20 (0.79) 6 (0.24) ICVoltage | Rectifier The rectifier is normal when there is ‘When there is Regulator ‘continuity with the tester © terminal ‘continuity in both ‘connected to "B” (battery) terminal and the | directions, or when '@ terminal to the rectifier holder, and when | there is no continuity in there is no continuity with their connections. | both directions, replace reversed. the rectifier. Battery Power V | <4HF4 | 4H 1-2 | 4HG1/4HG1-1> LR 250-504 (24\-60A) eee 28-29 LR 250-5088 (24V-50A) c DENSO(12V-36A) eae LR 250-510 (24V-50A) bara LR 180-510 _(12V-80A) I Output Current ry 4300rpm 2000rpm 4000rpm <4HF1 | 4HF1-2 / 4HG1 / 4HG1-T> LR 250-504 18 3583. LR 250-5088 153246 DENSO 12 (18 a LR250-510 15 32 © 43 LR 180-510 25 58 82 Pulley Ratio (CrankshafvGenerator) ua00-40 SERVICE INFORMATION Item Service Standard Service Limit ENGINE ELECTRICAL (CONT.) Vacuum | Pump Housing Inside (GHET-aHiF 1-2) Pump Diameter fren) ecard aa GHG HaHGi-1) (Reference) econ mit) 142-152 (0.559-0.508) CHENEY 2) (Reference) Performances 11900 rp 13 see or ess +1000 rpm 35 sec or less Mile ated (LR 180-510 only) Pressure to get to 5,000 rpm 4 sec or less: -66.7kPa 5,000 rpm 10 sec or less (-500mmHg /-8.7psi (UR 180-510 only) Oil Viscosity SAE 30 Oil Temperature : 70 5°C (158 + 9°F) Oil Pressure |: 447kPa (4.5 kg/cm /64psi) “Tank Capac : 7,000ce (427 cuvn) ‘Check Valve * Apply 98 — 490 kPa (1-5 kg/om? 14-71 psi) compressd ar to pump side of the check valve. + Check for air leakage from the check valve. -lf there is air leakage, the check valve must be replaced. Starter ‘Commutator Run-Out ‘mm (in) 0.08 (0.002 ) or less 0.2 (0.008) ‘Commutator wT 36.5 (1.437) 36.5 (1.398) Outside Diameter mm (in) AT 38.0 (1.496) 96.6 (1.441) Mica Segment Depth ‘mm (in 0.5 -0.8 (0.020 -0.031) 0.2 (0.008) Brush Length MT 15.0 (0.591) 10.5 (0.413) mm (in) | ArT 48.0 (0.709) 11.0 (80.443) Brush Spring wT 24.5 - 34.3 (25-36/55-7.7) Tension Nikg/b) | AT 28.4-35.3 (2.9-3.6/6.4-7.9) Load Characteristics, Terminal Voltage v MT: 18.55 AT: 14.30 Load Current A MT: 250 AT: 400 Torque MIT: 14.2 (1.45/ 10.5) or more Nem (kgem /Ibeft ) AT eee Speed tpm 1 m MT: 860 Terminal acc| B | on| st | 8: | Pr | Pe | w | w Lock Acc ON STARTSERVICE INFORMATION 00-41 ttem ‘Service Standard Service Limit ENGINE ELECTRICAL (CONT.) Preheating | Time required for the 35 system glow indicator to light up After the key switch is turned to (@osil) sec | "ON" position without engine turned. Time required for the 5 source voltage to be After the key switch is turned to supplied tothe glow plug “ON” posiion without engine tured Glow Relay Coil Rsseaaree a Nominal resistance 61.5, ‘Thermo Switch Operating | OFF -> ON: 7 - 13 (44.8 - 55.4) Temperature CPF) | ON-> OFF: Less 3 (37.4) Glow Plug Continuity fno continuity exists, must be replaced,00 - 42 SERVICE INFORMATION SERVICING ‘Servicing refers to general maintenance procedures to be performed by qualified service personnel. MODEL IDENTIFICATION Engine Serial Number ‘The engine number is stamped on the front left hand side of the oylinder body. = ‘Engine number AIR CLEANER Dry Type Washable Paper Element Element cleaning procedures will vary according to the condition of the element. Dust Fouled Element Rotate the element with your hand while apolying compressed air to the inside of the element. This will blow the dust free Compressed air pressure must not exceed 7 kg/om” (88.6 psl686 kPa) Carbon and Dust Fouled Element 1. Prepare a cleaning solution of Isuzu Genuine Element Cleaner (Donaldson D140) diluted with water. 2. Immerse the element in the solution for twenty minutes.SERVICE INFORMATION 00 - 43 3, Remove the element from the solution and rinse it well with running water. Water pressure must not exceed 2.8 kg/cm? (39.8 psil274KPa). 4, Dry the element in a well ventilated area. An electric fan will hasten drying. cAUTIO! Do not use compressed air or an open flame to dry the int quickly. Damage to the element will result. usually take two or three days for the element to dry completely. Therefore, it is a good idea to have a ‘spare on hand to use in the interi LUBRICATING SYSTEM Main Oil Filter (Disposable Spin-On Cartridge Element) Replacement Procedure 1. Loosen the used ol fiter by turning it counterclockwise with the filter wrench Fitter Wrench: 1-85221-097-0 2. Clean the ol iter fitting face This will allow the new oil filter to seat property, Apply alight coat of engine oil to the O-ring 4, Turin the new oil fiter until the filter O-ring is fitted against the sealing face. 5. Use the fitter wrench to turn in the fiter an additional, one full tur. 6. Check the engine oil level and replenish to the specified level if required Engine Oil Replenishment 0.7 (0.190.415) 7. Start the engine and check for oll leakage from the ‘main oll filter. lit (US/UK gal)00 - 44 SERVICE INFORMATION Engine Oil Replacement Draining 1. Remove the drain plug to completely drain the engine ol at Do this while the engine is hot [a=] 2. Replace the drain plug — 3. Tighten the drain plug to the specified torque. \) Drain Plug Torque Nem (kgerbet) 78 (8.0158) Replenishment 4, Remove the filer cap. 2. Pour the specified engine oil into the crankcase through the oil filer. 3. Replace the filer cap. Crankcase and Filter Oil Capacity lit (USIUK gal) 10.5 (2.8/2.3) 4. Start the engine and allow it to ide for a few minutes, 5. Stop the engine, 6. Use the dipstick to check the ol level. If the oil level is below the “MIN” line, add oll through the ol filer. If the ol level is above the "MAX’ ne, drain off the excess ol through the drain plug. FUEL SYSTEM Fuel Filter Replacement Procedure 1. Loosen the used fuel fiter by turning it counterclockwise with the universal filter wrench, 2. Clean the upper cover fiting fave. This will allow the new fuel filter to seat properly.SERVICE INFORMATION 00 - 45 3. Apply a light coat of engine oil to the O-ring, ‘Supply fuel to the new fuel iter to facitate bleeding 5. Tum in the new fuel fter until the filter O-ring is fitted against the sealing face. Be very careful to avoid fuel spillage. Use the fier wrench to turnin the fue! fiter an additional 1/3 to 2/3 of a tur. » 3 7. Operate the priming pump to bleed the air from the fuel line, Bleeding the Fuel System + Loosen the priming pump cap @. + Loosen the air bleeding plug: @. (4HG1-T model only) + Operate the priming pump. Pump the primer pump until fuel flow is free of air bubbles. (Except 4HG1-T model) + Tighten the air bleeding plug ®. oe (4HG1-T model only) + Loosen the bleeding plug ©. + Operate the priming pur. Pump the primer pump until fuel flow is free of air bubbles. + Tighten the bleeder plug ©. + Operate the priming pump. Pump the primer pump until fuel flow is free of air bubbles. (Except 4HE1-TC model) + Loosen the bleeding plug on the injection pump ®. (4HE1-TC model only) + Operate the priming pump. Pump the primer pump until fuel flow is free of air bubbles. (4HE1-TC model only) + Tighten the bleeding plug on the injection pump ©. (4HE1-TC model only) + Lock the priming pump cap ®. NOTE: Check for fuel leakage from around the injection pump, and the fuel filter.00-46 SERVICE INFORMATION Bi [ie] Pre-fuel Filter Water Draii Sub Fuel 8. Start the engine Crank the engine for ten seconds or unt it starts Ifthe engine does not start after ten seconds, repeat Step 7. fer (Dual Type) Replacement Procedure 1. Loosen the fuel fiters by turning them counterclockwise with the universal fiter wrench, 2. Clean the upper cover fiting faces, This will allow the new fuel filters to seat property. ‘Apply a thin coat of engine oil to the O-rings. 4, Install the fier assemblies. Carefully tum each assembly clockwise until the O-ring is fitted against the fier cover sealing face 5. Use the fiter wrench to turn in each fitter assembly an additional 1/3 to 2/3 of turn. 6. Operate the priming pump on the fuel fier to bleed the fuel system Refer to “AIR BLEEDING’ for more detailed information, 19 Procedure ‘The indicator light will come on when the water level in the water separator exceeds the specified level. Drain the water and foreign material from the water separator with the following procedure. 1. Place the end of a vinyl hose (beneath the drain plug) in a container. 2. Loosen the air intake plug and drain plug, then drain Water. 3. After draining, securely tighten the drain plug and air intake plug. 4, Then, operate the priming pump on the injection pump to bleed the fuel system, 5. After starting the engine, check to see that no fuel leaks from the drain plug.‘SERVICE INFORMATION 00 - 47 Injection Nozzle Pressure and Spray Condition Check 1. Use a nozzle tester to check the injection nozzle opening pressure. Ifthe opening pressure is above or below the specified value, the injection nazzle must be replaced or adjusted. Refer to “Adjustment. ae Injection Nozzle Opening Pressure Mpa (kg/em*ipsi) 4HFGHF1-2/4HG1 18.14 (1852,631) 4HE1-TC 21.57 (220/3,128) - jst 18.1 (185/2,631) paca 2nd 21.1 (215/3,057) jst 17.65 (180/2,560) aca 2nd_21.57 (220/3,128) 2. Check the spray coneiition, Refer to the illustration. Spray Condition © Correct @ Incorrect (Restrictions in orifice) @ Incorrect (Dripping) Ifthe spray condition is bad, the injection nazzle must be replaced or adjusted. Refer to “6C FUEL SYSTEM” [:-| Adjustment 1. Clamp the injection nozzle holder @ in a vise @, 2. Use a wrench to remove the injection nozzle retaining rut ©,00 - 48 SERVICE INFORMATION 3. Remove the injection nozzle holder from the vise. 4, Remove the injection nozzle @, the spacer ©, the spring seat © the spring @ and the adjusting shim ® 5. Install the new adjusting shim, the spring, the spring seat, the spacer, the injection nazzle, and the retaining rut 6. Clamp the injection nozzle holder in the vise. 7. Tighten the injection nozzle holder retaining nut to the specified torque. Injection Nozzle Hokler Retaining Nut Torque 7m (kgernibeft) 34 (3.5/25) 8. Remove the injection nozzle holder from the vise. 9. Attach the injection nozzle holder to the injection nozzle tester. 40. Apply pressure to the nozzle tester to check that the injection nozzle opens at the specified pressure. If the injection nozzle does not open at the specified pressure, instal or remove the appropriate number or adjusting shims to adjust it. Removing or installing one shim will increase or decrease the nazzle opening pressure approximately 3.77 kglem* (53.6 psi/370kPa). Adjusting Shim Availability mm (in) Range [0.51.5 (0.02 - 0.08) Increment 0.026 (0.001) Total Number of Shims 41 Air Bleeding (Except 4HF1-2 model onty) ‘Above works refer to "FUEL SYSTEM" in this section.‘SERVICE INFORMATION 00 - 49 Air Bleeding (4HF1-2 model only) 4. Actuate the priming pump © to send the air in the fuel system to the injection pump, 2. Loosen the sedimenter air bleeding plug @ and operate the priming pump until no bubbles appear. 3. Tighten the air bleeding plug completely. 4, Try to start the engine. If the engine is not started within 410 seconds, air bleeding should be conducted once agian. aa 5. Check that there is no fuel leak ,and then tighten the priming pump completely. Water Drain Iftmore water than specified has collected, the waming light is lit Under this condition, follow the following water drain procedure: 1. Place a container (Approximately 0.2 liters capacity) beneath the drain plug on the separator. 2. Loosen the drain plug and air bleeding plug 3. After draining, tighten the drain plug. 4, Operate the priming pump several times again and check for fuel leak. 5. Tighten the air bleeding plug 6. Make sure that the waming light in the instrument panel is off, (Except 4HE1-TC model) COOLING SYSTEM Coolant Level Check the coolant level and replenish the radiator reserve tank if necessary. If the coolant level falls below the "MIN" line, carefully check the cooling system for leakage. Then add enough coolant to bring the level up to the "MAX line. Good Quality Ethylene Glycol anti-treeze | \/ NOTE: a Do not overfill the reserve tank. 2.9 Remove the radiator filer eap only when absolutely Ett necessary. & ood} Always check the coolant level when the engine is -49 cold. (ri 5S 10S 20-25 36-35 a0 45 55 55 60 Mixing ratio(%) ‘Always refer to the chart at the left to determine the correct cooling water to antifreeze solution mixing ratio.00 - 50 SERVICE INFORMATION Cooling System Leakage Inspection Clog up the reserver tank hose carefully and check the cooling system for leakage with a radiator cap tester by applying an air pressure of 196 kPa (2 kg/om’/28 psi) from filer neck to inside the radiator. AAs the radiator upper tank is provided with a valve, the pressure fails to rise higher than the valve opening pressure unless the hose is clogged up. {[°] Radiator Valve Inspection Apply air pressure from filer neck using radiator cap tester and check the opening pressure of radiator valve. Ifthe valve opening pressure is out of the standard value range, replace with a new radiator valve. Radiator valve opening pressure kPa (kglem*/psi) 93 - 123 (0.95 - 1.25/13.5 - 17.8) Remove the radiator valve and check a negative pressure valve as the center of the valve seat side. Ifthe negative pressure valve does not work smoothly, clean or replace the radiator valve. Radiator valve fixing torque Nem (kgemilb-f) 6 (0.6/4) Conduct cooling system leakage check after reinstalling the radiator valve, ‘Thermostat Operating Test 4. Completely submerge the thermostat in water. 2. Heat the water. Stir the water constantly to avoid direct heat being applied to the thermostat. 3. Check the vaive intial opening temperature. Valve Initial Opening Temperature SCF) Standard without | Primary valve 83-87 (181 - 189) ore jiggle fo tele [Secondary valve | 60-84 (176-183) with jiggle vaive 83.5 - 86.5 (182 - 188) 4, Check the valve lift full opening temperature. Valve Lift Full Opening Temperature “c Standard without jiggle valve 95 (203) with jiggle valve 100 (212) © Thermometer © Thermostat © Aditating rod @ Heat ® Wooden pieceSERVICE INFORMATION 00-51 Fan Belt Check the drive belt tension, Depress the drive belt mid-portion with a 98 N (10 kg/22 Ib) force. Drive Belt Deflection mm (in) 8- 12(0.31-0.47)... New belt 10- 14 (0.39 - 0.66) ... Reuse belt Check the drive belt for cracking and other damage. + Crankshaft damper pulley + Generator pulley + Cooling fan pulley Fan Belt Adjustment Fan belt tension is adjusted by moving the generator. Torque Nem (kgerbeft) o 40 (4.1180) @ 24 (2.4/17) ® 46 (4.7134) If equipped with A/C compressor, loosen the AIC drive belt tension pulley adjust bolt and lock nut. Then free the A/C drive belt. When finishing the fan belt adjustment, adjust the A/C drive belt and check the belt tension, Air Conditioning (A/C) Compressor Drive Belt Check the drive belt tension. + Depress the drive belt mid-portion with a 98 N (10 kg/22 Ib) force. Drive Belt Deflection mm (in) 16 - 20 (0.63 - 0,79) ... New belt 18-22 (0.71 -0.87) ... Reuse belt Check the drive belt for cracking and other damage. AIC compressor drive belt tension is adjusted by moving the tension pulley. When finishing the fan drive bett, then adjust the A/C drive belt Locking Nut Torque 1m (kgeribsf) 27 (2.8720) ‘ANC compressor pulley Tension pulley Generator pulley Crankshaft damper pulley Tension pulley lock nut e0ee000 - 52 SERVICE INFORMATION ENGINE CONTROL Idling Speed Inspection 1. Set the vehicle parking brake and chock the drive wheels 2. Place the transmission in neutral 3. Start the engine and allow it to warm up. 4. Check that the idling control knob is in the engine idling position. 5. Seta tachometer to the engine 6. Check the engine idling speed Engine idling speed should be as below. Engine Idling Speed tom (MT) _850~600 (AT) 640~690 Ifthe engine idling speed is outside the specified range, it must be adjusted. [J] ldling Speed Adjustment 1. Loosen the idling set bolt lock nut on the injection pump. 2. Adjust the idling speed with the idling set bolt. 3. Tighten the lock nut. Idling Speed Check & Adjustment (4HF1-2 model only) 4. Warm up the engine. 2. Measure idling speed by means of tachometer. 3._Ifidling speed is out ofthe standard, adjust with an idling adjust bol (ingicated by an arrow mark) Idling speed: 575 - 625 rpm ACCELERATOR CONTROL x Accelerator Control Cable Adjustment 1. Loosen the accelerator cable clamp bolt ©. 2. Check that the idling control knob is in the engine idling position, 3, Hold the accelerator lever @ in the fully closed position and stretch the control cable @ in the direction indicated by the arrow to remove any slack.SERVICE INFORMATION 00-53 ENGINE STOP CONTROL [=] Adjustment 1. Check that the key switch is either in the “LOCK” position or removed from the engine. 2. Loosen the bolt ©. 3. Pull the fuel cut lever @ as far as possible and hold it, 4, Remove cable slackness @ by pulling the cable in the direction of the arrow in the illustration, 5. Tighten the bolt ©. «| Accelerator Pedal Adjustment 41. Press the accelerator pedal to the floorboard and hold it 2. Use the stopper bolt @ to adjust the clearance between the stopper bolt end and the accelerator pedal @ lower face. Accelerator Pedal Clearance mm (in) 0-2 (0-0.079) =] VALVE CLEARANCE ADJUSTMENT 41. Bring the piston in either the No.1 ylinder or the No.4 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft damper pulley timing mark is aligned with the TDG notched line. Not If there are two marks on the crank pulley, the front side of mark is for setting BTDC 49° and the rear side of mark is for setting TDC. 2. Tighten the rocker arm shaft bracket nuts and bolts to the specified torque in numerical order a litle at a time as shown in the illustration Rocker Arm Shaft Bracket Nut and Bolt Torque on (kgeerlbst) * Nut 27(2.8/20) Bolt 86(5.7/41) O Bott 27(2.8/20) + Apply engine oil to the threaded portion of the nuts marked with“ and the bolts with “m™" shown in the illustration left, and then tighten them to the specified torque.00 - 54 SERVICE INFORMATION 3. Cheok for play in the No.1 intake and exhaust valve rocker arms. If the No.1 cylinder intake and exhaust valve rocker arms have play, the No.1 piston is at TDC on the Compression stroke, If the No.1 cylinder intake and exhaust valve rocker arms are depressed, the No.4 piston is at TDC on the compression stroke. Adjust the No.1 or the No.4 cylinder valve clearance hile their respective oylinders are at TDC on the compression stroke. Valve Clearance mm (in) Atoold 0.40 (0.016) 4. Loosen each valve clearance adjusting screw as shown in the illustration, 5. Insert a feeler gauge of the appropriate thickness between the rocker arm and the valve stem end. 6. Tum the valve clearance adjusting screw until a slight drag can be felt on the feeler gauge. 7. Tighten the lock nut securely. Rotate the crankshaft 360 degrees. 8. Realign the crankshaft damper pulley timing mark with the TDC notched line. 10. Adjust the clearance for the remaining valves as shown in the illustration INJECTION TIMING ADJUSTMENT Injection Pump Notched Line Inspection 4. Check the injection pump bracket nuts © for looseness, Tighten as required. 2. Check that the notched lines on the injection pump bracket and the timing gear case are aligned. If the notched lines are not aligned, the injection timing must be checked. 3. Some time, check injection timing on the crank damper pulley. If the injection timing aligned with in correct, the injection timing must be readjusted.SERVICE INFORMATION 00-55 |+| Injection Timing Adjustment 4. Tum the crankshaft until the timing mark on the crankshaft damper pulley is aligned with the BTDC {injection timing of each engine model) mark in the illustration. Injection Timing deg 4HF1: 4HEI-TC BTDCS 4HG1 BTDC 9 4HEI-T BIDC7 2, Remove the two foam rubbers. 3. Loosen the four injection pump fixing nuts. This will allow the pump to pivot, Do not bend or scratch the fuel pipe. 4, Align the notched line between the injection pump bracket and the timing gear case. Make sure that the timing mark on the crank damper pully is aligned with correct injection timing, Note: In case the crank pulley has two marks as illustrated, @ BTDC 49° mark on the second crest and @ TDC mark on the third crest (as viewed from the front side), be sure to set at the mark @. (If there are two different SS ‘marks on one and same crest, set at the mark which ‘comes second when rotated in the normal direction.) ‘The mark © is used when installing the injection pump for 4HF1-2.00-56 SERVICE INFORMATION 5. Tighten the injection pump fixing nuts to the specified torque. Injection Pump Fixing Nut Torque Nem (kgenvb+t) 25 (2.6/9) Injection Timing Check (4HF1-2 model only) 4. Set No. 1 Cylinder to the TDC in the compression stroke. 