engine.pdf

Isuzu Motors Limited

Service Marketing Department

WORKSHOP MANUAL2007MY N-SERIES

ENGINE4JJ1

SECTION 6

ENGINE MECHANICAL (4JJ1) 6A-1

ENGINEENGINE MECHANICAL

(4JJ1)TABLE OF CONTENTS

ISUZU DIESEL ENGINE (4JJ1) . . . . . . . . . . . . . . 6A-3Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6A-3Work procedure . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6A-7

Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A-14Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18

Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-20

Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 6A-21Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23

Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-27

Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28Service Precautions . . . . . . . . . . . . . . . . . . . . . 6A-28Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31Torque specifications . . . . . . . . . . . . . . . . . . . . 6A-33

Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . 6A-34Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-37

Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 6A-38Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-45

Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-46Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-48Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-50

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-53Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54

Valve Stem Seal and Valve Spring . . . . . . . . . . . 6A-55Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-55Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-56Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-58

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-59Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-59Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59Head Disassembly . . . . . . . . . . . . . . . . . . . . . . 6A-64Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66Head Reassembly . . . . . . . . . . . . . . . . . . . . . . 6A-70Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-72Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-80Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-80

Piston and Connecting Rod . . . . . . . . . . . . . . . . 6A-82Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-82Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-83Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-87Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-90Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-90

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-91Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-95Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-95

Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . 6A-96Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-96Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-97Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-98

Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . 6A-99Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-99Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-100Torque Specifications . . . . . . . . . . . . . . . . . . .6A-102Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . .6A-102

Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . .6A-103Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-103Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-103Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-104

6A-2 ENGINE MECHANICAL (4JJ1)

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . .6A-104Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-105

Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-105Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-105Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .6A-106Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .6A-106Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-107Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-112Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-114

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-118

Lubrication System . . . . . . . . . . . . . . . . . . . . . . 6A-119Service Precautions . . . . . . . . . . . . . . . . . . . . 6A-119Functional Check . . . . . . . . . . . . . . . . . . . . . .6A-120

Oil Filter Element. . . . . . . . . . . . . . . . . . . . . . . .6A-121Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-121Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-121Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-121Torque Specifications . . . . . . . . . . . . . . . . . . .6A-122

Oil Filter Assembly and Oil Cooler . . . . . . . . . .6A-123Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-123Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-123Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .6A-124Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .6A-124Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-124

Crank Case and Oil Pan . . . . . . . . . . . . . . . . . .6A-126Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-126Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-126Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .6A-128Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .6A-128Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-128Torque Specifications . . . . . . . . . . . . . . . . . . .6A-130

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-131Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-131Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-131Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .6A-133Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .6A-133Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-133Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-135

Oil Pressure SW . . . . . . . . . . . . . . . . . . . . . . . .6A-137Components. . . . . . . . . . . . . . . . . . . . . . . . . .6A-137Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-137Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-137Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-138Circuit check. . . . . . . . . . . . . . . . . . . . . . . . . .6A-138

Air Cleaner Element . . . . . . . . . . . . . . . . . . . . .6A-139Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-139Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-139Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-139


ISUZU DIESEL ENGINE (4JJ1)Service Precautions

Matters that require attention in terms ofmaintenanceTo prevent damage to the engine and ensure reliabilityof its performance, pay attention to the following inmaintaining the engine:

• When lifting up or supporting the engine, do notapply a jack on the oil pan. When taking down the engine on the ground, donot make the bearing surface of the oil pan touchthe ground directly. Use a wooden frame, forexample, to support the engine with the enginefoot and the flywheel housing.Because there is only a small clearance betweenthe oil pan and the oil pump strainer, it can damagethe oil pan and the oil strainer.

• When the air duct or air cleaner is removed, coverthe air intake opening to prevent foreign matterfrom getting into the cylinder. If it getscontaminated, it can considerably damage thecylinder and others while the engine is operating.

• When maintaining the engine, never fail to removethe battery earth cable. If not, it may damage thewire harness or electrical parts. If you needelectricity on for the purpose of inspection, forinstance, watch out for short circuits and others.

• Apply engine oil to the sliding contact surfaces ofthe engine before reassembling it. This ensuresadequate lubrication when the engine is firststarted.

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

• When installing them, put them back in the samelocation they were removed from.

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

• As for parts where a liquid gasket is used, removean old liquid gasket completely and clean it upthoroughly so that no oil, water or dust is clingingto them. Then, apply the designated liquid gasketto each place anew before assembly.

• Surfaces covered with liquid gasket must beassembled within 5 minutes of gasket application.If more than 5 minutes has elapsed, remove theexisting liquid gasket and apply a new liquidgasket.

• When assembling or installing parts, fasten themwith the prescribed tightening torque so that theyare installed properly.

Matters that require attention in specifically dealingwith this engine.Holes or clearances in the fuel system, which serve asa passage of fuel, including the inside of the injector,are made with extreme precision. For this reason, theyare highly sensitive to foreign matter and if it gets in, itcan lead to an accident on the road, for instance; thus,make sure that foreign matter is prevented from gettingin.When servicing the fuel system, every precaution mustbe taken to prevent the entry of foreign material into thesystem.

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

• Perform the service procedures with clean hands.Do not wear work gloves.

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

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

Work procedure• The fuel opening must be quickly sealed when

removing the fuel pipe, injection pipe, fuel injector,fuel supply pump, and fuel rail.

• The eyebolts and gasket must be stored in a cleanparts box with a lid to prevent adhesion of foreignmatter.

• Fuel leakage could cause fires. Therefore, afterfinishing the work, wipe off the fuel that has leakedout and make sure there is no fuel leakage afterstarting the engine.


How to read the model

Legend1. Engine Model (Stamped)2. Engine Number (Stamped)

3. Front

Explanation of functions and operations

Electronic engine controlWith the control unit, the range from injection to airintake/exhaust, including fuel injection quantity,injection timing, intake air restriction, EGR, and idlingrpm, is controlled.

PistonThe piston is aluminum-alloy and a thermal flow pistonwith a strut cast, while the combustion chamber is around reentrant type.

Cylinder headThe cylinder head is aluminum-alloy and there are 4valves per cylinder. The angular tightening method ofthe cylinder head bolt further increases reliability anddurability.

EGR systemBased upon data, including water temperature, enginespeeds or engine loads, it is controlled via EngineControl Module (ECM) to purify exhaust by recyclingpart of it. Its main components include an EGR valve, an EGRcooler and various sensors.

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

Fuel rail-type electronic control injection systemThe fuel rail-type electronic control injection system iscomposed of a fuel supply pump that sets the targetpressure of high-pressure fuel and supply it, a fuel railthat measures such high-pressure fuel and a fuelinjector that turns it into a fine spray and injects it. Eachis controlled via ECM based upon various signals,while injection timing or fuel injection quantity iscontrolled under every possible driving condition.

LNW71BMF000101

3

1

2


Fuel injectorThe fuel injector is a 6-hole nozzle that adjusts fuelinjection quantity or injection timing by opening orclosing an electromagnetic valve on the head of thefuel injector.ECM corrects the dispersion of fuel injection quantitybetween fuel injector according to ID code data inmemory. At the replacement of fuel injector, ID codedata should be stored in ECM.

Fuel filter with sedimenterIt is a fuel filter with sedimenter that gets rid of water bymaking use of the difference in specific gravity betweenlight oil and water, which comes with an indicator thatnotifies you that it is filled with water.

Preheating systemThe preheating system consists of the ECM, the glowrelay, glow plugs and the glow indicator lamp. Thepreheating system is operated when the engine coolanttemperature is low, and makes the engine easy to start.

Lubrication systemIt is an oil filter with full-flow bypass, which uses awater-cool oil cooler and oil jet to cool the piston.

Functional inspectionInspection/adjustment of valve clearance

1. Inspection of valve clearance• Remove the injection nozzle harness assembly.• Remove the leak off hose.• Remove the cylinder head cover.• Rotate the crankshaft and make the No.1

cylinder compression top dead center (TDC).• Check TDC using a mirror etc.

Legend1. Crankshaft Damper Pulley2. Mirror3. TDC Mark

• Insert a 0.15 mm (0.006 in) thickness gaugebetween the roller of the rocker arm and thecamshaft to tighten up the adjusting screw ofthe rocker arm. When the movement of thethickness gauge becomes tight, fasten theadjusting screw nut of the rocker arm.

Valve clearance

NOTE:Adjust while cold.

2. Adjustment of valve clearance

mm (in)Intake valve 0.15 (0.006)Exhaust valve 0.15 (0.006)

LNW76ASH001101

1

2

3


• Loosen each adjusting screw of the rocker armcompletely.

Legend1. Screwdriver2. Ring Spanner3. Valve Clearance Adjust Nut Wrench

Special tool

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

• Insert a 0.15 mm (0.006 in) thickness gaugebetween the roller of the rocker arm and thecamshaft to tighten up the adjusting screw ofthe rocker arm. When the movement of thethickness gauge becomes tight, fasten theadjusting screw nut of the rocker arm.

Legend1. Camshaft Assembly (EX)2. Camshaft Assembly (IN)3. Intake Rocker Arm 4. Exhaust Rocker Arm

Tightening torque:

Rocker arm adjustment Screw nut

18 N⋅m (1.8 kg⋅m/ 13 lb ft)Adjustment table

• If the No.1 cylinder is the compression TDC,adjust a valve clearance with mark given onthe table and if the No. 4 cylinder is thecompression TDC, adjust that with × mark.

• Install the cylinder head cover.Refer to “Cylinder Head Cover”.

• Install the leak off hose.• Install the fuel injector harness assembly.

RTW56ASH003701

1

2

3

Cylinder No. 1 2 3 4

Valve arrangement IN EX IN EX IN EX IN EX

No. 1 cylinder

Compression TDC

No. 4 cylinder

Compression TDC

× × ×

LNW71BSH001201

4 3

1 2


Compression pressure inspection• Warm up the engine.• Remove a minus terminal of the battery.• Remove the all glow plugs.

NOTE:When the harness connector is removed, ECM judgesthat it broke down and DTC is recorded. Uponcompletion of measurement, never fail to clear thememory of the ECM.(For how to clear the memory of the ECM, refer to“ENGINE CONTROL SYSTEM” Section)

• Install the minus terminal of the battery.• Turn on the starter to emit foreign matter within the

cylinders.• Install an adapter and the gauge of the

compression gauge with the special tool.

Compression gauge: 5-8840-2675-0

Gauge adapter: 5-8840-2815-0

• Turn on the starter to inspect compressionpressure.

• Measure each cylinder one by one.

NOTE:To keep engine speed at 200 rpm or more, use fullycharged batteries.

• Remove the compression gauge with the specialtool.

• Remove the minus terminal of the batteries.• Install the glow plugs.• Install the minus terminal of the batteries.

A list of defective phenomena• Engine does not turn over.• Engine turns over but does not start.• Excessive black exhaust smoke.• Excessive white exhaust smoke.• Engine knocking.• Abnormal engine rotation.• Abnormal battery charging.• Turbocharger trouble shooting.

Trouble Shooting

Engine does not turn over

LNW76ASH001201

Condition Possible Cause CorrectionCondition Possible Cause CorrectionStarter motor does not rotate Dead or weak battery Charge battery

Replace batteryIncomplete circuit Connect

RepairStarter motor brushes stuck, worn,or broken

Replace brushes

Starter motor internal damage Repair motorStarter motor not meshed withflywheel

Ring gear abrasion Replace ring gearMagnetic switch (starter motor) notproperly adjusted

Adjust


Engine turns over but does not start

Excessive black exhaust smoke

Starter motor pinion meshed withring gear but does not rotate

Dead or weak battery Charge batteryReplace battery

Insufficient contact pressurebetween starter motor brushes andcommutator

Adjust pressure

Armature (starter motor) stuck Repair armatureEngine internal damage (Seizure) Repair engine

Condition Possible Cause CorrectionFuel is not delivered to fuel supplypump

Air in fuel system Bleed air from fuel systemAir entering fuel pipe Replace pipe and bleed air from

fuel systemEmpty fuel tank Replenish fuelClogged strainer (fuel suction) Clean or replace strainerClogged fuel pipe Clean or replace pipeFeed pump malfunction Replace pumpUse of wrong fuel for prevailingtemperatures

Drain existing fuel and replace withappropriate fuel

Clogged fuel filter Replace filterFuel is delivered to fuel supplypump

Loose injection pipe connections Tighten connectionsLoose or broken electricalconnectors

Tighten and/or replace connectors

Bad rotational sensor Replace sensorEngine control system malfunction System diagnosis

Insufficient or unstable fuel deliveryvolume

Air in fuel system Bleed air from fuel systemFeed pump malfunction Repair pumpLoose or broken electricalconnectors

Tighten and/or replace connectors

Clogged fuel filter Replace filterEngine control system malfunction System diagnosis

Condition Possible Cause CorrectionBad injection timing Engine control system malfunction System diagnosisBad fuel injector condition Carbon deposit at nozzle tip Clean fuel injector assembly

Sticking nozzle Replace fuel injector assemblyEngine control system malfunction System diagnosis

Condition Possible Cause Correction


Excessive white exhaust smoke

Insufficient compression pressure Excessive valve clearance Adjust clearanceSticking valve stem (valve open) Repair or replace valveDamaged valve spring Replace springValve seat abrasion Repair valve seatCompression leakage due todamaged piston ring

Replace piston ring

Damaged gasket Replace gasketPiston scoring Replace piston

Fuel condition Water in fuel Drain existing fuel and replace withnew fuel

Poor fuel quality Drain existing fuel and replace withnew fuel

Poor engine aspiration Clogged intake pipes Clean or replace pipesClogged air cleaner element Clean or replace element

Malfunction detected by enginecontrol system

Defective sensor Replace sensorEngine control system malfunction System diagnosis

EGR valve and/or intake throttlevalve malfunction

Intake throttle valve sticking Repair or replace valveEGR valve sticking Repair or replace valveExhaust brake valve sticking Repair or replace valveEngine control system malfunction System diagnosis

Turbocharger malfunction Damaged turbocharger blade Replace turbochargerRough turbocharger shaft rotation Replace turbochargerOil leakage from oil seal Replace turbochargerBroken actuator Replace turbochargerDefective booster sensor Replace sensor

Condition Possible Cause CorrectionBad injection timing Engine control system malfunction System diagnosisMalfunction detected by enginecontrol system

Defective sensor Replace sensorControl unit malfunction Replace unitEngine control system malfunction System diagnosis

Insufficient compression pressure Excessive valve clearance Adjust clearanceSticking valve stem (valve open) Repair or replace valveDamaged valve spring Replace springValve seat abrasion Repair valve seatCompression leakage due todamaged piston ring

Replace piston ring

Damaged gasket Replace gasketPiston scoring Replace piston

Fuel condition Water in fuel Drain existing fuel and replace withnew fuel



Engine knocking

Abnormal engine rotation

Abnormal battery charging

Excessive oil consumption Worn or damaged piston ring(s) Replace ring(s) Defective valve stem oil seal Replace oil sealDefective turbocharger oil seal Replace turbochargerClogged turbocharger oil returnpipe

Repair pipe

Condition Possible Cause CorrectionBad timing Engine control system malfunction System diagnosisMalfunction detected by enginecontrol system

Defective sensor Replace sensorControl unit malfunction Replace unitEngine control system malfunction System diagnosis

Fuel condition Poor quality fuel Drain existing fuel and replace withnew fuel

Poor engine aspiration Clogged intake pipes Clean or replace pipesEngine control system malfunction System diagnosis

Engine break-down Foreign material in cylinders Engine overhaulScored pistons and/or bearings Replace pistons and/or bearings

Condition Possible Cause CorrectionEngine speed cannot be increased Defective control unit Replace unit

Engine control system malfunction System diagnosisEngine speed unstable Defective control unit Replace unit

Engine control system malfunction System diagnosisClogged fuel filter element Replace elementDefective fuel injector(s) Replace fuel injector assemblyWater in fuel Drain existing fuel and replace with

new fuelAir in fuel system Bleed air from fuel systemExhaust brake valve sticking Repair or replace valve

Turbocharger malfunction Damaged turbocharger blade Replace turbochargerRough turbocharger shaft rotation Replace turbochargerBroken actuator Replace turbochargerDefective booster sensor Replace sensor

Condition Possible Cause CorrectionNo charging Open or shorted wiring and/or

connectorsRepair or replace wiring and/orconnectors

Defective generator Repair or replace generatorDefective battery Replace battery



Turbocharger Troubleshooting

Main Data and specifications

Insufficient charging Open or shorted wiring and/orconnectors

Repair or replace wiring and/orconnectors

Defective generator Repair or replace generatorLoose generator drive belt Adjust belt tension or replace beltDefective battery Replace battery

Excessive charging Shorted wiring Repair or replace wiringDefective generator Repair or replace generatorDefective battery Replace battery

Condition Possible Cause CorrectionEngine has less than normal power Air leakage from intake pipe rubber

hoseRepair

Air leakage from intake cover RepairClogged intercooler cooling section CleanClogged air cleaner element Clean or replaceIntake throttle valve stuck Repair or replaceTurbine and housing contact(Interference)

Replace

Excessive carbon deposit nearturbine exhaust port that interfereswith turbine

Clean or repair

Rough turbine shaft rotation Repair or replaceDamaged turbine blade Repair or replace

Blue exhaust smoke Oil leakage from turbocharger oilseal

Repair or replace

Clogged turbocharger oil returnpipe

Repair

Clogged center housing oilpassages

Repair or replace

Engine oil deterioration Change engine oilNoisy turbocharger operation Gas leakage from intake or exhaust

systemRepair

Turbine and housing contact(Interference)

Repair or replace

Damaged turbine blade ReplaceTurbine shaft bearing abrasion orscoring

Repair or replace

Excessive rotating part wear Engine oil deterioration Change engine oilClogged turbocharger oil feed pipe RepairLow engine oil pressure Repair

Item Engine model 4JJ1

Type Diesel/4-cycle/water cooling-type in-line DOHC



Combustion chamber type Direct injection type

Cylinder liner type Liner less

Number of cylinders -cylinder mm (in) 4-95.4 (3.76) × 104.9 (4.13)

bore X strokes

Displacement cc (cu.in) 2999 (183)

Compression ratio 17.5

Compression pressure MPa (psi)/rpm 3 (435)/200

Idling speed rpm 700 ± 25

Valve clearance Intake 0.15 (0.006) (cold)

mm (in) Exhaust 0.15 (0.006) (cold)

Ignition type Compressed ignition

Injection order 1 - 3 - 4 - 2

Lubricating system

Lubricating type Pressure delivery type

Oil pump type Gear type

Volume of lubricating oil L (qts) 10 (10.6)

Oil filter type Full flow filter (cartridge type)

Oil cooling type Built-in-type, water cooling

Cooling system

Cooling type Water cooling type

Radiator type Corrugated fin (pressure type)

Water pump type Centrifugal, belt drive type

Thermostat type Wax-type units

Thermostat valve-opening temperature °C (°F) 85 (185)

Volume of coolant L (qts) 10 (10.6) (incl. radiator)

Fuel system

Injection pump type Fuel supply pump common rail type

Injection nozzle type Electronic control injector

6-hole

Fuel pump type Into the fuel tank type

Charging system

Generator type AC type

Power output V-A 24 - 50 , 24 - 80

Regulator type IC

Starting system Engage magnet type

Starter type Reduction type

Power output V-kW 24 - 4.0, 24 - 4.5

Preheat system type Glow plug



Special Tools

Glow plug standard voltage/electric current V-A 23 - 3.5


Illustration Tool Number/ Description

5-8840-2822-0Valve clearance adjust

nut wrench

5-8840-2675-0Compression gauge

5-8840-2815-0Compression gauge

adapter

5884028220

5884026750

5884028150


Engine AssemblyRemovalNOTE:Instructions for engine removal

• Be sure to lock the vehicle's wheels in a fixedposition.

• Use an engine hoisting attachment that canadequately sustain the engine's weight.

• Do not get underneath the engine while the engineis being lifted.

• Do not insert fingers into any location where theymay be caught.

1. Detach the negative cable from the battery.2. Drain the coolant.3. Remove the starter.4. Remove the front exhaust pipe.