2. Disconnect Injection Pipe. 3. Put down Wax CSD lever, insert a spacer (10 - 20 mmi0.39 - 0.47 in) thick between the plunger and adjust bot, and cancel the Wax CSD, Water nose a 4, Remove the pump rear plug, connect a dial gage and 2 set the lft at 11mm (0.039 in). Special Tool Measuring device: 5-8840-0145-0 5, Set the crankshaft damper pulley TOC mark to the pointer or 45° before TDC. 6. Set the dial gage to the “0” position, 7. Tum the crankshaft leftwise and rightwise a tte and make sure that the needle stays in the “O” position. 8. Tum the crankshaft in the normal direction and read, the measuring device's indication at the 12° before ‘TDC position. NOTE: As there is no 12° mark, set midway between the 11° and 13° marks. Standard value: 0.5 mm (0.0197 in)‘SERVICE INFORMATION 00 - $7 Injection Timing Adjustment (4HF1-2 model only) If injection timing is out ofthe specified range, follow the following procedure for adjustment: 1. Loosen injection pump fiixng nuts and bracket bolt. 2. Adjust the mounting angle of injection pump + Ifinjection timing is too fast, bring the injection pump closer to the engine. + Ifinjection timing is too slow, put the injection pump more distant from the engine. 3, When the dial gage has indicated the specified value, tighten the fixing nuts and bolt to specified toraue: Nut Tightening Torque Nem (kgenvibet) 24 (2.4/17) Bolt Tightening Torque 48 (4.9/5) 4, Disconnect the dial gage, install and tighten the plug to specified torque. (Make sure of a copper washer being attached to the plug) Plug Tightening Torque Nem (kgsmioeft) 47 (4.7712) 5. Release the wax CSD and connect the injection pipe Pipe Sleeve Nut Tightening Torque Nem (kgrbeft 29 (3.0/22)00 - 58 SERVICE INFORMATION COMPRESSION PRESSURE MEASUREMENT 1. Start the engine and allow it to warm up. Engine Coolant Temperature: Above 80°C (176°F) 2. Stop the engine. 3, Remove the following parts. * Glow plugs. * Incase VE pump; Fuel cut solenoid connector. « Incase line pump; Numiver 17 fuse in fuse box. 4, Set the adapter and the compression gauge to the No.1 oylinder glow plug hole. Compression Gauge (With Adapter): 5-8840-2675-0 Adapter: 5-8531-7001-0 5. Connect a tachometer and check that engine cranking speed is 200 rpm or higher. 6. Tum the engine over with the starter motor and take the compression gauge reading 7. Repeat the procedure (steps 4,5 and 6) for the remaining cylinders. Compression Pressure kPa (kglom*ipsi) at 200 rpm ‘Standard More than 2,942 (30/426) Limit for use 2,157(22/312) Variance in pressure Ae ae Less than 294 (3/43) If the measured valve is less than the specified limit, above ‘works refer to "TROUBLESHOOTING" Section in manual QUICK-ON-START Il SYSTEM [i®] inspection Procedure 4. Disconnect the thermoswitch connection on the thermostat outlet pipe. 2. Tum the key switch to the “ON" position. If the Quick-ON-Star Il system is operating properly, the flow relay will make a clicking sound within three seconds. 3. Measure the glow plug terminal voltage with a circuit tester as soon as possible after turning the key switch tothe "ON" positon. 4. Check the glow plug heating time. Approximate Glow Plug Heating Time sec 48SERVICE INFORMATION 00-59 FIXING TORQUE CYLINDER HEAD, HEAD GASKET AND HEAD COVER Nem (kgemilbeft) ZAG EREY| 18 (1.8/13) (ae Tana [a [5810/2 47 srv06) 20-60" Aly wt molybdenum sie rest (hear ets an sting se00 - 60 SERVICE INFORMATION CYLINDER HEAD, HEAD GASKET AND HEAD COVER Nem (kgem/Ibeft) 4HE1-TC (Engine) “TL t011.0771 rm 18(1.8/13), 38 (3.9728), P, zo4 Hm ee, ena] BS “ast | 2nd 3rd ‘aeisaray 14 8/108| 20-80 | I ‘Appi with molodenum doutide grease | akg {othe Dol tren and sting eeeSERVICE INFORMATION 00-61 CRANKSHAFT, FLYWHEEL, DAMPER PULLEY, CONNECTING ROD AND OIL PAN Nem (kgsmilb-ft) ads and vetting faces ts 2nd ard | 98 (10.0/72)/132(13.5/98)) 30-60 ™ ania00 - 62 SERVICE INFORMATION GEAR TRAIN, CAMSHAFT, ROCKER ARM SHAFT, FRONT RETAINER, FLYWHEEL HOUSING Nem (kasmi/lbeft) [27 28/20) 56 (5.7/41) a 22(2.2/16) mea | x [rae (145/105) [ 95 19.7/70) ——____| 133 (13.6/98) [26.98/70 76.17.7156) | XN SPD 14W0 model ae & (49/35) pez seman 76 (77156) v ; (aD model) ey ie 133 (13.6/98) 120 2880 | 19 (19/14)SERVICE INFORMATION 00 - 63 INLET COVER AND EXHAUST MANIFOLD Nem (kgsm/Ibeft) 4HF1/4HG1 Engine [psizsi 34i8.5725)| teiisn2) N aii) toit.07) /00 - 64 SERVICE INFORMATION INLET COVER AND EXHAUST MANIFOLD Nem (kaemi/lbsft) 4HEI-T / AHE1-TC Engine YP EL? S x SOS a a No 4 Sy OF Se Za ir vas}SERVICE INFORMATION 00 - 65 TURBOCHARGER, WATER PIPE AND OIL PIPE Nem (ka-mi/lbsft)00-66 SERVICE INFORMATION WATER PUMP, WATER OUTLET PIPE, OIL PUMP, OIL COOLER AND OIL FILTER Nem (kgsm/lbsft) 24 (24/171 / 26 (2.4/17) 2a arin 24 (2.4/17) 13 (1.3/9) ces f \ gO) He (wan) & [ew] [2ai617) 4a am) Ds - Bs buen) aSERVICE INFORMATION 00 - 67 GENERATOR, STARTER AND GLOW PLUG Nem (kgsm/Ibeft) 46 (4.7/34) | (28 (2.a/17) [40 (4.1/30) 126 (12.9 / 93)00-68 SERVICE INFORMATION ENGINE MOUNTING Nem (kg*m/lbeft) ____ » 51 (5.2/38) |SERVICE INFORMATION 00 - 69 INJECTION PUMP, INJECTION PIPE AND FUEL PIPE Nem (kgsmi/lbeft) J 300s | A, 2 =m [eeis5i28)] | 4104.2/30) | 2913.0/22) soul [ascorz | (ata | [aaa] = _/ 2424/7) 34 (35/25) |00 - 70 SERVICE INFORMATION (©) SPECIAL TOOLS iw Iustration Part No. Part Name Remarks 1 CY) 41-8522-1097-0 | oilfiter wrench we 2 fi 5-8840-2675-0 | Compression gauge with adapter 3 5-8531-7001-0 | Compression gauge adapter For angular 4 5-8640-0266-0 | Angle gauge bolt and nut tightening 5 5-8840-9018-0 | Piston installer 6 5-8840-2230-0 | Crankshaft stopper For crankshatt 7 5.8640-2360-0 | slinger puller front and rear singer remove For crankshaft 8 5-8840-2431-0 | Oil seal setting tool kit eed slinger install 9 5-8840-2240-0 | Clutch pilot aligner 10 5-8840-2228-0 | Valve spring compressorSERVICE INFORMATION 00-74 i lustration Patt No. Part Name Remarks 1" 4 5-8840.2227-0_ | Va guide replacer 12 f 8.0430-6815-0 | Valve guide seal installer 2 QO 5-8840-2222-0_ | Sealing cup installer 14 £ 9-8523-1169-0 | Cylinder liner remover 5.8640-2220-0 45 5-8640-2397-0 | Cylinder liner remover ankle (aHe1) Ojlinder Liner Installer 7) 6) 9-8840-2337-0 | (aye 4-7 and 4HE1-TC only) 7 eB 8-9439-6818-0 | Crankshaft gear remover 18 8-9439-6819-0 | Crankshaft gear installer ‘8 o 5201020100 |comodbush eee 20 OQ 5-8640-2094-0 | cil fier wrench AWD model00-72 SERVICE INFORMATION LUBRICATING SYSTEM GENERAL DESCRIPTION LUBRICATING OIL FLOW AHF Model Swish tegieme5 Tos 4HF1-2 Model Sumteh 0 M@fewsi6 Tost ease 4HG1 Model Cos oe Kevsmiten [Banery ater, - I Faucets bie Ful Fos de Boqy Oi Cale lS Lo oui Barocas 1 erm an enor © (Vaive [Eanksnatl| cnecc IMecharsm)) Searing || Valve ASSn y | i u es Gea I[Gpanod Frmoomm — [agae" | fst | Seas 4HE1-T Model (4HE1-TC Model pen |Full Flow =¥>-o[_Olcooler of Cylinder Body 0: Galler 1 Bypass I 20gem? 4 Skgtem: Gravee] 288 See 2peaaS pe ee, t , ° Yai _|fenkanar | Gheck ic Feo Pump pon [Me™ |] Fas Btanag! Suet? tt! Jo b ft 4 ‘The engine lubricating system is a full flow type. Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil fer and the oill cooler. It then delivered to the vital parts of the engine from the cylinder body oil gallery. il ets installed on the cylinder body spray engine oil to the piston inside faces to achieve maximum cooling effect.GENERAL ENGINE MECHANICAL 6A-1 SECTION 6A ENGINE MECHANICAL CONTENTS Cylinder Head. Valve Spring, Valve Guide Camshaft .. Seal, Valve, Valve Guide. Rocker Arm Assembly. Oil Pump... Crankshaft Piston and Connecting Rod. Cylinder Block. PAGE 6A- 2 6A- 8 6A-16 6A-19 6A-23 6A-29 6A - 53 6A-636A-2 GENERAL ENGINE MECHANICAL CYLINDER HEAD Disassembly steps 1. Glow plug connector 2. Glow plug 3. Injection nozzle holder assembly 4. Rocker arm shaft assembly 6. Valve cap Reassembly steps 6. Camshaft bearing cap To reassemble, follow the disassembly 7. Camshaft bearing upper stops in the reverse order. 8 Camshaft assembly. 9. Camshaft bearing lower 10. Cylinder head NoTE: + During disassembly, be sure that the valve train components are kept together and identified so that they can be re-installed in their original locations. + Before removing the cylinder head from the engine and before disassembling the valve mechanism, make a compression test and note the results. [#-) DISASSEMBLY Glow Plug Connector Glow Plug Injection Nozzle Holder Assembly Mark the nozzle holder assemblies fiting positions by tagging each nozzle holder assembly with the cylinder number from which it was removed.GENERAL ENGINE MECHANICAL 6A -3 4, Rocker Arm Shaft Assembly 1) Loosen the rocker arm shaft bracket nuts and bolts in numerical order a litle at a time and remove the rocker arm shaft assembly with the camshaft brackets. 2) Leave the @ indicated bolt unremoved on this occasion, since itis the rocker arm fixing bolt CAUTION: Failure to loosen the rocker arm shaft bracket nuts and bolts in numerical order a little at a time will adversely affect the rocker arm shaft. 5. Valve Cap CAUTION: Take sufficient care not to let valve caps fall into the gear case or oil return hole. Camshaft Bearing Cap Camshaft Bearing Upper Camshaft Assembly Camshaft Bearing Lower If the camshaft bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. SON 10. Cylinder Head Loosen the cylinder head bolts in numerical order a litle at atime, CAUTION: Failure to loosen the cylinder head bolts in numerical order alittle at a time will adversely affect the cylinder head lower surface, + Refer to Section 6A3 “CYLINDER HEAD”. F& CLEAN + Cylinder head botts + Cylinder head Carefully remove all varnish, soot and carbon to the bare metal. Do not use a motorized wire brush on any gasket sealing surface.6A-4 GENERAL ENGINE MECHANICAL fe] INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. + Cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, determine the cause; = Improper installation = Loose or warped cylinder head - _ Insufficient torque on head bolts = Warped case surface 41) Cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools. \V caution: Suspected bolts must be replaced. 2) Cylinder head for cracks, especially between valve seats and in the exhaust ports. 3) Cylinder head deck for corrosion, sand particles in head and porosity. Ys caution: Do not attempt to weld the cylinder head. Replace it. [| Cylinder Head Lower Face Warpage 41) Use a straight edge and a feeler gauge to measure the ‘our sides and the two diagonals of the cylinder head face. 2) Ifthe measured values exceed the specified limit, the cylinder head must be replaced. NOTE: Do not regrind the cylinder head lower face. Cylinder Head Lower Face Warpage mm (in) Standard Limit 0.05 (0.002) or less 0.2 (0.008) jold (2) Mai 19 Face Warpage Use a straight edge and a feeler gauge to measure the manifold cylinder head fiting face warpage. Reagrind the manifold cylinder head fiting faces if the measured value is greater than the specified limit. Manifold Fitting Face Warpage mm (in) Standard Limit (0.05 (0.002) or less 0.2 (0.008)GENERAL ENGINE MECHANICAL 6A-5 Exhaust Manifold Warpage Use a straight edge and a feeler gauge to measure the manifold cylinder head fiting face warpage. If the measured values exceed the specified limit, the [| Vv A manifold must be replaced Exhaust Manifold Warpage mm(in) Standard Limit 0.08 (0.002) or less 0.24 (0.008) +, REASSEMBLY Install the cylinder head gasket with its “PART NUMBER® mark facing up and toward the left of the engine. ‘CAUTION: Do not reuse the cylinder head gasket. ‘Above works refer to "CYLINDER BLOCK’ section in this, manual. 10. Cylinder Head 4) Align the cylinder body dowels and the cylinder head dowel holes. 2) Carefully place the cylinder head on the cylinder head gasket. 3) Apply a coat of molybdenum disulfide grease to the M14 oylinder head bolt threads and setting faves and apply a coat of engine oil to the M10 cylinder head bolt threads and setting faces. 4) Use the angular tightening method to tighten the botts (N14) to the specified torque in three steps following the numerical order shown in the illustration, Cylinder Head Bott Torque (M14) (® ~@) Nem (kgernibeft) Aststep 2nd step 3rd step 98 (10/72) 147 (15/108) 30° - 60" 5) Tighten the cylinder head to the flywheel housing bolts (N10) to the specified torque. Cylinder Head Bott Torque (M10) (@~@) Nem (kgenbft) 38 (3.9728)6A~—6 GENERAL ENGINE MECHANICAL |. Camshaft Bearing Lower . Camshaft Assembly 41), Tum the crankshatt in the direction of normal rotation Lunt the timing mark on the crankshaft damper pulley is aligned with the TDC notched line. (Confirm that the No. 1 cylinder piston comes to the compression top dead center.) 2) Apply engine oil to the camshaft journal and the camshaft bearing surfaces before installation 3) Carefully align the camshaft gear “I” mark and the cylinder head upper face shown in the illustration . Camshaft Bearing Upper . Camshaft Bearing Cap 1) Install the bearing caps with the bearing cap head mark (arrow) facing forward 2) Apply a coat of engine cil to the bearing cap bolt and stud threads. 3) Tighten the bearing cap bolts and studs to the specified torque. Camshaft Bearing Cap Nut and Bolt Toraue Nem (kgemibefty 27 (2.8720) . Valve Cap Apply engine oil tothe inside of the valve caps and install them to the valve stem end, CAUTION: ‘Take sufficient care not to let valve caps fall into the gear. |. Rocker Arm Shaft Assembly 1) Temporarily tighten the bolts marked with the arrow in the illustration. 2) Loosen the rocker arm adjust screws and apply engine oil fo the rocker arm roller portions. 3), Install the rocker arm assembly on the cylinder head.GENERAL ENGINE MECHANICAL 6A-7 4) Tighten the rocker arm shaft bracket nuts and bolts to the specified torque in numerical order a litle at a time as shown in the illustration. Rocker Arm Shaft Bracket Nut and Bott Torque Nem (kgenvbet + Nut 27 (2.8120) = Bot 56 (6.7/41) D Bot 27 (2.8120) 5) Apply engine oil to the threaded portion of the nuts marked with "*” and the bolts with “m@” shown in the ilustration left, and tighten them to the specified torque. Adjust the valve clearance. Valve Clearance Atcold mm (in) 0.4 (0.016) Above works refer to “SERVICING” “VALVE CLEARANCE ADJUSTMENT previously section in this manual. . Injection Nazzle Holder Assembly Tighten the nozzle holder flange nuts to the specified torque in the numerical order shown in the illustration Nozzle Holder Flange Nut Torque 7m (kgeribef) 19 (1.9/14) 2. Glow Plug Glow Plug Torque Nem (kgernib+t) 23 (23/17) 41. Glow Plug Connector6A~—8 GENERAL ENGINE MECHANICAL VALVE SPRING, VALVE GUIDE OIL SEAL, VALVE, VALVE GUIDE Disassembly stops 1, Split collar 2. Spring upper seat ale spring (and exhaust valve Vive guide seat Spring lower seat 3 4 6 Reassemblt steps To reassemble, follow the disassebly steps in the reverse order DISASSEMBLY Preparation + Remove all the parts only with the cylinder head assembly left (Above works refer to "CYLINDER HEAD GASKET" section 6A3 in this manual.) 4. Cotter Collar 4) Place the cylinder head on a flat wooden surface. 2), Use the valve spring compressor to remove the cotter collar. Do not allow the valve to fall from the cylinder head. Valve Spring Compressor: §-8840-2228-0 2. Spring Upper Seat 3. Valve SpringGENERAL ENGINE MECHANICAL 6A-9 4, Intake and Exhaust Valve If the intake and exhaust valves are to be reinstalled, mark their installation positions by tagging each valve with the cylinder number from which it was remaved, Ifthe intake and exhaust valves are to be replaced, the valve guides must also be replaced. 5. Valve Guide Seal 6. Spring Lower Seat (2) INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. [1] Valve Spring Free Height Use a vernier caliper to measure the valve spring free. height. Ifthe measured valve is less than the specified limit, the valve spring must be replaced. Valve Spring Free Height mm (in) 4HP 4: 4HF1-2: 4HG1: 4HG1-T Nominal Size Limit aa 62.5 (2.46) 59.4 (2.34) AHE1T: 4HEt-TC: Nominal size Limit Intake Inner 53.2 (2.094) 50.4 (1.972) Intake Outer 55.6 (2.188) 52.5 (2.067) Exhaust Inner 58.6 (2.307) 56.5 (2.185) Exhaust Outer | 62.0 (2.441) 58.9 (2.319)6A-10 GENERAL ENGINE MECHANICAL a 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 4.0 (0.04) @ Vv Valve Spring Tension Use spring tester to measure the valve spring tension, If the measured valve is less than the specified limit, the valve spring must be replaced Valve Spring Tension N (kg/lb) Setterat | sarcad Lim waar? 47.0 (1.85) (42.2 - 48.6193 - 107) 401 (40.9/98) Valve Guide CAUTION: Taking care not to damage the valve seat contact surface, when removing carbon adhering to the valve head. Carefully inspect the valve stem for scratching or abnormal wear. If these conditions are present, the valve and the valve guide must be replaced as a set. Valve Stem and Valve Guide Clearance (Measuring Method-) 1) Set the dial indicator to the valve stem measuring point 2) Move the valve stem end from side to side, Read the dial indicator. Note the total indicator reading. If the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set. Total Dial Indicator Reading (Valve Stem and Valve Guide Clearance) mm (in) Valve Standard Limit 0.038 - 0.071 0.20 Intake Valve | (0.0015- 0.0028) | _ (0.0079) Exhaust Vaive | 0,084 0.086 a (0.0025 - 0.0038) | __ (0.0098)GENERAL ENGINE MECHANICAL 6A~-11 (Measuring Method-tI) 1) Measure the valve stem outside diameter. Refer to the "Valve Stem Outside Diameter.” 2) Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter. 3), Calculate the clearance between the valve guide inside diameter and the valve stem outside diameter. Ifthe clearance exceeds the specified limit, the valve and the valve guide must be replaced as a set. [1] Valve Stem Outside Diameter (Q) (9) Measure the valve stem diameter at three points. If the measured valve is less than the specified limit, the valve and the valve guide must be replaced as a set Valve Stem Outside Diameter mm (in) Valve Standard Limit 8.946 - 8.962 2.88 inte Vane) (0.3522 - 0.3528) (0.350) 8.921 -8.936 2.20 Exraust Valve | (0.3512-0.3529) | (0.348) Valve Guide Replacement [++] Valve Guide Removal Use a hammer and the valve quide replacer to drive out the valve guide from the cylinder head lower face, Valve Guide Replacer: §-8640-2227-0 [++] Valve Guide Installation 4) Apply engine oil to the valve guide outer circumference. 2) Attach the valve guide installer to the valve guide. Valve Guide Replacer: 5-8840-2227-0 3) Use a hammer to drive the valve guide into position from the cylinder head upper face.6A-12 GENERAL ENGINE MECHANICAL 4) Measure the height (H) of the valve guide upper end from the cylinder head upper face. Valve Guide Upper End Height (H) mm (in) 14.1 0.2 (0.555 + 0.008) NOTE: If the valve guide has been removed, both the valve and the valve guide must be replaced as a set. VALVE AND VALVE SEAT INSERT | [©] valve Thickness and Depression fa 41) Measure the valve thickness, Ifthe measured value is less than the specified limit, the valve and the valve seat insert must be replaced as aset Intake and Exhaust Valve Thickness mm in) Valve Nominal Size Limit om inlet 1.8 (0.071) 7.3 (0.051) Exhaust 1175 (0.069) | _1.3(0051) 2) Install the new valve © to the cylinder head ®. 3) Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface. Ifthe measured value exceeds the specified limit, the valve seat insert and/or the valve must be replaced. Intake and Exhaust Valve Depression mm (in) Standard Limit 0.7 - 1.2 (0.028 - 0.047) 2.5(0.098) Valve Contact Width + 1) Check the valve contact faces for roughness and unevenness, SS f 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 corrected or replaced, Valve Contact Width mm (in) aan Valve Nominal Size Limit Intake 2.5 (0.098) 3.0 (0.118) Exhaust 2.0 (0.079) 2.5 (0.098)GENERAL ENGINE MECHANICAL 6A - 13 [@] Contact Surface Angle on Valve Seat on Valve 1) Measure contact surface angle on valve seat. 2) Ifthe measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Standard Degrees 45° Valve Seat Insert Replacement ++] Valve Seat Insert Removal 1) Arc weld the entire inside circumference © of the valve seat insert @ 2) Allow the valve seat insert to cool for a few minutes, This will invite contraction and make removal of the valve seat insert easier. 