5. Remove the transmission assembly.• Refer to Transmission section.

6. Disconnect the air intake hose.• Disconnect the PCV hose (1) from the air intake

hose (2).• Disconnect the air intake hose (2) from the

turbocharger side.• Do not disconnect the air intake hose from the

air cleaner side.

7. Remove the air intake pipe with the hoses.• Disconnect the hose from the intercooler side.• Remove the air intake pipe with the hoses from

the turbocharger side.• Do not disconnect the hoses from the air intake

pipe.

8. Disconnect the two connectors from the ECM.9. Remove the air intake pipe with the hoses.

• Disconnect the connector from the boostsensor.

• Disconnect the hose from the intercooler side.• Remove the air intake pipe with the hoses from

the intake throttle valve.• Do not disconnect the hoses from the air intake

pipe.

LNW76ASH000101

LNW76ASH000201

1

2

LNW76ASH000301


10. Disconnect the radiator upper hose.• Disconnect the hose from the radiator side.

11. Detach the A/C compressor.• Detach the A/C compressor drive belt.• Detach the compressor from the A/C

compressor bracket.• Fix the compressor and hose in an appropriate

position with wire etc.12. Disconnect the engine ground cable from the

frame.13. Disconnect the vacuum hose.

• Disconnect the hose(1) from the vacuum pumpside(2).

14. Disconnect the radiator lower hose.• Disconnect the hose from the engine side.

15. Disconnect the fan guide bracket.• Remove the bolts(3).

NOTE:The bracket on the right side of the engine(1) is usedas an engine hanger when the engine is lifted.

16. Remove the cooling fan assembly.• Remove the cooling fan and the fan clutch.

17. Disconnect the power steering pump.• Disconnect the power steering pump with its

hose attached from the engine side.• Fix the pump and hose in an appropriate

position with wire etc.18. Disconnect the heater hose (1) from the heater

pipe (2).

19. Install an engine hanger (1).

Special tool

Engine Hanger: 5-8840-2823-0 • Install the engine hanger to the rear left side of

the engine.

LNW76ASH000501

LNW76ASH000601

1

2

LNW76ASH000701

1

2

3

3

LNW76ASH000801

1

2


NOTE:The FR engine hanger is not used for this engine.

20. Engine Mounts• Before removing the engine mounts, lift the

engine with a hoist.• Remove the mounting nuts from side of the

engine mount's chassis.21. Disconnect the fuel hose.

• Disconnect the hose from fuel filter side.

22. Engine Assembly• Operate the hoist slowly, and raise the engine

until it is above and protruding from the chassisframe.

Installation1. Fit the engine assembly.

• Fit hoist wire to the engine hanger and hoist theengine.

• Operate the hoist and move the engine into theinstallation position.

2. Fit the engine mounts.• Align the engine mounts to the engine mounting

cross member holes, and once fitted , tighten tothe specified torque.

Tightening torque:

Front independent suspension model

122 N⋅m (12.4 kg⋅m / 90 lb ft)

Front rigid suspension model

94 N⋅m (9.6 kg⋅m / 68 lb ft)3. Fit the fuel hose.

4. Fit the heater hose to the heater pipe.5. Fit the power steering pump.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)6. Fit the radiator lower hose.7. Fit the vacuum hose.

• Connect the hose(1) to the vacuum pump (2).

LNW76ASH000901

LNW76ASH001001

LNW76ASH001001


8. Attach the engine earth cable to the frame.9. Fit the A/C compressor.

• Fit the A/C compressor, and tighten to thespecified torque.

Tightening torque: 51 N⋅m (5.2 kg⋅m / 38 lb ft)• Attach the drive belt, and adjust the belt's

tension with the tension pulley adjustment belt.• Refer to "Drive Belt" section in the "Cooling

System" chapter for details concerning belttension adjustment.

• By hand, press the center part of the belt with aforce of 98N (10kg / 142psi), and check with ascale that the degree of deflection is within thespecified range. Also, check that the belt is notdamaged.

A/C Compressor Belt Degree of Deflection:

(5.5 - 7.3 mm / 0.2165 - 0.2874 in) (new belt)

(7.6 - 9.2 mm / 0.2992 - 0.3622 in) (used belt)• After adjusting belt tension, tighten the tension

pulley's lock nut.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)10. Fit the cooling fan Assembly.

• Tighten the fan clutch to the fan pulley at thespecified torque.

Tightening torque: 8 N⋅m (0.8 kg⋅m / 69 lb in)

11. Fit the fan guide.

12. Fit the radiator upper hose.13. Fit the air intake pipe and hose.

• Fit the pipe and the hose between the intakethrottle valve and the intercooler.

• Connect the boost sensor connector.• Use new clips. Tighten the clip according to the

marking.


14. Connect the ECM harness connector.15. Fit the air intake pipe and hose.

• Fit the pipe and the hose between theturbocharger and the intercooler.


marking.


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1

2

LNW76ASH000701

1

2

3

3

LNW76ASH000501


16. Fit the air intake hose (2).• Fit the hose between the air cleaner and

turbocharger.• Fit the PCV hose (1) to the air intake hose.

17. Remove the engine hanger.• Remove the engine hanger from the rear left

side of the engine.18. Fit the transmission assembly.

• Refer to removal procedure for"TRANSMISSION".

19. Install the front exhaust pipe and gaskets.a. Tighten temporarily.b. Tighten turbocharger side.

Tightening torque: 67 N⋅m (6.8 kg⋅m / 48 lb ft)c. Tighten the clamp.

Tightening torque: 41 N⋅m (4.2 kg⋅m / 30 lb ft)d. Tighten DPD side.

Tightening torque: 67 N⋅m (6.8 kg⋅m / 49 lb ft)

20. Fit the starter.

Tightening torque:127 N⋅m (13.0 kg⋅m / 94 lb ft)21. Replenish the coolant.22. Reattach the negative cable to the battery.

Special Tools

LNW76ASH000301

LNW76ASH000201

1

2

LNW76ASH000101


5-8840-2823-0Engine Hanger

5884028230


Engine MountComponents

Legend1. Engine Mount

Removal1. Remove the engine assembly.

• Refer to “Engine Assembly“.2. Remove the engine mount.

• Before removing the engine mount, hang theengine with a hoist.

• Remove the nuts fastened to the engine footand engine mount.

• Remove the nuts fastened to the engine mounton the chassis frame side.

• Hoist the engine assembly slightly to removethe engine mount.

LNW76AMF000101

1

LNW46ASH002501


Installation1. Install the engine mount and tighten up with the

specified torque.The nuts on the chassis frame side

Tightening torque:

Front independent suspension model

122 N⋅m (12.4 kg⋅m / 90 lb ft)

Front rigid suspension model

94 N⋅m (9.6 kg⋅m / 68 lb ft)

The nuts on the engine foot side


2. Install the engine assembly.• Refer to “Engine Assembly“.

Torque Specifications

LNW76ASH001501

LNW76AMF000201

51 (5.2/38)

94 (9.6/69)

40 (4.1/30)


Cylinder Head CoverComponents

Legend1. Oil Filler Cap2. Oil Filler Cap Gasket3. Engine Cover4. Cylinder Head Cover5. Bolt

6. Head Cover Mounting Rubber7. Oil Seal8. Head Cover Gasket9. Nut

Removal1. Remove the engine cover.

• Remove the oil filler cap before removing theengine cover.

LNW71BLF000401

9

6

2

1

3

4

5

6

7

8


2. Remove the fuel injector connector (2) and theleak-off hose(1).

NOTE:Do not reuse the leak-off hose clips (1).

3. Disconnect the blow-by hose.4. Remove the cylinder head cover.

5. Remove the nozzle seal cover from the cylinderhead cover.• Remove from the lower side of cylinder head

cover.6. Remove the cam end gasket (1).

• Remove the liquid gasket that has adhered tocylinder head completely.

LNW76ASH002201

RTW76ASH000101

1

2

LNW76ASH002101

1

LNW71BSH000401


Installation1. Install the nozzle seal cover.

• Insert from the lever side of cylinder headcover.

• Apply soapy water or engine oil to the surfaceof cylinder head cover side.

• Insert the nozzle seal cover as far as it will go.2. Install the cam end gasket.

• Apply the liquid gasket (ThreeBond TB-1207Bor equivalent) and mount.

Legend1. Cam End Gasket2. Apply The Liquid Gasket3. 2.0 to 3.0 mm (0.079 to 0.118 in)

• Apply attaching cam end gasket. Apply theliquid gasket (ThreeBond TB-1207B orequivalent).

Legend1. 3.0 - 5.0 mm (0.118 - 0.197 in)2. 3.0 - 5.0 mm (0.118 - 0.197 in)

3. Install the cylinder head cover.• Tighten the bolts and a nut in order shown in

the illustration.


4. Install the blow-by hose.5. Install the leak-off hose and the fuel injector

connector.6. Install the engine cover.

• Install the oil filler cap after installing the enginecover.

RTW56ASH020501

1

RTW56ASH020601

3

2

1

RTW56ASH022701

2

1

1

LNW76ASH001701

12 11 2 9 8

43

71314

15

1 5 6

10


Intake ManifoldComponents

Legend1. Intake Manifold Gasket2. Intake Manifold3. EGR Valve Assembly Gasket

4. EGR Valve Assembly5. Intake Throttle Assembly Gasket6. Intake Throttle Assembly

Removal1. Remove the engine cover.

• Remove the oil filler cap before removing theengine cover.

LNW71BLF000101

1

2

3

4

5

6


2. Remove the air intake pipe with the hoses.• Disconnect the connector from the boost

sensor.• Disconnect the hose from the intercooler side.• Remove the air intake pipe with the hoses from


pipe.

3. Remove the A/C compressor.• Remove the A/C belt.• Disconnect the A/C compressor harness

connector.4. Remove the A/C compressor bracket.5. Remove the engine oil level guide tube.

6. Remove the intake throttle connector(2) and theEGR valve connector(1).

7. Remove the injection pipe (No.1 to 4).

8. Remove the intake manifold and gasket.• Remove the intake manifold with the EGR valve

and the intake throttle.9. Remove the EGR valve (2) from the intake

manifold (1).

LNW76ASH002201

LNW76ASH000501

LNW71BSH001101

1

2

LNW71DSH000101

1


10. Remove the intake throttle (3) from the intakemanifold (1).

Installation1. Install the EGR valve to the intake manifold.

Tightening torque: 27 N⋅m (2.8 kg⋅m / 20 lb ft)2. Install the intake throttle to the intake manifold.

Tightening torque: 10 N⋅m (1.0 kg⋅m / 87 lb in)3. Install the intake manifold.

a. Install the gasket and the intake manifold andtighten temporarily.

b. Tighten the bolts and nuts in the orderdescribed in the drawing.


4. Install the injection pipe (No.1 to 4).5. Connect the intake throttle connector and EGR

valve connector.

6. Install the engine level guide tube.7. Install the A/C compressor bracket.8. Install the A/C compressor.

• Install the A/C belt.9. Install the intake air pipe and hose.


• Use new clips. Tighten the clip according to themarking.


10. Connect the boost sensor connector.11. Install the engine cover.

• Install the oil filler cap after installing the enginecover.

LNW71BSH001001

1

2

3

LNW71BSH000901

3

5

1 2

4

6

10

8 7 9

LNW76ASH000501



LNW76ALF000101

25(2.5/18)

27(2.8/20)

27(2.8/20)

25(2.5/18)

10(1.0/87lb·in)

25(2.5/18)


TurbochargerService Precautions

• The turbocharger is a high precision componentand cannot be disassembled (spins at approx.100,000 rpm). If any damage whatsoever, such asdents and scratches, is discovered on the turbocharger's fins or housing, the entire turbo chargermust be replaced.

• While carrying out maintenance, take appropriatemeasures to prevent foreign materials fromentering into the turbine housing, compressorhousing, or oil inlets/outlets.

• After servicing the turbocharger, pour clean engineoil (3-5 cc) into the pipe connecting port beforeinstalling the oil pipe.

Components

Legend1. Turbocharger Assembly2. Oil Feed Pipe3. Turbocharger Duct4. Exhaust Adaptor

5. Water Feed Pipe6. Water Return Pipe7. Oil Return Pipe

LNW71JLF000101

1

2

3

5

6

7

4


Removal 1. Drain the coolant.2. Remove the front exhaust pipe and exhaust brake.

3. Remove the following parts.a. Inlet hose (5)b. PCV hose (2)c. Air duct (1)d. Right side noise cover (6)e. Fan guide bracket (3)f. Water feed pipe and VGS vacuum hose (4)

4. Remove the AC generator.• Disconnect the generator terminals.

5. Remove the exhaust adapter from theturbocharger.• Remove the adapter's bracket (3). • Remove the exhaust adapter (2).

6. Remove the heat protector (1).

7. Remove the oil feed pipe.8. Remove the water return pipe.9. Remove the oil return pipe.

10. Remove the turbocharger assembly from theexhaust manifold.

Inspection Visual and noise inspection The turbine housing outlet's adaptor and thecompressor housing inlet's rubber hose must beremoved before a visual inspection on the turbochargercan take place.The turbocharger can not be disassembled or adjusted.

• Check the turbocharger for abnormal noise duringoperation.

LNW76ASH000101

LNW71BSH000101

1 2 3

4

5

6

LNW71JSH000301

1

2

3

LNW71JSH000101


• Check the compressor cover and turbine housingfor scratches and/or cracks caused by contact withthe fin.

• Check the inner surface of the housing for oilleakage.

• Check the turbine exhaust port for excessivecarbon deposits that may interfere with the fin.

• Turn the turbine shaft by hand and check fordragging or sticking conditions.

• Move the shaft and check for excessive clearancein axial and radial directions.

Axial play on the wheel shaft • Use a dial gauge to measure the axial play on the

wheel shaft.• Alternately, apply a force of approximately 12 N

(1.2 kg / 2.6 lb) to the compressor wheel end.

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

between wheel shaft and bearing.

Legend1. Oil Outlet Port 2. Oil Inlet Port

Waste gate operation (EURO 3 Specification)1. Remove the hose from the waste gate actuator.2. Install the pressure gauge (general tool). Refer to

the illustration.

Legend1. Waste Gate Actuator2. Waste Gate Hose3. Pressure Gauge (General Tool)

3. Use the pressure gauge pump to apply pressure(load) to the waste gate actuator (the engine mustbe off).

Axial Play mm(in)

Standard 0.03 - 0.08(0.0012-0.0031)

Limit 0.09(0.0035)

Clearance mm(in)

Standard 0.08 - 0.1(0.0031-0.0039)

Limit 0.17(0.0067)

LNW71JSH000401

LNW71JSH000501

1

2

LNW21BSH022401

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31


4. Note the pressure at which the control rod moves 2mm (0.078 in). This pressure must be within thespecified limit.

Actuator operation (EURO 4 Specification)1. Install a vacuum pump (2) to the actuator (1) as

shown in the illustration.

2. Operate the vacuum pump and apply vacuumpressure to the actuator.

3. Place a vernier caliper on the end of the control rodof actuator.Release the vacuum pressure and check thecontrol rod moves.Measure the length of the control rod moving.

Installation1. Install the turbocharger assembly.

• Install the gaskets and turbocharger assembly,and tighten to the specified torque.

2. Install the oil return pipe.• Install the O-rings into both sides of the oil

return pipe, and tighten the bolt to the specifiedtorque.

3. Install the water return pipe.• Tighten the water return pipe's eye bolt to the

specified torque.

4. Install the oil feed pipe.• Install the eye bolt to the oil feed pipe on the top

of turbocharger, and tighten the bolt to thespecified torque.

5. Install the exhaust adapter to the turbocharger,and tighten to the specified torque.

6. Fit the heat protector and tighten with the bolt.

Control rod pressure range: kPa (mmHg / psi)143 - 154 (1068 - 1158 / 20.7 - 22.4)

Working vacuum pressure

kPa (mmHg / psi)

Reference 44 (330 / 6.38)

Standard length 7 mm (0.28 in)

Tightening torqueNut 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)Bolt 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

LNW71JSH000201

2

1

Tightening torqueTurbocharger side: 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)Crank case side: 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)

Tightening torque: 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft)

Tightening torque: 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)

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

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

LNW71JSH000101


Legend1. Heat Protector; Turbocharger 2. Exhaust Adapter 3. Exhaust Adapter Bracket

7. Install the AC generator.8. Install the following parts.

a. Water feed pipe and VGS vacuum hose (4)b. Fan guide bracket (3)c. Right side noise cover (6)d. Air duct (1)e. PCV hose (2)f. Inlet hose (5)

9. Install the front exhaust pipe and gaskets.a. Tighten temporarily.b. Tighten turbocharger side.


c. Tighten the clamp.

Tightening torque: 41 N⋅m (4.2 kg⋅m / 30 lb ft)d. Tighten DPD side.

Tightening torque: 67 N⋅m (6.8 kg⋅m / 49 lb ft)10. Replenish the coolant.

LNW71JSH000301

1

2

3

LNW71BSH000101

1 2 3

4

5

6


Torque specifications

LNW76ALF001001

25 (2.5/1.8)

25 (2.5/1.8)

25 (2.5/1.8)

22.5 (2.2/16)

27 (2.8/20)

27 (2.8/20)

10 (1.0/87 lb·in)

10 (1.0/87 lb·in)

10 (1.0/87 lb·in)


Exhaust ManifoldComponents

Legend1. EGR Cooler2. Heat Protector; EGR Cooler3. Heat Protector; Exhaust Manifold4. Gasket

5. Exhaust Manifold6. Gasket7. Turbocharger Assembly8. Gasket

Removal1. Drain the coolant.2. Remove the turbocharger assembly.

Refer to "Turbocharger".

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7

5

8


3. Remove the EGR cooler heat protector.

4. Remove the EGR cooler.• Disconnect the rubber hoses of the water

pipe(IN, OUT) from the EGR cooler.• Remove the EGR cooler and the gasket from

the exhaust manifold.5. Remove the exhaust manifold heat protector.

6. Remove the exhaust manifold.• Remove the exhaust manifold and gasket.

Inspection• Inspection of the exhaust manifold.

Inspect the plane surface of the plane on which themanifold and the cylinder head are to be installed.

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

• Check a crack in the exhaust manifold visually.Carefully inspect the turbocharger for abrasionand/or excessive wear. Make any necessaryadjustments, repairs, and/or part replacements.

Installation1. Install the exhaust manifold.

• Put the gasket in to install the exhaust manifold.• Tighten in order described in the drawing.


2. Install the exhaust manifold heat protector.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18lb ft) 3. Install the EGR cooler.

Manifold installation plane surface mm (in)Standard 0.3 (0.01) or lower

LNW71FSH000101

LNW71BSH000701

Limit 0.5 (0.02)

LNW21BSH006601

LNW71BSH000801

7 3 1 5

6248


a. Put the gasket in to install the EGR cooler.b. Temporary tightening order.

1 → 2 → 3 → 4 → 5 → 6c. Fully tightening order.

3 → 4 → 5 → 1 → 2 → 6

Tightening torque

Bolt, Nut (1 - 5) : 27 N⋅m (2.8 kg⋅m / 20 lb ft)

Bolt (6) : 52 N⋅m (5.3 kg⋅m / 38 lb ft)

4. Connect the rubber hoses to the water pipe(IN,OUT) of the EGR cooler.

5. Install the EGR cooler heat protector.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)6. Install the turbocharger.

Refer to “Turbocharger”.7. Replenish the coolant.

LNW71FSH000201

6

4

53

2

1



LNW76ALF000701

52(5.3/38)

27(2.8/20)

25(2.5/18)25(2.5/18)

27(2.8/20)

52(5.3/38)


Timing Gear TrainComponents

Legend1. Oil Pump Gear2. Crankshaft Gear3. Idle Gear D4. Exhaust Camshaft Gear5. Intake Camshaft Gear6. Idle Gear D Sprocket7. Timing Chain

8. Injection Pump Sprocket9. Injection Pump Gear

10. Idle Gear A11. Vacuum Pump Gear12. Power Steering Oil Pump Gear13. Idle Gear C

Removal1. Drain the engine coolant.2. Remove the radiator upper hose.

RTW56ALF001101

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4

13

12

11

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9

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5


3. Remove the fan guide bracket.

Legend1. Fan Guide Bracket(RH)2. Fan Guide Bracket(LH)3. Bolt

4. Remove the cooling fan and fan pulley.

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

6. Remove the crank pulley.

NOTE:Do not reuse the crank pulley bolt and washer.

7. Remove the power steering pump with hose. 8. Remove the vacuum pump.

• Remove the vacuum pipe bracket and vacuumpipe.

• Remove the oil pipe (feed side and return side)of vacuum pump.

9. Remove the cover of the gear case cover(1).

10. Remove the gear case cover.

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

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1

2

3

3

RTW56ASH025401

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1

RTW56ASH019701


12. Remove the idle gear A and idle gear A flange, idlegear A shaft.

13. Remove the idle gear C and idle gear C shaft.

14. Remove the crankshaft gear.

Disassembly1. Remove the scissor gear assembly.

• Clamp the vise. Insert soft metal protectors(aluminum) between the vise and component.Use snap ring pliers to remove the scissor gearassembly.

Legend1. Snap Ring2. Sub-gear3. Spring4. Idle Gear A

Reassembly1. Install the scissor gear assembly.

RTW56ASH011301

RTW56ASH011401

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1

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3

4


• Clamp the vise. Insert soft metal protectors(aluminum) between the vise and component.Press against the pin on the left side of the idlegear A spring to make a gap on the right side ofthe spring. Push the spring into place.

• Align the sub gear pin with the hole in the rightside of the idle gear A spring. Press the sub-gear into place.

Legend1. Snap Ring2. Sub-gear3. Spring4. Idle Gear A

• Use snap ring pliers to snugly install the snapring.

Inspection1. Measurement of idle gear backlash

• Apply a dial gauge on the teeth of the idle gearto be measured and move the gear to right andleft lightly to read how much the dial gaugeshook (never fail to fix the gear).

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

• Measure backlash of the idle gear beforeremoving the idle gear A.

2. Measurement of end clearance of the idle gear.• Insert a thickness gauge between the idle gear

and the thrust collar to measure a clearance.

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

• Measure an end clearance of the idle gearbefore removing the idle gear B.

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

diameter of each idle gear shaft.• If the measurement exceeds the limit, replace

the shaft.

4. Clearance between the idle gear and the idle gearshaft• Measure an inside diameter of the idle gear

bush to calculate a clearance between the idlegear and the idle gear shaft.

Backlash of the idle gear mm (in)Standard 0.10 - 0.17 (0.004 - 0.006)

Limit 0.30 (0.01)

RTW56ASH022001

1

2

3

4

End clearance of the idle gear mm (in)Standard 0.080 - 0.155 (0.003 - 0.006)

Limit 0.20 (0.008)

External diameter of the idle gear A shaft mm (in)Standard 44.950 - 44.975 (1.7697 - 1.7707)

Limit 44.80 (1.764)

External diameter of the idle gear C shaft mm (in)Standard 24.959 - 24.980 (0.9826 - 0.9835)

Limit 24.80 (0.976)

RTW56ASH021601


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

Installation1. Install the crankshaft gear.2. Install the idle gear C.

• Apply engine oil over the part where the gear ofthe idle gear shaft is to be put together.

• Apply engine oil to the bolt screw thread andseat, and temporarily tighten together with theflange (tighten fully in later process).

3. Install the idle gear A.4. Tighten sub gear setting bolt.

• Use the M6 bolts and lever to turn sub gear toright direction until it aligns with the M6 bolt holebetween idle gear A and sub gear.

• Tighten the M6 bolt to a suitable torque toprevent the sub gear from moving.

• Apply engine oil over the part where the gear ofthe idle gear shaft is to be put together.

• Install the idle gear A and idle gear A flange,idle gear A shaft at the position shown in thefigure.

• Apply engine oil to the bolt screw thread andseat, and temporarily tighten together with theflange (tighten fully in later process).

Clearance between the idle gear A and the shaft

mm (in)

Standard 0.025 - 0.075 (0.0010 - 0.0030)Limit 0.200 (0.0079)

Clearance between the idle gear C and the shaft

mm (in)

Standard 0.020 - 0.062 (0.0008 - 0.0024)Limit 0.200 (0.0079)

LNW21BSH003601

RTW56ASH011401

RTW56ASH011501


• Align the oil hole of the cylinder body (2) withthe oil hole of the idle gear A shaft (3).Install the flange so that the front mark (1) facetoward the front.

• Attach, aligning with the gear crank: idle A andtiming mark.

5. Tighten the bolts of idle gear A and idle gear C tothe specified torque.

Tightening torque:

idle gear A: 32 N⋅m (3.3 kg⋅m / 24 lb ft)

idle gear C: 59 N⋅m (6.0 kg⋅m / 44 lb ft)

LNW71BSH000501

1

2

3

RTW56ALH000301


Legend1. Idle Gear A Bolt2. Idle Gear C Bolt

6. Remove the M6 bolt from the idle gear A.7. Install the gear case cover.

• Apply the liquid gasket (ThreeBond TB-1207Bor equivalent).

Legend1. Apply the liquid gasket

• Install the gasket in slot of the gear case cover.• Tighten the bolts to the specified torque.


8. Install the vacuum pump.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)• Install the oil pipe (feed side and return side) of

vacuum pump.• Install the vacuum pipe bracket and vacuum

pipe.9. Install the power steering pump.

• Tighten the nut to the specified torque.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft) 10. Install the cover of the gear case cover11. Install the crank pulley.

Tightening torque: 294 N⋅m (30 kg⋅m / 217 lb ft)12. Install the A/C compressor drive belt and fan

belt.Refer to drive belt tension check procedure forHeating and air conditioning and Engine cooling inthis manual.

13. Install the cooling fan.14. Install the fan guide bracket.15. Install the radiator upper hose. 16. Replenish the engine coolant.

RTW56ASH011701

1

2

RTW56ASH020101

1

RTW56ASH012101



LNW76ALF000601

59(6.0/43)

32(3.3/24)

130(13.3/96.2)

294(30/217)8(0.8/69lb in)


Camshaft AssemblyComponents

Legend1. Snap Ring2. Sub Gear3. Knock Pin4. Damper Spring

5. Camshaft Gear and Camshaft6. Cam Cap7. Bolt

Removal1. Rotate the crankshaft to make the No.1 cylinder

compression TDC. • Check TDC using a mirror etc.

RTW56ALF000901

1

2 3

4

5

6

7



2. Remove the cylinder head cover.Refer to "Cylinder Head Cover".

3. Install the M5 lock bolt of fixing sub gear.

4. Remove the baffle plate.

Legend1. Baffle Plate

5. Remove the camshaft bearing cap and camshaft.• Check the engraved making on the camshaft

bearing caps.

LNW76ASH001101

1

2

3

RTW56ASH007101

RTW56ASH006301

1

RTW56ASH018401

1E

2E

3E

4E

5E

1I

2I

3I

4I

5I


Disassembly1. Remove the sub gear assembly.

• Clamp the camshaft in a vise. Insert soft metalprotectors (aluminum) between the visesurfaces and the camshaft.

• Use a camshaft gear tool (5-8840-2591-0) toturn sub gear to right direction to remove theM5 bolt.

• Use snap ring pliers to remove the scissor gearassembly.

NOTE:Take care not to damage the camshaft cams andjournals.

2. Remove the camshaft gear.• Use a press and socket to remove the camshaft

gear.

Legend1. Press2. Socket3. Camshaft Gear

3. Remove the dowel pin.4. Inspect the camshaft visually.

RTW56ASH013801

LNW76ASH002601

LNW76ASH002501

RTW56ASH006501

1

2

3


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

5. Inspect an end clearance of the camshaft.• Use a thickness gauge to measure an end

clearance of the camshaft gear and thecamshaft bracket.

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

NOTE:Measure an end clearance of the camshaft beforedisassembling.

6. Check if the cam lobe is worn.

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

• If the height of the cam lobe is at the limit orless, replace the camshaft.

7. Check if the camshaft journal is worn.• Use a micrometer to measure wear which is not

even with a diameter of the camshaft journal.• If the measured uneven wear exceeds the limit,

replace the camshaft.

End clearance of the camshaft mm (in)Standard 0.050 - 0.170 (0.002 - 0.007)

Limit 0.25 (0.009)

LNW21BSH020201

RTW56ASH013901

Height of the cam lobe mm (in)Inlet Exhaust

Standard 40.6 (1.60) 40.6 (1.60)Limit 39.6 (1.56) 39.6 (1.56)

External diameter of the camshaft journal part

mm (in)

Standard 29.909 - 29.930 (1.1775 - 1.1783)Limit 29.809 (1.1736)

Partial wear of the camshaft journal part mm (in)Limit 0.05 (0.0019)

LNW21BSH020401


8. Check if the camshaft is bent.• Place the camshaft on a V block to measure a

bend with a dial gauge.• Rotate the camshaft slowly to measure how

much the dial indicator shook. If it exceeds thelimit, replace the camshaft.

9. Measure a camshaft journal oil clearance.a. Measure an inside diameter of the camshaft

bearing with a dial gauge.

b. Read the difference between the insidediameter of the camshaft bearing and thediameter of the camshaft journal.If the measured oil clearance exceeds the limit,replace the camshaft bearing.

Reassembly1. Install the dowel pin.2. Install the camshaft gear.

Bent of the camshaft mm (in)Limit 0.05 (0.0019 )

LNW21BSH020501

LNW21BSH020601

Clearance of the journal part mm (in)Standard 0.030 - 0.112

(0.0012 - 0.0044 )Limit 0.15 (0.0059 )

LNW21BSH054601


• Align the knock pin with the slot in the camshaftgear. Use a press to install the camshaft gear tothe camshaft.

Legend1. Camshaft2. Dowel Pin3. Camshaft Gear

3. Install the sub gear assembly.• Clamp the camshaft in a vise. Insert soft metal

protectors (aluminum) between the visesurfaces and the camshaft. Press against thepin on the left side of the camshaft gear spring(3) to make a gap on the right side of the spring.Push the spring into place.

• Align the sub gear pin (2) with the hole in theright side of the camshaft gear spring (3). Pressthe sub-gear into place.

Legend1. Snap Ring2. Sub Gear3. Spring4. Camshaft Gear

• Use snap ring pliers to snugly install the snapring.

4. Tighten sub gear setting bolt.• Use a camshaft gear tool (5-8840-2591-0) to

turn sub gear to right direction until it aligns withthe M5 bolt hole between camshaft driven gearand sub gear.

RTW56ASH006601

1

2

3

LNW76ASH002401

1

2

3

4

LNW76ASH002501


• Tighten the M5 bolt to a suitable torque toprevent the sub gear from moving.

Installation1. Rotate the crankshaft to make the No.1 cylinder

compression TDC. • Check TDC using a mirror etc.


2. Install the camshaft assembly.• Align timing mark on intake camshaft and

exhaust camshaft to idle gear D.

Legend1. Exhaust Camshaft Gear2. Intake Camshaft Gear3. Idle Gear D

3. Camshaft bearing caps, tighten ten bolts on oneside bank to the specified torque.• Apply engine oil to camshaft journal and

bearing surface of camshaft bearing caps.

LNW76ASH002601

LNW76ASH001101

1

2

3

RTW56ASH007001

1 2

3

RTW56ASH018401

1E

2E

3E

4E

5E

1I

2I

3I

4I

5I


4. Check that the alignment marks (camshaft bearingcap and camshaft) (1) are aligned.

• Apply engine oil over the screw part and tightenup the bearing cap with the prescribed torque.

Tightening torque: 18 N⋅m (1.8kg⋅m / 13 lb ft)5. Remove the M5 lock bolt of fixing sub gear. 6. Adjustment of valve clearance.

Refer to installation procedure for inspection /adjustment of valve clearance in this manual.

7. Install the baffle plate. Tighten the bolts to the specified torque.

Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)8. Install the cylinder head cover.

Refer to "Cylinder Head Cover".


RTW56ASH006901

1

RTW56AMF001701

10 (1.0kg·m/87lb in)18 (1.8/13)

N·m(kg·m/lb ft)

Lubricate with engine oil


Special ToolsIllustration Tool Number/ Description

5-8840-2591-0Camshaft gear tool


Valve Stem Seal and Valve SpringComponents

Legend1. Exhaust Rocker Arm Shaft Assembly2. Bolt (Long)3. Bolt (Short)4. Intake Rocker Arm Shaft Assembly5. Fuel Injector Assembly6. Fuel Injector Clamp Bolt7. Fuel Injector Clamp

8. Pin9. Spring Lower Seat

10. Valve Stem Oil Seal11. Valve Spring12. Spring Upper Seat13. Split Collar14. Valve Stem End Cap

Removal1. Remove the cylinder head assembly.

Refer to "Cylinder Head".2. Remove the valve stem end cap.3. Remove the split collar.

• To prevent the valve from falling into thecylinder, move the piston to TDC.

RTW56ALF001301

13

14

12

11

10

9

1

2

3

2

4

3

56

7

8


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

Special tool

Valve spring replacer: 5-8840-2818-0

Pivot: 5-8840-2819-0

Legend1. Valve spring replacer2. Pivot

4. Remove the spring upper seat.• Remove the special tool to remove the upper

seat.5. Remove the valve spring.

Put the removed valve springs in order by cylindernumber.

6. Remove the valve stem oil seal.• Use pliers to remove the oil seal.

NOTE:Do not reuse the oil seal.

7. Remove the spring lower seat.

InspectionInspect the valve springNOTE:Check the valve spring visually and if there is cleardamage or wear, replace it.

1. Free length• Measure free length of the spring and if it is

shorter than the prescribed limit, replace thespring.

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

the valve spring squareness.If the measuredvalue exceeds the specified limit, the valvespring must be replaced.

RTW56ASH012301

1

2

RTW56ASH012401

Free length of the valve spring IN / EX mm (in)Standard 49.04 (1.93) / 57.57 (2.27)

Limit 48.15 (1.89) / 56.52 (2.23)

Valve spring squareness IN / EX mm (in)Limit 2.1 (0.083) / 2.5 (0.098)

LNW21BSH017001


3. Tension• Use a spring tester to compress the spring to

the installation height. Measure tension of thecompressed spring. If the measurement islower than the limit, replace the spring.

Installation1. Install the spring lower seat.2. Install the valve stem oil seal.

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

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

Special tool

Valve stem seal installer: 5-8840-2817-0

3. Install the valve spring.4. Install the spring upper seat.5. Install the split collar.

• Apply compressed air over the cylinder from theglow plug holes to keep the valve at the homeposition.

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

Special tool


Pivot: 5-8840-2819-0

Installation length mm (in) 37.80 (1.488)

Tension of the valve spring N (kg / lb)Inlet / Exhaust

Standard 213 (21.7 / 157) / 409 (41.7 / 301)

Limit 188 (19.2 / 138) / 370 (37.7 / 272)

LNW21BSH017101

LNW21BSH056701

RTW56ASH013701



NOTE:Move it up and down to check if it moves smoothly.

6. Install the valve stem end cap.7. Install the cylinder head assembly.

Refer to "Cylinder Head".

Special Tools

RTW56ASH012301

1

2


5-8840-2818-0Valve spring replacer

5-8840-2819-0Pivot assembly

5-8840-2817-0Valve stem seal installer

5884028180

5884028190

5884028170


Cylinder HeadComponents

Legend1. Timing Chain Tensioner2. Glow Plug3. Intake and Exhaust Valves4. Fuel Injector Assembly

5. Fuel Injector Clamp6. Cylinder Head7. Timing Chain Guide8. Timing Chain Tension Lever

NOTE:To avoid electric shock;Set the switch to the 'OFF' position and disconnectbattery negative cable before checking or repairing thefuel injector, wiring or/and connectors.

Removal1. Drain the engine coolant.

2. Remove the turbocharger.Refer to “Turbocharger“.

LNW71BLF000901

1

7

5

4

6

3

2

8


3. Remove the EGR cooler heat protector.

4. Remove the EGR cooler.5. Remove the water by pass pipe (1).

6. Remove the air intake pipe with the hoses.• Disconnect the connector from the boost

sensor.• Disconnect the hose from the intercooler side.• Remove the air intake pipe with the hoses from


pipe.

7. Remove the LH noise cover.8. Remove the radiator upper hose.9. Remove the A/C compressor drive belt.

10. Remove the A/C compressor.• Remove the compressor from the A/C

compressor bracket.• Fix the compressor and hose in an appropriate

position with wire etc.11. Remove the A/C compressor bracket.12. Remove the A/C compressor adjust pulley.

Legend1. Bolt2. Nut

13. Remove the cylinder head cover.Refer to “Cylinder Head Cover“.

14. Remove the oil level gauge tube.

LNW71FSH000101

RTW56ASH008401

1

LNW76ASH000501

LNW76CSH001101

2 1


15. Remove the injection pipes (NO.1 to 4).

16. Disconnect the heater hose.• Disconnect the heater hose from the cylinder

block side.17. Remove the fan guide bracket (LH).18. Remove the noise shield cover (1) from the lower

timing chain cover.

19. Remove the harness connector of camshaftposition sensor (1), water temperature sensor (2).

20. Remove the timing chain cover.a. Remove the lower cover (2).b. Remove the upper cover (1).

21. Remove the fuel injector.Refer to “Fuel Injector“ in “FUEL SYSTEM“section.

22. Remove the glow plug connector.23. Remove the glow plug .

LNW71DSH000101

1

RTW56CSH001401

1

LNW76CSH001801

2

1

LNW76CSH001001

1

2


24. Install M5 bolts to the sub gear of the camshaft.

25. Remove the baffle plate (1).

26. Remove the camshaft bearing cap.

27. Remove the camshaft.

RTW56ASH007101

RTW56ASH006301

1

RTW56ASH018401

1E

2E

3E

4E

5E

1I

2I

3I

4I

5I

RTW56ASH013801


28. Remove the timing chain tensioner (1) and gasket(2).

29. Remove the idle gear D.• Timing chain is dropped behind.

30. Remove the timing chain tension lever pivot.

31. Remove the timing chain from the supply pumpsprocket.

32. Remove the chain guide bolt from the cylinderhead.

33. Remove the rocker arm shaft assembly.

NOTE:Keep the removed rocker arm shaft assembly properlyso that they may be put back to the original place.

LNW71BSH001401

1

2

RTW56ASH022101

RTW56ASH019401

RTW56ASH019501


Legend1. Exhaust Rocker Arm Shaft Assembly2. Bolt (Long)3. Bolt (Short)4. Intake Rocker Arm Shaft Assembly5. Front

NOTE:Pay full attention so as not to drop the parts in the gearcase of the front part of the cylinder head or a hole intowhich oil pours back in the front.

34. Remove the cylinder head gear case bolts (2) andnuts (1).

35. Remove the cylinder head bolts.• Loosen the cylinder head bolts in the order

described in the drawing.

NOTE:Do not reuse the cylinder head bolts.

36. Remove the cylinder head assembly.• Remove the cylinder head assembly with the

exhaust manifold and the intake manifold.• Remove the cylinder head gasket.

NOTE:Replace the head gasket with a new one once it isremoved.

Head Disassembly1. Remove the intake manifold assembly.2. Remove the exhaust manifold assembly.3. Remove the water outlet pipe.4. Remove the valve stem cap.5. Remove the split collar.

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

Special tool


Pivot: 5-8840-2819-0

RTW56ASH012201

1

2

32

4

5

3

RTW56ASH020801

2

1

1

RTW56ASH008601

2 6 10 14 18 15 11 7 3

1

5 9 13 17 16 12 8 4



6. Remove the spring upper seat7. Remove the valve spring.

• Put the removed valve springs in order bycylinder number.

8. Remove the intake and exhaust valve.• Put the removed valves in order by cylinder

number.

9. Remove the valve stem oil seal.

10. Remove the spring lower seat.11. Remove the valve guide.

• Use the valve guide replacer to press out thevalve guides from the bottom side of thecylinder head.

Special tool

Valve guide remover and installer:

5-8840-2816-0

RTW56ASH012301

1

2

LNW21BSH016801

RTW56ASH012401

RTW56ASH008701


12. Remove the cam end gasket (1).

13. Remove the oil seal.

InspectionMake the necessary adjustments, repairs, and partreplacements if excessive wear or damage isdiscovered during inspection.