3). Use a screwdriver @ to pry the valve seat insert free. Take care not to damage the cylinder head @ 4) Carefully remove carbon and other foreign material from the cylinder head insert bore ++| Valve Seat Insert Installation 41) Carefully place the attachment © (having a smaller outside diameter than the valve seat insert) on the valve seat insert © NOTE: ‘The smooth side of the attachment must contact the valve seat insert. 2) Use a bench press @ to gradually apply pressure to the attachment and press the valve seat insert into place VY caution: Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat insert will result. 3), The valve should be lapped before final assembly to ensure a good valve seal ‘Above works refer to “Valve Seat Insert Correction” section in this manual.6A-14 GENERAL ENGINE MECHANICAL Valve Seat Insert Correction 1) Remove the carbon from the valve seat insert surface, 2) Use a valve cutter (15°, 45°, and 75” blades) to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not fo cut away unblemished areas of the valve seat surface. Valve Seat Angle Degrees 45° NoTE: Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside the valve guid 3) Apply abrasive compound to the valve seat insert surface. 4) Insert the valve into the valve guide. 5) Tum the valve while tapping it to it the valve seat insert, 6) Check to see if the valve contact width is correct. 7) Check to see if the valve seat insert surface is in contact with the entire circumference of the valve [==] REASSEMBLY 6. Spring Lower Seat 5. Valve Guide Seal 41) Apply a coat of engine oil to the valve guide seal inner face. 2) Use a valve guide seal installer to install the valve guide seal to the valve guide Valve Guide Seal Installer: 8-9439-6815-0GENERAL ENGINE MECHANICAL 6A - 15 Lr NC were | Ge . Si |. Intake and Exhaust Valve 1), Apply a coat of engine cil to each valve stem before installation, 2) Install the intake and exhaust valve. 3) Tum the cylinder heed up to install the valve spring, Take care not to allow the installed valves to fall free. . Valve Spring Install the valve spring with its fine pitched (or painted) end side sown. 1g Upper Seat |. Cotter Collar 1), Use the valve spring compressor to push the valve spring into position. Valve Spring Compressor: §-8840-2228-0 2). Install the cotter collar to the valve stem. 3). Set the cotter collar by tapping around the head of the collar with a rubber hammer.6A-16 GENERAL ENGINE MECHANICAL CAMSHAFT Disassembly steps 1, Rocker arm shaft assembly 2. Valve cap 3, Camshaft bearing cap) 4, Cemshaft Deering upper 5, Camshaft assembly 8, Camshatt bearing lower 7, Camshatt gear a Key Reassembly steps To instal, follow the disassembly steps in the reverse order, Pare [4+/ DISASSEMBLY Rocker Arm Shaft Assembly Valve Cap ‘Camshatt Bearing Cap ‘Camshaft Bearing Upper ‘Camshaft Assembly ‘Camshaft Bearing Lower Above works refer to "CYLINDER HEAD” section in this manual. ‘Camshaft Gear Use the universal puller to pull out the camshaft gear. Universal puller: §-8840-2027-0/(5-8840-0086-0) KeyGENERAL ENGINE MECHANICAL 6A - 17 fe] INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection, | Camshaft End Play Use a thickness gauge to measure the clearance between the camshaft gear © and the camshaft bracket @ Ifthe measured value exceeds the specified limit, the camshaft gear or the camshaft must be replaced Camshaft End Play mm (in) Standard Limit 0.085 - 0.205 (0.0083 -0.0081) 0.25 (0.0098) [1] Camshaft Journal Diameter Use a micrometer to measure each camshaft journal diameter in two directions (O and @). If the measured value is less than the specified limit, the camshaft must be replaced, Camshaft Joumal Diameter mm (in) Standard Limit 39,950 - 29.975 (1.5728 - 1.5738) eamnneeey [] Cam Height Measure the cam height “H with a micrometer. If the measured value is less than the specified limit, the camshaft must be replaced, (Cam Height *H’ mm (in) Engine model Standard Limit Other mode! 52.8 (2.078) 51.8 (2.039) HET ciel 53.6 (2.110) 52.6 (2.071) [@) Camshaft Run-Out 1) Mount the camshaft on V-blocks. 2) Measure the run-out with a dial indicator. If the measured value exceeds the specified limit, the camshaft must be replaced. Camshaft Run-Out mm (in) Limit 0.08 (0.002)6A-18 GENERAL ENGINE MECHANICAL [| Camshaft and Camshaft Bearing Clearance Use an inside dial indicator to measure the camshaft bearing inside ciameter. Camshaft Bearing Inside Diameter mm (in) Standard 40,000 - 40.037 (1.5748 - 1.5763) If the clearance between the camshaft bearing inside diameter and the journal exceeds the specified limit, the camshaft bearing must be replaced, Camshaft Bearing Clearance mm (in) Standard Limit 0.025 - 0.087 0.15 (0.00098 - 0.00343) (0.0059) [E+] REASSEMBLY 8 7 Key Camshaft Gear + With the projection of the camshaft gear center boss tumed to the camshaft side, set it to the knock pin and install the camshaft gear. Camshaft Gear Bolt Torque 142 (14.5/105) 1m (kgemilbt) Py Paae Camshaft Bearing Lower Camshaft Assembly Camshaft Bearing Upper Camshaft Bearing Cap Valve Cap Rocker Arm Shaft Assembly ‘Above works refer to “CYLINDER HEAD’ section in this manual.GENERAL ENGINE MECHANICAL 6A - 19 ROCKER ARM ASSEMBLY Removal steps 1. Rocker arm assembly 7. Camshaft bracket 2. Valve cap. 8. Rocker arm shaft 3. Camshaft bracket, 4. Rocker arm Installation steps 5. Spring To install, follow the removal 6. Rocker arm bracket steps in the reverse order. [4+] DISASSEMBLY 4. Rocker Arm Shaft Assembly 41) Loosen the rocker arm shaft bracket nuts and bolts in numerical order alittle at a time and remove the rocker arm shaft assembly with the camshaft brackets. 2) Leave the @ indicated bott unremoved on this cccasion, since itis the rocker arm fixing bolt CAUTION: Failure to loosen the rocker arm shaft bracket nuts and bolts in numerical order a litte at a time will adversely affect the rocker arm shaft. . Valve Cap YY caution: Take sufficient care not to let valve caps fall into the gear case or oil retum hole, Camshaft Bracket Rocker Arm Spring Rocker Arm Bracket, Camshaft Bracket Rocker Arm Shaft wea e PNOMERE6A-20 GENERAL ENGINE MECHANICAL @ INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection, Rocker Arm Shaft Run-Out 4) Place the rocker arm shaft on V-blocks. 2) Use a dial indicator to measure the rocker arm shaft central portion run-out If the run-out is very slight, correct the rocker arm shaft run-out with @ bench press. The rocker arm must be at cold condition. If the measured rocker arm shaft run-out exceeds the specified limit, the rocker arm shaft must be replaced Rocker Arm Shaft Run-Out mm (in) Limit 0.3 (0.012) Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm fiting portion outside diameter. If the measured value is less than the specified limit, the rocker arm shaft must be replaced. Rocker Aim Shaft Outside Diameter mm (in) Standard 21,979 - 22.000 (0.8653 - 0.8661) q Rocker Arm Bushing Inside Diameter Use either a vernier caliper or a dial indicator to measure the rocker arm bushing inside diameter. Rocker Arm Bushing Inside Diameter mm (in) Standard Limit 22.010- 22.035 22.15 (0.8665 - 0.8675) (0.8720) Rocker Arm and Rocker Arm Shaft Clearance __mm (in) Standard it 0.010- (0.0004 3.056 02 0022) (0.0079) Check to see ifthe rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm oil port.GENERAL ENGINE MECHANICAL 6A - 21 Rocker Arm Roller and Rocker Arm Pin 1) Passa string through the rocker arm-roller clearance and measure the roller protrusion while pulling both tends of the string in the arrowrindicated directions to push out the roller. 2), Mark the measuring point and draw out the string — Measure the roller protrusion again while the roller is Depth Gouge pushed in, 3) Note the difference in the above measurements is the aul standard roller-rocker arm pin clearance. Should the clearance exceed the limit, replace the rocker arm. ce Standard Limit 0.040 - 0.084 08 (0.0016 - 0.0033) (0.02) [@) Valve Cap Wear Inspect the valve cap surface contacting the rocker arm Valve Cap Worn mm (in) Limit 0.1 (0.004) REASSEMBLY6A-22 GENERAL ENGINE MECHANICAL 7 Rocker Arm Shaft 1) Use compressed air to thoroughly clean the rocker arm shaft oil holes. 2) Apply @ coat of engine oil to the rocker arm shaft, 3). Install the rocker arm shaft with the “Front” mark facing up and toward the front of the engine. Camshaft Bracket Install the camshaft bracket to the rocker arm shaft and temporarily tighten the camshaft bracket fixing bolt 2s shown in the illustration, Rocker Arm Apply engine oil to the rocker arm bushing and the roller pin and then install it to the rocker arm shaft. Spring Insert the spring end into the rocker arm. Rocker Arm Bracket Camshaft Bracket ‘Temporarily tighten the camshaft bracket fixing bolt, Valve Cap Rocker Arm Shaft Assembly ‘Above works refer to “CYLINDER HEAD" section in this manualGENERAL ENGINE MECHANICAL 6A - 23 OIL PUMP Disassembly steps 1. Power staering pump idle gear cover 2. Power steering pump idle 3. Flywheel housing 4. Idle gear A. 5. Oil pump assembly | 6:Briven gear and sate | 7. cotter ain B. Spring seat 9, Oi relief valve spring 10, Oi eliet valve 11, Pump cover Reassembly steps To install, follow the disassembly steps in the reverse order. [4+] DISASSEMBLY 4. Power Steering Pump Idle Gear Cover 2. Power Steering Pump Idle Gear6A-24 GENERAL ENGINE MECHANICAL 3. Flywheel Housing NOTE: Be careful not to fail to remove the bolts shown in the illustration. FS |. Idle Gear A . Oil Pump Assembly 6. Driven Gear and Shaft 7. Cotter Pin 8. Spring Seat . Oil Relief Valve Spring 10. Oil Relief Valve ‘11. Pump Cover °GENERAL ENGINE MECHANICAL 6A - 25 [@) Gear and Cover Clearance fe] INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection, [© Gear Teeth and Cover Inner Wall Clearance Use a feeler gauge to measure the clearance between the gear teeth and the cover inner wall If the clearance between the gear teeth and the cover inner wall exceeds the specified limit, the oil pump assembly must be replaced Gear Teeth and Cover Inner Wall Clearance mm (in) Standard Limit 0.125 - 0.220 03 (0.0049 - 0.0087) (0.012) Use a feeler gauge to measure the clearance between the cover and the gear. If the clearance between the gear and the cover exceeds the specified limit, the oil pump assembly must be replaced, Gear and Cover Clearance mm (in) Standard it 0.064 - 0.109 02 (0.0025 - 0.0043) (0.008) [@) Driven Gear Shaft and Bushing Clearance 4) Use a micrometer to measure the gear shafts outside diameter. Gear Shaft Outside Diameter mm (in) Standard Limit 15.989 - 16.000 159 (0.6295 - 0.6299) (0.626) 2) Use an inside dial indicator or inside micrometer to measure the pump cover bushing inside diameter and the oylinder body inside diameter. If clearance between the gear shaft and the bushing exceeds the specified limit, the oil pump assembly must be replaced. Gear Shaft and Bushing Clearance mm (in) Standard Limit 0.04- 0.07 02 (0.0016 - 0.0028) (0.012)6A-26 GENERAL ENGINE MECHANICAL ig REASSEMBLY 14. Pump Cover 10. Oil Relief Valve 9. Oil Reliof Valve Spring 8. Sprig Seat 7. Cotter Pin 6. Driven Gear and Shaft Apply the engine oil to the driven gear shaft 5. Oil Pump Assembly 41) Carefully wipe any foreign material from cylinder body rear surface. 2) Apply the recommended liquid gasket (Three Bond 1141E) or its equivalent to the shaded areas shown in the illustration. CAUTION: Be careful that no liquid gasket gets into the holes the arrow-marked portion in the illustration and the inside of the oil pump cover. 3) Install the oil pump to the cylinder body. 4) Tighten the oil pump to the specified torque. Oil Pump Bolt Torque Nem (kgerbet) 31 (2.2123)GENERAL ENGINE MECHANICAL 6A - 27 4, Idle Gear A 41) Tum the crankshaft clockwise so that the engagement mark of the crankshaft gear faces to the shaft center of the idle gear A and the No.1 cylinder piston comes to the top dead center. [Ea] 2) Align the crankshaft gear with the engagement mark of the idle gear and install the idle gear A. Idle Gear A Bolt Torque Nem (kgemilbft) 133 (13.6/98) a 3. Flywheel Housing 1). Carefully wipe any foreign material from the cylinder body rear face. 2) Apply the recommended liquid gasket (Three Bond 41207C) or its equivalent to the shaded areas shown in the illustration, Ae ‘Align the cylinder body knock pins with the flywheel housing knock pin holes. Sse 2X) 4) Tighten the flywheel housing bolts to the specified At torque shown in the illustration. a Eloaiecel Uouelnd| 20x Lone eeamume er. OsUeZt) - 96 (9.8/71) B95) oc. 966) ee mes) 76 (7.7186) wm 889) + Tighten the bots marked with" 4." or“ " from the injection pump side, and those with 4” from the cylinder body side. Flywheel Housing Bolt Torque n (kgernibett) ® 96 (9.8/71)6A-28 GENERAL ENGINE MECHANICAL 2. Power Steering Pump Idle Gear 1) Apply the engine oil to the idle gear shaft 2) Install the idle gear shaft © with the idle gear @ to the cylinder body “A" portion as shown in the illustration. Idle Gear Shaft Bolt Torque Nem (kgernibt) 133 (13.6/98) 4. Power Steering Pump Idle Gear Cover Install the gear cover with the O-ring, Gear Cover Balt Torque Nem ¢kgemibft) 19 (1.9714)CRANKSHAFT GENERAL ENGINE MECHANICAL 6A - 29 Disassembly stops 1. Cylinder head assembly 2 Cylinder haed gasket 43. Cluten pressure plate assembly 4 Drives plate 5. Engine control wire 6. Engine contral lever assembly 7 Olpive 8. Oi filter assembly 9. Vacuum pump oll pipe 10. Vacuurn pump rubber hose 11. Fanbett 12. Generator 13. Engine foot 14 Injection pump assembly 15. Fan bet adjust pate 16, Generator bracket 17, Canksnatt pulley 18, Crankshaft front ol seal 19, Cankshatt front stinger 20. Flywheel 21. Crankshat ear ol seal 22. Granksnat eat singer 23. Spacer rubber 24. OW pan 25. Oil pump strainer 26, Water pump pulley 22. Water pump 28, Front reainar 28, Oil tnerma valve 130. Power steering pump idle oar 31, Poner steering pump idle gear 432, Flywneel mousing 33. idle wear A ‘34. Oil pump asersly 36, Connecting rod cap assembly 36, Connecting rod lower bering 37. Piston and connecting 38, Crankease 539, Theut bearing lower 40, Crankshaft bearbg lower 41. Crankshaft assembly 42. Thrust bearing upper 48, Crankshaft bearing upper 44 Crankshit gear 45. Grankshatt Reassembly steps “To reassemble, follow the disassembly steps in the verse order6A-30 GENERAL ENGINE MECHANICAL V o Slinger DISASSEMBLY 4. Cylinder Head Assembly ‘Above works refer to “CYLINDER HEAD’ section in this manual Cylinder Head Gasket CAUTION: Do not reuse the cylinder head gasket. 2 Clutch Pressure Plate Assembly Driven Plate Engine Control Wire Engine Control Lever Assembly Oil Pipe Oil Filter Assembly Vacuum Pump Oil Pipe 10. Vacuum Pump Rubber Hose 11. Fan Belt 12. Generator 13. Engine Foot 14, Injection Pump Assembly 415. Fan Belt Adjust Plate 16. Generator Bracket ‘Above works refer to “CYLINDER BLOCK’ section in this manual 47. Crankshaft Damper Pulley 1) Use the crankshaft stopper to prevent the crankshaft from turing. Crankshaft Stopper: 5-8840-2230-0 2) Loosen the damper pulley bolts and remove the damper pulley. 18. Crankshaft Front CAUTION Be careful not to damage the crankshaft oll seal contact surface during the removal procedure. SealGENERAL ENGINE MECHANICAL 6A~-31 aoa Flex a NS Weaver hate fa Sleeve 49. Crankshaft Front Slinger Use the slinger puller to pull out the slinger. Slinger Puller: 5-8840-2360-0 NOTE: If the oil seal has been removed, both the oil seal and slinger must be replaced as a set. 20. Flywheel Assembly 1), Use the crankshaft stopper to prevent the crankshaft from tuming Crankshaft Stopper: 5-8840-2230-0 2) Loosen the flywheel bolts in numerical order a little at a time as shown in the illustration, 3) Remove the flywheel stopper and the flywheel assembly. For the A/T vehicle, loosened the flywheel fixing bolts, and remove the washer, the flexible plate, the flywheel and the sleeve in this order. 21. Crankshaft Rear Oil Seal CAUTION: Be careful not to damage the crankshaft oil seal contact surface during the removal procedure. 22. Crankshaft Rear Slinger Use the slinger puller to pull out the slinger. Stinger Puller 5-8840-2360-0 23. Spacer Rubber (NKR model only)6A~32 GENERAL ENGINE MECHANICAL 24, Oil Pan 25. Oil Pump Strainer 26. Water Pump Pulley 27. Water Pump 28. Front Retainer Install the three front retainer fixing bolts to the front retainer replacer holes as shown in the illustration, and tighten the bolts alternately a little at a time. 29. Oil Thermo Valve (4HF1, 4HF1-2, 4HG1, 4HG1-T) Pull out the thermo valve from the cylinder body. 29-1. Bypass Valve (4HE1-T, 4HE1-TC) Pull out the bypass valve from the cylinder body. 30. Power Steering Pump Idle Gear Cover 31. Power Steering Pump Idle Gear 32. Flywheel Housing 33. Idle Gear A 34. Oil Pump Assembly ‘Above works refer to “OIL PUMP" section in this manual.GENERAL ENGINE MECHANICAL 6A - 33 35. Connecting Rod Cap 36. Connecting Rod Lower Bearing 1), Take out the connecting rod bearing cap bolts and remove the bearing cap with the lower bearing, 2) Ifthe connecting rod lower bearings are to be reinstalled, mark their fiting positions by tagging each bearing with the cylinder number from which it was removed 37. Piston and Connecting Rod Assembly 1) To facilitate smooth removal of piston, remove carbon from the upper part of the cylinder wall using a scraper or equivalent. 2) Remove the piston and connecting rod assembly upward by pushing on the edge of the connecting rod with a hammer handle or equivalent 3) Ifthe connecting rod bearing are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. eee V7 CAUTION: Do not bend or damage the oiling jet. NOTE: When removing the piston and connecting rod assembly, pull the connecting rod in parallel with the cylinder bore. 38. Crankcase 1) Loosen the crankcase bolts in numerical order a litle atatime. 2). Install the three crankcase fixing bolts (See left arrow marks) to the crankcase replacer holes as shown in the illustration, and tighten the bolts alternate a little at atime. NoTE: ‘When removing the crankcase, be sure to remove the oil pump and the generator bracket before that. 39. Thrust Bearing Lower 40. Crankshaft Bearing Lower6A~34 GENERAL ENGINE MECHANICAL {) 41. Crankshaft Assembly 42, Thrust Bearing Upper 43. Crankshaft Bearing Upper 44, Crankshaft Gear 1), Use the crankshaft gear remover to remove the crankshaft gear. Crankshaft Gear Remover: 8-9430-6818-0 2) Remove the crankshaft feather key. 45. Crankshaft INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive Wear or damage is discovered during inspection. Crankshaft End Play 41). Sot the dial incicator to the crankshaft end and measure the end play. 2) Ifthe measured value exceeds the specified limit, the thrust bearings must be replaced Crankshaft End Play mm (in) Standard Limit 0104-0205 (0.0041 - 0.0081) aaa CRANKSHAFT AND BEARING Inspect the surface of the crankshaft journals and, crankpins for excessive wear and damage, Inspect the oil seal fing surfaces for excessive wear and damage. Inspect the oil ports for obstructions.GENERAL ENGINE MECHANICAL 6A - 35 [@]) Crankshaft Run-Out 1) Set a cial indicator to the center of the crankshaft journal. 2). Genily tum the crankshaft in the normal direction of rotation. Read the dial indicator as you tum the crankshaft. If the measured value exceeds the specified limit, the crankshaft must be replaced. Crankshaft Run-Out mm (in) om Standard Limit (0.05 (0.002) or 0.30 (0.012) less Bearing Spread Use a vernier caliper to measure the bearing spread, Ifthe measured value is less than the specified limit, the bearing must be replaced. Bearing Spread mm (in) Limit 87 (3.43) Diameter [@) Crankshaft Journal and Crankpit 1) Use a micrometer to measure the crankshaft journal diameter across points O - D and ® - @. 2) Use the micrometer to measure the crankshaft journal diameter at the two points @ and @. 3) Repeat Steps 1 and 2 to measure the crankpin diameter. Ifthe measured values are less than the limit, the crankshaft must be reground or replaced, Crankshaft Journal and —Grankpin Diameter mim fin Engine model Standard | Limit au | No-t.24and | 81.905 - 81.925 | 61.85 Joumal | (3.2246 - 3.2264) | (3.2224) 1.601 61.911 | 81.85 AL No.3 Joumal | (3.7240 - 3.2248) | (3.2224) Except 65.902 -65.922 | 65.85 4HE1-T Cranky cae (2.5946 - 2.5964) | (2.5025) 4HE1-T 72.902 -72.922 | 72.85 ante | rankein | (2.e702 - 2.8433) | (2.8681)6A~36 GENERAL ENGINE MECHANICAL Pe) i ‘Crankshaft Journal and Crankpin Diameter Uneven Wear mm (in) Except 4HEA-T, 4HE-TC | Limit Sa 4HE1-T, 4HE1-TC (0.0050 (0.0002) Crankshaft Journal and Bearing Clearance 1) Clean the cylinder body and crankcase, the journal bearing fitting surface, and the journal bearings. 