Cylinder Head Lower Face Warpage1. Use a straight edge and a thickness gauge to

measure the four sides and the two diagonals ofthe cylinder head lower face.

2. The cylinder head lower surface warpage is morethan the limit, it should be replaced.

NOTE:The cylinder head lower face cannot be reground.

RTW56ASH020501

1

RTW56ASH008801

Cylinder Head Lower Face Warpage mm (in)Standard 0.05 (0.002) or less

Limit 0.20 (0.0079)

Cylinder Head Height (H) (Reference) mm (in)Standard 143.4 (5.646)

RTW56ASH008901

LNW61ASH003901

A

B

C D

FE


Manifold Fitting Face WarpageUse a straight edge and a thickness gauge to measurethe manifold cylinder head fitting face warpage.Regrindthe manifold cylinder head fitting surfaces if themeasured values are greater than the specified limitbut less than the maximum grinding allowance.If themeasured values exceed the maximum grindingallowance, the cylinder head must be replaced.

Exhaust Manifold WarpageUse a straight edge and a thickness gauge to measurethe manifold cylinder head fitting face warpage.If themeasured values exceed the specified limit, themanifold must be replaced.

Valve Stem CapMake the necessary part replacements.If excessivewear or damage is discovered during inspection.

Valve Stem Outside DiameterMeasure the valve stem diameter at three points.If themeasured value is less than the specified limit, thevalve and the valve guide must be replaced as a set.

Manifold Fitting Face Warpage mm (in)Standard 0.05 (0.002) or less

Limit 0.20 (0.008)Maximum Grinding Allowance 0.40 (0.016)

RTW56ASH017401

H

RTW56ASH017501

Exhaust Manifold Warpage mm (in)Standard 0.05 (0.002) or less

Limit 0.20 (0.008)

Valve Stem Outside Diameter mm (in)Intake Valve Exhaust Valve

Standard 6.955 - 6.970(0.2738 - 0.2744)

6.939 - 6.949(0.2732 - 0.2736)

Limit 6.935(0.2730)

6.920(0.2724)

LNW21BSH001601


Valve Stem and Valve Guide Clearance1. Measure the valve stem outside diameter.Refer to

the item "Valve Stem Outside Diameter".2. Use a caliper calibrator or a telescoping gauge to

measure the valve guide inside diameter.If the measured values exceed the specified limit,the valve and the valve guide must be replaced asa set.

Valve ThicknessMeasure the valve thickness.If the measured value isless than the specified limit, the valve and the valveguide must be replaced as a set.

Valve Depression1. Install the valve (1) to the cylinder head (2).2. Use a depth gauge or a straight edge with steel

rule to measure the valve depression from thecylinder head lower surface.If the measured value exceeds the specified limit,the valve seat insert must be replaced.

Valve Stem Clearance mm (in)Intake Valve Exhaust Valve

Standard 0.030 - 0.060(0.0012 - 0.0023)

0.038 - 0.068(0.0015 - 0.0027)

Limit 0.200(0.008)

0.250(0.0098)

LNW21BSH017301

LNW61ASH004001

Intake and Exhaust Valve Thickness mm (in)Standard 1.3 (0.051)

Limit 1.1 (0.045)

Valve Depression mm (in)Standard 0.5 (0.02)

Limit 2.5 (0.098)

LNW21BSH017801


Valve Contact Width1. Check the valve contact faces for roughness and

unevenness. Make smooth the valve contactsurfaces.

2. Measure the valve contact width.If the measured value exceeds the specified limit,the valve seat insert must be replaced.

Repair of the seat surface• Remove carbon from the surface of the valve

insert seat.

• Use a seat cutter to minimize the scratch and otherroughness (15/45/75 degree-blade), therebyreturning the contact width to the standard value.

NOTE:Remove only scratches and roughness, and do not cutthe surface too much.Use the free adjustment valve cutter pilot.Do not let the valve cutter pilot waver inside the valveguide.

• Attach compound in the valve insert seat.• Insert the valve into the valve guide.• Attach compound on the valve seat surface, rotate

the valve and hit it lightly to grind it, and confirmthat it has even contact all round.

Valve Contact Width mm (in)Intake Exhaust

Standard 2.26 (0.089) 2.12 (0.083)Limit 2.2 (0.087) 2.5 (0.078)

LNW61ASH004101

1

2

LNW61ASH004201

Valve Seat Angle Degree45

LNW21BSH018201

150

90

30

LNW21BSH056101


NOTE:Remove compound completely after grinding.

Replace the valve seat insert.

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

insert.• Cool the valve seat insert for two to three minutes.

Contraction due to cooling makes it easier toremove the valve seat insert.

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

Legend1. Arc-Weld2. Valve Seat Insert3. Screw Driver

Install the valve seat insert• Carefully place a washer (the outer diameter is

smaller than the valve seat insert) on the valveseat insert.

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

NOTE:Do not apply too much pressure with the press. Attachcompound on the valve seat surface, rotate the valveand hit it lightly to grind it, and confirm that it has evencontact all round.

Legend1. Washer2. Valve Seat Insert3. Press

Head Reassembly1. Install the oil seal.

• Install on the surface of the injection pipe insert.• Hammer it in so that the seal does not incline.

NOTE:Be sure not to harm the Lip.

Special tool

Injection pipe oil seal installer: 5-8840-2820-0

LNW21BSH031801

LNW21BSH056001

1

3

2

LNW21BSH018601

1

3

2


Legend1. Cylinder Head2. Injection Pipe Oil Seal Installer

2. Install the valve guide.• Hammer in the valve guide from the upper

surface of the cylinder head, using the valveguide installer.

Special tool

Valve guide remover and installer:

5-8840-2816-0

Height from the upper surface of the cylinder headto the edge surface of the valve guide;

NOTE:When replacing the valve guide, it must be replacedtogether with the valve.

Legend1. 12.6 ± 0.1 mm (0.50 ± 0.0039 in)2. Cylinder Head

3. Install the valve spring lower seat.4. Install the valve stem oil seal.

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

RTW56ASH008801

RTW56ASH009101

12

RTW56ASH009001

RTW56ASH023001

2

1


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

Special tool

Valve stem seal installer: 5-8840-2817-0

5. Install the intake and exhaust valve.• Apply engine oil on the valve stem part and

install the valve.

6. Install the valve spring.7. Install the valve spring upper seat.8. Install the split collar.

• Apply compressed air over the cylinder from theglow plug holes to keep the valve at the homeposition.

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

Special tool


Pivot: 5-8840-2819-0


NOTE:Move it up and down to check if it moves smoothly.

9. Install the valve stem end cap.10. Install the exhaust manifold assembly.

Refer to “Exhaust Manifold”.11. Install the intake manifold assembly.

Refer to “Intake Manifold”.

Installation1. Select the cylinder head gasket.

RTW56ASH013701

LNW21BSH018801

RTW56ASH012301

1

2


Cylinder Head Gasket SelectionCylinder head gasket is determined by the piston headprojection from the cylinder body upper surface, inorder to improve engine performance.Three types of gasket are provided with difference ofthickness. Select the appropriate one out of threegrades of gasket, according to the following procedure.Before measurement, clear off carbon from the pistonhead and cylinder body surface and also clean theplace where the gasket was installed.

1. Use a dial indicator to measure the pistonprojection amount.

2. Refer to the illustration for the piston headprojection measuring positions. All measuringpositions should be as close as possible to thecylinder block.

3. Measure the points 1, 2, 3, 4 and obtain twodifferences 1-2 and 3-4 on each cylinder. Calculatethe average value of the piston head projection oneach cylinder.

4. Obtain the maximum value in the four cylinders.5. Determine the gasket grade required to the

maximum value described above in accordancewith the following table.

Cylinder Head Gasket Combination mm(in)

LNW21BSH068001

RTW36ASH001701

4

3

2

1

LNW61ASH004301

2 1 3 4

RTW76ASH000301

A

Gasket Grade Mark Gasket ThicknessPiston Projection

0.067-0.117

(0.0026-0.0046)

0.95

(0.0374)

0.117-0.167

(0.0046-0.0066)

1.00

(0.0394)

0.167-0.217

(0.0066-0.0085)

1.05

(0.0413)

B

C


NOTE:Difference of each piston projection must be equal orwithin 0.05 mm (0.002 in).

6. Select the gear case gasket.• This should be of the same grade as cylinder

gasket is chosen.7. Apply liquid gasket (ThreeBond 1207B or

equivalent) at the two locations .

8. Install the cylinder head gasket and gear casegasket within 5 minutes of application of the liquidgasket.

9. Install the cylinder head assembly.• Wipe the cylinder head assembly lower face.• Install the cylinder head assembly, adjusting the

dowel of the cylinder block.10. Install the cylinder head bolt.

• Please use new cylinder head bolt.

• Use a torque wrench and angle gauge totighten the head bolts in the order described inthe drawing.

Tightening torque:

1st step = 70 N⋅m (7.1 kg⋅m / 51 lb ft)

2nd step = 70 N⋅m (7.1 kg⋅m / 51 lb ft)

3rd step = 60° (degrees)

4th step = 60° (degrees)

Special tool

Angle gauge: 5-8840-0266-011. Install the cylinder head gear case bolts (2) and

nuts (1).• Tighten the bolts and nuts to the specified

torque.


12. Install the rocker arm shaft assembly.• Apply the engine oil.

RTW56ASH009501

RTW56ASH020901

2

1

RTW56ASH009701

17

18

13 9 5 1 4 8 12 16

14 10 6 2 3 7 11 15

RTW56ASH020801

2

1

1


• Attach the rocker arm shaft assembly insequence from No.1 to No.4.


Legend1. Exhaust Rocker Arm Shaft Assembly2. Bolt (Long)3. Bolt (Short)4. Intake Rocker Arm Shaft Assembly5. Front

13. Install the water by pass pipe.Apply soapy water tothe O-ring.Tighten the bolt to the specified torque.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft) 14. Install the chain guide bolt from cylinder

head.Tighten the bolt to the specified torque.

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

15. Install the tension lever.

16. Rotate the crankshaft to make the No.1 cylindercompression top dead center (TDC).


17. Install the timing chain with idle gear D.• Apply the engine oil bolt thread and seat.


RTW56ASH012201

1

2

32

4

5

3

RTW56ASH019501

LNW76ASH001101

1

2

3

RTW56ASH021801


• Align the timing marks at two locations asshown.

Legend1. Timing Chain2. Timing Mark3. Blue Link4. Yellow Link

18. Install the timing chain tension lever pivot.Tightenthe bolt to the specified torque.


19. Hold the latch(3) depressed.Insert the plunger(2).Attach the hook(4) to the pin(1) to hold the plungerin place.

20. Install the timing chain tensioner (1) and gasket(2). Tighten the bolt to the specified torque.


21. Unlock the tensioner hook.• Press the place of the arrow in the figure.• The hook is opened. The plunger pushes the

tension lever.

RTW56ASH020301

2

4

1

3

2

RTW56ASH019401

LNW71BSH001501

1

2

4

3

LNW71BSH001401

1

2


22. Install the camshaft assembly.• Align timing mark on intake camshaft and

exhaust camshaft to idle gear D.


23. Install the camshaft bearing cap.• Apply engine oil to all of the cylinder head

journals.


24. Align mark (1) on camshaft to mark on camshaftbearing cap.• Align mark on intake camshaft and exhaust

camshaft to mark of bearing cap.

25. Remove the M5 lock bolt from the camshaft Gear.26. Turn the crank pulley two rotation (720°CA)

• Align mark on camshaft to mark on camshaftbearing cap.

RTW56ASH020401

RTW56ASH007001

1 2

3

RTW56ASH013801

RTW56ASH006901

1



Legend1. Timing Chain2. Timing Mark3. Dark Plate4. Yellow Plate

27. Apply liquid gasket to timing chain cover upper.Refer to procedure for fuel system in this manual.

28. Install the timing chain cover upper.Refer to procedure for fuel system in this manual.

29. Apply liquid gasket to timing chain cover lower.Refer to procedure for fuel system in this manual.

30. Install the timing chain cover lower.Refer to procedure for fuel system in this manual.

31. Install the noise cover.Refer to procedure for fuel system in this manual.

32. Inspection and adjustment of valve clearance.Refer to procedure for service precautions in thismanual.

33. Install the fuel injector.Refer to procedure for fuelsystem in this manual.

34. Install the baffle cover.Refer to procedure forcamshaft in this manual.

35. Install the cam end gasket.• Apply the liquid gasket (ThreeBond TB-1207B

or equivalent).

Legend1. Cam End Gasket2. 2.0 to 3.0 mm (0.078 to 0.118 in)

36. Install the cylinder head cover.Refer to “Cylinder Head Cover”.

37. Install the glow plug. Tighten the glow plug to thespecified torque.

Tightening torque: 18 N⋅m (1.8 kg⋅m / 13 lb ft) 38. Install the glow plug connector. Tighten the nuts to

the specified torque.

Tightening torque: 2 N⋅m (0.2 kg⋅m / 17 lb in) 39. Install the fuel injection pipe.

Attachment order No.2→No.1→No.3→No.4 40. Tighten the fuel injector clamp bolt to the specified

torque.

Tightening torque: 26 N⋅m (2.7 kg⋅m / 20 lb ft)41. Tighten the injection pipe to the specified torque.

Tightening torque: 30 N⋅m (3.1 kg⋅m / 22 lb ft)42. Install the fuel injection pipe clip .Tighten the nut to

the specified torque.


RTW56ASH020701

1 2

3

RTW56ASH020301

2

4

1

3

2

RTW56ASH020601

3

2

1


43. Install the engine oil level gauge guide.• Apply engine oil to the O-ring. Tighten the bolt

to the specified torque.

Tightening torque: 25 N⋅m (2.6 kg⋅m / 19 lb ft)44. Install the A/C compressor bracket.Tighten the bolt

to the specified torque.

Tightening torque: 25 N⋅m (2.6 kg⋅m / 19 lb ft)45. Install the A/C compressor adjust pulley. Tighten

the bolt (1) and nut (2) to the specified torque.

Tightening torque: bolt 25 N⋅m (2.6 kg⋅m/19 lb ft) (Dry)

Tightening torque: nut 41 N⋅m (4.2 kg⋅m/30 lb ft)

46. Install the A/C compressor and connector.Tighten the bolt to the specified torque.

Tightening torque: 44 N⋅m (4.5 kg⋅m / 33 lb ft)47. Connect each connector.

• Barometric Sensor• EGR Valve• Glow plug• Water temperature sensor• Camshaft Position sensor• Throttle Assembly

48. Install the exhaust front pipe.Refer to procedure for exhaust system in thismanual.

49. Install the EGR cooler.Refer to procedure for exhaust system in thismanual.

50. Install the EGR cooler water pipe.Refer to procedure for exhaust system in thismanual.

51. Install the EGR cooler heat protector.Refer to procedure for exhaust system in thismanual.

52. Install the cooling fan.Refer to procedure for Engine cooling in thismanual.

53. Install the A/C drive belt.Refer to Procedure for Intake Manifold in thismanual.

54. Install the fan guide bracket.55. Install the radiator upper hose.56. Install the Turbocharger.

Refer to “Turbocharger“.57. Replenish the coolant.

LNW76CSH001101

2 1



Special Tools

LNW76ALF000801

70(7.1/51)

70(7.1/51)

60

60

18(1.8/13)

26(2.7/20)

25(2.5/18)

27(2.8/20)

10(1.0/87lb in)

25(2.5/18)

25(2.5/18)

2(0.2/17lb in)


5-8840-2820-0Injection pipe oil seal

installer

5884028200

5-8840-2816-0Valve guide remover and

installer


5884028160


5-8840-2817-0Valve stem seal installer

5-8840-2818-0Valve spring replacer

5-8840-2819-0Pivot

5-8840-0266-0Angle gauge


5884028170

5884028180

5884028190


Piston and Connecting RodComponents

Legend1. Piston Pin Snap Ring2. Piston Pin3. Piston Ring

4. Piston5. Connecting Rod6. Bearing

Removal1. Demount the engine assembly.

Refer to "Engine Assembly".2. Remove the cylinder head cover.

Refer to "Cylinder Head Cover".3. Remove the camshaft assembly.

Refer to "Camshaft Assembly".4. Remove the cylinder head.


5. Remove the gear case assembly.Refer to "Gear Case Assembly".

6. Remove the oil pan.Refer to "Oil Pan and Crank Case" .

7. Remove the connecting rod cap.

NOTE:Sort the removed bearings according to cylinders byusing tags.

RTW56ALF001601

4

1

5

2

1

3

6


8. Remove the piston and connecting rod.• Remove carbon on the upper side of the

cylinder block with a scraper.• Pull out the piston and connecting rod towards

the cylinder head.

NOTE:Be sure not to damage the oil jet and cylinder blockwhen pushing out the connecting rod.

9. Remove the connecting rod bearing.

NOTE:Sort the bearings in the order of cylinders when reusingthem so that they are not confused with the bearings ofother cylinders.

Disassembly1. Remove the piston ring.

• Use ring pliers to remove the piston ring.

NOTE:Sort the piston rings in the same order as the cylinderswhen reusing them so that they are not confused withthe pistons and piston rings of other cylinders.

2. Remove the snap ring.3. Remove the piston pin.

NOTE:Sort the disassembled piston pins, pistons andconnecting rods together in the same order as thecylinders.

4. Remove the connecting rods from the piston.5. Piston

• Carefully clean carbon that is adhered to thehead of the piston and the groove of the pistonring.

NOTE:Do not use a wire brush to clean the piston because itscratches the piston.Visually inspect the piston for cracks, burns and otherexcessive wear, and replace it if there is anyabnormality.

LNW21BSH004901 LNW21BSH005101

LNW21BSH005201


6. Measure the gap between the piston and the innerdiameter of the cylinder bore.Inner diameter of the cylinder block.• Use a cylinder bore dial indicator to measure

the cylinder block inner diameter both in thethrust and radial directions in the designatedposition.

• Measurement position (from the upper surfaceof the cylinder block) 20 mm (0.79 in)

• Measure the cylinder block inner diameterbased on the average value of the actualmeasurement values on 2 positions.

Legend1. 20 mm (0.79 in)2. Radial3. Thrust

Piston outside diameter• Use a micrometer to measure the outside

diameter of the piston in the right angle to thepiston pin in the designated position.

• Measurement position (from the bottom surfaceof the piston) 11.00 mm (0.43 in).

Legend1. 11 mm (0.43 in)

NOTE:If it is found that the gap between the cylinder blockinner diameter and the piston exceeds the standardvalue, replace the piston or cylinder block.

7. Piston replacement• The head of the piston has a marking of grade

A, B or C.The mark shows the grade of the piston.

• If oversize pistons are installed, rebore thecylinder block.Refer to "Cylinder Block".

Cylinder block inner diameter mm (in)95.421 - 95.450 (3.75673 - 3.75787)

LNW21BSH039801

1

33

2

2

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

mm (in)

Standard 0.082 - 0.100 (0.0032 - 0.0039)

Piston Grade (Service Part) mm (in)A 95.340 - 95.369 (3.75354 - 3.75469)B 95.350 - 95.379 (3.75394 - 3.75508)C 95.360 - 95.389 (3.75433 - 3.75547)

RTW56ASH023101

1


Legend1. Grade2. Front Mark Cut

8. Inspect the piston ring.• Insert the piston ring horizontally (in the position

it would assume if it were installed to the piston)into the cylinder liner.

• Push the piston ring into the cylinder bore untilit reaches the measuring point 1 or 2 where thecylinder liner bore is the smallest.Do not allowthe piston ring to slant to one side or the other.It must be perfectly horizontal. Measuring Point 1 10 mm (0.4 in)orMeasuring Point 2 20 mm (0.8 in)

• Use a thickness gauge to measure the pistonring gap.If the measured value exceeds the specifiedlimit, the piston ring must be replaced.

LNW76ASH001401

2

1

LNW21BSH034801

Piston ring gap mm (in)Standard Limit

1st compression ring 0.27 - 0.51 (0.0106 - 0.0200)

1.50 (0.059)

2nd compression ring 0.42 - 0.66 (0.0165 - 0.0260)

1.50 (0.059)

LNW61ASH004401

1

LNW61ASH004501

2


Measure the clearance between the piston ringgroove and the piston.

• Remove carbon in the piston ring groove.• Put the piston ring in the piston ring groove, use

a thickness gauge to measure the gap betweenthem.

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

*Measurement is impossible

9. Inspect the piston pin.• Visually inspect the piston pin for cracks,

scratches and other damages, and replace it ifnecessary.

• Use a micrometer to measure the outerdiameter of the piston pin. If the measuredvalue exceeds the limit, replace the piston pin.

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

• If it feels a large looseness or instability innormal temperatures, replace the piston orpiston pin.

• Measure the bush of the small edge of theconnecting rod. If the clearance of the bushinner diameter and the pin diameter exceedsthe limit, replace the bush or connecting rodassembly, and the pin.

Oil ring 0.27 - 0.56 (0.0106 - 0.220)

1.50 (0.059)

Piston ring and piston ring groove clearance

mm (in)

Standard Limit1st compression ring —* —*

2nd compression ring 0.05 - 0.09 (0.0020 - 0.0035)

1.50 (0.059)

Oil ring 0.03 - 0.07 (0.0012- 0.0028)

1.50 (0.059)

Piston pin outer diameter mm (in)Standard 33.995 - 34.000 (1.33838 - 1.33858)

Limit 33.970 (1.33740)

LNW21BSH009501

Piston pin and connecting rod small end bushing clearance

mm (in)

Standard 0.008 - 0.020 (0.0003 - 0.0008)Limit 0.05 (0.0020)

LNW21BSH009601

LNW21BSH009701


10. Measure the clearance between the piston and thepiston pin.• Apply engine oil on the piston pin. Use your

finger to push it in the piston hole and rotate it.If the pin smoothly rotates without instability, theclearance is normal. If there is instability,measure the clearance. If the clearanceexceeds the limit, replace the piston and thepiston pin.

11. Measure the connecting rod alignment.• Use a connecting rod aligner to measure the

torsion and parallel level of the big end hole andthe small end hole. If the measured valueexceeds the limit, replace it.

12. Measure the bearing oil clearance.• Install the bearing to the connecting rod big

end.• Tighten the bearing cap to the two step of

angular tightening method.• Use an inside dial indicator to measure the

connecting rod bearing inside diameter.

If the clearance between the measured bearinginside diameter and the crank pin exceeds thespecified limit, the bearing and/or thecrankshaft must be replaced.

Reassembly1. Install the piston.2. Install the connecting rod.

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

• Install the snap ring of one side.

Piston pin and piston pin hole clearance mm (in)Standard 0.008 - 0.019 (0.0003 - 0.0007)

Limit 0.04 (0.0016)

Connecting rod alignment(par length of 100 mm (3.94 in)) mm (in)

Standard LimitDistortion 0.08 (0.003) or less 0.20 (0.008)

Parallelism 0.05 (0.002) or less 1.50 (0.006)

LNW21BSH009801

Connecting rod bearing cap bolt torque: mm (in)1st step 29.4 (3.0 / 22)2nd step 45 deg

Crank pin and bearing clearance mm (in)Standard 0.029 - 0.083 (0.0011 - 0.0026)

Limit 0.10 (0.0039)

LNW21BSH010401


Legend1. Front Mark2. Forging Mark (Projecting)

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

4. Use snap ring pliers to install the snap ring.

NOTE:Make sure that the snap ring is installed in the ringgroove properly. Make sure that the connecting rodmoves smoothly.

5. Use ring pliers to install the piston ring.• Install the piston rings in the order shown in the

illustration.• Install 2nd and 1st compression rings in this

order so that the marks "2N" and "N" faceupward.

• Insert the expander coil into the oil ring grooveso that there is no gap on either side of theexpander coil before installing the oil ring.

Legend1. Compression Ring 1st2. Compression Ring 2nd3. Oil Ring4. Expander

Installation1. Install the connecting rod bearing.

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

2. Install the piston and connecting rod assembly.• Apply enough engine oil on the piston ring, ring

groove and piston side surface.• Dislocate the piston ring end gap so that (1) is

1st ring, (3) is 2nd ring and (2) is oil ring, asshown in the drawing.

• With the piston front mark cut facing forward,use the piston ring compressor to insert thepiston in the cylinder liner.

NOTE:• Be sure not to make the connecting rod touch the oil

jet when pushing in the piston.• Be sure not to harm the inside of the cylinder block

when pushing in the piston.

LNW41BSH003701

1

2

LNW61ASH004601

RTW56ASH023201

3 1

42

3

2

1

4


Special toolPiston ring compressor: 5-8840-9018-0

3. Install the connecting rod cap.• Install the bearing on the connecting rod cap

and apply engine oil.• Install the cap, matching the numbers (1, 2, 3,

and 4) of the caps and connecting rods.

• Apply engine oil on the screw part and thesetting face of the tightening bolt and tighten itwith the designated torque.

Tightening torque:

1st step = 29.4 N⋅m (3.0 kg⋅m / 22 lb ft)

2nd step = 45° (degrees)Special toolAngle gauge: 5-8840-0266-0

NOTE:Make sure that the crankshaft smoothly rotates.

4. Install the oil pan.Refer to "Oil Pan and Crank Case".

5. Install the gear case assembly.Refer to "Gear Case Assembly".

6. Install the cylinder head.Refer to "Cylinder Head".

7. Install the camshaft assembly.Refer to "Camshaft Assembly".

8. Install the cylinder head cover.Refer to "Cylinder Head Cover".

LNW21BSH072201

LNW61ASH004801

LNW21BSH011401



Special Tools

RTW56AMF001801

Lubricate with engine oil

29.4(3.0/22)

1st STEP

45

2nd STEP

N·m(kg·m/lb ft)


5-8840-9018-0Piston ring compressor


5884090180


FlywheelComponents

Legend1. Pressure Plate Assembly2. Driven Plate 3. Pilot Bearing4. Washer5. Flywheel

6. Bearing Stopper7. Flywheel Housing8. Flywheel (Smoother E)9. Flexible Plate

Removal1. Remove the starter.2. Remove the transmission assembly.

Refer to "transmission assembly removal andinstallation".

3. Remove the clutch pressure plate.• Remove the pressure plate installation bolts in

the order shown in the drawing.• Remove the pressure plate from the flywheel.

LNW71BMF000601

7

8

9

3

4

4

6

1

5

2

10


4. Remove the driven plate.• Remove the driven plate from the flywheel

along with the clutch aligner (1).5. Install the crankshaft stopper in the starter

installation part of the flywheel housing.

NOTE:Make sure that the stopper is applied with the ring gearand installed properly.

Special tool

Crankshaft stopper: 5-8840-0214-0

6. Remove the flywheel.• Gradually loosen the flywheel installation bolts

in the order shown in the drawing so that theflywheel does not rotate.

• After loosening the bolts, remove the stopperand remove the flywheel.

• In the case of A/T car, after loosening theflywheel installation bolts, remove the washer,flexible plate, flywheel and sleeve in this order.

7. Remove the pilot bearing.• Remove the pilot bearing from the flywheel.

Special toolPilot Bearing Remover: 5-8840-2000-0Sliding Hammer: 5-8840-0019-0

8. Remove the ring gear.• Put a bar on the ring gear and hit it with a

hammer to remove it.

LNW21BSH002501

1 5

7

9

4

26

8

10

3

LNW21BSH007701

LNW21BSH072801

1

6

3 8

5

2

74

LNW21BSH029301

1

2

3


Inspection1. Visual inspection

• Inspect the flywheel friction surface for cracksand damages, and replace it if it hasabnormality.

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

2. Measurement of the friction surface• Measure the depth of the friction surface of the

flywheel.• Adjust it if the measured value is within the

standard value and the limit.• If the measured value exceeds the limit, replace

the flywheel.

Depth = From the pressure installation surface tothe friction surface.

3. Flywheel installation bolts.• There is no damage in appearance.• Exchange for a new part if damage is

extensive.

Installation1. Install the pilot bearing

• Place the crankshaft pilot bearing right angleacross the crankshaft bearing installation hole.

• Tap around the edges of the crankshaft pilotbearing outer races with a brass hammer todrive the bearing into the crankshaft bearinginstallation hole.

2. Install the ring gear.• Heat the ring gear evenly with a gas burner to

invite thermal expansion. Do not allow thetemperature of the gas burner to exceed 200°C(390°F).

• Install the ring gear when it is sufficientlyheated. The ring gear must be installed with thechamfer facing the clutch.

NOTE:• Install the ring gear so that the side with a pattern

faces forward.• Shrink fit the ring gear to the flywheel.Make sure

that flywheel and ring gear adhesion is complete.

Depth of the friction surface of the flywheel mm (in)Standard 12 (0.4724)

Limit 13 (0.5118)

LNW21BSH012001

LNW21BSH011901


3. Install the flywheel.• Install the flywheel of the crankshaft, tighten

them in the order shown in the illustration.• Apply molybdenum disulfide on the screw part

and setting face of the bolt.• Install the crankshaft stopper on the starter

installation part of the flywheel housing.

Tightening torque:

1st step = 59 N⋅m (6.0 kg⋅m / 43 lb ft)

2nd step = 60° - 90° (degrees)Special toolCrankshaft stopper: 5-8840-0214-0

4. Install the driven plate.• Use a clutch aligner to install the driven plate on

the flywheel.

Legend1. Clutch Aligner

5. Install the clutch pressure plate.• Install the pressure plate on the flywheel so that

the installation hole of the pressure platematches with the dowel pins of the flywheel.

• Tighten the pressure plate in the order shown inthe drawing.

Tightening torque: 51N⋅m (5.2 kg⋅m / 38 lb ft)

6. Install the transmission assembly.Refer to "transmission assembly removal andinstallation".

7. Install the starter.

Tightening torque: 127 N⋅m (13 kg⋅m / 94 lb ft)

LNW21BSH012101

LNW71BSH001301

1

9

3

8

6

2

4

7

5

LNW21BSH002601

1

LNW21BSH002501

1 5

7

9

4

26

8

10

3



Special Tools

LNW76AMF000301

59(6.0/43) 60 to 90

59(6.0/43) 60 to 90

51(5.2/38)


5-8840-2230-0Crankshaft stopper


5884022300


Gear Case AssemblyComponents

Legend1. Adjust Plate2. Generator

3. Gasket4. Gear Case Assembly


Refer to “Engine Assembly”.2. Remove the cylinder head.

Refer to “Cylinder Head”.3. Remove the adjustment bracket of generator.4. Remove the vacuum pump and pipe.

Refer to removal procedure for brake in thismanual.

5. Remove the power steering pump.Refer to removal procedure for power steering inthis manual.

6. Remove the water pump.Refer to removal procedure for water pump in thismanual.

7. Remove the fuel supply pump.Refer to removal procedure for fuel supply pump inthis manual.

LNW76ALF000301

1

2

4

3


8. Remove the crankshaft pulley.Refer to removal procedure for crankshaft front oilseal in this manual.

9. Remove the gear case cover.Refer to removal procedure for gear case cover inthis manual.

10. Remove the idle gear A and idle gear A shaft, idlegear C and idle gear C shaft.Refer to “Timing Gear Train”.

11. Remove the oil pump.Refer to “Oil Pump”.

12. Remove the timing gear case (1) and gasket (2).

Installation1. Install the gasket of the timing gear case.

• Apply liquid gasket (ThreeBond 1207B orequivalent) on the joint (1) of the cylinder blockand the crank case.

2. Install the timing gear case.

• Install the timing gear case to match with thedowel pins, install bolts them in the order shownin the illustration.

• Do not remove the bolts(11) when maintaining.

Legend1. Gear Case Assembly2. Bolt L = 20 mm (0.79 in)3. Bolt L = 60 mm (2.36 in)4. Bolt L = 45 mm (1.77 in)5. Bolt L = 35 mm (1.38 in)6. Bolt L = 16 mm (0.63 in)7. Bolt L = 20 mm (0.79 in)8. Bolt L = 25 mm (0.98 in)9. Nut

10. UP10. Bolt

• Tighten the bolts and nuts to the specifiedtorque.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)3. Install the oil pump.

Refer to “Oil Pump”.4. Install the idle gear C shaft and idle gear C, idle

gear A shaft and idle gear A.Refer to “Timing Gear Train”.

5. Install the gear case cover.Refer to removal procedure for gear case cover inthis manual.

6. Install the crankshaft pulley.Refer to removal procedure for crankshaft front oilseal in this manual.

7. Install the fuel supply pump.Refer to installation procedure for fuel supplypump in this manual.

8. Install the water pump.Refer to installation procedure for water pump inthis manual.

RTW76ASH001201

1

2

RTW56ASH016301

1

LNW76ASH002701

10

3

111

11

11

2

2

2

2

2

222

8

2

2

929

2

5

4

46

7


9. Install the power steering pump.Refer to removal procedure for power steering inthis manual.

10. Install the vacuum pump and pipe.Refer to removal procedure for brake in thismanual.

11. Install the adjustment bracket of generator.Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)12. Install the cylinder head.

Refer to “Cylinder Head”.13. Install the engine assembly.

Refer to “Engine Assembly”.


LNW76ALF000401

25 (2.5/18)

25 (2.5/18)

25 (2.5/18)

51 (5.2/38)


Crankshaft Front Oil SealComponents

Legend1. Bolt2. Washer3. Crankshaft Damper Pulley4. Crankshaft Front Oil Seal

5. Gear Case Cover6. Slinger7. Crankshaft Gear

Removal1. Remove the radiator.

Refer to “Radiator“ in ENGINE COOLING section.2. Remove the fan assembly.

• Remove the fan assembly unscrewing fourmounting nuts.

LNW76AMF000401

3

2

1

4

5

6

7

LNW61BSH003601


3. Remove the fan belt.4. Remove the crankshaft pulley.

NOTE:Do not reuse the crankshaft pulley bolt and the washer.

5. Remove the crankshaft front oil seal.• Use the special tool to remove the front oil seal.

Special tool

Remover: 5-8840-0027-0• Put a rod and a wooden piece etc. as shown in

the illustration. And pull the rod to the frontslowly, and remove the crankshaft front oil seal.

Legend1. Rod2. Remover3. Wooden Piece

6. Remove the gear case cover.7. Remove the slinger.

• Remove the slinger with a screwdriver etc.avoiding damage to the surface of thecrankshaft gear.

NOTE:The slinger does not need to be replaced if there are noscratches nor damages.

Installation1. Install the slinger.

• Use the special tool to install the slinger.

• Tighten the bolt as far as it will go.

Special tool

Oil seal and slinger installer: 5-8840-2855-0

The length from the surface of the crankshaft gear tothe surface of the slinger:

Legend1. Bolt2. Washer3. Slinger Installer4. Slinger5. Crankshaft Gear6. Crankshaft

2. Install the gear case cover.3. Install the crankshaft front oil seal.

• Use the special tool to install the front oil seal.Use only one of the special tools when the oilseal is installed.

Special tool

Oil seal and slinger installer: 5-8840-2855-0

The length from the surface of the crankshaft gear tothe surface of the oil seal:

LNW76ASH002801

1

2

3

5.8 - 6.2 mm (0.228 - 0.244 in)

14.75 - 15.25 mm (0.581 - 0.600 in)

LNW76ASH002901

1

2

3 4

5 6


Legend1. Bolt2. Washer3. Front Oil Seal Installer4. Gear Case Cover5. Front Oil Seal6. Slinger7. Crankshaft Gear8. Crankshaft

• Apply engine oil to the lip of the oil seal.4. Install the crankshaft damper pulley.

• Install the crankshaft pulley aligning with thekey on the crankshaft.

• Hold the flywheel ring gear stationary to preventthe crankshaft from turning when tightening thedamper pulley bolt.

• Tighten in the sequence shown.• Take care not to damage the crankshaft

damper pulley boss.

Tightening torque: 294 N⋅m (30 kg⋅m/217 lb ft)5. Install the fan belt.

Refer to "Engine Cooling"6. Install the radiator.

Refer to “Radiator“ in ENGINE COOLING section.

LNW76ASH003001

1

2

3

54 6 7 8



Special Tool

LNW76AMF000501

294(30/217)


5-8840-0027-0Remover

5-8840-2855-0Oil seal and slinger

installer

5884028550


Crankshaft Rear Oil SealComponents

Legend1. Starter2. Transmission Assembly3. Clutch Pressure Plate4. Driven Plate

5. Flywheel6. Crankshaft Rear Oil Seal7. Transmission Assembly8. Flexible Plate

Removal1. Remove the flywheel.

Refer to "Flywheel".• With the oil seal pushed in deep, install the

special tool as shown in the illustration andremove the oil seal.Oil Seal Remover: 5-8840-2360-0

LNW71BLF000501

8

7

2

3 4

5

1

6


Installation1. Install the crankshaft rear oil seal.

• Use an oil seal install to install the crankshaftrear oil seal.Oil Seal Installer: 5-8840-2359-0

2. Install the flywheel.Refer to "Flywheel".

Special Tools

LNW76ASH002301

RTW56ASH022901

12.5±0.3mm

(0.49±0.01in)


5-8840-2359-0Oil seal installer

5-8840-2360-0Oil seal remover


CrankshaftComponents

Legend1. Upper Bearing2. Thrust Bearing3. Gear

4. Crankshaft5. Lower Bearing6. Bearing Cap



Refer to "Cylinder Head Cover".3. Remove the camshaft.



5. Remove the fuel supply pump and common rail.Refer to "Fuel Supply Pump and Common Rail" inthe fuel system section.

6. Remove the front cover.Refer to "Front Cover".

7. Remove the crankshaft rear oil seal.Refer to "Crankshaft Rear Oil Seal".

RTW56ALF002601

1

2

3

4

5

6


8. Remove the water pump.Refer to "Water Pump" in the Cooling SystemSection.

9. Remove the timing gear train.Refer to "Timing Gear Train".

10. Remove the oil pump.Refer to "Oil Pump".

11. Remove the gear case assembly.Refer to "Gear Case Assembly".

12. Remove the crankshaft gear.

13. Remove the crank case.Refer to "Crank Case and Oil Pan".

14. Remove pistons and connecting rods.Refer to "Pistons and Connecting Rods".

15. Remove the bearing cap.• Loosen the crankshaft bearing cap bolts in

numerical order a little at a time.

16. Remove the lower crankshaft bearings.17. Remove the crankshaft assembly.

18. Remove the thrust bearing.19. Remove the upper crankshaft bearings.

Disassembly1. Remove the crank angle sensor rotor.

Legend1. Crank Angle Sensor Rotor2. Bolt

Reassembly1. Install the crank angle sensor rotor

• Attach by making a rotor tooth's running outside into a front side.

• Apply Loctite #262 or the equivalent to the boltthreads (if a new bolt is used, Loctiteapplication is not required).


LNW61ASH005501

LNW21BSH037601

37 10 6 2

15984

RTW56ASH016801

1

2


Legend1. Crank Angle Sensor Rotor2. Bolt

Inspection1. Thrust clearance

• Measure the crankshaft end play at the centerjournal of the crankshaft.

• Do this before removing the crankshaft bearingcaps. If the measured value exceeds thespecified limit, the crankshaft thrust bearingmust be replaced.

NOTE:Measure the thrust clearance before dismounting.

2. Main bearing clearance• Remove the crankcase.Set out disassembled

main bearings in the order of the numbers.• Remove the crankshaft. Remove the main

bearings.• Clean the crankshaft journal and upper and

lower bearings.• Check the bearings for damage or excessive

wear.If you find damage or excessive wear, replacethe bearings in pairs.

• Place the upper bearings and the crankshaft onthe cylinder block. Install the crankshaft so thatit is horizontal.

NOTE:Turn the crankshaft about 30 degrees to allow thebearings to settle in.

• Place Plastigage on the crankshaft journal asshown.

Axial play of the crankshaft mm (in)Standard 0.10 (0.004)

RTW56ASH016701

1

1

2

LNW61ASH005701


• Place the lower bearings at original positions onthe bearing cap.