2)_ Install the bearings to the cylinder body and crankcase. 3) Install the crankcase to the cylinder body. 4) Tighten the crankcase to the specified torque in the numerical order shown in the illustration Crankcase Bolt Torque(M14: 1~10) mn (kgerstbeft) iststep 2nd step 3rd step 98 (10/72) 132 (13.5/98) 30° - 60° Crankcase Bott Torque(M10:D~ ©) 37 (3827) on (kgeribe) 5). Use a dial indicator to measure the crankshaft journal inside diameter. 6) Ifthe clearance between the crankshaft journal and the bearing exceeds the specified limit, the crankshaft must be either reground or replaced. Crankshaft Journal and Bearing Clearance rm (in) Standard Limit No.1, 2.4 0.087 - 0.072 ont and 5 Jounal | (0.0015- 0.0028) | __ (0.0043) (0.081 - 0.086 ot No.3 Jounal — | (.9920-.0.0034) | (0.0043) 7) Remove the crankcase and the bearings. Undersized Crankshaft Journal Bearing Availabilty (Except 4HE1-T, 4HE1-TC) mm (in) 0.25 (0.01) 0.50 (0.02)GENERAL ENGINE MECHANICAL 6A - 37 Crankshaft Bearing Selection Refer to the following table when replacing the crankshaft andlor the crankshaft bearings, Crankshaft bearing selection is based on the measured diameters of the crankshaft joumals and the bearing housing, 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 Insert Grade Mark Position ‘The crankshaft bearing housing grade marks (1 oF 2) are stamped collectively forall cylinders on the underside of the lett front portion of the crankcase. Example: 1 2 1 1 2 t t 1 t t NeBiema No.2 Ne Pasa Ne $E5y Ne. 5 Being vouey" “igtire”? “var” vauang™” “Yara Crankshaft Journal Grade Mark Position ‘The crankshaft journal grade marks (1 oF 2) are stamped collectively forall cylinders on the front side of the crankshaft No.1 balancer. ‘The clearance between the crankshaft joumal and the bearing must be the same for each position after installation of the crankshaft and the crankshaft bearings. Example: 2 1 2 2 1 t t t t t No1 No2 N03 Nod NOS Journal Jounal Journal Journal Journal Crankshaft Bearing Combination (Reference) _mm (in) Bearing | Crankshat Journal | Crankshat Housing No245 | Bowne | oF ‘Grace (Grace olor | learence Ree, Diameter 34°] Diameter | Goler oom | [@ze-tio| Oe6A~38 GENERAL ENGINE MECHANICAL GL BY Z Beary] Craton surat Grnthat rowan no Seng | ‘Grade’ |Grade| Color | Clearance 2%] pameer [S23] cane | Soke Crankpin and Connecting Rod Bearing Clearance 41) Clean the crankshaft, the connecting rod, the bearing cap, and the bearings. Install the bearing to the connecting rod and the bearing cap. ‘Apply a coat of molybdenum disulfide grease to the bearing cap bol threads and setting faces, 4) Prevent the connecting rod from moving, 5). Tighten the bearing cap to the specified torque. Connecting Rod Bearing 2) 3 Cap Balt Torque Nem (kgemibeft) ‘iststep 2nd step 3rd step 39 (4.0129) 6° 30° 6) Use the dial indicator to measure the connecting rod bearing inside diameter. Crankpin and Connecting Rod Bearing Clearance mm (in) Standard Limit 0.036 - 0.077 (0.0014 - 0.0030) 0.10 (0.004) 7) Ifthe clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit, the bearing and/or the crankshaft must be replace or reground. (Except 4HE1-T, 4HE1-TC) 8) Remove the bearing cap and the bearings. Undersized Connecting Rod Bearing Availability 0.25 (0.01) mm (in) 0.50 (0.02)Cylinder No. GENERAL ENGINE MECHANICAL 6A - 39 Connecting Rod Bearing Selection Refer to the following table when installing or replacing the connecting rod bearings. Pay close attention to the size mark on the big end of the connecting rod. Do not confuse the size mark on the big end of connecting rod with the alignment cylinder No. mark. Connecting Rod Bearing Combination mm (in) Engine | Concecinarcd | Cyan [OommcingRed] OF Mos | "Big ena ee [I Beamng | Cearance crate Gametee | oemeser | Coke Werk Coe anes aieo |, |pese—enmo|eeam—e0m| ay, | 0-007 Eat res 2res 2 re: 2 ann — avert am-rsa oor-oar AMENTC| |g cao [BBO Sey Clearance Measurements (With Plastigage) [1] Crankshaft Journal and Bearing Clearance Fl 1) Clean the ctindr body ad crankcase the journal bearing fg sree ad the pumal bears ++ 2) Install the bearings to the cylinder body and crankcase. 2) Cretulyploce the cnkehat onthe bearing, 4) Rotate the crankshaft approximately 30 degrees to ‘seat the bearing. 5) Place the Plastigage (arrow) over the crankshaft journal across the full width of the bearing6A-40 GENERAL ENGINE MECHANICAL [++] (8) 6) Install the crankcase to the cylinder body. 7) Tighten the crankcase to the specified torque in the ‘numerical order shown in the illustration. Crankcase Bolt Torque (M14: 1~10) 7m (kgernibt) Aststep 2nd step 3rd step 98 (10/72) 192 (13.51/98) 30° - 60° Crankcase Bolt Torque (M10: @~ @) 3.9207 (282 51387) 1m (kerb) Do not allow the crankshaft to tun during bearing cap installation and tightening, 8) Remove the bearing beam and the crankcase with bearings. 9) Compare the width of the Plastigage attached to either the crankshaft or the bearing with the scale printed on the Plastigage container. Crankshaft Journal and Bearing Clearance mm (in) Standard Limit No.1,2,4and | 0.037 -0.072 0.14 SJoumal | (0.0015- 0.0028) | _ (0.0043) 0.051 - 0.086 ott No3 Joumal | (999. 0.0034) | (0.6043) 410) Ifthe measured value exceeds the limit, perform the following additional steps + Use a micrometer to measure the crankshaft outside diameter. + Use an inside dial indicator to measure the bearing inside diameter. Ifthe crankshaft journal and bearing clearance exceeds the limit, the crankshaft and/or the bearing must be reground (Except 4HE1-T, 4HE1-TC) or replaced. Undersized Crankshaft Journal Bearing Availabilty (Except 4HE1-T, 4HE1-TC) __mm (in) 0.25 (0.01) 0.50 (0.02) 141) Remove the crankshaft and bearings.GENERAL ENGINE MECHANICAL 6A~-41 FQ) Crankpin and Connecting Rod Bearing Clearance 41), Clean the crankshaft, the connecting rod, the bearing cap, and the bearings. 2) Install the bearing to the connecting rod and the bearing cap. Do not allow the crankshaft to move when instaling the bearing cap. 3) Prevent the connecting rod from moving, 4) Attach the Plastigate to the crankpin. Apply engine oil to the Plastigate to keep it from faling 5) Apply a coat of molybdenum disuifide grease to the bearing cap bolt threads and setting faces. 6) Install the bearing cap and tighten it to the specified torque Do not allow the connecting rod to move when installing and tightening the bearing cap. Connecting Rod Bearing Cap Bolt Torque | cs | ‘ uy 20. Flywheel Assembly 1) Apply molybdenum disulfide grease to the flywheel bolt threads and setting faces. @) For AUT refer to section 6A3 "Flywheel and pilot bearing’ 2) Align the flywheel with the crankshaft knock pin and temporarily tighten the flywheel bolts. q 3), Use the crankshaft stopper to prevent the crankshaft, from turning Crankshaft Stopper: 5-8840-2230-0 Crank at 2 rutot 4) Install the washer and the flywheel bolts and tighten to the specified torque in numerical order show in the ilustration Flywheel Bolt Torque 1m (kgemnilbft) ist step 2nd step 78 (8.0/58) 90° - 120° 5) Remove the crankshaft stopper.6A~50 GENERAL ENGINE MECHANICAL Crankshath Sleeve 49. Crankshaft Front Slinger Press in the singer using oil seal setting tool Kit il Seal Setting Tool Kit: §-8840-2431-0 Front slinger and oil seal setting tools Part Name ‘Stamp | Slinger | Oil Seal =p Adaper a a) Sleeve FT © ° Comer bat oleeclacecterira a 7 Adagcer —_WashertSrm) Center bolt e © ° TH ‘Adapter bolt 5 © ° 1) Insert the slinger © into the end of adapter @ and install the adapter on the crankshaft. 2) Cover the sleeve @ and tighten the bolt until the sleeve comes to contact the adapter stopper ©. 3) Make sure of measurements specified in the illustration 2 well as of slinger deflection. @® + 40.5 + 0.3 mm (1.594 + 0.012 in) @ 5 3400.1 mm (1.339 + 0.004 in) NOTE: Be sure to replace the slinger and oil seal as a set. Use about Smm thickness plain washer on the center bolt,GENERAL ENGINE MECHANICAL 6A ~ 51 18. Crankshaft Front Oil Seal 1) Apply engine cil tothe lip of the oil seal 2) Press in the oil seal using front oil seal setting tool kit. 3). Remove the slinger sleeve and insert the oil seal © into the adapter ®. 4) Install the adapter ring into the sleeve 5) Install the oil seal sleeve © to the adapter ® and tighten the center bolt until the sleeve comes to contact the adapter stopper ©. 6) Make sure of the measurements specified in the illustration ©: 810.3 mm (1.220: 0.012 in) 47. Crankshaft Damper Pulley 1), Apply a coat of engine oil to the threads of the bolts. 2) Align the damper pulley with the crankshaft knock pin c and tighten the bolts to the specified torque in a) rrumetical order. [J Damper Pulley Bolt Torque Nem (kgemilbeft) 200 (20.4/147) 46. Generator Bracket 45, Fan Belt Adjust Plate 14, Injection Pump Assembly 43. Engine Foot 12. Generator 11. Fan Belt6A-52 GENERAL ENGINE MECHANICAL Fan Belt Adjustment 10. Vacuum Pump Rubber Hose 9. Vacuum Pump Oil Pipe 8. Oil Filter Assembly 7. Oil Pipe 6. Engine Control Lever Assembly 5. Engine Control Wire 4, Driven Plate 3. Clutch Pressure Plate Assembly 2. Cylinder Head Gasket ‘Above works refer to "CYLINDER BLOCK’ section in this, manval, 4. Cylinder Head Assembly Above works refer to "CYLINDER HEAD” section in this manual,GENERAL ENGINE MECHANICAL 6A - 53 PISTON AND CONNECTING ROD For aHEDTE: Disassembly steps 1. Cylinder head assembly 2. Cylinder head gasket 3, Spacer rubber 4. Oil pan 5. Gil pump strainer 6. Connecting rod cap 7. Piston and connecting rod 8, Connecting rod bearing 9. Piston ring 10. Piston pin snap ring 11 Piston pir 12, Connecting rod 13, Piston Reossombly steps To install, follow the disassembly steps in the reverse order. [4] DISASSEMBLY 4. Cylinder Head Assembly ‘Above works refer to "CYLINDER HEAD" section in this manval, 2. Cylinder Head Gasket YY caution: Do not reuse the cylinder head gasket. Spacer Rubber 4, OilPan e6A-54 GENERAL ENGINE MECHANICAL 5. Oil Pump Strainer 6. Connecting Rod Cap 1) Take out the connecting rod bearing cap bolts and remove the beating cap with the lower bearing 2) Ifthe connecting rod lower bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed 7. Piston and Connecting Rod Assembly 4), To facilitate smooth removal of piston, remove carbon ‘from the upper part of the cylinder wall using a scraper oF equivalent. 2) Remove the piston and connecting rod assembly upward by pushing on the edge of the connecting rod with a hammer handle or equivalent. 3) the connecting rod bearing are to be reinstalled, mark thelr fiting positions by taggfing each bearing with the cylinder number from which it was removed. CAUTION: Do not bend or damage the oiling jet. NOTE: When removing the piston and connecting rod assembly, pull the connecting rod in parallel with the cylinder bore. 8. Connecting Rod Bearing If the connecting rod bearings are to be reinstalled, mark. their iting positions by tagging each bearing with the cylinder number from which it was removed.GENERAL ENGINE MECHANICAL 6A - 55 iston Ring 1) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2) Use piston ring replacer to remove the piston rings. Do not attempt to use some other tool to remove the piston rings. Piston ring stretching will result in reduced piston ring tension, 40. Piston Pin Snap Ring Use a pair of snap ring pliers to remove the piston pin snap rings. 14. Piston Pin 42. Connecting Rod 43. Piston ‘Tap the piston pin out with a hammer and a brass bar. If the pistons are to be reinstalled, mark their installation, positions by tagging each piston with the cylinder number from which it was removed, \i?| INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection, [| Piston Grade Selection and Cylinder Bore Measurement Refer to the Section “CYLINDER BLOCK, Item "Cylinder Liner Bore Measurement’ for details on piston grade selection and cylinder liner bore measurement. Piston Ring J @] Piston Ring Gap | oO teen reer ‘would assume if it wer cylinder liner bore. stalled to the piston) into the6A-56 GENERAL ENGINE MECHANICAL 2) Push the piston ring into the cylinder liner bore until it reaches the point where the oylinder liner bore is the smallest Do not allow the piston ring to stant to one side or the other. It must be perfectly horizontal Measuring Point mm (in) ‘Approx. 150 (6) 3) Use a feeler gauge to measure the piston ring gap. If the measured valve exceeds the specified limit, the piston ring must be replaced, Piston Ring Gap / 4HF1 / 4HF1-2 mm (in) Standard Limit Tstcompression | 0.24-0.39 ring gap (0.0094 - 0.0153) 2nd compression | 0.35 - 0.50 4.50 fing gap (0.0138-0.0197) | (0.0591) 0.02 - 0.40 Oilting gep (0.0008 - 0.0157) Piston Ring Gap / 4HG1 / 4HG1-T mm (in) Standard Limit stcompression | 0.24-0.30 ring gap (0.0094 - 0.0153) ‘nd compression | 0.35 - 0.50 1.50 fing gap (0.0138-0.0197) | (0.0591) 0.18- 0.35 Clk (0.00591 - 0.0138) Piston Ring Gap / 4HE1-T mm (in) Standard Limit ‘stcompression | 024-040 ring gap (0.0094 0.0157) 2nd compression | 0.66-0.71 1.80 fing gap (0.0220- 0.0278) | (0.0581) 0.20- 0.40 einer (0.0078 - 0.0157) Piston Ring Gap / 4HE1-TC mm (in) Standard Limit stcompression | _ 0.24-0.40 ring gap (0.0094 0.0157) 2nd compression | 0.30-0.450 4.50 fing gap (0.0118-0.0177) | (0.0591) 0.20- 0.40 ieee, (0.0078 - 0.0157)GENERAL ENGINE MECHANICAL 6A - 57 Piston Ring and Piston Ring Groove Clearance 1), Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove at several points around the piston. Piston Ring and Piston Ring Groove Clearance / 4HF1, 4HF1-2: 4HG1, 4HG1-T mm (in) Standard Limit ‘st Compression | 0.062 -0.092 020 cx Ring (0.0024 -0.0036) | _ (0.0079) 2nd Compression 0.04- 0.08 Ring (0.0015 - 0.0031) 0.18 0.02 - 0.08 (0.0089 oe (0.0008 - 0.0024) aaa Groove Clearance | 4HE1-T: 4HE1-TC mm (in) Standard Limit ‘1st Compression 0.09 - 0.13 Ring (0.0035 - 0.0051) 020 2nd and Src 0.09 - 0.13 (0.0078) ‘Compression Ring | _ (0.0036 - 0.0051) CO’ Ring 0.03 - 0.07 0.45 (0.0012 - 0.0028) | (0.0059) 2), Visually inspect the piston ring grooves. Ifa piston ring groove is damaged or distorted, the piston must be replaced, Piston Pin [Bj] Piston Pin Diameter Use a micrometer to measure the piston pin outside diameter at several points, If the measured value is less than the specified limit, the piston pin must be replaced. Piston Pin Diameter mm (in) Engine model ‘Standard Limit Except 35.995 - 36.000 35.970 AHE1-T - dneurg | (14171 1.4173) (1.4161) 4HE1-T 39.995 - 40.000 39.970 aHerto | (1.5746-1.5748) (1.5736) [@] Piston Pin Hole and Piston Pin Clearance Use an inside dial indicator to measure the piston pin hole (in the piston), on Pin Hole and Piston Pin Clearance mm (in) Standard Limit 0.004 - 0.017 0.04 (0.00016 - 0.00067) (0.006)6A-58 GENERAL ENGINE MECHANICAL If an inside dial indicator is not avaitable, use the following procedure to check the piston pin clearance. 1) Use a piston heater to heat the piston to approximately 80-100°C (176-212°F) 2) Push strongly against the piston pin with your thumbs. ‘The piston pin should move smoothly with litle or no resistance. Connecting Rod [] Connecting Rod Alignment Use a connecting rod aligner to measure the distortion and the parallelism between the connecting rod big end hole and the connecting rod small end hole. If either the measured distortion or parallelism exceeds the specified limit, the connecting rod must be replaced, Connecting Rod Alignment mm (in) Per Lenath of 100 (3.94) Standard Limit Distortion 0.08 (0.002) 0.20 Parallelism or less (0.008) [| Piston Pin and Connecting rod Small End ~~ Bushing Clearance Use a caliper calibrator and a dial indicator to measure the clearance between the piston pin and connecting rod small end bushing. Ifthe clearance between the piston pin and the connecting rod small end bushing exceeds the specified limit, replace the piston pin and/or the connecting rod bushing Piston Pin and Connecting Rod ‘Small End Bushing Clearance mm (in) Standard Limit 0.012 - 0.027 0.05 (0.0005 - 0.0011) (0.002) Connecting Rod Bushing Replacement /-»] Connecting Rod Bushing Removal Ie] __ 1) Set the collar ©, the connecting rod @, and the collar @ to the setting bar @ Connecting Rod Bushing Replacer: §-8840-2340-0 2) Hand-tighten the nut © until there is no more gap.GENERAL ENGINE MECHANICAL 6A - 59 3). Set the connecting rod bushing replacer base © to the. bench press, 4) Set the connecting rod to the connecting rod bushing replacer base. 5) Tighten the bolt ©. 6) Use the bench press to force the bushing from the connecting rod. |++| Connecting Rod Bushing Installation 41). Set connecting rod bushing replacer base © to the bench press. Connecting Rod Bushing Replacer: 5-8840-2340-0 2) Set the connecting rod to the connecting rod replacer base. ‘The connecting rod must be perfectly horizontal. 3) Tighten the bott © to hold the connecting rod small end in place. 4)_ Install the two collars @ and the new bushing ® to the. setting bar ©. ‘Align the bushing clinch line and the collar setting marks. Tighten the nut ©. 5). Use the bench press to press the new bushing into position inside the connecting rod. Check that the bushing oil holes and the connecting rod oil holes are aligned. 6) Use a pinhole grinder to finish the new bushing. ‘Connecting Rod Small End Bushing Inside Diameter mm (in) AHEL-TC 40.012 - 40.022 (1.6753 - 1.5767) [+] REASSEMBLY 43, Piston 10. Piston Pin Snap Ring Use a pair of snap ring pliers to instal the piston pin snap ring to the piston.6A-60 GENERAL ENGINE MECHANICAL 42. Connecting Rod 1) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2) Install the connecting rod so that the piston head front mark © and the connecting rod forging mark (projecting) © are set in the same direction. 11. Piston Pin If could not be installed piston pin, it is recommended to remove it by following procedure. 4) Use a piston heater to heat the piston to 80-100°C. (176-212°F). 2) Apply @ coat of engine oil to the piston pin, 3). Use your fingers to force the piston pin into the piston ntl it makes contact with the snap ring. 4) Cheok to See if the connecting rod moves smoothly on the piston pin, 10. Snap Ring 9. Piston Ring 41) Use a piston ring replacer to install the three piston rings. Insta the piston ngs in the order shown inthe illustration. © 1st compression ring ® 2nd compression ring @ 3rd compression ring (For 4HE1-TC) ® Oilring NOTE: 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. Install the compression rings with the stamped side facing up. 2) Apply engine oil o the piston ring surfaces. 3) Check to see if the piston rings rotate smoothly in the piston ring grooves. Fi ® Connecting Rod Bearing Carefully wipe any oil or other foreign material from the connecting rod bearing back face and the connecting rod bearing fiting surface, 7. Piston and Connecting Rod Assembly NOTE: ‘When installing new connecting rod and/or connecting rod bearings, refer to the selection table. Above works refer to “CRANKSHAFT” section in this manual.GENERAL ENGINE MECHANICAL 6A -61 Front mark Boss ierimating thetrort t 4). Apply 2 coat of engine oil to the circumference of each piston ring and piston. 2) Position the piston ring gaps as shown in the illustration © 1st compression ring @ 2nd compression ring @ 31d compression ring (4HE1-TC only) ® Oilring © Coil expander 3) Apply 2 coat of molybdenum disulfide grease to the two piston skirt. This will facilitate smooth break-in when the engine is first started after reassembly. 4) Apply a coat of engine oil to the upper bearing surfaces, 5) Apply 2 coat of engine oil to the cylinder wall 6) Position the piston head front mark so that its facing the front of the engine 7) Use the piston ring compressor to compress the piston rings. Piston Ring Compressor: §-8840-9018-0 8) Use a hammer grip to push the piston in until the Connecting rod makes contact with the crankpin. ‘tthe same time, rotate the crankshaft until the crankpin is at bottom dead center. CAUTION Do not bend or damage the ig jet. . Connecting Rod Cap 1) Install the connecting rod bearing caps. 2) Align the bearing cap ylinder number marks and the connecting rod cylinder number marks. 3) Apply a coat of molybdenum disulfide grease to the threads and setting faces of each connecting rod cap bolts. 