• Install the bearing cap and tighten bolts to thespecified tightening torque.

• Tighten the bearing cap in the sequence shownusing a torque wrench and an angle gauge.


NOTE:Do not turn the crankshaft after you have tightened thebearing cap.

• Loosen the bolts and gently remove the bearingcap.

• Measure the widest part of the Plastigageflattened by tightening the bearing cap todetermine the clearance.

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

• Remove the Plastigage from the bearings andthe crankshaft.

Inspection of the crankshaft• Check the crankshaft journal and crank pin

surfaces for wear and damage. Check the oilseal contact surface for excessive wear anddamage.

• Check the oil port for clogging.3. Crankshaft run-out

Carefully set the crankshaft on the V block. Slowlyturn the crankshaft to measure the run-out. If thecrankshaft run-out exceeds the limit, replace thecrankshaft.

Journal oil clearance mm (in)

LNW61ASH005801

LNW21BSH038701

8 41

7

3 2 6

5 9

10

#1,#2,#4,#5 0.030 - 0.054 (0.0012 - 0.0021)#3 0.042 - 0.066 (0.0016 - 0.0026)

Crankshaft run-out mm (in)Standard 0.05 or less (0.0020 or less)

LNW21BSH024401


4. Measure the journal and the crank pin diametersand uneven wear.• Measure outer diameters of the journal and the

pin and calculate differences between themaximum and the minimum values. Takemeasurements at four positions for both thejournal and the pin.

NOTE:Tufftriding (soft nitriding treatment) is applied toenhance strength of the crankshaft. Therefore, youshould not polish the surface of the crankshaft.

Crankshaft bearing selection• Crankshaft bearing selection is based on the

measured diameters of the crankshaft journalsand the bearing inserts.

• Match the crankshaft bearing housing grademarks and the crankshaft journal grade marksin the table below to determine the correctcrankshaft bearing size.

• Crankshaft bearing housing grade marks 1, 2 or3 are stamped on the rear right hand side of thecylinder body.

Legend1. No.12. No.23. No.34. No.45. No.5

• The crankshaft journal grade marks (1 or -, 2 or--, 3 or ---) are stamped on each crankshaftjournal web. The crankshaft journal and bearingclearance must be the same for each positionafter installation of the crankshaft and thecrankshaft bearings.

NOTE:The crankshaft journal mark No. 4 is stamped oncrankshaft No. 4 journal web front side or rear side.

Crankshaft Outside Diameter mm (in)

Standard Limit

Journal 69.917 - 69.932(2.7526 - 2.7532)

69.91(2.7524)

Pin 52.915 - 52.930(2.0833 - 2.0839)

52.9(2.083)

LNW21BSH024501

LNW21BSH024601

LNW76ASH003101

1

1 1 12 2

2 3 4 5


Legend1. No.12. No.23. No.34. No.45. No.5

NOTE:Be careful about difference in the shape of the bearingswhen installing them.

RTW56ASH017201

1 2 53 4


Legend1. Lot No2. Size Code

Bearing Selection Table (#1, #2, #4, #5)

Bearing Selection Table (#3)

mm (in)Crankshaft

Bearing Housing Crankshaft Journal Crankshaft Bearing

Size CodeGrade Mark Diameter Grade

Mark Diameter

1

73.992-74.000

(2.9131-2.9134)

1 or -

69.927-69.932

(2.7530-2.7532)

4

2 or - -

69.922-69.927

(2.7528-2.7530)

3 or - - -

69.917-69.922

(2.7526-2.7528)

5

2

73.983-73.991

(2.9127-2.9130)

1 or -

69.927-69.932

(2.7530-2.7532)

2

2 or - -

69.922-69.927

(2.7528-2.7530)

3

3 or - - -

69.917-69.922

(2.7526-2.7528)

4

RTW56ASH017301

1

2

3

73.975-73.982

(2.9124-2.9127)

1 or -

69.927-69.932

(2.7530-2.7532)

1

2 or - -

69.922-69.927

(2.7528-2.7530)

2

3 or - - -

69.917-69.922

(2.7526-2.7528)

mm (in)Crankshaft

Bearing Housing Crankshaft Journal Crankshaft Bearing

Size CodeGrade Mark Diameter Grade

Mark Diameter

1

73.992-74.000

(2.9131-2.9134)

1 or -

69.927-69.932

(2.7530-2.7532)

2

2 or - -

69.922-69.927

(2.7528-2.7530)

3 or - - -

69.917-69.922

(2.7526-2.7528)

3

2

73.983-73.991

(2.9127-2.9130)

1 or -

69.927-69.932

(2.7530-2.7532)

0

2 or - -

69.922-69.927

(2.7528-2.7530)

1

3 or - - -

69.917-69.922

(2.7526-2.7528)

2


Installation1. Install the crankshaft upper bearing.

• The crankshaft upper bearings have an oil holeand an oil groove. The lower bearings do not.

• Carefully wipe any foreign material from theupper bearing.

• Locate the position mark applied atdisassembly if the removed upper bearings areto be reused.

NOTE:Do not apply engine oil to the bearing back faces andthe cylinder body bearing fitting surfaces.

2. Install the crankshaft assembly.Apply an amplecoat of engine oil to the crankshaft journals and thecrankshaft bearing surfaces before installing thecrankshaft.

3. Install the thrust bearing.• Apply an ample coat of engine oil to the thrust

bearings before installation. Install the thrustbearings to the crankshaft center journal.

• The thrust bearing oil grooves must be facingthe sliding faces.

4. Install the lower crankshaft bearing.• Before the crankshaft bearing installation,

select the appropriate bearings in accordancewith the description in CRANK BEARINGSELECTION of INSPECTION AND REPAIR.

5. Install the bearing cap.

3

73.975-73.982

(2.9124-2.9127)

1 or -

69.927-69.932

(2.7530-2.7532)

9

2 or - -

69.922-69.927

(2.7528-2.7530)

0

3 or - - -

69.917-69.922

(2.7526-2.7528)

LNW21BSH038301

LNW61ASH006101

LNW21BSH037401


• Install the bearing caps with the bearing caphead arrow mark facing the front of the engine.The bearing cap numbers must be facing up.

• Tighten the crankshaft bearing cap bolts to thespecified torque a little at time in the sequenceshown in the illustration.

Check to see the crankshaft turns smoothly byrotating it manually.

NOTE:Confirm that the crankshaft turns smoothly.

6. Install pistons and connecting rods.Refer to "Pistons and Connecting Rods".

7. Install the crank case.Refer to "Crank Case and Oil Pan".

8. Install the crankshaft gear.

9. Install the gear case assembly.Refer to "Gear Case Assembly".

10. Install the oil pump.Refer to "Oil Pump".

11. Install the timing gear train.Refer to "Timing Gear train".

12. Install the water pump.Refer to "Water Pump" in the Cooling SystemSection.

13. Install the front cover.Refer to "Front Cover".

14. Install the crankshaft rear oil seal.Refer to "Crankshaft Rear Oil Seal".

15. Install the fuel supply pump and common rail.Refer to "Fuel Supply Pump and Common Rail".




19. Mount the engine assembly on the chassis.Refer to "Engine Assembly".

Crankshaft Bearing Cap Torque N⋅m (kg⋅m / lb ft)166 (16.9 / 122)

LNW21BSH038601

1 2 3 4 5

LNW21BSH038701

8 41

7

3 2 6

5 9

10

RTW56ASH017001



RTW56AMF001301

12N·m(1.2kg·m/104 lb in)

N·m(kg·m/lb ft)166(16.9/122)


Cylinder BlockComponents

Legend1. Cylinder Block



Refer to "Cylinder Head Cover".3. Remove the camshaft assembly.


Refer to "Cylinder Head".5. Remove the fuel supply pump and fuel rail

assembly.Refer to "Fuel Supply Pump” and “Fuel RailAssembly" in FUEL SYSTEM section.

6. Remove the oil filter assembly and oil cooler.Refer to "Oil Filter Assembly and Oil Cooler".

7. Remove the crankshaft front oil seal.Refer to "Crankshaft Front Oil Seal".

8. Remove the crankshaft rear oil seal.Refer to "Crankshaft Rear Oil Seal".

9. Remove the oil pan.Refer to "Oil Pan".

10. Remove the water pump.Refer to "Water Pump" in the Cooling SystemSection.

11. Remove the front cover.Refer to "Front Cover".

12. Remove the timing gear train.Refer to "Timing Gear Train".

13. Remove the oil pump.Refer to "Oil Pump".

14. Remove pistons and connecting rods.Refer to "Pistons and Connecting Rods".

15. Remove the crankshaft.Refer to "Crankshaft"

16. Remove the piston cooling pipe.

Inspection1. Carefully remove water stains or other foreign

matters on the surface of the cylinder block.

RTW76ASF000101

1

RTW76ASH001101


• Be careful not to damage the cylinder block.2. Carefully remove the liquid gasket on the

crankcase mounting surface.3. Clean up the cylinder block.4. Visually inspect the cylinder block.

• Conduct color check and hydraulic (orpneumatic) test and if you find a crack or otherdamage, replace the cylinder block.

5. Cylinder block wear measurement.• Use a cylinder indicator to measure the cylinder

bore at measuring point (1) in the thrust (2-2)and axial (3-3) directions of the crankshaft.

• Measuring Point (1): 20 mm (0.79 in).If the measured value exceeds the specifiedlimit, the cylinder block must be replaced orrebored.

6. Cylinder Reboring.• Select oversize pistons to fit the largest cylinder

bore (previously measured).• At a point 11 mm (0.43 in) above the lower

edge of the piston skirt, measure the pistondiameter at a right angle to the piston pin.Calculate the additional cylinder boring requiredfor each cylinder.

Legend1. 11 mm (0.43 in)

• FormulaBoring inside diameter = D + C - H ± ED = Piston outside diameter(Measured Oversize Piston)C = Piston and cylinder bore clearance0.082 - 0.100 mm (0.0032 - 0.0039 in)H = Honing allowance0.03 mm (0.0012 in) or lessE = Boring machine error

• Bore and hone the cylinders individually asrequired.

• Once again, measure each cylinder bore.

Cylinder block bore diameter mm (in)

RTW76ASH000801

LNW21BSH039801

1

33

2

2

Standard 95.421 - 95.450 (3.7567 - 3.7579)Limit 95.48 (3.7590)

Piston size mm (in)Standard 95.340 - 95.389 (3.7535 - 3.7555)

Oversize(0.25) 95.590 - 95.639 (3.7634 - 3.7653)Oversize(0.50) 95.840 - 95.889 (3.7732 - 3.7752)Oversize(0.75) 96.090 - 96.139 (3.7831 - 3.7850)

Each cylinder bore remainder mm (in)

RTW56ASH023101

1


7. Cylinder block upper face warpage.• Use a straight edge (1) and a thickness gauge

(2) to measure the four sides and the twodiagonals of the cylinder body upper face.

• If the measured values exceeds the limit, thecylinder body must be replaced.

Installation1. Install the piston cooling pipe.

• Align the dowel pin of the piston cooling pipewith the pin hole on the cylinder block andtighten with the relief valve.

Tightening torque:

Relief valve 30 N⋅m (3.1 kg⋅m / 22 lb ft)

bolts M8 25 N⋅m (2.5 kg⋅m / 18 lb ft)

bolts M6 8 N⋅m (0.8 kg⋅m / 69 lb in)

NOTE:Be careful not to deform or damage the piston coolingpipe nozzle.

2. Install the crankshaft.Refer to "Crankshaft".

3. Install pistons and connecting rods.Refer to "Pistons and Connecting Rods".

4. Install the oil pump.Refer to "Oil Pump".

5. Install the timing gear train.Refer to "Timing Gear Train".

6. Install the front cover.Refer to "Front Cover".

7. Install the water pump.Refer to "Water Pump" in the Cooling SystemSection.

8. Install the oil pan.Refer to "Oil Pan".9. Install the crankshaft rear oil seal.

Refer to "Crankshaft Rear Oil Seal".10. Install the crankshaft front oil seal.

Refer to "Crankshaft Front Oil Seal".11. Install the oil filter assembly and oil cooler.

Refer to "Oil Filter Assembly and Oil Cooler".

0.02 (0.0008) or less.

Cylinder block upper face warpage mm (in)Standard 0.05 or less (0.002 or less)

Limit 0.20 (0.079)

Cylinder body height (H) (Reference) mm (in)Standard 262.945 - 263.055 (10.352 - 10.356)

LNW61ASH006501

1

2

LNW71BSH000301

H

RTW76ASH001101


12. Install the fuel supply pump and fuel rail assembly.Refer to "Fuel Supply Pump” and “Fuel RailAssembly" in FUEL SYSTEM section.




16. Mount the engine assembly on the chassis.Refer to "Engine Assembly”.


LNW71BSF000301

25 (2.5/18)30 (3.1/22)

8 (0.8/69lb in)


Lubrication SystemService Precautions

• During each disassembly, remove the old gasketadhering to each part and mating part completelyusing a scraper at the location, where the fluidgasket is to be used, clean the traces of oil,moisture, and dirt completely using waste cottonand apply the specified new fluid gasket at eachlocation.

• Avoid excessive or insufficient coating volume.Note that seizure may occur in case of excessivecoating due to clogging of the oil gallery and oil jet,and oil and water leakage may occur if the coatingis insufficient.

• Always, the start and end of the application shouldbe overlapped.

Explanations on functions and operationThe lubrication system uses the filter elementcombined with a full flow bypass, water-cooled oilcooler, and oil jet for piston cooling.

Lubricating system diagram

Legend1. Oil Pump Relief Valve Operating Pressure: 490 -

686 kPa (5.0 - 7.0 kg/cm2 / 71 - 100 psi)2. Oil Cooler Relief Valve Opening Pressure: 176 -

216 kPa (1.8 - 2.2 kg/cm2 / 26 - 31 psi)

LNW76ALF000201

Oil Pan

Oil Gallery

4. Oil Press.SW

WarningLamp

VacuumPump

Turbo-charger

CamshaftBearing

Rocker Arm

Timing ChainOil Jet

CrankshaftBearing

Idler GearShaft

5. RegulatingValve

3. ReliefValve

1. ReliefValve

2. ReliefValve

Oil Filter

Oil Cooler

Oil Pump

OilStrainer

Oil Filter & Cooler Assembly

ConnectingRod Bearing

Timing Gear

PistonCooling Jet


3. Oil Filter Relief Valve Opening Pressure: 80 -120 kPa (0.8 - 1.2 kg/cm2 / 11 - 17 psi)

4. Oil Pressure Switch Operating Pressure: 29.4 -49.0 kPa (0.3 - 0.5 kg/cm2 / 4.3 - 7.1 psi)

5. Regulating Valve: 176 - 216 kPa (1.8 - 2.2 kg/cm2 / 26 - 31 psi)

Functional CheckOil pressure check

1. Check whether the engine oil is contaminated withdirt, light oil, or water. If contaminated with dirt,light oil, or water (after examining the cause andtaking the appropriate measures for light oil orwater contamination), replace the oil.

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

3. Remove the oil pressure switch on the nipple.4. Install the oil pressure gauge on the nipple.5. Warm the engine.6. Measure the oil pressure, to check whether it is

more than 400 kPa (4 kg/cm2 / 58 psi) at 3600rpm.

7. Stop the engine.8. Remove the oil pressure gauge.9. Install the oil pressure switch.

10. Start the engine and check for oil leakage.

Engine oilEnsure the car is on level ground. Before starting theengine or when 30 minutes or more have elapsed afterstopping the engine, check the engine oil volume usingthe level gauge. The volume is appropriate if the engineoil is between the upper and lower limits of the levelgauge. Replenish the engine oil, if level is below thelower limit. Also, check for contamination of the engineoil.

Legend1. Lower Limit2. Upper Limit

Engine oil leakage• In the lift up condition, confirm that there are no

leaks from the cylinder head cover and oil pan.

RTW56ASH015701

ADD FULL

1 2


Oil Filter ElementComponents

Legend1. Oil Cooler2. Oil Filter Element3. Gasket4. Plate5. Spring

6. Center Bolt7. O-ring8. O-ring9. Drain Plug

10. Oil Filter Case

Removal1. Place a tray under the oil filter.2. Remove the drain plug, and oil in the filter is

drained.3. Remove the center bolt, and remove the element

in the case.

NOTE:Do not reuse the two O-rings and the gasket.

Installation1. Install the oil filter element.

• Apply grease(Besco L2, L3 or equivalent) orengine oil to the O-rings and the gasket.

• Tighten the bolt and the drain plug using thespecified torque.

Tightening torque:

Center bolt 44 N⋅m (4.5 kg⋅m / 33 lb ft)

Drain plug 24 N⋅m (2.4 kg⋅m / 17 lb ft)

LNW71HSF000101

1

2

3

4

5

6

7

8

9

10



LNW76ASF000101

25(2.5/18)44(4.5/33)


Oil Filter Assembly and Oil CoolerComponents

Legend1. Oil Filter Assembly and Oil Cooler2. Water By Pass Pipe

3. Water Intake Pipe

Removal1. Remove the turbocharger.

Refer to “Turbocharger”.2. Remove the exhaust manifold.

Refer to “Exhaust Manifold”.

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

LNW71HMF000101

1

2

3

RTW56ASH008401

1


4. Remove the water intake pipe (1).

Legend1. Water Intake Pipe2. Bracket3. Bracket4. Bolt

5. Remove the oil cooler and oil filter.

Disassembly1. Remove the element mounting nuts(1).

2. Remove the element (1).3. Remove the gasket (2).

Reassembly1. Install the gasket on the element.2. Install the element.3. Tighten the element fixing nuts using the specified

torque.


Installation1. Install the oil filter and cooler.

• Install the O-ring on the oil filter and cooler,apply grease.

RTW56ASH012601

2

1

3

4

LNW71HSH000101

RTW56ASH012901

1

RTW56ASH013001

1

2


• Apply the liquid gasket and mount within 5minutes. Apply liquid gasket (ThreeBond TB-1207C or equivalent) to the flange surfacegroove (cylinder block). Bead diameter mustbe between 2 and 3 mm (0.008 and 0.012 in).Refer to the illustration for the offset position(no more than 1 mm (0.004 in)).

Legend1. Liquid Gasket2. O-ring

• Align the oil filter and cooler holes with thecylinder block studs. Install the oil cooler to thecylinder clock.

Legend1. Bolt 35 mm X 112. Bolt 70 mm X 43. Bolt 90 mm X 24. Nut X 2

• Tighten the bolts to the specified torque in theorder shown in the illustration.


2. Install the water intake pipe.• After applying soapy water to O-ring, set it on

water intake pipe and insert into the oilcooler.Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft) 3. Install the water by pass pipe.

• After applying soapy water to O-ring, set it onby pass pipe and insert into the cylinderhead.Tighten the bolts to the specified torque.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)4. Install the bracket of generator.

Tighten the bolts to the specified torque.

Tightening torque: 51 N⋅m (5.2 kg⋅m / 38 lb ft)5. Install the adjustment bracket of generator.


Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)6. Install the generator.

Refer to Installation procedure for generator in thismanual.

7. Install the exhaust manifold.Refer to Installation procedure for turbochargerand exhaust manifold in this manual.

LNW76ASH001801

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2

LNW76ASH001901

1 1 1 1 1 1 4 2

2

51111

3

22

4

1

LNW76ASH002001

4 5 6 7 8 9

10

1 11

12

1314151617

1819

2022

2

22

3


Crank Case and Oil PanComponents

Legend1. Flywheel Housing2. Cylinder Block3. Oil Strainer

4. Crank Case5. Oil Pan


Refer to “Engine Assembly“. 2. Remove the oil level gauge guide tube. 3. Remove the heater pipe and hose.

LNW76ALF000501

1

2

3

4

5


4. Remove the oil pan.

5. Remove the flywheel.Refer to “Flywheel”.

6. Remove the flywheel housing.

Legend1. Bolt2. Bolt3. Nut

7. Remove the cylinder head.Refer to “Cylinder Head”.

8. Remove the timing gear case.Refer to “Timing Gear Case”.

9. Remove the retainer.

Legend1. Retainer2. Bolt

10. Remove the crank case.

Legend1. O-ring2. Crank Case

NOTE:Take care not to damage an O-ring.

LNW76ASH001301

LNW71BSH001601

3

2

1

RTW76ASH002001

2

1

RTW56ASH021901

2

1


Disassembly1. Remove the oil strainer.

Legend2. Oil Strainer3. Bolt4. Crank Case

ReassemblyInstall the oil strainer.

• Install the packing on the strainer.• Tighten the bolts to the specified torque.


Installation1. Install the crank case.

• Apply the liquid gasket (ThreeBond TB-1207Cor equivalent) and mount within 5 minutes.


Legend1. 2.0 - 3.0 mm (0.079 - 0.118 in)2. 4.0 - 5.0 mm (0.157 - 0.179 in)

2. Install the oil pan.Apply the liquid gasket (ThreeBond TB-1207B orequivalent)and mount within 5 minutes.


Legend1. 2.0 mm (0.079 in)2. 3.0 mm (0.118 in)

3. Install the retainer.• Apply the liquid gasket (ThreeBond TB-1207C

or equivalent) and mount within 5 minutes.


RTW66ASH009201

1

2

3

4

RTW56ASH015301

2

1

RTW56ASH015201

1 2


Legend1. 2 - 2.5 mm (0.079 - 0.098 in)2. 2 - 2.5 mm (0.079 - 0.098 in)

Legend1. Retainer2. Bolt

4. Install the heater pipe and hose.

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

6. Install the cylinder head.Refer to “Cylinder Head”.

7. Install the Flywheel housing.• Tighten the bolts to the specified torque.

Tightening torque:

Bolt (1) : 106 N⋅m (10.8 kg⋅m / 78 lb ft)

Bolt (2) : 82 N⋅m (8.4 kg⋅m / 61 lb ft)

Bolt (1) : 51 N⋅m (5.2 kg⋅m / 38 lb ft)

8. Install the flywheel. Refer to “Flywheel”.

9. Install the oil level gage guide tube.• Apply the engine oil to the O-ring.• Tighten the bolts to the specified torque.


RTW56ASH017701

1

2

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2

1

LNW76ASH001301

LNW71BSH001601

3

2

1


10. Install the engine assembly.Refer to “Engine Assembly“.


LNW76ALF000901

25(2.5/18)

25(2.5/18) 51(5.2/38)

44(4.5/33)

22(2.2/16)

82(8.4/61)

25(2.5/18)

106(10.8/78)


Oil PumpComponents

Legend1. Bolt 2. Oil Pump Assembly

Removal1. Drain the engine coolant.2. Remove the radiator upper hose.

RTW66AMF000701

2

1



Legend1. Fan Guide Bracket (RH)2. Fan Guide Bracket (LH)3. Bolt

4. Remove the fan and fan clutch.• Loosen the fan clutch nuts.• Remove the fan together with the fan clutch.

Take care not to damage the radiator core.5. Remove the fan drive belt and pulley.

• Loosen the tension adjust bolt on the generatorand A/C.

• Remove the fan drive belt with the fan pulley.6. Disconnect the power steering pump.7. Remove the vacuum pump.

• Remove the vacuum pipe bracket and vacuumpipe.

• Remove the oil pipe (feed side and return side)of vacuum pump.

8. Remove the noise cover (1).

9. Remove the crank pulley.

NOTE:Do not reuse the crank pulley bolt and washer.

10. Remove the cover of the gear case cover(1).

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1

2

3

3

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LNW76ASH003201

1


11. Remove the gear case cover.

12. Remove the oil pump.

Legend1. Oil Pump

Disassembly1. Remove the spring pin.2. Remove the spring seat.3. Remove the spring.4. Remove the valve.

Reassembly1. Install the valve. 2. Install the spring.3. Install the spring seat.

4. Install the spring pin.

Legend1. Spring Pin2. Spring Seat3. Spring4. Valve

InspectionNOTE:Think to match direction of ditch of gear whenassembling it.

1. Measure the clearance between the driven gear/drive gear shaft and the bush.• Measure the outside diameter of the driven

gear shaft using a micrometer.

RTW56ASH019701

RTW56ASH020001

1

Outside diameter of the driven gear shaft/drive gear shaft

mm (in)

Standard 15.989 - 16.000 (0.62949 - 0.62992)Limit 15.900 (0.62598)

RTW56ASH015901

1

2 3 4


• Measure the inside diameter of the bushes ofthe cylinder block using the dial gauge.

• If the clearance between the driven gear shaft/drive gear shaft and bush exceeds the limit,replace the oil pump assembly.

2. Measure the clearance between the gear sidesurface and the gear side surface of the oil pumphousing.

• Measure the width size the driven gear/drivegear.

• Measure the Depth size of the gear casehousing surface and the oil pump housing gearcase side.

Clearance between the driven gear shaft/drive gear shaft and bush

mm (in)

Standard 0.04 - 0.07 (0.0016 - 0.0028)Limit 0.20 (0.0079)

RTW56ASH025601

RTW56ASH014701

Depth size the gear case housing surface mm (in)Standard 14.500 - 14.527 (0.5709 - 0.5719)

Clearance between the gear side surface and the gear side surface of the oil pump housing

mm (in)

Standard 0.065 - 0.109 (0.0026 - 0.0043)Limit 0.20 (0.0079)

RTW56ASH025501

RTW56ASH014801


Installation1. Install the oil pump.

• Apply engine oil to the oil pump attachmentgearbox.

• Tighten the bolts to the specified torque.


Legend1. Oil Pump

• Installed pump gear should be smooth to rotate.2. Install the gear case cover.

• Apply the liquid gasket (Threebond TB-1207Bor equivalent) mount within 5 minutes.

Legend1. Apply The Liquid Gasket in Area

• Install the gasket in the slot of the gear casecover.



3. Install the cover of the gear case cover.4. Install the crank pulley.


Tightening torque: 294 N⋅m (30 kg⋅m / 217 lb ft)5. Install the noise cover.


Tightening torque: 10 N⋅m (1.0 kg⋅m / 87 lb in) 6. Install the vacuum pump.

• Tighten the nuts to the specified torque.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)• Install the oil pipe (feed side and return side) of

vacuum pump.• Install the vacuum pipe bracket and vacuum

pipe.7. Install the power steering pump.

• Tighten the nuts to the specified torque.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)8. Install the fan drive belt and pulley.

• Install the fan drive belt with the fan pulley.9. Install the fan and fan clutch.


Tightening torque: 8 N⋅m (0.8 kg⋅m / 69 lb in)10. Adjust the drive belt of generator and A/C

compressor.• Apply tension to the fan drive belt by moving

the generator.

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1

RTW56ASH020101

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RTW56ASH012101


• Apply a force of 98 N (10 kg / 22 lb) to the drivebelt mid portion to check the drive beltdeflection.

11. Install the fan guide bracket.12. Install the radiator upper hose.13. Replenish the engine coolant.

Generator drive belt deflection mm (in)New belt 5 - 6 (0.20 - 0.24)

Reuse belt 7 - 8 (0.28 - 0.32)

A/C compressor drive belt deflection mm (in)New belt 6 - 7 (0.24 - 0.28)

Reuse belt 8 - 9 (0.32 - 0.35)


Oil Pressure SWComponents

Legend1. Oil Pressure SW2. Gasket

3. Nipple; Oil Pressure Warning SW

Removal1. Remove the oil pressure SW. 2. Remove the nipple; oil pressure warning SW and

gasket.

Installation1. Install the nipple; oil pressure warning SW and

gasket.

Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)2. Install the oil pressure SW.


LNW76AMF000601

3

1

2


InspectionCheck the continuity between the switch terminal andthe body grounding in a no-load condition.If there is noconnectivity, replace with normal parts.

Circuit check1. Turn the starter switch to ON.2. Disconnect the oil pressure switch connector, and

confirm that the oil pressure-warning lamp lightswhen the connector on the harness side isgrounded.If the warning lamp does not light up, check thecircuit between the meter and the oil pressureswitch, and repair the disconnected locations.

LNW21HSH003301

LNW21HSH003401


Air Cleaner ElementRemoval

1. Remove the air cleaner cover fixing bolt.2. Remove the air cleaner element assembly.

CleaningDry type element

• Rotate the element with your hand while applyingcompressed air to the inside of the element. Thiswill blow the dust free.

Installation1. Install the air cleaner element assembly.2. Install the air cleaner cover.

Compressed air pressure kPa (kg/cm2 /psi)690 (7 / 100)

LNW46ASH003201

MEMO................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

ENGINE COOLING (4JJ1) 6B-1

ENGINEENGINE COOLING


Main Data and Specifications . . . . . . . . . . . . . . . . 6B-2Main Data and Specifications. . . . . . . . . . . . . . . 6B-2General Description . . . . . . . . . . . . . . . . . . . . . . 6B-3

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7

Draining and Refilling Cooling System . . . . . . . . . 6B-8Draining and Refilling Cooling System. . . . . . . . 6B-8

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9Removal and Installation . . . . . . . . . . . . . . . . . . 6B-9

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-11Removal and Installation . . . . . . . . . . . . . . . . . 6B-11

Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13Removal and Installation . . . . . . . . . . . . . . . . . 6B-13Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15Radiator Core. . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15Flushing the Radiator. . . . . . . . . . . . . . . . . . . . 6B-15Cooling System Leakage Check . . . . . . . . . . . 6B-15Engine coolant change . . . . . . . . . . . . . . . . . . 6B-17

Fan Clutch with Cooling Fan. . . . . . . . . . . . . . . . 6B-18Inspection and Repair . . . . . . . . . . . . . . . . . . . 6B-18Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19

6B-2 ENGINE COOLING (4JJ1)

Main Data and SpecificationsMain Data and Specifications

ItemDescription

M/T Smoother

Cooling system Engine coolant forced circulation

Water pump type Centrifugal impeller type

Pump to crankshaft speed ratio (To 1) 1.25

Delivery volume lit (US/UK gal)/min 240 (63.1/53.3)

Pump speed at 5600 rpm

Water temperature at 30°C (86°F)

Pump bearing type Double row shaft

Thermostat type Wax pellet with jiggle valve

Valve initial opening temperature °C (°F) 85 (185)

Valve full opening temperature °C (°F) 100 (212)

Valve lift at fully open position mm (in) 10 (0.39)

Radiator Tube type corrugated

Heat radiation capacity kW 91.2

Heat radiation area m2 (ft2) 10.9 (117.3)

Radiator front area m2 (ft2) 0.242 (2.6)

Radiator dry weight N (kg/lb) 125.5 (12.8 / 28.2) 128.5 (13.1 / 28.9)

Radiator cap valve opening pressure kPa (psi) 93.3 – 122.7 (13.5 – 17.8)

Engine coolant capacity lit (U.S pint) 6.7 (7.1)

Engine coolant total capacity lit (U.S pint) 10 (10.6)


General DescriptionCoolant Flow

The engine cooling system consists of the radiator, thewater pump, the cooling fan, and the thermostat.To quickly increase cold engine coolant temperature forsmooth engine operation, the coolant is circulated bythe water pump and thermostat through the bypasspipe and back to the cylinder body. The coolant does not circulate through the radiator.When the coolant temperature reaches specified value,the thermostat will begin to open and a graduallyincreasing amount of coolant will circulate through theradiator.The thermostat will be fully open when the coolanttemperature reaches specified value. All of the coolantis now circulating through the radiator for effectiveengine cooling.

RTW76BLF000301

Reservoir

Tank

Radiator

Cooling fan

Water

pump

Cylinder blockCar heater

Oil cooler

EGR

Cooler

Turbocharger

Cylinder head

Thermostat


Water Pump

A centrifugal type water pump forcefully circulates thecoolant through the cooling system.The water pump is not disassembled type.

Thermostat

A wax pellet type thermostat is used.

RTW56BSF000101

RTW56BSF000201


RadiatorThe radiator is a tube type with corrugated fins. In orderto raise the boiling point of the coolant, the radiator isfitted with a cap in which the valve is operated at 93.3 –122.7 kPa (0.95 – 1.25 kg / cm2 / 13.5 – 17.8 psi)pressure. (No oil cooler provided for M/T)

Engine Coolant1. About the engine coolant concentration

• Take the concentration corresponding to theminimum temperature because the freezingtemperature varies according to theconcentration of the engine coolant.

• Use only genuine Isuzu engine coolant.• Use engine coolant with a mix ratio in the range

of 30 to 60% because over heating is likely tooccur if the ratio is greater than 60% andcorrosion prevention is inadequate if the ratio isless than 30%.

2. Engine coolant density measurementMethods for measuring specific gravity• Measure the specific gravity and the

temperature of the cooling water using an anti-freeze specific gravity meter and thermometer.

Take precautionary measures as the boiledcooling water may gush out at hightemperatures if the cap is removed.

• Use a deep container to suit the height of thespecific gravity meter.

Legend1. Anti-Freeze Specific Gravity Meter2. Radiator

• Fix the temperature of the cooling water beingmeasured in the range of 0 to 50 °C (32 to122 °F).

LNW76BSH002801

LNW46BSH001301

ANTIFREEZE CONCENTRATION (%)

0 10

-10

-20

-30

-40

-50

20 30 40 50

FREEZINGTEMPERATURE(°C)

Freezingtemperature

guideline

Mix ratioLiter (qts) Concentration

of engine coolantEngine

coolantTap

water

-18°C (-0.4°F) 3.5 (3.7) 6.5 (6.9) 35%

-25°C (-13°F) 4.2 (4.4) 5.8 (6.1) 42%

-35°C (-31°F) 5.0 (5.3) 5.0 (5.3) 50%

-40°C (-40°F) 5.3 (5.6) 4.7 (5.0) 53%

LNW46BSH001001

2

1


• Measure the temperature and specific gravityand determine the concentration from the tablegiven below.

Coolant scooping method• Measure the concentration using the coolant

scoop.

LNW46BMH000101

1100

1090

1080

1070

1060

1050

1040

1030

1020

1010

1000

0 10 20 30 40 50 60 70

TEMPERATURE (°C)

SPECIFIC

GRAVITY

10%

20%

40%

50%

60%

30%


DiagnosisDiagnosis

Condition Possible Cause CorrectionEngine overheating Low Engine Coolant level Replenish

Thermo meter unit faulty ReplaceFaulty thermostat ReplaceFaulty Engine Coolant temperaturesensor

Repair or replace

Clogged radiator Clean or replaceFaulty radiator cap ReplaceLow engine oil level or use ofimproper engine oil

Replenish or change oil

Clogged exhaust system Clean exhaust system or replacefaulty parts

Faulty Throttle Position sensor Replace throttle valve assemblyOpen or shorted Throttle Positionsensor circuit

Repair or replace

Damaged cylinder head gasket ReplaceEngine overcooling Faulty thermostat ReplaceEngine slow to warm–up Faulty thermostat Replace

Thermo unit faulty Replace


Draining and Refilling Cooling SystemDraining and Refilling Cooling SystemBefore draining the cooling system, inspect the systemand perform any necessary service to ensure that it isclean, does not leak and is in proper working order.The engine coolant (EC) level should be between the"MIN" and "MAX" lines of reserve tank when the engineis cold. If low, check for leakage and add EC up to the"MAX" line.There should not be any excessive deposit of rust orscales around the radiator cap or radiator filler hole,and the EC should also be free from oil.Replace the ECif excessively dirty.

1. Completely drain the cooling system by openingthe drain plug at the bottom of the radiator.

2. Remove the radiator cap.

WARNING:To avoid the danger of being burned, do not remove thecap while the engine and radiator are still hot. Scaldingfluid and steam can be blown out under pressure.

3. Disconnect all hoses from the EC reserve tank.Scrub and clean the inside of the reserve tank withsoap and water. Flush it well with clean water,then drain it. Install the reserve tank and hoses.

4. Refill the cooling system with the EC.

Procedure for filling with coolant (in case of fullchange)

• Confirm that the engine has cooled.• Open the radiator cap and the reserve tank cap.• Unscrew the air bleeding bolt(2).• Pour the coolant up to the filler neck.

• Press the radiator upper hose(1) 2 to 3 times asshown in the illustration. If the coolant level isdown caused by the air was bled, poor the coolantagain.

• Pour the coolant up to the "MAX" line in thereserve tank.

• Tighten the air bleeding bolt firmly.• Close the radiator cap and the reserve tank cap

and start the engine. Stop the engine after runningfor about 2 to 3 minutes at the idling rpm. Open theradiator cap again and replenish if the water levelis low.

WARNING:Do not loosen or remove the radiator cap when thetemperature of the cooling water is high. Steam orboiling water will gush out and you may be burnt. Toopen the radiator cap, cover the cap with a thick clothwhen the cooling water is cool, release the pressure byslowly turning the cap, and then remove the cap.

• After tightening the radiator cap, warm up theengine by running it at about 2000 rpm.

• When the pointer of the thermometer crosses themedian and the thermostat has activated, run atidling rpm for another 5 minutes, then stop theengine and leave it as-is.

• After the engine has cooled down sufficiently,check the water level in the filler neck part andreplenish if necessary. If the level is extremely low,check for leaks in the cooling water conduit systemand reserve tank hose.

LNW76BSH002901

1

2


Water PumpRemoval and InstallationRead this Section carefully before performing anyremoval and installation procedure. This Section givesyou important points as well as the order of operation.Be sure that you understand everything in this Sectionbefore you begin.

Removal1. Remove the engine cover.2. Radiator Upper Hose

a. Partially drain the engine coolant.b. Remove the radiator upper hose.

3. Water Outlet Pipea. Disconnect the turbocharger-cooling pipe from

the outlet pipe.b. Loosen the fixing bolt and remove the water

outlet bolt.4. Fan guide bracket

Legend1. Fan Guide Bracket RH2. Fan Guide Bracket LH3. Bolt

5. Fan and Fan Clutcha. Loosen the fan clutch nuts.b. Remove the fan together with the fan clutch.

Take care not to damage the radiator core.6. Fan Drive Belt and Pulley

a. Loosen the tension adjust bolt on the generator.

b. Remove the fan drive belt with the fan pulley.

7. Water Pumpa. Remove the water pump bolts and nuts.b. Remove the water pump.

Inspection and RepairThe water pump is not disassembled type.Makenecessary parts replacement if extreme wear ordamage is found during inspection. Should any of thefollowing problems occur, the entire water pumpassembly must be replaced.

• Cracks in the water pump body.• Coolant leakage from the sealed unit.• Excessive radial play or abnormal noise in the fan

center when rotated by hand.• Excessive thrust play in the fan center (Standard

play: less than 0.2 mm (0.0078 in)).

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1

2

3

3

RTW56ASH025401

RTW56BSH000201


• Cracks or corrosion in the impeller.

Installation1. Water Pump

a. Install the water pump with a new gasket.b. Tighten bolts and nuts to specified torque.

Water Pump Bolt/Nut Torque:

25 N⋅m (2.5 kg⋅m /18 lb ft)2. Fan Drive Belt and Pulley and Fan and Fan Clutch.

a. Install the fan drive belt and fan pulley and fanand fan clutch.

b. Tighten the nuts to specified torque.

Fan Clutch Nut Torque: 8 N⋅m (0.8 kg⋅m /69 lb in)c. Apply tension to the fan drive belt by moving

the generator.

d. Apply a force of 98 N (10 kg/22 lb) to the drivebelt mid-portion to check the drive beltdeflection.

3. Fan guide bracket4. Water Outlet Pipe.

a. Install the water outlet pipe to the thermostathousing.

b. Tighten the outlet pipe bolt to specified torque.

Outlet Pipe Bolt Torque:

25 N⋅m (2.5 kg⋅m /18 lb ft)c. Connect the turbocharger-cooling pipe to outlet

pipe.5. Radiator Upper Hose.

a. Connect the radiator upper hose to the wateroutlet pipe.

b. The knob of clamp shall be directed tohorizontal.

c. Replenish the engine coolant.6. Install the engine cover.

RTW56BSH000201

RTW56ASH025401

Fan Drive Belt Deflection mm (in)New belt 5 - 6 (0.20 – 0.24)

Reuse belt 7 - 8 (0.28 – 0.32)


ThermostatRemoval and InstallationRead this Section carefully before performing anyremoval and installation procedure. This Section givesyou important points as well as the order of operation.Be sure that you understand everything in this Sectionbefore you begin.