4) Tighten the connecting rod caps to the specified torque. Connecting Rod Bearing Cap Bolt Torque Nem (kgemibt) Aststep 2nd step 3rd step 39 (4.0128) 60° 30° Angle gauge: 5-8840-0266.06A-62 GENERAL ENGINE MECHANICAL Oil Pump Strainer Oil Pan Spacer Rubber (NKR model only) Cylinder Head Gasket Above works refer to "CYLINDER BLOCK’ section in this manual. . Cylinder Head Assembly ‘Above works refer to “CYLINDER HEAD” section in this manual.GENERAL ENGINE MECHANICAL 6A -63 CYLINDER BLOCK Disassembly steps ‘ylinse” head accornbly Cylinder head gosker Clutch pressure plate assembly Driven bate Engin Engin Bi pipe Di Fter assemby vacuum pump rubber hose Fan belt Generator Engine oot jestion pump rubbar cpacer Se pulley brake Heater pife Water auction pipe Giteooter assembly Fan batt agjust plate Generator bracket Cover Crankshaft pulley Gontshat ane ei seal Crankehatt font shinger Flywneel assembly (MT) Ccrankshatrear ol sal romksnatt rea slinger Spacer uber Suipan Gitpump stsines Water pump pulley Frome eetainee Onltherme valve Power steeting purp ile eas Power stesting pur idle geat Flywheel housing lle gear A Fate gear Tale gear 8 shat 44, 01 purnp assembly 45. Connecting rod cap 45. Connecting ro tower bearing 47. stom ana cannecting 4 Crankeace 49. Thruat Deering lower 0: Crankshaft bearing lower BI. Grankshatt assembly 52. Thnust bearing upper 53. Crankshaft beeing upper 54. Piston oll jet 55. Cylinder tock 56 Flywheel (&Ty Reassembly steps Toreassernbie, flow the6A-64 GENERAL ENGINE MECHANICAL [=] DISASSEMBLY 4. Cylinder Head Assembly ‘Above works refer to “CYLINDER HEAD’ section in this manual. 2. Cylinder Head Gasket CAUTION: Do not reuse the cylinder head gasket. . Clutch Pressure Plate Assembly 41) Insert the clutch pilot a sligner to the clutch assembly. Clutch Pilot Aligner: §-8840-2240-0 2) Loosen the pressure plate bolts in numerical order a litte at a time as shown in the illustration, 3) Remove the pressure plate assembly. 4. Driven Plate Remove the driven plate wth the clutch pilot aligner. © Clutch pilot algner ® Clutch pressure plate assembly @ Driven plate 5. Engine Control Wire 6. Engine Control Lever Assembly 7. Oil Pipe 8. Oil Filter Assembly 9, Tachometer Sensor 10. Fuel Pipe BracketGENERAL ENGINE MECHANICAL 6A ~ 65 REY TD | _ 11. Vacuum Pump Oil Pipe i, i 42. Vacuum Pump Rubber Hose al 43. Fan Belt 7 44, Generator 2 i 45. Engine Foot 46. Injection Pump Assembly 4) Remove the injection pump bracket bolts and the injection pump rear bracket botts. 2) Then remove the injection pump assembly. 17. Injection Pump Rubber Spacer 18, Idle Pulley Bracket (If equipped with A/C) 19, Heater Pipe 20. Water Suction Pipe6A-66 GENERAL ENGINE MECHANICAL 21. Oil Cooler Assembly 4), Remove the oil cooler bolts. 2) Install a oil cooler fixing bolt to the oil cooler replacer hole as shown in the illustration, and tighten the bolt alternately a little at a time. 2. Fan Belt Adjust Plate 23. Generator Bracket 24, Cover 25. Crankshaft Damper Pulley 26. Crankshaft Front Oil Seal 27. Crankshaft Front Slinger 28. Flywheel Assembly 29. Crankshaft Rear Oil Seal 30. Crankshaft Rear Slinger ‘31. Space Rubber (NKR model only) 32. Oil Pan 33. Oil Pump StrainerGENERAL ENGINE MECHANICAL 6A - 67 34, Water Pump Pulley 35. Water Pump 36. Front Retainer 37. Oil Thermo Valve 38. Power Steering Pump Idle Gear Cover 39. Power Steering Pump Idle Gear 40. Flywheel Housing 41. Idle Gear A 42. Idle Gear B 43. Idle Gear B Shaft 44, Oil Pump Assembly 45. Connecting Rod Cap 48. Connecting Rod Lower Bearing 47. Piston and Connecting Rod Assembly 48. Crankcase 49. Thrust Bearing Lower 50. Crankshaft Bearing Lower 51. Crankshaft Assembly 52. Thrust Bearing Upper 53. Crankshaft Bearing Upper Above works refer to “CRANKSHAFT” section in this manual 54. Oiling Jet Loosen the check valves to remove both the check valves and the oling jets. ‘Take care not to bend or damage the oiling jets. ‘55. Cylinder Block le INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. 4) Remove the gasket and any other material adhering to the upper surface of the cylinder block. Be very careful not to allow any material to accidentally drop into the cylinder block. Be very careful not to scriatch the cylinder block. 2) Carefully remove the oil pump, Rear Oil Seal, and cil pan installation surface seal Fl 2) Wipe the cylinder block clean6A-68 GENERAL ENGINE MECHANICAL Cylinder Body Upper Face Warpage 1) Remove the cylinder body dowel. 2) Remove the cylinder liner. Refer to “Cylinder Liner Replacement.” 3) Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder body upper face, 4) Ifthe measured values exceed the specified limit, the cylinder body must be replaced. CAUTION: Do not regrind the cylinder body upper face. Cylinder Body Upper Face Wampage mm (in) Standard Limit 0.05 (0.002) oF less 0.20(0.008) Cylinder Body Height (H) (Reference) mm (in) Standard 279.965 - 280.035 (11.022 - 11.025) 5). Reinstall the cylinder liner. Refer to the “Cylinder Body Bore Measurement.” 6) Reinstall the cylinder body dowel. Cylinder Liner Bore Measurement Use a cylinder indicator to measure the cylinder bore at measuring points ©, @ and @ in the @ - @ and ® - @ directions of the crankshaft Measuring points: © 20mm (0.79:in) @ 90 mm (3.54 in) ® 160 mm (6.30 in) Ifthe measured value exceeds the specified limit, the cylinder liner must be replaced. Cylinder Liner Bore mm (in) Standard Limit HFA 112.021- 112.050] 112.20 AHP 12 | (4.4103-4.4114) (4.417) 4HG1 115.021- 115.050] 116.20 4HG1-T | (4.5284- 4.5295) (4.535) aHei-T — ]110.041- 110.080] 110.23 4HET-TC | (4.9323 - 4.3338) (4.340)GENERAL ENGINE MECHANICAL 6A - 69 NOTE: The inside of the dry type cylinder liner is made of thin cast iron. It cannot be rebored or honed. If the inside of the cylinder liner is scored or scorched, the cylinder liner must be replaced. [@) Cylinder Liner Projection Inspection Use a dial gauge to measure the projection of each cylinder. Cylinder Liner Projection mm (in) ‘Standard 0,09 - 0.14 (0.0035 - 0.0055) ‘The difference in the cylinder liner projection height between any two adjacent cylinders must not exceed 0.03 mm (0.0012 in), Cylinder Liner Replacement eS i **| Cylinder Liner Removal If could not be removed cylinder liner, itis recommended to remove it by following procedure. [@] 1) Set the cylinder liner remover © to the cylinder liner @. 2) Check to see if the remover shaft ankle @ is firmly ripping the cylinder liner bottom edge. 3). Slowly tum the remover shaft handle @ clockwise to pull the cylinder liner free. Cylinder Liner Remover: 9-8523-1169-0 Cylinder Liner Remover Ankle: 5-8840-2220-0 ‘Ankle: §-8840-2397-0 (4HG1) V caution: ‘Take care not to damage the cylinder body upper face during the cylinder liner removal procedure. Cylinder Liner Grade Selection and Standard Fitting Interference Accurately measured fiting interference and proper cylinder liner grade selection are extremely important, If the cylinder liner fitting interference is too small, engine cooling efficiency will be adversely affected. If the cylinder liner fitting interference is too large, it will be difficult to insert the cylinder liner into the cylinder body.6A-70 GENERAL ENGINE MECHANICAL [++| Cylinder Liner Installat ‘A mark was stamped on the left side of the cylinder block during production to indicate the correct liner. The liner grade (i.e.1, 2, 3) is indicated in metal stamp. Cylinder Liner Grade HPA 4HPA-2 Line | GylinderBore | Service | Liner Ouse Grade | Diametermm in) | Grade | Diametermm én.) 116.001 - 115.010 |_| 114.991 - 115.000 (4.5276 - 4.5279) (4.5272 - 4.5276) 115.011 - 115.020 1 a (4.5280 - 4.5283) 3X 115.001 - 115.010 3 115.021 - 115.030 (4.8276 - 4.5279) (4.5284 - 4.5287) 4HG1/ 4HG1-T 4 118.001 - 118.010 | 4 117.991 - 118.000 (4.6457 - 4.6461) (4.645; 6457) 2 118.011 - 118.020 (4.6461 - 4.6464) 3X 118.001 - 118.010 3 118.021 - 118.030 (4.6457 - 4.6461) (4.6465 - 4.6468) 4HE1-T | 4HE1-TC 115.001- 115.010 | yy | 115.021- 115.030 1 (45276-46279) (4.5284 4.5287) > | 115011 - 115.020 | (as2e0-4.5289) | 4 | 115.031- 115.040 3 115.021 - 115.030 (4.5289 - 4.5291) (4.5284 - 4.5287) “The cylinder liner grade is stamped on the outsile of the cylinder liner. in (For 4HF1, 4HF1-2, '— 4HG1 and 4HG1-T Engine) a Vv 4) Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores. 2) Use compressed air to blow dry the cylinder liner and bore surfaces. CAUTION: All foreign material must be carefully removed from the cylinder liner and the cylinder bore before installation. 3), Install cylinder liner perpendicularly to cylinder bore. Do not give any excessive force such as knocking while inserting cylinder liner into cylinder bore.GENERAL ENGINE MECHANICAL 6A-71 [++] Cylinder Liner Installation (For 4HE1-T and "_ 4HE1-TC Engine) iy Vv 41) Cylinder Liner Installation Using The Special Too! + Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores. + Use compressed air to blow-dry the cylinder liner and bore surfaces. CAUTION: All foreign material must be carefully removed from the cylinder liner and the cylinder bore before installation. + Insert the cylinder liner © into the eylinder body @ from the top of the cylinder body. + Set the cylinder liner installer @ to the top of the cylinder liner. Cylinder Liner Installer: §-8840-2337-0 + @is directly beneath the bench press shatt center ®, CAUTION: Check that the cylinder liner is set perpendicular to the bench press and that there is no wobble. + Use the bench press to apply a seating force of 4,900 N (500 kgj/1,102.5 Ib) to the eylinder liner. + Apply a force of 24,500 N (2,500 kg/5,512.5 lb) to fully seat the cylinder liner. + After installing the cylinder liner, measure the cylinder liner projection. Refer to “Cylinder Liner Projection Inspection’ 2) Cylinder Liner installation Using Dry loe If the cylinder liner is a chrome plated dry type, itis advisable to use dry ice during the installation procedure, Cooling the cylinder liner with dry ice will cause the cylinder liner to contract, thus making installation easier. CAUTION: Itis important that the cylinder liner be inserted to the cylinder body immediately after it has been cooled. WARNING: Dry ice must be used with great care. Careless handling of dry ice can result in severe frostbite.6A-72 GENERAL ENGINE MECHANICAL @ Part No, Front mark PISTON GRADE SELECTION Measure the cylinder liner bore after installing the cylinder liner. Then select the appropriate piston grade for the installed cylinder liner. 1) Measure the cylinder liner bore. Refer to the “Cylinder Liner Bore Measurement Measuring Point © 20 mm (0.79 in) Measuring Point © 90 mm (3.64 in) Measuring Point @ 160 mm (6.30 in) Cylinder Liner Bore mm (in) Standard Limit HFA 112.021 - 112.050 112.20 AHF 1-2 (4.4103 - 4.4114) (4417) 4HG1 115.021 - 115.050 115.20 4HG1-T | (4.5284 - 4.5295) (4.535) 4HEt-T | 110.041 - 110.080 110.23 4HE1-TC | (4.3323- 4.3338) (4.340) CAUTION Itis most important that the correct piston grade be used. Failure to select the correct piston grade will result in engine failure. Always measure the cylinder bore and select the correct piston grad 2), Measure the piston outside diameter (Reference), Piston Measuring Point ®: 82 mm (3.23 in) Cylinder Liner and Piston Clearance mm (in) AHF 4HF1-2: 0.081 - 0.118 (0.0032 - 0.0044) 4HG1 / 4HG1-T: 0.081 - 0.116 (0.0032 - 0.0046) 4HE1-T / 4HE1-TC: 0.091 - 0.131 (0.0036 - 0.0052) The piston grade (i.e. A, B, C) is indicated in metal stamp cn the piston upper face. Piston Grade Engine | Cylinder Liner | 2’ | piston Outside Model | Bore Diameter | SSM°| Diameter 4HE1 | 112.041 - 112.060 4HEL2 | (4.4111-4.4118) | aH@t | 115,040 - 115.060 4HGIT | (4.5291 - 4.5299) 111.947 - 111.960 (4.4074 - 4.4079) 114,944 - 114,959 (4.5253 - 4.5259) 108,944 - 109.959 4HE1-T | 110.086 - 110.075 | (4.3285 - 4.3201) AHEI-TC, (4.3333- 4.3337) 109,960 - 109.975 (4.3291 - 4.3297)GENERAL ENGINE MECHANICAL 6A -73 Cylinder liner kit clearances are preset. However, the cylinder liner installation procedure may result in slight decreases in cylinder liner clearances. Always ‘measure the cylinder linner clearance after installation to be sure that it is correct. [++] REASSEMBLY 55. Cylinder Block Use compressed air to thoroughly clean the inside and Outside surfaces of the cylinder body, the oil holes, and the water jackets. 54, Olling Jet 1) Install the oiling jets together with the check valves. Take care not to damage the oiling jet nozzles. 2) Tighten the check valves and oiling jets to the specified torque. Check Valve and Oiling Jet Torque 24 (2.1718) m (kgeenibt) 53. Crankshaft Bearing Upper ‘52. Thrust Bearing Upper 51. Crankshaft Assembly 50. Crankshaft Bearing Lower 49. Thrust Bearing Lower 48, Crankcase Above works refer to “CRANKSHAFT” section in this, manual 47. Piston and Connecting Rod Assembly 48. Connecting Rod Bearing 48. Connecting Rod Cap Above works refer to "PISTON AND CONNECTING ROD" section in this manual 44, Oil Pump Assembly 43. Idle Gear B Shaft Idle Gear 8 Shaft Bolt Torque 34 (3.2123) 1m (komo) Apply the engine oil to the idle gear shaft after installation6A-74 GENERAL ENGINE MECHANICAL fe] 42. Idle Gear B ‘The face of the idle gear B with longer boss should be _____ positioned toward the rear side shown in the illustration, [| lle Gear B Bott Torque Nem (kgernibeft) 440 (14.2/81) 41. Idle Gear A 40. Flywheel Housing 39. Power Steering Pump Idle Gear 38. Power Steering Pump Idle Gear Cover Above works refer to “OIL PUMP” section in this manual 37. Oil Thermo Valve 36, Front Retainer Above works refer to “CRANKSHAFT” section in this manual, 36. Water Pump Assembly 4) Apply 3mm-4mm bead of the recommended liquid gasket (Three Bond 1207C) or its equivalent on the water pump fiting surface. 2) Install the water pump to the front retainer. Water Pump Bolt Torque Nem (kgemibeft) 24 (24/17) + Install the water pump within 7 minutes after application =a of liquid gasket. + For the dislocation of liquid gasket, refer to the illustration CAUTION: ‘The water pump clamping bolt is also used to tighten the front retainer. $o, install the water pump before liquid gasket gets dry immediately after installation of the front retainer. (34, Water Pump Pulley (Ea) Water Pump Ply Bot Torque 24 (2.4117) m (kgemnilbf)GENERAL ENGINE MECHANICAL 6A-75 33. Oil Pump Strainer Install the O-ring © to the oil pump strainer pipe and instal the oil pump strainer tothe cylinder body shown in the ilustration il Pump Strainer Bolt Torque Nem (kgsribft) 24 (2.4/17) 32. Oil Pan 1) Apply a3 mm (0.tinch) bead of recommended liquid gasket (Three Bond 1207C) or its equivalent to the shaded areas shown in the illustration. [\) 3). Tighten the oilpan nuts and bolts to the specified torque in the numerical order as shown in the ilustration ‘A marks are located on nut positions. Oil Pan Nuts and Bolts Torque 14 (1.1/8)6A-76 GENERAL ENGINE MECHANICAL 31. Spacer Rubber (NKR model only) ‘Spacer Rubber Bolt Torque 76 (7.7/56) 7 (kgeenilbst) 30. Crankshaft Rear Slinger 29 Crankshaft Rear Oil Seal 28. Flywheel Assembly 27. Crankshaft Front Slinger 28. Crankshaft Front Oil Seal 25. Crankshaft Damper Pulley Above works refer to "CRANKSHAFT" section in this manual. 24. Cover Cover Bolt Torque Nem (kgemilbst) 13 (1.3/9) 23. Generator Bracket Generator Bracket Bolt Torque (kgemilbett) 48 (4.9135) 22. Fan Belt Adjust Plate Install the adjust plate and temporarily tighten the adjust plate bott.GENERAL ENGINE MECHANICAL 6A -77 Laud eake Orne 21. Oil Cooler Assembly 4) Apply 2 mm -3 mm bead of the recommended liquid gasket (Three Bond 1207C) or its equivalent on the oil cooler fiting surface. 2) Apply a coat of engine oil to the O-rings (2 pieces) and install the O-rings to the oil cooler. NOTE: Take care that the O-ring is not smeared with liquid gasket. + Install it within 7 minutes after application of liquid gasket. + For the dislocation of liquid gasket, refer to the ilustation. 3). Tighten the oil cooler bolts and nut to the specified torque a litle at a time in the sequence shown in the illustration, Gil Cooler Bott and Nut Torque 24 (2.4/17) om (kgeribst) 20. Water Suction Pipe 4) Apply 2 mm -3 mm bead of the recommended liquid gasket (Three Bond 1207C) or its equivalent on the groove of the water suction pipe fitting surface. 2) Install the water suction pipe to the oil cooler. + For the dislocation of liquid gasket, refer to the illustration ‘Water Suction Pipe Bott and Nuts Torque m (kgemllbf) 24 (2.4117) NTE: Install the water suction pipe immediately after the installation of the oil cooler.6A-78 GENERAL ENGINE MECHANICAL 19. Heater Pipe 1) Install the O-ring to the heater pipe. 2) Install the heater pipe to the oil cooler. Heater Pipe Bolt Torque 24 (2.4/17) 18. Idle Pulley Bracket (If equipped with A/C) Idle Pulley Bracket Bolt Torque 7 (kgemnbsft) 48 (4.9735) 17. Injection Pump Rubber Spacer Stick the rubber spacer to the location indicated in the illustration with pressure sensitive adhesive double coated tape. 16. Injection Pump Assembly (Except 4HF1-2) 1) Tum the crankshaft until the timing mark on the crankshaft damper pulley is aligned with "13" line. NOTE: BTDC 13° tobe eae with the injection timing. 2), Remove the inspection hole plug from the cylinder ogy. 3) Install the O-ring tothe injection pump bracket. 4) Align the injection pump bracket sit wth the timer sit 5) Install the injection pump assembly to the cylinder ith here is an angle at which talled, and has nothing to do ‘When the injection pump has a poor gear engagement while installing the assembly to the cylinder body, insert a screwdriver into the slit on the timer peripheral with the pump bracket slit used as a guide, and move it up and down to get it into forcibly.GENERAL ENGINE MECHANICAL 6A -79 \ Pointer DS ouide ei Mark Mark 6) After installation ofthe injection pump, the injection timing can be checked through the timing check hole provided to the injection pump bracket. Set the No.1 cylinder to BTDC (Injection timing of each engine model) on the compression stroke. When the pointer of the timing check hole comes in line with the mark on the timer periphery of the injection pump as shown in the illustration, the injection timing is normal ‘After completion of the injection timing check, tighten the check hole plug to the specified torque, Injection Timing deg HPI: AHE1-TC BTDC 8 4HG1 BTDC 9 4HGI-T BTDC 7 (Except Colombia) BTDC 8 (For Colombia) HET BTDC 7 7) Tum the crankshaft until the timing mark on the crankshaft damper pulley is aligned with “8° line. NOTICE: Position in its normal rotating direction. (for 4HE1-TC only) 8) Adjust injection pump downward so that the “8 comes to postion in the timing check hole. (for 4HE1-TC only) NOTE: When ever the injection pump is replaced, be sure to adjust the injection timing for the details of the adjustment, refer to the “SECTION 00 SERVICING: INJECTION TIMING INSPECTION AND ADJUSTMENT.” Note: In case the crank pulley has two marks as illustrated, © BTDC 49° mark on the second crest and @ TDC mark on the third crest (as viewed from the front side), be sure to set at the mark @. (If there are two different marks on one and same crest, set at the mark which comes second when rotated in the normal direction.) The mark © is used when installing the injection pump for 4HF1-2.6A-80 GENERAL ENGINE MECHANICAL 9) Tighten the injection pump bracket nuts and bolts to the specified torque. Injection Pump Bracket Nut and Bolt Torque Nem (kgemibeft) 48 (4,9/38) 10) Install the injection pump rear bracket. Injection Pump Rear Bracket Bolt Torque m (kgemllbft) 48 (4.9735) 11) Install the inspection hole plug. Inspection Hole Plug Torque m (kgernilbt) 48 (4.9/5) 46-1 Injection Pump Assembly (4HF1-2 model only) 1) Tum the crankshaft to set No.1 cylinder to 49° before TDC in ts compression stroke. (49° is a pump installing alignment angle, not related to injection timing.) 2) Install O-ring to the injection pump. 3), Apply paint on the @ (Z) marked side of the injection pump gear. 4) Align the pump bracket mark with the tooth (under side of the pump) just before the @ (Z) marked tooth. 5) Insert the pump using the block side of stud bolt as a guide. 6) After installing the injection pump, remove the tachometer sensor from the housing, and make sure that the painted gear is at the center of the sensor mounting hole, 7) Tighten injection pump clamping bolt and nut to specified torque: Bolt Tightening Torque Nem (kgemnibft) 48 (4.9135) Nut Tightening Torque 24 (2.4117) 8) With reference to Injection Timing Check & Adjustment, set No. 1 Cylinder to 12° before its TDC,GENERAL ENGINE MECHANICAL 6A~-81 Note: In case the crank pulley has two marks as illustrated, ‘@ BTDC 49° mark on the second crest and @ TDC mark on the third crest (as viewed from the front side), be sure to set at the mark @. (If there are two different marks on one and same crest, set at the mark which comes second when rotated in the normal direction.) Injection Timing Check (4HF1-2 model only) 1. Set No. 1 Cylinder to the TDC in the compression eve stroke. 2. Disconnect Injection Pipe. 3. Put down Wax CSD lever, insert a spacer (10 - 20 ‘mmi0.39 - 0.47 in) thick between the plunger and adjust bolt, and cancel the Wax CSD. 4, Remove the pump rear plug, connect a dial gage and . set the lift at 1 mm (0.039 in). Special Too! Measuring device: 5-8840-0145-0 5. Set the crankshaft damper pulley TOC mark to the pointer or 45° before TDC. 6. Set the dial gage to the “0” position, 7. Tum the crankshaft leftwise and rightwise a litle and make sure that the needle stays in the “0” position. 8. Tum the crankshaft in the normal direction and read the measuring device's indication at the 12° before ‘TDC position’ NOTE: As there is no 12° mark, set midway between the 11° and 13° marks. Standard value: 0.5 mm (0.0197 in)6A-82 GENERAL ENGINE MECHANICAL Injection Timing Adjustment (4HF1-2 model only) IFinjection timing is out of the specified range, follow the following procedure for adjustment: 1. Loosen injection pump fibmng nuts and bracket bolt 2. Adjust the mounting angle of injection pump: + Ifinjection timing is too fast, bring the injection pump closer to the engine, + Ifinjection timing is too slow, put the injection pump more distant from the engine. 3. When the dial gage has indicated the specified value, tighten the fixing nuts and bolt to specified torque: Nut Tightening Torque Nem (kgernibft) 24 (2.4117) Bolt Tightening Torque m (kgemllbsf) 48 (4.9135) 4. Disconnect the dial gage, install and tighten the plug to specified torque. (Make sure of a copper washer being attached to the plug) Plug Tightening Torque 1 (kgernitbt) 17 (1.712) 5. Release the wax CSD and connect the injection pipe. Pipe Sleeve Nut Tightening Torque Nem (kgemilbet) 29 (3.0722) Note: If there are two marks on the crank pulley, the front side of mark is for setting BTDC 49° and the rear side of mark is for setting TDC.GENERAL ENGINE MECHANICAL 6A - 83 45. Engine Foot Engine Foot Bott Torque 7m (kgeribeft) 51 (6.2/38) 14, Generator NoTE: Before tightening the generator securely, tighten it temporarily in advance after adjusting the fan belt. Put the lower fixing bolt through from the rear side and tighten it with the nut on the front side as shown in the illustration. 13. Fan Belt Check the drive belt tension Depress the drive belt mid-portion with a 10 kg (22 Ibi 98 N) force, Drive Belt Deflection mm (in) 0.47)... New belt 55)... Reuse belt Check the drive belt for cranking and other damage. |<] Fan Belt Adjustment Fan belt tension is adjusted by moving the alternator. Toraue Nem (kgemibt ® 40 (4.1/30) ® 2a 2aN17) @ 46 (47184) 42. Vacuum Pump Rubber Hose 14. Vacuum Pump Oil Pipe Cylinder Body Side Nem (kgsmibft) 41 (4.2130) Generator 3 (kgernilbt) 23 (2.3/7) 40. Fuel Pipe Bracket6A-84 GENERAL ENGINE MECHANICAL 9. Tachometer Sensor Tachometer Bolt Torque (kgemitbstt) 8 (0.8/6) 8. Oil Filter Assembly (BR = Fnack pin [eI Oil Filter Bolt Torque Nem (kgeniibeft) 48 (4.9138) = 7 Oil Pipe [\) Oil Pipe Joint Bott Torque (kgemibetty 17 (4.7/12) . Engine Control Lever Assembly Engine Control Lever Bolt Torque m (kgernllbft) 24 (2.4/17) 5 Engine Control Wire 4, Driven Plate Use the clutch pilot aigner to install the driven plate. Clutch Pilot Aligner: 5-8840-2240-0 © Clutch pilot aligner ® Clutch pressure plate assembly © Driven plate Clutch Pressure Plate Assembly 41) Align the clutch pressure plate withthe flywheel knock pin. 2) Tighten the pressure plate bots tothe specified torque in numerical order. Clutch Pressure Plate Bolt Torque Nem (kgernibst) 40 (4.1/30)GENERAL ENGINE MECHANICAL 6A -85 2. Cylinder Head Gasket 1). When any of the cylinder block, crankshaft, crankshaft bearing, connecting rod, connecting rod bearing, and piston is replaced with @ new one, cylinder head gasket thickness should be determined ney. 2) When replacing the cylinder head gasket alone without, replacing any of the parts mentioned in 1) above, the gasket to be used should be the same grade as the one used before, 3) Correct cylinder head gasket thickness is important. Installing the wrong thickness gasket can result in greatly reduced engine performance. 4) There are three cylinder head gaskets available. [2] Piston Head Projection Measurement + Select a cylinder head gasket. FAL ~ clean thorough the top faces ofthe piston head and the oylinder body. + Use the dial gauge to measure the piston head projection. Take measurements at two locations for each cylinder. + The measurement points ofthe piston head and the reference point of the cylinder body are shown in the illustration lef Measurement points: Points G’1 and G2 of the piston head Reference point: Point R on the top face of the cylinder body NOTE: Note that there are three types of a cylinder head gasket available as shown in the table below, according to the piston projection. + For each cylinder, calculate the average value (Ti) of the piston projection, + Find the maximum value (Timax) of the average value (Ti) of each cylinder. + Based on the Timax obtained, select a gasket of the appropriate grade,6A-86 GENERAL ENGINE MECHANICAL Baw aN GT AHF A/4HF1-2/4HG1-T Cylinder Head Gasket Selection mn (in) Gasket Thickness Gosket Grede Timex ae A Q-— | 0579-0659 | 4 70 (0.0669) (0.0228 - 0.0259) e 0.659- 0.739 (0.0259 - 0.0291) 0,739- 0.819 © 0 — | ogget 0.0322) | +80.0.0708) 1.75 (0.0689) 4HEA-TIMHE1-TC Cylinder Head Gasket Selection mm (in) Gasket Grade Timax eee Ao — | eave 0crao) | 179(0.0869) 8 Or —~ | errao-o0ven | 179000580 © Or —~ | cosy: .ds00) | 18900708) + Apply a 3mm (0.1 inch) bead or recommended liquid gasket or its equivalent to the shaded areas shown in the illustration, + Install the cylinder head gasket with its “PART NUMBER’ mark facing up and toward the lett of the. engine. CAUTION: Do not reuse the \der head gasket. |. Cylinder Head Assembly Above works refer to "CYLINDER HEAD’ section 63 in, this manual.ENGINE 6A3-1 SECTION 6A3 ENGINE (4HF1 / 4HF1-2 / 4HE1-T / 4HE1-TC / 4HG1 / 4HG1-T) CONTENTS PAGE General Description. 6A3- 2 Engine Mount (RH, LH) 6A3 - 10 Cylinder Head Cover... . GA3- 12 Inlet Cover/inlet Case .. . GA3- 14 Exhaust Manifold. 6A3 - 20 Timing Gear Replacement 6A3 - 23 Valve Guide Seal & Valve Spring... . GA3- 33 Rocker Arm Shaft Assembly... . 6A3~ 37 Camshaft Assembly 6A3 - 39 Cylinder Head. 6A3 - 42 GA3 - 52 Oil Filter Assembly .. .. 6A3- 57 Oil Filter Cartridge... . 6A3- 59 Oil Cooler 6A3 - 60 Oil Pan. 6A3- 69 Oil Pump Assembly . 6A3- 72 Oil Relief Valve. . 6A3- 77 Piston, Piston Ring, Piston Pin and Connecting Rod 6A3 - 78 Flywheel and Pilot Bearin GA3- 83 Crankshaft Front Oil Seal.. 6A3 - 88 Crankshaft Rear Oil Seal... . 6A3- 93 Crankshaft... . 6A3- 98 Cylinder Block. 6A3 -113 Engine Assembly.. 6A3 -1356A3~2 ENGINE GENERAL DESCRIPTION ‘The engine is a four-cycle, four-cylinder, inline, direct _ cleanness, economy and durability. Its torque fue! injection type diesel engine with the piston characteristics promise dynamic ride at high speed, displacement of 4,334 oc. It features a gear driven high power at low speed, and smooth end continuous OHC (overhead camshaft timing train and the unique _ torque at medium to high ranges. mechanisms and systems designed for outstanding RIGHT SIDE VIEW LIFT SIDE VIEW For 4HF1 For 4HF1ENGINE 6A3-36A3~4 ENGINE CYLINDER HEAD Ladder frame The cylinder head is made of cast iron and has crossfiow layout with the intake system in the left side: and the exhaust system in the right side, designed to reduce resistance in the intake and exhaust systems, ‘The valve diameter is increased to offset the mass of the valve operating system reduced by the introduction of the OHC mechanism. In addition, the intake and exhaust ports are put in @ smoother and less resistant layout to enhance intake and exhaust efficiency. ‘The cylinder head gasket is ofthe laminated steel of least fatigue in combination with the anguler cylinder head bolt tightening method, equally designed to increase reliability against gas and water leakage. in addition, selective assembly of gaskets of various thicknesses minimizes the wasted space between the piston and the cylinder head to maintain performance at ahigh level ‘The cylinder head cover is made of aluminum to reduce noise. CYLINDER BLOCK ‘The cylinder block is made of cast iron having dry oylinder liner and five bearings, ‘The bearing cap has a ladder frame construction integrating the crankcase to increase rigidity The cylinder liner is made of thin iron plus special alloys and is combined with the chrome-plated piston ring to ensure good resistance against weer. ‘The oil pan is made of vibration-damping stee! to reduce noise.ENGINE 6A3-5 ina wager an pioted 2ndring [__} Oi ring SHE Nitriging Crankshaft oll seal oO Axial ype Radial type PISTON, CONNECTING ROD, AND CRANKSHAFT ‘The piston is made of aluminum alloy. A ring trigger is, cast into the top ring groove end chrome plating is applied to four sides of the top ring to ensue sufficient strength and wear resistance of the ring and the ring groove. The piston bottom has a thermal flow shape to increase cooling efficiency of the oil jet. This design reduces thermal load while increasing rigidity (see figure). ‘The combustion chamber has @ square shelf of proven performance to ensure outstanding stability in exhaust gas control (see figure). The autothermatic piston and offset piston pin reduces piston flapping and other noise. The crankshaft is made of cast carbon stee! with five bearings and eight counterweights to reduce revolution load to the bearing. The ladder frame design that integrates the bearing cap and the crankcase increases bearing rigidity. The angular tightening method of the bearing bol further increases reliability and durability The connecting rod is made of cast carbon stee! and the cap is bolted by angular tightening method to maintain reliability, ‘The bearing, as well as the crank journal and crank pin bearings, are made of Kelmet metal il clearance is controlled accurately through selective assembly by thickness to reduce noise and increase reliability. The crankshaft has the axial type oil seal that drastically improves durability and reliability Compared with the conventional radial type (ips in @ radial orientation), the axial type oil seal has lips in an axial orientation to minimize lip Wear. It also precludes lip peeling and damage, spring dislocation and other problems associated with the radial type oil seal (see figure).6A3~6 ENGINE VALVE TRAIN Cit pum crmnk—F/S pump Sieger Sow lew 1 Injection pump Pie Power cring : Pin Section The gear train is located at the end of the cylinder block to minimize influence of the torsional vibration of the Crankshaft and the radiant sound. Noise is further reduced, to the same level as a timing belt driven system, by integrating the crank gear with the crankshaft by shrink fit and by careful tuming of the geer precision, teeth contact ratio of geer, backlash, bearing rigidity, neutral frequency, ete. (See figure). Gears are of the forged type. Gears are tuffrided to secure sufficient durability ‘The camshaft is made of carbon steel with five bearings. The cam's nose and the journal are induction-hardened to secure sufficient durability. ‘The cam hes Fouriet-dyne profile to maximize the intake and exhaust valve lis and the valve opening and closing timing is optimized to increase intake and exhaust efficiency. The valve spring is a single spring having an eggshaped cross section to reduce weight while reducing stress. Coupled with the unique cam profile, the spring increases the jump-and bounce-free limit at high-speed operation to provide reserve characteristics. The rocker arm is made of diecast aluminum and is of the center pivot type having a roller. This increases reliability while reducing friction and contributes to increased power output and fuel efficiency (See figure). The rocker shaft is chrome plated to secure sufficient durabilityENGINE 683-7 FUEL SYSTEM i Straightening wall The injection pump is of Bosch A type with the plunger outside diameter of 9.5mm and cam lt of mm. “The plunger has a special notch for advancing the timing at starting ‘The governor is of a mechanical RLD type to ensure sustained power at high speed ‘The timer is of the SCDM(eoventric) type. “The injection nozzle is of the P type to bring it as technically close as possible to the center of the combustion chamber. The nozzle inclination is also reduced to minimum to increase combustion efficiency. “The nozzle has four jets and the valve opening pressure is set at 185kg/om’(2,630 psi, 18,142 kPa) (See figure). “The injection pipe is laid in such @ way that the overall length is minimized to enhance performance. INTAKE AND EXHAUST SYSTEMS The resin-made intake manifold is of the cover type having an inner cover made of rubber and steel. This design effectively reduces radiant sound and transmitted sound. The intake manifold has a straightening Vane inside to stabilize swirl and improve performance. It also contains a built-in Positive Crankcase Ventilation (PCV) valve to minimize the overall size(See figure). “The exhaust manifold is mode of cast iron and heatresisting alloys. Ports are shaped carefully to minimize exhaust resistance.6A3~8 ENGINE Fan pulley J Fan center Seat unit be ern Ball bearing! LUBRICATION SYSTEM The oil pump is driven by the crank gear directly to increase durability while maintaining sufficient delivery. The pump body is partially integrated with the cylinder block to reduce the overall size and weight (See figure) ‘The oil filter is ofthe cartridge type integrating the {ullfow fer and bypass fiter as a single unit. This presents several advangates such as an extended interval between oil exchanges and greater ease of maintenance resulting in cost reduction. The bypass valve is fitted to the body itsef to avoid flow of foreign matter due to bypassing of oil thereby maintaining sufficient retiabilty The oil cooler is of a large-capacity, water-cooled and ‘muttiple-partition type built into the side of the cylinder block. This design maintains necessary stability in oil temperature. It also has @ bypass valve to minimize delay of the oil gallery pressure build-up for cold starting COOLING SYSTEM ‘The water pump is driven by a V-belt and the pump body is made of diecast aluminum. Part of the sswirlchamber is built into the engine front cover to reduce the overall size and weight. sintered carbon type seal unit is chosen to secure reliability. The shaft bearing combines roller bearing and bell bearing to maintain necessary durability. The Cutt for draining is located behind the pulley to prevent dust from entering the system as much as possible.(See figure) ‘The cooling fan operation is regulated by a temperature-sensitive clutch to enhance fuel efficiency while reducing noise.ENGINE 683-9 IMPORTANT OPERATIONS. 4 ‘Axial Type Oil Seal + Ascrankshatt front and reer oil seals are both axial type, attention must be paid to the following when replacing, replace oil seal and slinger as a set. + Be sure to use the special tool correctly since oil seal and slinger must be set accurately in their longitudinal direction, Valve Cap + As intake and exhaust valves have caps, take sufficient care not to let them fall into the gear case or oil return hole during disassembly or reassembly, Application of Liquid Gasket + Oil pan, crankcase, oil cooler, retainer front, and water pump are not sealed with sheet gasket but with liquid gasket only + Prior to application, be sure to remove old hardened liquid gasket or ol from those surfaces to which new gasket will be applied. Further, ifthe old gasket can hardly be removed, mask such surfaces with gasket remover (Three Bond PANDO-301D; ISUZU Genuine Parts No.1-8844-0542- 0) of equivalent in accordance with the instructions manuel + Liquid gasket should be applied evenly so that no breaks and omissions may be made. Further, where O-ring is used should not be exposed to liquid gasket. Plastic-Region Angular Nut & Bolt Tightening Method + Clamping bolts of connecting rod and cylinder head (M14 only) are tightened by plastic region angular nut and bolt tightening method. This method is applied with bolt threads and setting faces coated with molybdenum disulfide grease.6A3—10 ENGINE ENGINE MOUNT (RH,LH) a Removal steps (MT only) 2. Fan guide 3. Engine mount Installation steps To instal follow the removal steps in the reverse order. [++] REMOVAL Proparation Disconnect battery ground cable. Tilt the cab. 4. Transmission Panel (M/T only) 2, Fan Guide Remove the fan guide and hang it on the fan side.ENGINE 6A3-11 3. Engine Mount 11) Hang the engine by the hoist before dismounting the engine mount 2) Remove the nuts that fix the engine foot and the engine mount. 3) Remove the fixing bolts on the chassis frame side of the engine mount. 4) Hoist the engine assembly a litle, and dismount the engine mount. [++ INSTALLATION 3. Engine Mount Tighten the fixing bolts to the specified torque. Chassis Frame Side Bolt Torque Nem (kgemilbft) 48 (4.9135) [EX] Engine Foot Side Nut Torque 82 (8.4161) 1m (kgemnilbf) 2. Fan Guide 4. Transmission Panel (M/T only) 1) Connect the negative battery cable. 2) Lower the cab 3) Start the engine, and check for any abnormal Conditions with the engine mount.6A3—12 ENGINE CYLINDER HEAD COVER at Removal steps 1, Nozzle caver 2. Cylinder head cover 3. Cylinder head cover gasket 4. Rubber plug Front Installation steps To install, fallow the removal steps in the reverse order. [++) REMOVAL Preparation * Disconnect battery ground cable, + Tiltthe cab. Nozzle Cover Cylinder Head Cover Cylinder Head Cover Gasket Rubber Plug eensENGINE 6A3~-13 "Apply liquid gaaket tothe errow marked wection Mounting rubber Nut Head cover Stud Gasket o @ © 9 4 gS 2 | [++] INSTALLATION Rubber Plug 1) Apply a 2mm-4mm bead of the recommended liquid gasket (Three Bond 1207B) or its equivalent to the cylinder head front and rear plug arch. 2) Install the rubber plugs to the cylinder head upper faces, 3) Apply a 3mm-4mm bead of the recommended liquid gasket (Three Bond 12078) or its equivalent to the rubber plugs and cylinder head upper faces. Refer to the illustration. Install the cylinder head cover within 7 minutes after application of liquid gasket. Cylinder Head Cover Gasket Install the gasket to the cylinder head cover. Cylinder Head Cover 41) Install the cylinder head cover. 2) Tighten the cylinder head cover nuts and bolts to the specified torque in the numerical order shown in the illustration. Cylinder Head Cover Nut and Bolt Torque Nem (kgemillo-t) 18 (1.813) Nozzle Cover + Connect the negative battery cable. + Lower the cab. + Start engine and check for oil leakage carefully.6A3—14 ENGINE INLET COVER / INLET CASE for 4HF1 Removal steps 1. Intake aie duct 2. Vacuum hose 3. Nozale cover 4, Leak off pipe 5, Fuel pine 6, PCV hose 7. Injection pipe 8 Engine harness 9, Oi! Installation steps To install, follow the removal steps in the reverse order. [++] REMOVAL Preparation + Disconnect battery ground cable, Tilt the cab. 4. Intake Air Duct 1) Remove the clips at the connections with the inlet cover and with the air cleaner. 2) Remove the intake air duct with the connector hose attached, x . Vacuum Hose 3. Nozzle CoverENGINE 6A3-15 4, Leak off Pipe 5. Fuel Pipe Fast fiter Do not apply excessive force to the fuel pipes. 6. Positive Crankcase Ver n (PCV) Hose Disconnect the PCV hose from inlet cover. 7. Fuel injection 1) Loosen the injection pipe sleeve nuts ©. 2), Do not apply excessive force to the injection pipes ©. 3) Loosen the injection pipes clips @. 4) Remove the injection pipe assembly. Plug the delivery valve holder @ ports and nozzle holder ® ports with caps to prevent the entry of foreign material.6A3—16 ENGINE ___Engine harness Groove Gasket 8 Engine Harness Disconnect thermometer unit, thermo switch, tachometer sensor and glow plug harness connectors and separate hamess from clips. 9. Oil Level Gauge Guide Tube Remove the guide tube fixing bolt and pull out the guide tube. 10. Inlet Cover 11. Inlet Case Remove the inlet case while removing the liquid gasket. ++] INSTALLATION 11. Inlet Case [S] 1) Apply 2 mm-3 mm bead of the recommended liquid gasket (Three Bond 1207C) or its equivalent on the groove of the inlet case fiting surfaces shown in the illustration + Clean the inlet case fiting surface of the cylinder head. 2) Install the inlet case to the cylinder head. + Install the inlet case within 7 minutes after application of liquid gasket. 3). Tighten the inlet case to the specified torque. Inlet Case Nuts and Bolts Torque Nem (kgemilbet) 19 (1.9714)ENGINE 6A3-17 [AX] 10. Inlet Cover 1) Attach hamess clips (D, © and @) and tighten the inlet cover bolts and nuts to the specified torque in the ‘numerical order shown in the illustration, 2). * marks are located on the nut positions. ® o ® Inlet Cover Bolt and Nut Torque Nem (kgemibft) Inet cover Mounting 43 (1.3/9) Bot Tubber . Oil Level Gauge Guide Tube 1) Install the O-rings to the guide tube lower portion and insert the guide tube completely to the cylinder body. 2) Tighten the guide tube bolt to the specified torque. Guide Tube Bolt Torque Nem (kgerbeft) 13 (4.3/9.4) . Engine Hamess Connect thermometer unit, thermo switch, tachometer sensor and glow plug hamess connector and fasten the engine hamess with clips, . Fuel Injection Pipe Assembly 1) Install the injection pipe assembly and temporarily tighten the injection pipe sleeve nuts, 2) Set the clips in the prescribed position showm in the ilustration, CAUTION: Make absolutely sure that the clip is correctly positioned. ‘An improperly positioned result in injection pipe breakage and fuel pulsing noise. Clip Screw Torque Nem (kgemitbsin) 3 (0.3728) 3) Tighten the injection pipe sleeve nuts to the specified torque. Injection Pipe Sleeve Nut Torque 1m (kgernibef) 29 (3/22)6A3—-18 ENGINE Fuel Injection Pipe Assembly (4HF1-2 model only) 1) Install the injection pipe assembly and temporarily tighten the injection pipe sleeve nuts. 2), Set the clips in the prescribed position shown in the illustration, CAUTION: Make absolutely sure that the cli positioned. ‘An improperly positioned clip will resutt in injection pipe breakage and fuel pulsing noise. Clip Screw Torque Nem (kgenbsin) 3 (0.3726) correctly 3) Tighten the injection pipe sleeve nuts to the specified torque. Injection Pipe Sleeve Nut Torque 7 (kgeribeft) 29 (3/22) . Positive Crankcase Ventilation (PCV) Hose . Fuel Pipe Do not apply excessive foros tothe fuel pipe Fuel Pipe Joint Bolt © Torque Nem (kgerbft 41 (4.2730) Fuel Pipe Joint Bolt @ Torque Nem (kgeribet 23 (2.3/7) Clip Screw Torque Nem (kgembsin) 4 (0.4135)ENGINE 6A3-19 4, Leak Off Pipe [EX] —_Leak-Off Pipe Joint Bolt Torque Nem (kgsmfbin) 13 (1.9113) 3. Nozzle Cover 2. Vacuum Hose 4. Intake Air Duct + Connect the negative battery cable. + Lower the cab. + Start engine and check for fue! leakage carefully6A3~ 20 ENGINE EXHAUST MANIFOLD Removal steps AC compressor {iF equipped with AIC) AUC compressor bracket {iF equipped with Arch Front exhaust pipe Heat protector Exhaust manifold Installation steps To install, follow the removal steps in the reverse order [++) REMOVAL Preparation + Disconnect battery ground cable + Titthe cab. 4. Air Conditioning (A/C) Compressor (if equipped with AIC) 1) Disconnect magnetic clutch harness connector. 2) Dismount the compressor together with the hoses from the AIC compressor bracket, and fasten it to the appropriate location with a wire.6 5 ENGINE 6A3-21 AIC Compressor Bracket (If equipped with A/C) Front Exhaust Pipe Heat Protector Exhaust Manifold Exhaust Gasket [++] INSTALLATION Exhaust Gasket Insert the gasket into the stud provided to the cylinder head (withthe projection of the gasket on this side). Exhaust Manifold 4) Install exhaust manifold gaskets @, exhaust manifold ©, distance pieces @, dish washers © and nuts ® to the stud bolts shown in the illustration. 2), Tighten the nuts to the specified torque in the numerical order shown in the illustration. Exhaust Manifold Nut Torque Nem(kgerntbef) 34(3.5/25) Heat Protector Heat Protector Bolt Torque 3 (kgeribeft) 101.07) . Front Exhaust Pipe Exhaust Manifold Side 3m (kgernbst) 67 (68/49) Exhaust Brake Side 1 (kgernbst) 17 (1.7/2)6A3~ 22 ENGINE 2 a Air Conditioning (A/C) Compressor Bracket (If ‘equipped with AIC) Tighten fixing bolts to the specified torque. AIC Compressor Bracket Bolt Torque 48 (4.9135) Nem (kgenibet) ANIC Compressor (If equipped with A/C) 1) Tighten fixing bolts to the specified torque. ‘AIC Compressor Bolt Torque Nem (kgenribft) 48 (49/35) Note ‘When tightening the compressor fixing bolts, tighten first the 2 bolts on the rear side, and then the remaining 2 on the front. 2) Install drive belt adjust belt tension by adjusting bolt and tighten locking nut to the specified torque. 3). Depress the drive belt mid-portion with @ 98N (10kg/22Ib) force. Drive Belt Deflection mm (in) 16 - 20 (0.63 - 0.79)... New belt 18-22 (0.71 -0.87) .. Reuse belt Locking Nut Torque Nem (kgemibeft) 27 (2.8/20) + Connect the negative battery cable. + Lower the cab. + Start engine and check for gas leakage carefully.ENGINE 6A3- 23 TIMING GEAR REPLACEMENT Romoval steps 1 Engine ascembiy 13, Clutoh pressure plate assembiy 28, Power steering pump idle gear 2. Nozzle cover 14, Orivan plate 15, Engine control wire 3. Cylinder hood cover 25, Power steering pump idle gear 36. Engine contro! lever assembly 26. Fiywneal housing 44 Hoad cover gasket 5. Rocker arm shaft assembly 21. Idle gear A 8. Valve cap) 28. Idle gear 8 7. Camshaft bearing cap 28. Idle gear B shaft 30. Flywheel (AT) 8 Camshaft bearing upper 3, Camshaft assembly. 10. Camsnakt bearing lower 11. Gylinder head assembiy 31. Flexible plate (AT 22. Spacer rubber NKR model only) 12, Gyinder head naskot 23. Ol'pan oa 7 Installation steps. Toingtal fellow the cemoval epsin the reverse order6A3~ 24 ENGINE Vv Vv REMOVAL Preparation + Disconnect battery ground cable. + Tiltthe cab. + Drain coolant and engine oll Engine Assembly ‘Above works refer to “ENGINE ASSEMBLY” section in this, manual. 2. Nozzle Cover 3. Cylinder Head Cover 4, Head Cover Gasket 5. Rocker Arm Shaft Assembly 1) Loosen the rocker arm shaft bracket nuts and bolts in numerical order a little at a time and remove the rocker arm sheft assembly with the camshaft brackets. 2) Leave the @ indicated bolt unremoved on this cccasion, since itis the rocker arm fixing bolt CAUTION: Failure to loosen the rocker arm shaft bracket nuts and bolts in numerical order a little at a time will adversely affect the rocker arm shaft. 6. Valve Cap CAUTION Take sufficient care not to let valve caps fall into the gear case or oil retum hole. 7. Camshaft Bearing Cap 8. Camshaft Bearing Upper 9. Camshaft Assembly 40. Camshaft Bearing Lower If the camshaft bearings are to be reinstalled, merk their fitfing positions by tagging each bearing with the cylinder umber fram which it was removed. 11. Cylinder Head Assembly ‘Above works refer to “CYLINDER HEAD’ section in this manual.ENGINE 6A3~ 25 Knock pin 12. Cylinder Head Gasket 43. Clutch Pressure Plate Assembly 1) Insert the clutch plot aligner to the clutch assembly. Clutch Pilot Aligner: 5-8840-2240-0 2) Loosen the pressure plate bolts in numerical order a litle ata time as shown in the illustration. 3) Remove the pressure plate assembly. 14. Driven Plate Remove the driven plate with the clutch pilot aligner. © Clutch pilot aligner ® Clutch pressure plate assembly ® Driven plate 46. Engine Control Wire 46. Engine Control Lever Assembly 47. Oil Pipe 18. Injection Pump Assembly 41) Remove the injection pump bracket bolts and the injection pump rear bracket bolts 2) Then remove the injection pump assembly.6A3~ 26 ENGINE 19. Flywheel Assembly 11) Use the crankshaft stopper to prevent the crankshaft from turing, Crankshaft Stopper: §-8840-2230-0 Loosen the flywhee! bolts in numerical order a litle at @ time as shown in the illustration. Remove the flywheel stopper and the flywheel assembly 2) 3) For the A/T vehicle, after loosening the flywheel fixing bolt, remove the washer, the flexible plate, the flywheel and the sleeve in this order. 20. Crankshaft Rear Oil Seal cauTior Be careful not to damage the crankshaft oil seal contact surface during the removal procedure. 21. Crankshaft Rear Slinger Use the slinger puller to pull out the slinger. Slinger Puller: 5-8840-2360-0 22. Spacer Rubber (NKR model only) (For the 4WD model vehicle, remove the stiffener before. removing the spacer rubber.) 23. Oil Pan(re) ENGINE 6A3- 27 24, Power Steering Pump Idle Gear Cover 25. Power Steering Pump Idle Gear 26. Flywheel Housing NOTE: Be careful not to fail to remove the bolts shown in the illustration. 27. Idle Gear A 28. Idle Gear B 29. Idle Gear B shaft INSPECTION Idle Gear Backlash Measurement 1) Set a dial indicator to the timing gear to be measured. Hold both the gear to be checked and the agjoining gear stationary. 2) Move the gear to be checked right and left as far as possible, Take the dial indicator reading ‘Timing Gear Backlash Gear to Gear mm (in) Standard Limit 0.10~0.17 (0.0038 ~ 0.0067) 0.30 (0.012)6A3~ 28 ENGINE | __ Idler Gear End Play Measurement Insert a feeler gauge between the idler gear and the thrust collar to measure the gap and determine the idler gear end, play, Ifthe measured value exceeds the specified limit, the thrust collar must be replaced. Idler Gear End Pay mm (in) Standard Limit 0.058 - 0. (0.002 - 0.2 (0.008) Idler Gear Shaft Outside Diameter Use a micrometer to measure the idler gear shaft outside diameter. Ifthe measured value is less than the specified limit, the idler gear must be replaced Idler Gear Shaft Outside Diameter mm (in) Standard Limit 29,959 - 29.980 (11795 41803) 29,80 (1.1732) [] _ ldler Gear inside Diameter Use an inside dial indicator or an inside micrometer to measure the idler gear inside diameter. Idler Gear Inside diameter mm (in) Standard Limit 30.000 - 30.021 30.100 (4.1811 - 4.1819) (7.1850) If the clearance between the idler gear shaft outside easel diameter and the idler gear inside diameter exceeds the limit, the idler gear must be replaced. Idler Gear Shaft and Idler Gear clearance mm (in) Standard Limit 0.020 - 0.062 0.200 (0.0008 - 0.0024) (0.0079) [++] INSTALLATION 29. Idler Gear B Shaft [Al] Idle Gear B Shaft Bolt Torque eX 31 (8.2723) m (kgernibt) [E]Aopty te engie ol othe ide oar set ater naalitonENGINE 6A3~-29 28. Idle Gear B ‘The face of the idle gear B with longer boss should be positioned toward the rear side shown in the illustration, Idle Gear B Bolt Torque Nem (kgemibft) 110 (11.2181) 27. Idle Gear A 1), Tum the crankshaft clockwise so that the engagement mark of the crankshaft gear faces to the shaft center of the idle gear A and the No.1 cylinder piston comes to the top dead center. 2) Align the crankshaft gear with the engagement mark of the idle gear and install the idle gear A. Idle Gear A Bolt Torque Nem (kgemibft) 133 (136/98) Alignment mark position for le gear amhatt gear wach gear Injection pump gear |) ©, (it pump dive rar Cronksate rar Power seeing <> 26. Flywheel Housing 4). Carefully wipe any foreign material from the cylinder body rear face. 2) Apply the recommended liquid gasket (Three Bond 1207C) of its equivalent to the shaded areas shown in the illustration,6A3~30 ENGINE 3) Align the cylinder body knock pins with the flywhee! housing knock pin holes. 4) Tighten the flywheel housing bolts to the specified torque shown in the illustration, af Qe Flywheel Housing Bolt Torque Nem (kgemnilb-ft) & - * 96 (9.8771) * 48 (4.9135) o 94 (9.6169) am . 25 (2.6/19) 4 76 (7.7166) a 48 (4.9135) + Tighten the bolts marked with" A" or" from the injection pump side, and those with " 4" from the cylinder body side. Flywheel Housing Bolt Torque 96 (98/71) Nem (kgurtbst 25. Power Steering Pump Idle Gear 1) Apply the engine oil to the idle gear shaft 2) Install the idle gear shaft ( with the idle gear @ to the cylinder body A portion as shown in the illustration. [Q} Idle Gear Shaft Bolt Torque mn (kgeriibst) 135 (13.6/98) 24, Power steering Pump Idle Gear Cover Install the gear cover with the O-ring. Gear Cover Bolt Torque Nem (kgerbet) 19.(4.9/14)ENGINE 63-31 23. Oil Pan 22. Spacer Rubber (NKR model only) ‘Above works refer to “OIL PAN’ section in this manual 24. Crankshaft Rear Slinger 20. Crankshaft Rear Oil Seal 49. Flywheel Assembly Above works refer to "CRANKSHAFT REAR Ol. SEAL” section in this manual 48. Injection Pump Assembly ‘Above works refer to INJECTION PUMP ASSEMBLY” section in this manual, __ 17. Oil Pipe [QJ Oi Pipe Joint Bott Torque Nem (kgernilbeft) 47 (4.72) 416. Engine Control Lever Assembly [EJ Engine Control Lever bolt Torque m (kgemnibft) 24 (2.4/7) 15. Engine Control Wire @] 14. Driven Plate Use the clutch pilot aligner to install the driven plate. Clutch Pilot Aligner: §-8840-2240-0 © Clutch pilot algner. © Clutch pressure plate assembly. © Driven plate6A3 ~ 32 ENGINE ‘rock iv 13. Clutch Pressure Plate Assembly 4) Align the clutch pressure plate with the flywheel knock pin 2) Tighten the pressure plate botts to the specified torque in numerical order. Clutch Pressure Plate Bott Torque Nem ¢kgemibet) 40 (4.1130) 12. Cylinder Head Gasket Above works refer to “CYLINDER HEAD GASKET’ section in this manual. 11. Cylinder Head Assembly Above works refer to “CYLINDER HEAD GASKET’ section in this manual. 10. Camshaft Bearing Lower 9, Camshaft Assembly 8. Camshaft Bearing Upper 7. Camshaft Bearing Cap 6. Valve Cap 5. Rocker Arm Shaft Assembly Above works refer to "CAMSHAFT ASSEMBL this manual. Head Cover Gasket Cylinder Head Cover ‘Above works refer to “CYLINDER HEAD COVER’ section in this manual. Nozzle Cover . Engine Assembly Above works refer to “ENGINE ASSEMBLY” section in this manual, section in ee ayVALVE GUIDE SEAL & VALVE SPRING ENGINE 6A3~-33 Removal steps 1. Nozzle cover 2 Leak off pipe 3 Injection pipe 4, Glow plug connactor 5. Glow plug 6. Injection noz2le holder assembly 7. Cylinder head caver 8. Cylinder head cover gasket 8, Rocker arm shaft assembly 10. Valve cap 11. Camshatt bearing cap 12. Camshatt bearing upper 13. Camshaft assembly 14. Camshaft bearing lower 18. Cotter collar 16. Spring upper seat 17. Valve Spring 18. Valve guide seal Installation steps follow the removal steps in ‘order6A3~ 34 ENGINE [++] REMOVAL Preparation + Disconnect battery ground cable. + Tiltthe cab. 4. Nozzle Cover 2. Leak Off Pipe 3. Injection Pipe + Loosen the injection pipe sleeve nuts ©. Do not apply excessive force to the injection pipes ©. + Loosen the injection pipes clips @ Remove the injection pipe assembly. Plug the delivery valve holder @ ports and nozzle holder @ ports with caps to prevent the entry of foreign material 4, Glow Plug Connector 5. Glow Plug 6. Injection Nozzle Holder Assembly Mark the nozzle hokier assemblies fiting positions by tagging each nozzle holder assembly with the cylinder ‘number from which it was removed. 7. Cylinder Head Cover 8 Cylinder Head Cover Gasket 9. Rocker Arm Shaft Assembly Above works refer to “ROCKER ARM SHAFT ASSEMBL section in this manual 10. Valve Cap 11. Camshaft Bearing Cap 12. Camshaft Bearing Upper 13. Camshaft Assembly 14, Camshaft Bearing Lower + Ifthe camshaft bearings are to be reinstalled, mark their fiting positions by tagging each bearing with the cylinder number from which it was removed.ENGINE 6A3~-35 15. Cotter Collar 16. Spring Upper Seat 17. Valve Spring + Apply compressed air to cylinder from the glow plug hole to hold the valve in place, + Using special tool, compress valve spring and remove cotter collar. Valve Spring Compressor: 5-8840-2228-0 48. Valve Guide Seal [++] INSTALLATION 48. Valve Guide Seal + Apply a coat of engine oil to the valve guide seal inner face. + Use a valve guide seal installer to install the valve Quide seal to the valve guide Valve Guide Seal Installer: 8-9439-6818-0 17. Valve Spring Install the valve spring with its fine pitched (or painted) end side down 16. Spring Upper Seat 18, Cotter Collar 41). Use the valve spring compressor to push the valve spring into position. Valve Spring Compressor. 6-8840-2228-0 2)_ Install the cotter collar to the valve stem. 3). Set the cotter collar by tapping around the head of the collar with a rubber hammer. 14, Camshaft Bearing Lower6A3~36 ENGINE 13. Camshaft Assembly 12. Camshaft Bearing Upper 11. Camshaft Bearing Cap 10. Valve Cap ‘Above works refer to “CAMSHAFT ASSEMBLY" section in this manual 9. Rocker Arm shaft Assembly Above works refer to “ROCKER ARM SHAFT ASSEMBLY" section in this manual 8. Head Cover Gasket 7. Cylinder Head Cover ‘Above works refer to “CYLINDER HEAD COVER’ section in this manual. 6. Injection Nozzle Holder Assembly ‘Tighten the nazzle holder flange nuts to the specified torque in the numerical order shown in the illustration. Nozzle Holder Flange Nut Torque Nem (kgemibet) 19 (1.9/4) 5. Glow Plug Glow Plug Torque 23 (2.3/7) |. Glow Plug Connector . Injection Pipe . Leak Off Pipe ‘Above works refer to “INJECTION PUMP ASSEMBLY” section in this manual, Nozzle Cover + Connect the negative battery cable + Lower the cab + Start engine and check for fuel leakage carefully.ENGINE 6A3- 37 ROCKER ARM SHAFT ASSEMBLY y S Removal steps. 1, Nozzle cover 2. Cylinder head cover 3. Gylinder head cover gasket 44, Rocker arm shaft assembly Installation steps To install follow the removal a steps in the reverse order. [++] REMOVAL Preparation + Disconnect battery ground cable. + Tithe cab. 1. Nozzle Cover 2. Cylinder Head Cover 3. Cylinder Head Cover Gasket Rocker Arm Shaft Assembly 1), Loosen the rocker arm shaft bracket nuts and bolts in numerical order a little at a time and remove the rocker, arm shaft assembly with the camshaft brackets 2) Leave the @ indicated bolt unremoved on this ‘occasion, since itis the rocker arm fixing bolt. CAUTION: Failure to loosen the rocker arm shaft bracket nuts and bolts in numerical order a little at a time will adversely affect the rocker arm shaft.6A3~ 38 ENGINE 4 [++] INSTALLATION Rocker Arm Shaft Assembly 4). Slightly loosen the bolts marked with the arrow in the illustration, Loosen the rocker arm adjust screws and apply engine oil to the rocker arn roller portions, 3) Install the rocker arm assembly on the cylinder head. 4) Tighten the rocker arm shaft breaker nuts and botts to the specified torque in numerical order a litle at a time as shown in the illustration. 2) Rocker Arm Shaft Bracket Nut and Bolt Torque Nem (kgernlbft) * Nut 27 (2.8120) = Bolt 56 (5.7141) O Bott 27 (2.8120) 5) Apply engine oll to the threaded portion of the nuts marked with "” and the bolts with “im shown in the illustration left, and then tighten them to the specified torque. Adjust the valve clearance. Valve Clearance Atcold mm (in) 0.4 (0.016) Mounting rubber tua Nut ay ott ree Gasket Head cover a2 © 02 & Above works refer to “SERVICING” VALVE CLEARANCE ADJUSTMENT" previously section in this manual. Head Cover Gasket Install the gasket to the cylinder head cover. . Cylinder Head Cover 41), Install the cylinder head cover. 2) Tighten the cylinder head cover nuts and bolts to the specified torque in the numerical order shown in the ilustration, Cylinder Head Cover Nut and Bolt Torque Nem (kguribet 18(1.8/13) |. Nozzle Cover + Connect the battery ground cable. + Lower the cab. + Start the engine and check for the oil leakage carefully.ENGINE 6A3~-39 CAMSHAFT ASSEMBLY Removal steps 1. Nozzle cover 2. Cylinder head cover 3. Cylinder head cover gasket 4, Rocker arm shaft assembly 5. Valve cap Camshaft bearing cap . Camshaft bearing upper 8. Camshaft assembly 8. Camshatt bearing lower Installation steps To install, follow the removal steps in the reverse order. REMOVAL Preparation * Disconnect battery ground cable. + Titthe cab. 4. Nozzle Cover 2. Cylinder Head Cover 3. Cylinder Head Cover Gasket6A3- 40 ENGINE 4, Rocker Arm Shaft Assembly Above works refer to “ROCKER ARM SHAFT ASSEMBLY" section in this manual Valve Cap Camshaft Bearing Cap Camshaft Bearing Upper Camshaft Assembly Camshaft Bearing Lower + Ifthe camshaft bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. PEN ee [-*] INSTALLATION . Camshaft Bearing Lower . Camshaft Assembly 41) Tum the crankshaft in the direction of normal rotation Until the timing mark on the crankshaft damper pulley is aligned with the TDC notched line. 2) Apply engine cil to the camshaft journal and the camshatt bearing surfaces before installation 3). Carefully align the camshaft gear ‘l” mark and the cylinder head upper face shown in the illustration. . Camshaft Bearing Upper . Camshaft Bearing Cap + Install the bearing caps with the bearing cap head mark (arrow) facing forward + Apply 2 coat of engine oil to the bearing cap bolt and stud threads, ‘+ Tighten the bearing cap bolts and studs to the specified torque. Camshaft Bearing Cap Nut and Bolt Torque Nem (kgsmilbft) 27 (2.8720)ENGINE 6A3- 41 . Valve Cap 4. Apply engine oil to the inside of the valve caps and install them to the valve stem end, CAUTION: Take sufficient care not to let valve caps fall into the gear. Rocker Arm Shaft Assembly Above works refer to "ROCKER ARM SHAFT ASSEMBLY” section in this manual Cylinder Head Cover Gasket Cylinder Head Cover Above works refer to "CYLINDER HEAD COVER’ section in this manwal. |. Nozzle Cover + Connect the battery ground cable. + Lower the cab. + Start engine and check for oil leakage carefully.6A3~ 42 ENGINE CYLINDER HEAD (Engine right side) Removal steps 1. Front exhaust pipe 2. AIC compressor drive belt equipped with AIC) 3. AC compressor {if equipped with A/C) Installation steps To instal, follow the removal steps in the reverse order. [++) REMOVAL Preparation + Disconnect battery ground cable + Titthe cab. + Drain coolant 4. Front Exhaust Pipe 2. Air Conditioning (A/C) Compressor Drive Belt (If equipped with A/C) 3. AIC Compressor (If equipped with A/C) 4) Disconnect magnetic clutch hamess connector. 2) Dismount the compressor together with the hoses from the AIC compressor bracket, and fasten it with @ wire to the appropriate locationENGINE 6A3~ 43 (Engine left side) Removal steps 1. Intake air duct 2. Vacuum hose 3. Nozzle cover 4 Leak off pipe 5. Fuel pipe 6. Fuel filter and bracket 7, Water bypass hose 8, PVC hose 8, Injection pipe 10. Engine harness 11, Oil level guide tube Installation steps. To instal, follow the removal steps in the reverse order.6A3~44 ENGINE Fuel fiter [++] REMOVAL 4. Intake Air Duct 1) Remove the clips at the connections with the inlet cover and with the air cleaner. 2) Remove the intake air duct with the connecting hoses attached, 2. Vacuum Hose 3. Nozzle Cover 4, Leak Off Pipe 5. Fuel Pipe 6. Fuel filter & Bracket 7. Water Bypass Hose 8, Positive Crankcase Ventilation (PCV) Hose 9, Injection Pipe 1) Loosen the injection pipe sleeve nuts © Do not apply excessive force to the injection pipes ©. 2) Loosen the injection pipes clips @ 3) Remove the injection pipe assembly. Plug the delivery valve holder @ ports and nozzle holder @ ports with caps to prevent the entry of foreign material 10. Engine Hamess Disconnect thermometer unit, thermo switch, tachometer sensor and glow plug hamess connectors an separate harness from clips.ENGINE 63-45 11. Oil Level Gauge Guide Tube Remove the guide tube fixing bolt and pull out the guide tube. Removal steps 4, Radiator upper hose 2 Coolant reserve tank hose(Bypass hose Cylinder head Gyiinder Glow piu Injection nozzle holder assembly Rocker arm shaft assembly Valve cap. Camshaft bearing cap Camshaft bearing upper Camshaft assembly Camshatt bearing lower Cylinder head assembly Cylinder head gasket Installation steps To install, follow the removal steps in the reverse order. [++] REMOVAL Radiator Upper Hose Coolant Reserve Tank Hose/Bypass Hose Cylinder Head Cover Cylinder Head Cover Gasket Peps6A3~ 46 ENGINE 5. Glow Plug Connector 6. Injection Nozzle Holder Assembly Mark the nozzle holder assemblies fiting positions by tagging each nazzle holder assembly with the cylinder ‘number from which it was removed. 7. Rocker Arm Shaft Assembly 8 Valve Cap 9. Camshaft Bearing Cap 10. Camshaft Bearing Upper 11. Camshaft Assembly 12. Camshaft Bearing Lower Above works refer to "ROCKER ARM SHAFT ASSEMBLY AND CAMSHAFT ASSEMBLY’ section in this manual, 43, Cylinder Head Assembly Loosen the cylinder head bolts in numerical order a little at atime, caution: Failure to loosen the cylinder head bolts in numerical order alittle ata time will adversely affect the cylinder head lower surface. 14. Cylinder Head Gasket YW caution: Do not reuse the cylinder head gasket. [++ INSTALLATION 14, Cylinder Head Gasket 41) When any of the cylinder block, crankshaft, crankshaft bearing, connecting rod, connecting rod bearing, and piston is replaced with @ new one, cylinder head gasket thickness ahold be determined newly. 2), When replacing the oylinder head gasket alone without replacing any of the parts mentioned in 1) above, the gasket to be used should be the same grade as the one used before. 3) Correct cylinder head gasket thickness is important Installing the wrong thickness gasket can result in greatly reduced engine performance. 4) There are three cylinder head gaskets available.ENGINE 6A3- 47 Point Gt Fi [| Piston Head Projection Measurement + Select a cylinder head gasket. + Clean thoroughly the top faces of the piston head and the cylinder body. + Use the dial gauge to measure the piston head projection. Take measurements at two location for each cylinder. + The measurement points of the piston head and the reference point ofthe cylinder body are shown in the ilustration lef. Measurement points : Points G1 and G2 of the piston head Reference point: Point R on the top face of the cylinder body NOTE: Note that there are three types of a cylinder head gasket available as below, according to the piston Projection. + For each cylinder, calculate the average value (Ti) of the piston projection. + Find the maximum value (Timax) of the average of each cylinder. + Based on the Timax obtained, select a gasket of the appropriate grade. 4HFAI4HF1-2/4HG1-T Cylinder Head Gasket Selection mm (in) Gasket Grade Timax cots Ao | eaze-aczs)| 170100560 8 or — | ctas9-o02e| 17500058) 0.739-0.819 (0.0291 - 0.0322) | 1-80 (0.0708) HEA -T/MHE1-TC Cylinder Head Gasket Selection mm fin) Gasket Grade Timax See so [GES | 00m 8 or — | eltzao-o026n | 178100889) CO | ee oee) | 180.(0.0708) (0.0267 - 0.0300)6A3~ 48 ENGINE Vv 5) Apply a 3mm (0.1 inch) bead or recommended liquid gasket (Three Bond 1207C) or its equivalent to the Shaded areas shown in the illustration 6) Install the cylinder head gasket with its “PART NUMBER’ mark facing up and toward the left of the engine. CAUTION: Do not reuse the cylinder head gasket. 13. Cylinder Head Assembly 4) Align the cylinder body dowels and the cylinder head dowel holes. 2) Carefully place the cylinder head on the cylinder head gasket. 3) Apply @ coat of molybdenum disulfide grease to the M14 cylinder head bolt threads and setting faces and apply a coat of engine oil to the M10 cylinder head bolt threads and setting faces. 4) Use the angular tightening method to tighten the bolts (M114) to the specified torque in three steps following the numerical order shown in the illustration, Cylinder Head Bolt Torque (M14) (O~ @) Nem (kgemibet) Ast Step 2nd Step 3rd Step 98 (10/72) 147 (15/108) 30° - 60° 5) Tighten the cylinder head to the flywheel housing bolts (N10) to the specified torque, Cylinder Head Bolt Torque (M10) (19 ~ 20) m (kgemiibf) 38 (3.9728)ENGINE 6A3- 49 12. Camshaft Bearing Lower 11. Camshaft Assembly 10. Camshaft Bearing Upper 9. Camshaft Bearing Cap 8. Valve Cap Above works refer to “CAMSHAFT ASSEMBLY" section in this manual 7. Rocker Arm Shaft Assembly Above works refer to "ROCKER ARM SHAFT ASSEMBLY’ section in this manual . Injection Nozzle Holder Assembly Tighten the nozzle holder flange nuts tothe specified torque in the numerical order shown in the ilustration Nozzle Holder Flange Nut Torque Nem (kgemibeft) 19 (1.9714) . Glow Plug Connector . Head Cover Gasket Install the gasket to the cylinder head cover. Ew 3, Cylinder Head Cover Above works refer to "CYLINDER HEAD COVER’ section in this manual. 2. Coolant Reserve Tank Hose/Bypass Hose . Radiator Upper Hose i++ INSTALLATION (Engine left side) 11. Oil Level Gauge Guide Tube 1) Install the O-rings to the guide tube lower portion and insert the guide tube completely to the cylinder bady. 2) Tighten the guide tube bolt to the specified torque. Guide Tube Bolt Torque Nem (kgerfbsin) 13 (1.9/113) 40. Engine Hamess Connect thermometer unit, thermo switch, tachometer sensor and glow plug hamess connector and fasten the engine hamess with clips,6A3~ 50 ENGINE 9. Fuel injection Pipe Assembly ‘Above works refer to “INJECTION PUMP ASSEMBLY" section in this manual, 8. Positive Crankcase Ventilation (PCV) Hose 7. Water Bypass Hose 6. Fuel Filter & Bracket Fuel Filter Bracket Torque Nem (kgemibft 34 (8.525) 5. Fuel Pipe Do net apply excessive force tothe fuel pipe. Fuel Pipe Joint Bolt © Torque Nem (kgeroft 41 (4.2780) Fuel Pipe Joint Bolt @ Torque Nem (kgemioe) 23 (2.3/7) Clip Screw Torque Nem (kgemibsin) 4 (0.4/35) 4. Leak Off Pipe Leak-off Pipe Joint Bolt Torque 13 (1.9113) 1m (Kgemiibsin) 3. Nozzle Cover 2. Vacuum Hose 4. Intake Air DuctENGINE 63-51 | 2 3] INSTALLATION (Engine right side) 3. Ai Conditioning (A/C) Compressor (If equipped with AIC) Tighten fixing bolts to the specified torque. AIC Compressor Bolt Torque 48 (4.9135) m (kgemllbft) Note: ‘When tightening the compressor fixing bolts, tighten first the 2 bolts on the rear side, and then the remaining 2 on the front side. 2. AIC Compressor Drive Belt (If equipped with A/C) 1). Install drive belt adjust belt tension by adjusting bolt and tighten locking nut to the specified torque. 2) Depress the drive belt mid-portion with a 10kg (221b/98N) force. Drive Belt Deflection mm (in) 16-20 (0.63 - 0.79)...New belt 18-22 (0.71 - 0.87)... Reuse belt Locking Nut Torque Nem (kgemiibeft) 27 (2.8720) 4. Front Exhaust Pipe Exhaust Manifold Side Torque Nem (kgemilbeft) 67 (6.68/49) Exhaust Brake Side Nem (kgemibft) 47 (1.712) + Connect the negative battery cable. + Lower the cab. + Start engine and check for cil, fuel and water leakage care fully.6A3 ~ 52 ENGINE CIRCUMFERENCE PARTS OF CYLINDER HEAD 4HEITC Removal steps 4. Inlet cover/iniet case 2. AC compressor bracket (if equipped with AC) 3, Heat protector 4 Exhaust manifola 5. Exhaust gasket 6. Water outlet pipe 7. Thermostat 8 Idle gear C cover 9. Idle gear C 16. Glow plug 11. Fuel fitor bracket 12. Engine hanger 13. Turbacharger Installation steps To install, follow the removal steps in the coverse order. [+=] REMOVAL Preparation Disconnect battery ground cable Tilt the cab Drain coolant Remove each part from the cylinder head assembly. For details, refer to the “CYLINDER HEAD" in this section.ENGINE 6A3- 53 Cylinderhead \ Screwdriver Loft cear side Inlet Cover/inlet Case ‘Air Conditioning (A/C) Compressor Bracket (if equipped with AIC) Heat Protector Exhaust Manifold Exhaust Gasket Water Outlet Pipe Thermostat Ne gee 8 Idle Gear C Cover Tap the outside of the sealing cup with a screwdriver to deform one end of it and draw it out with pliers. 9. Idle Gear C 10. Glow Plug 11. Fuel Filter Bracket 412. Engine Hanger [++ INSTALLATION 12. Engine Hanger 14. Fuel Filter Bracket A] Fuel Filter Bracket Bolt Torque 1 (kgemitbeft) 404 (106/77) 10. Glow Plug Glow Plug Torque 1m (kgerntbeft) 23 (2.3/7)6A3 ~ 54 ENGINE ‘casket ‘Top face of 7 Gaet 9. Idle Gear C 1) Apply engine oil to the idle gear shaft, bushing and idle gear before installation 2), Install the idle gear with the boss side facing to the camshaft as shown in the illustration. Idle Gear C Bolt Torque 95 (9.7/70) Nem (kgebeft) 8. Idle Gear C Cover 41) Apply the recommended liquid gasket (LOCTITE 262) Or its equivalent to the outside ofthe sealing cup and instal it to the cylinder head. 2) Use the sealing cup installer and a hammer to drive the sealing Cup into position from the cylinder head side as shown in the illustration, Sealing Cup Installer: 5-8840-2222-0 7. Thermostat Install the gaskets to the thermostat and install them to the cylinder head as shown in the illustration. 6. Water Outlet Pipe Water Outiet Pipe Bolt Torque 24 (2.4/17) m (kgemnilbft) 5. Exhaust Gasket Insert the gasket into the stud provided to the cylinder head (with the projection of the gasket on this side).ENGINE 63-55 a) 4, Exhaust Manifold 1. Install exhaust manifold gaskets @, exhaust manifold @, distance pieces ©, dish washers © and nuts © to the stud bolts shown inthe illustration. 2. Tighten the nuts to the specified torque in the numerical order shown in the illustration. Exhaust Manifold Nut Torque Nem (kgemilbet) 34 (3.5/25) 3. Heat Protector Heat Protector Bolt Torque Nem (kgemibin) 10 (1.0087) 2. Air Conditioning (A/C) Compressor Bracket {lf equipped with AIC) Tighten fixing bolts to the specified torque. ‘NIC Compressor Bracket Bolt Torque 48 (4.9735)6A3~ 56 ENGINE I eon Tubber L |. Inlet Cover/inlet Case 4). Apply 2mm-3mm (0.16-0.20 in) bead of the recommended liquid gasket (Three Bond 1207C)or its equivalent on the groove of the inlet case fiting surfaces shown in the illustration. + Clean the inlet case fitting surface of the cylinder head, 2) Install the inlet case to the cylinder head. + Install the inlet case within 7 minutes after application of liquid gasket. + Attach hamess clips (D, © and ®) and tighten the inlet cover bolts and nuts to the specified torque in the ‘numerical order shown inthe illustration + * marks are located on nut positions. Inlet Cover Bolt and Nut Torque Nem (kgsmibft) 13 (1.3/9) Referring to “CYLINDER HEAD" in this section, install the remaining parts.ENGINE 6A3- 57 OIL FILTER ASSEMBLY Removal steps 1. Oil pipe 2. Oil pressure switch 3, Oil fiker 7 4. O-ring Installation steps To install, follow the removal teps in the reverse arder, [++] REMOVAL Preparation + Disconnect battery ground cable. + Place a receptacle beneath the oil filter to contain the drained oll 2. Oil Pressure Switch 3. Oil Filter Body 4. O-ting Ue INSPECTION iter Cover 1. Check the partial fiter orifice for any clogging, 2. Send air into the arrow-marked hole in the illustration, and check to see ifthe air blows out from the small holes in the center sleeve. [++] INSTALLATION 4, O-Ring Apply a coat of engine oil to the O-rings and install them to the cylinder body.6A3~ 58 ENGINE . Oil Filter Body Oil Filter Cover Bolt Torque 48 (4.9135) (kgemitbstt) . Oil Pressure Switch 41) Apply the recommended liquid gasket (LOCTITE 262) or its equivalent to at least 2-3 ofthe oil pressure switch threaded areas, 2) Install the oil pressure switch to the oil fiter cover. Gil Pressure Switch Torque Nem (kgemifbsin) 13(1.3/113) |. Oil Pipe Oil Pipe Joint Bott Torque 47 (4.712) (kgemitbett) + Connect battery ground cable. + Start engine and check for oil leakage carefully.ENGINE 6A3~-59 OIL FILTER CARTRIDGE Removal steps 1, Oil filter cartridge Installation steps To install, follow the removal steps in the reverse order. [++] REMOVAL Preparation + Disconnect battery ground cable, + Place a receptacle beneath the oil fiter to contain the drained oll. 4. Oil Filter Cartridge @] Use an oil filter wrench to remove the oil fier cartridge. Oil Filter Wrench: 1-8522-1097-0 5-8840-2084-0 (4WD model) [++ INSTALLATION 4. Oil Filter Cartridge FA) 1) Clean the oit iter fiting face. 2) Apply a light coat of engine oil to the O-ring, 3) Tum in the new oil fiter until the fier O-ring is fitted against the sealing face. [@] 4) Use an oil fiter wrench to install the new il filter cartridge, Oil Filter Wrench: 1-8522-1097-0 '5-8840-2094-0 (4WD model) Nem (kgemibft) 64 (6.5/47)6A3~ 60 ENGINE OIL COOLERENGINE 6A3-61 7 2 < eels6A3 ~ 62 ENGINE [++] REMOVAL Preparation + Disconnect the battery ground cable + Drain coolant 4. Vacuum Hose 2. Oil Level Guide Tube Remove the guide tube fixing bolt and pull out the guide tube. 3. Intake Air Duct 4, Engine Stop Cable Loosen the locking nut at the bracket and disconnect engine stop cable from injection pump stop lever. 5. Accelerator Control Cable Loosen the locking nut at the bracket and disconnect accelerator control cable from injection pump control lever. 6. Engine Control Cable 7. Engine Control Lever 8. Oil Pipe 9. Fuel Retum Hose 10. Fuel Feed Hose Disconnect fuel hose from injection pump side and take care not to spill and enter dust. 411. Nozzle CoverENGINE 6A3- 63 For 4HEL-TC auei2 12. Leak Off Pipe 13. Fuel Pipe 14, Positive Crankcase Ventilation (PCV) Hose 15. Water Bypass Hose 16. Injection Pipe 17. Injection Pump Assembly Above works refer to “INJECTION PUMP ASSEMBLY” section in this manual 48. Injection Pump Rubber Spacer (for 4HF1/4HG1T/MHE1-T) 19. Air Conditioning (A/C) Drive Belt (If equipped with A/C) 20. Idle Pulley Bracket (if equipped with A/C) After removal of the A/C drive belt, remove the 3 bracket fixing bolts. Then, remove the bracket with the tensioner and the idler attached 21. Heater Hose 22. Radiator Lower Hose 23. Heater Pipe 24, Water Suction Pipe 25. Oil Cooler Assembly 4) Remove the cil cooler bolts. 2) Install a oil cooler fixing bolt to the oil cooler replace hole as shown in the illustration, and tighten the bolt alternately alte at atime. 26. O-Ring6A3~64 ENGINE NS [| DISASSEMBLY ( 4. Element fixing bolts 2. Element 3. O-Ring il Cooler Assembly) [x+| REASSEMBLY 3. O-Ring Apply a coat of engine oil to the O-rings and install the O- rings the oil cooler. . Element . Element fixing bolts Nem (kgemilbet) 20 (2.0714) ean eee ea Ones [++] INSTALLATION 26. O-Ring 25. Oil Cooler Assembly 2 1) Apply 2mm-3mm (0.08-0.1 in) bead of the recommended liquid gasket (Three Bond 1207C) or its equivalent on the oil cooler fitting surface. 2) Apply a coat of engine oil to the O-rings (2 pieces) and install the O-rings to the oil cooler. NOTE: ‘Take care that the O-ring is not smeared with liquid gasket. Install the oil cooler within 7 minutes after application of liquid gasket. For the dislocation of liquid gasket, refer to the _ illustration [EX] 3) Tighten the oil cooler bolts and nut to the specified torque a litle at a time in the sequence shown in the ilustration. Oil Cooler Bott and Nut Torque m (kgemilbt) Liguia gasker 24 (2.4/17) 24, Water Suction Pipe [2] 1) Apply 2mm-3mm bead of the recommended liquid gasket (Three Bond 1207C) or its equivalent on the groove of the water suction pipe fitting surface. 2) Install the water suction pipe to the oil cooler. + For the dislocation of liquid gasket, refer to the. Liquid aisker illustration.ENGINE 63-65 ‘Water Suction Pipe Bolt Torque Nem (kgemilbft) 24 (24/17) NOTE: Install the water suction pipe immediately after the installation of the oil cooler. 23. Heater Pipe 1) Install the O-ring to the heater pipe. 2) Install the heater pine to the oil cooler. Heater Pipe Bolt Torque Nem (kgemilbet) 24 (2.4117) 22. Radiator Lower Hose 21. Heater Hose 20. Idle Pulley Bracket (If equipped with A/C) lle Pulley Bracket Bolt Torque Nem (kgemibeft) 48 (4.9/5)6A3~ 66 ENGINE 49. Air Conditioning (A/C) Drive Belt (If equipped with A/C) *+ Install drive belt adjust belt tension by adjusting bolt and tighten locking nut to the specified torque. + Depress the drive belt mi-portion with a 10kg (221b/98N) force. Drive Bolt Deflection mm (in) 46 - 20 (0.63 -0.79) .... New belt 18-22 (0.71 -0.87) .... Reuse belt Locking Nut Torque Nem (koro) 27 (2.8720) 18. Injection Pump Rubber Spacer (4HF1/4HG1T/4HE1-T) 17. Injection Pump Assembly 16. Injection Pipe 18. Water Bypass Hose 14, Positive Crankcase Ventilation (PCV) Hose 43. Fuel Pipe 12. Leak Off Pipe 11. Nozzle Cover 10. Fuel Feed Hose 9, Fuel Retum Hose Air Bleeding ‘Above works refer to “INJECTION PUMP ASSEMBLY” section in this manual 8, Oil Pipe 7. Engine Control Lever Assembly Engine Control Lever Bott Torque Nem ¢kgemilbet) 24 (2.4/17) 6. Engine Control CableENGINE 6A3- 67 5. Accelerator Control Cable 1) Check to see if the ialing control knob is turned to the ‘utmost limit to the left. 2), Install the end tip of the cable to the engine control lever. 3) With the outer cable pulled toward the front of the vehicle, provide the engine control wire and the inner cable with the appropriate play. Then, fasten the clamp with a nut, 4) Check to see if the control lever of the injection pump is set at the idling position (with the lever attached to the stopper bot 4, Engine Stop Cable 4) Install the end tip of the cable to the engine stop lever. 2) Pull the cable toward the rear of the vehicle, and fasten the clamp with @ nut at the position where the lever stops. 3. Intake Air Duct 2. Oil Level Gauge Guide Tube 1) Install the O-rings to the guide tube lower portion and insert the guide tube completely to the cylinder body. 2) Tighten the guide tube bolt to the specified torque. Guide Tube Bolt Torque Nem (kgemibin) 13(1.9/113)