Removal1. Remove the engine cover.2. Radiator Upper Hose

a. Partially drain the engine coolant.b. Remove the radiator upper hose.c. Remove the engine harness clip.

3. Water Outlet Pipea. Disconnect the turbocharger-cooling pipe from

outlet pipe.b. Loosen the fixing bolt and remove the water

outlet bolt.4. Thermostat

Remove the thermostat from the thermostathousing.Take care not to damage the thermostat.

Legend1. Jiggle Valve2. Thermostat

Inspection and RepairMake the necessary adjustments, repairs, and partreplacements if excessive wear or damage isdiscovered during inspection.

Operating Test of Thermostat1. Completely submerge the thermostat in water.

2. Heat the water.Stir the water constantly to avoiddirect heat being applied to the thermostat.

3. Check the thermostat initial opening temperature.

4. Check the thermostat full opening temperature.

Legend1. Agitating Rod2. Thermometer3. Wooden Piece

LNW71CSH000401

2

2

1

Thermostat Initial Opening Temperature: °C (°F)85 (185)

Thermostat Full Opening Temperature: °C (°F)100 (212)

Valve Lift At Fully Open Position: mm (in)10 (0.39)

LNW61BSH003501

1

3

2


Installation1. Thermostat

Install the thermostat.Mount the jiggle valve with the valve facing enginefront.

Legend1. Jiggle Valve2. Thermostat

2. Water Outlet Pipe.a. Install the water outlet pipe with a new gasket to

the thermostat housing.b. Tighten the outlet pipe bolt to specified torque.

Outlet Pipe Bolt Torque:

25 N⋅m (2.5 kg⋅m /18 lb ft)c. Connect the turbocharger-cooling pipe to outlet

pipe.d. Install the engine harness clip.

3. Radiator Upper Hose.a. Connect the radiator upper hose to the water

outlet pipe.b. The knob of the clamp should be directed to the

horizontal side.c. Replenish the engine coolant.

4. Install the engine cover.

LNW71CSH000401

2

2

1


RadiatorRemoval and InstallationRadiator and Associated Parts

Legend1. Reserve Tank Hose2. Radiator Upper Hose3. Radiator & Intercooler

4. Fan Guide5. Radiator Lower Hose

Removal1. Disconnect battery ground cable.2. Loosen the drain plug to drain the engine coolant.

• After draining the coolant, tighten the drainplug.

LNW76BLF001901

13 4

2

5


Legend1. Radiator Drain Plug

3. Remove the air intake pipe with the hoses.• Disconnect the hose from the intercooler side.• Remove the air intake pipe with the hoses from

the turbocharger side.• Do not disconnect the hoses from the air intake

pipe.

4. Disconnect the ECM harness connector.5. Remove the air intake pipe with the hoses.




pipe.

6. Remove the radiator upper hose on the radiatorside.

7. Remove the radiator lower hose on the radiatorside.

8. Remove the coolant reserve tank hose from theradiator side.


Legend1. Fan Guide Bracket RH2. Fan Guide Bracket LH3. Bolt

10. Remove the inter cooler.

LNW46BSH000401

1

LNW76ASH000301

LNW76ASH000501

LNW76ASH000701

1

2

3

3


11. Take care to avoid damage to the radiator corefrom the fan blade, and remove the brackets onthe right and left sides of the radiator.Simultaneously remove the radiator.

Inspection and RepairMake the necessary adjustments, repairs, and partreplacements if excessive wear or damage isdiscovered during inspection.

Radiator CapMeasure the valve opening pressure of thepressurizing valve with a radiator filler captester.Replace the cap if the valve opening pressure isoutside the standard range.

Valve opening pressure:

93.3 – 122.7 kPa (0.95 – 1.25 kg / cm2 / 13.5 – 17.8psi)Cap tester: 5-8840-0277-0Adapter: 5-8840-2603-0Check the condition of the vacuum valve in the centerof the valve seat side of the cap. If considerable rustor dirt is found, or if the valve seat cannot be moved byhand, clean or replace the cap.

Valve opening vacuum:

1.96 – 4.91 kPa (0.02 – 0.05 kg / cm2 / 0.28 – 0.71 psi)

Radiator Core1. A bent fin may result in reduced ventilation and

overheating may occur. All bent fins must bestraightened. Pay close attention to the base of thefin when it is being straightened.

2. Remove all dust, bugs and other foreign material.

Flushing the RadiatorThoroughly wash the inside of the radiator and theengine coolant passages with cold water and milddetergent. Remove all signs of scale and rust.

Cooling System Leakage CheckUse a radiator cap tester to force air into the radiatorthrough the filler neck at the specified pressure of 196kPa (2.0 kg / cm2 / 28.5 psi) with a cap tester:

• Leakage from the radiator.• Leakage from the coolant pump.• Leakage from the water hoses.• Check the rubber hoses for swelling.

LNW76BSH003001

LNW21BSH000201


Installation1. Ensure that no damage occurs to the radiator core

because of the fan brade.Mount the brackets onthe left and right sides of the radiator on the frameaccording to the figure.

Tightening Torque: 26 N⋅m (2.6 kg⋅m /19 lb ft)

Legend1. Flange nut2. Rubber3. Stud Bolt4. Bracket5. Bracket on the Radiator Side6. Washer

2. Install the intercooler.3. Install the fan guide bracket.4. Mount the reserve tank hose of the coolant on the

radiator.5. Mount the radiator lower hose.

6. Mount the radiator upper hose.7. Pour engine coolant up to filler neck of radiator,

and up to MAX mark of reserve tank. Important operation (in case of 100% engine coolant change)procedure for filling with engine coolant.• Confirm that the engine has cooled.• Open the radiator cap and the reserve tank

cap.• Unscrew the air bleeding bolt(2).• Pour the coolant up to the filler neck.• Press the radiator upper hose(1) 2 to 3 times as

shown in the illustration. If the coolant level isdown caused by the air was bled, poor thecoolant again.

• Pour the cooling water up to the "MAX" line inthe reserve tank.

• Tighten the air bleeding bolt firmly.• Close the radiator cap and the reserve tank cap

and start the engine. Stop the engine afterrunning for about 2 to 3 minutes at the idlingrpm. Open the radiator cap again and replenishif the water level is low.

WARNING:Do not loosen or remove the radiator cap when thetemperature of the cooling water is high. Steam orboiling water will gush out and you may be burnt. Toopen the radiator cap, cover the cap with a thick clothwhen the cooling water is cool, release the pressure byslowly turning the cap, and then remove the cap.

• After tightening the radiator cap, warm up theengine by running it at about 2000 rpm.

• When the pointer of the thermometer crossesthe median and the thermostat has activated,run at idling rpm for another 5 minutes, thenstop the engine and leave it as-is.

LNW21BSH000301

LNW46BSH000101

1

2

3

4

5

6 LNW76BSH002901

1

2


• After the engine has cooled down sufficiently,check the water level in the filler neck part andreplenish if necessary. If the level is extremelylow, check for leaks in the cooling water conduitsystem and reserve tank hose.

Legend1. Reserve Tank2. MAX Line (Upper Limit)3. MIN Line (Lower Limit)

Engine coolant changeRefer to change procedure for Draining and RefillingCooling System in this section.

LNW76BSH000101

2

1

3


Fan Clutch with Cooling FanInspection and RepairMake necessary correction or parts replacement ifwear, damage or any other abnormal condition arefound through inspection.Visually inspect for damage, leak (silicon grease) orother abnormal conditions.

1. Inspection (on-vehicle)a. Turn the fan clutch by hand when in a low

temperature condition before starting theengine, and confirm that it can be turnedreadily.

b. Start the engine to warm it up until thetemperature at the fan clutch portion gets toaround 85°C(185°F). Then stop the engineand confirm that the fan clutch can be turnedwith considerable effort (clutch torque) whenturned by hand.If the fan clutch rotates more readily, however,this indicates that the silicone grease is leakinginternally.Replace the fan clutch with a new one.

2. Inspection (in unit)Warm up the bimetal of the fan clutch by using theheat gun until the temperature gets to about85°C(185°F) when measured with the thermistor.Then confirm that the fan clutch can be turned withconsiderable effort (clutch torque).If the fan clutch rotates more readily at this time,this indicates that the silicone grease is leakinginternally.Replace the fan clutch with a new one.

3. Clearance between fan and fan guideThe clearance in three places must be 3mm(0.118in) or more.

RTW56ASH025401

LNW61BSH003701

Heat gun

Thermistor

LNW71CSH000501


Special ToolsIllustration Tool Number/ Description

5-8840-02770-0Cap tester

5-8840-2603-0Adapter

5884026030

MEMO................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

FUEL SYSTEM (4JJ1) 6C-1

ENGINEFUEL SYSTEM


Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-2Service Precautions . . . . . . . . . . . . . . . . . . . . . .6C-2Work procedure . . . . . . . . . . . . . . . . . . . . . . . . .6C-2Fuel System Check . . . . . . . . . . . . . . . . . . . . . .6C-7

Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . .6C-9Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9

Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . .6C-10Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-10Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-10

Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-14Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-16

Fuel Pressure Sensor . . . . . . . . . . . . . . . . . . . . .6C-17Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17

Fuel Pressure Limiter . . . . . . . . . . . . . . . . . . . . .6C-18Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18

Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . .6C-19Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-22Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-23

Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .6C-24Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-24Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-24Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-28Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-33

Fuel Sedimenter Switch . . . . . . . . . . . . . . . . . . .6C-34Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-34

Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-36

Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . .6C-37Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-39

6C-2 FUEL SYSTEM (4JJ1)

Fuel SystemService PrecautionsParts of the fuel system such as the internal part of thefuel injector, and holes and clearances that formpassages for fuel are finished to a very high degree ofaccuracy. They are therefore highly sensitive to foreignmatter and the entry of foreign matter could causedamage to the fuel passage. Therefore, effectivemeasures should be taken to prevent the entry offoreign matter.If a water removal agent is used in the fuel then it willabsorb moisture in the light oil and may cause rust.Therefore, do not use a water removal agent in the fueltank.When servicing the fuel system, every precaution mustbe taken to prevent the entry of foreign material into thesystem.

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

• Perform the service procedures with clean hands.Do not wear work gloves.

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

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

Discard gaskets and O-rings and replace them withnew ones.

Work procedure• The fuel opening must be quickly sealed when

removing the fuel pipe, injection pipe, fuel injector,fuel supply pump, and fuel rail.

• The eyebolts and gasket must be stored in a cleanparts box with a lid to prevent adhesion of foreignmatter.

• Fuel leakage could cause fires. Therefore, afterfinishing the work, wipe off the fuel that has leakedout and make sure there is no fuel leakage afterstarting the engine.

Explanations on functions and operationFuel system diagram

Legend1. Fuel Rail2. Pressure Limiter3. Leak Off Pipe4. Fuel Injector5. Fuel Return Pipe6. Fuel Feed Pipe

7. Fuel Tank8. Priming Pump9. Fuel Filter With Sedimenter

10. Recirculation valve11. Fuel Supply Pump

LNW71DSF000101

10 69 811

5

6

1 2

3

4 7


Fuel Rail Assembly

Legend1. Pressure Limiter 2. Fuel Rail Pressure Sensor

RTW76CLF000601

1

2


Fuel Supply Pump

Legend1. Fuel Temperature Sensor2. Suction Control Valve3. High Pressure Pipe

4. Camshaft Key5. Camshaft Nut

LNW71DLF000101

4

5

2

3

1


Fuel Injector

Legend1. Terminal2. Fuel Injector ID Code3. Two Dimensional Barcode4. Parts Number5. Part for Mounting the Injection Pipe6. O-ring

Fuel Filter

Legend1. Element2. Case3. Drain Plug4. Switch Connector

Functional CheckAir Bleeding

1. Before starting the enginea. Fit a tray below the fuel filter (below the air

bleed plug).b. Loosen the plug adequately and operate the

priming pump more than 20 times until the fuelnear the plug overflows.

c. Tighten the plug, and operate the priming pumpmore than 10 times until it is filled with fuel.

d. Tighten the plug firmly and wipe the fuel in thesurrounded area. Operate the priming pump(10 to 15 times) till it is filled with fuel and thensend fuel to the engine.

2. After starting the enginea. Start the engine by rotating the starter without

depressing the accelerator pedal.b. After starting, maintain the idling rotation for 5

seconds.c. Slowly rotate the idling control knob clockwise

and maintain it for 3 minutes.d. Fully depress the accelerator pedal and

increase the rotations to maximum.(Repeat thisoperation several times)

e. Rotate the idling knob counterclockwise andreturn to idling more.

RTW76CMH000201

1

2

3

4

5

6

LNW76CSH000101

1

4 3

2


NOTE:If the air bleeding work is insufficient then it could leadto faults in the engine. Therefore, the procedures afterstarting the engine should always be implemented.

Water drainA warning lamp will light up if water above the specifiedvolume collects in the sedimenter. In such cases, drainout the water by performing the following operations:

• Set a container at the tip of the plastic hose.• Loosen the air bleeding plug and the drain plug.

• Discharge the water.• Tighten the drain plug after discharging the water.• Tighten the air bleeding plug to the specified

torque.

Tightening torque : 7.5 N⋅m (0.7 kg⋅m/26 lb in)• Ignition switch is turned ON for 15 seconds check

for fuel leakage.• Check that the warning lamp in the meter is off.

Trouble Shooting

Problems with starting

Hunting during idling

Insufficient horsepower

Condition Possible Cause CorrectionProblems with starting Fuel tank is empty Fill the tank.

Air has entered the fuel system. Bleed the air.Fuel line is clogged or damaged.Connection to the fuel line is loose.

Repair or replace the fuel line. Re-tighten the connection.

Fuel filter element is clogged. Replace the cartridge.Fault in the feed pump Replace the fuel supply pump.Regulating valve is open. ReplaceSticking of the fuel injector Replace the fuel injector.Defective engine control system Diagnose the engine control

system.

Condition Possible Cause CorrectionHunting during idling Air has entered the fuel system. Bleed air from the fuel system.

Leakage or clogging of the fuelsystem

Repair or replace the fuel system.

Drops of water have entered thefuel system.

Replace the fuel.

Fuel filter element is clogged. Replace the fuel filter element kit.Sticking of the fuel injector Replace the fuel injector.Defective engine control system Diagnose the engine control

system.

Condition Possible Cause CorrectionInsufficient horsepower Air has entered the fuel system. Bleed air from the fuel system.

Leakage or clogging of the fuelsystem

Repair or replace the fuel system.

Water mixes in the fuel system Replace the fuel.Fuel filter element is clogged. Replace the element kit.Sticking of the fuel injector Replace the fuel injector.Defective engine control system Diagnose the engine control

system.


Maximum engine speed is too low

Engine does not stop

Exhaust gas is blue or black

Fuel System CheckDescriptionConforms to a fuel leak. Engine acceleration raises fuelpressure and which increases the leak. Leak could bein the following pipes and locations.

• Between injectors and fuel rail.• Between fuel rail and fuel supply pump.• Between fuel supply pump and fuel filter.• Between fuel filter and fuel tank.• Between pressure limiter and fuel tank.• Between injector over flow and leak off pipe.

Diagnostic AidsCheck the following items.

• Air in the fuel line

• Clogged fuel filter• Fuel pipe malfunction (Crushing, breakage,

clogging, disconnection, etc.)• Fuel tank malfunction• Injector malfunction• Fuel supply pump malfunction• Pressure limiter malfunction

An intermittent may be caused by a poor connection,rubbed-through wire insulation or a wire broken insidethe insulation. Check for poor connections or adamaged harness.Inspect the ECM harness and connector for impropermating, broken locks, improperly formed or damagedterminals, poor terminal-to-wire connection, anddamaged harness.ECU may set a DTC, if there is adequate air in fuel line.Schematic Reference: Engine Controls Schematics

Condition Possible Cause CorrectionMaximum engine speed is too low Fuel line is clogged or damaged. Repair or replace the fuel line.

Defective engine control system Diagnose the engine controlsystem.

Condition Possible Cause CorrectionEngine does not stop Defective engine control system Diagnose the engine control

system.

Condition Possible Cause CorrectionExhaust gas is blue or black. Reduction in injection-valve

opening pressure or defectiveatomizing status

Replace the fuel injector.

Engine control system malfunction System diagnosis.

Step Action Value(s) Yes No

1Check the fuel quantity.

Was a problem found?—

Go to Step 2Add fuel and go to

Step 2

2

Check the fuel quality.1. Discharge the fuel from fuel tank2. Replenish the tank with specified fuel3. Bleed the air from the fuel system4. Start the engine

Could the engine be started?

—

Go to Step 7 Go to Step 3

3Bleed the air from fuel system. Refer to FuelSystem Air Bleeding in this section.

Is the action complete?—

Go to Step 4 —


4

Check the main fuel filter for clogging.Clean, repair, or replace as required.Notice: Replacement of a fuel filter ischecking to a dealer.

Is the action complete?

—

Go to Step 5 —

5

Check the fuel line for damage and leakage.Clean, repair, or replace as required.• Crushed areas• Breakage• Cracks• Loose connections


—

Go to Step 6 —

6

Check the fuel tank.If a problem is found, clean, repair, or replaceas necessary.• Foreign material (Clogged suction port)• Bent or cracked suction pipe• Fuel tank distortion• Fuel tank improper installation• Clogged fuel cap hole• Water


—

Go to Step 7 —

7Rebleed the air from the fuel pipe. Refer toFuel System Air Bleeding in this section.

Is the action complete?—

Verify repair —

Step Action Value(s) Yes No


Fuel Filter AssemblyComponents

Legend1. Bolt2. Fuel Feed Hose

3. Fuel Return Hose4. Sedimenter Harness Connector

Removal1. Disconnect the sedimenter harness connector.2. Remove the feed hose and the return hose from

the fuel filter and plug it so that the fuel does notflow out.

3. Remove the bolts for mounting the fuel filter.4. Remove the fuel filter assembly.

Installation1. Install the fuel filter assembly.2. Install the bolts for mounting the fuel filter.3. Install the feed hose and the return hose.4. Connect the sedimenter harness connector.5. Bleed out the air.

• Refer to "Fuel System".

LNW76CSF000101

3

2

1

4


Fuel Filter ElementRemoval

1. Remove the fuel in the element case.a. Loosen the drain plug at the bottom of the

element case.b. When the air breather of the body is loosened,

the is run out from the drain plug.2. Remove the harness of the water warning switch.3. Remove the element case from the body by

rotating the case in a counterclockwise direction,using a socket (width of double socket: 29mm(a)).After removing the case, confirm that the float atthe inside bottom can move up and downsmoothly.If foreign materials, sludge or other dirty materialsare deposited at the bottom of the case, remove itclearly.

4. Remove the O-ring of the body by pulling out theelement downward.

5. If foreign material is attached on the surface of thebody inner circumference, wipe it with clean cloth.

Legend1. Cap2. Air bleeder3. Filter body4. O-ring5. Fuel filter element6. Element case7. O-ring8. Drain plug9. Wiring connector

Installation1. Place the O-ring, packaged with the element kit,

into the groove on the outer circumference of thebody.Careful handling of the O-ring is needed to preventbeing damaged by the threaded area of the body.

2. Apply a thin layer of fresh diesel fuel on thegaskets, inside and outside of the element, andthen insert the gasket until it hits the end.

NOTE:Be careful not to insert any foreign materials into thefour holes (clean side) next to the inside gasket.

BLW61DMH000101

1

2

3

4

5

6

7

8

9

a


Legend1. Salient for socket2. Float3. Outside gasket4. Inside gasket5. Clean side hole6. Element kit7. O-ring grove

3. Apply a thin layer of fresh diesel fuel on the innercircumference of the element case (or the O-ringsection at the body side). Turn the element in aclockwise direction until it hits to the body carefully.Biting with the O-ring must be avoided.No hitting of the element to the case means thatthe element does not have compete insertion.Turn the element and push it in again.

4. Tighten the element case with a torque wrench.


5. Tighten the drain plug of the element case, andreconnect the connector of the water warningswitch.

Tightening torque:

0.4 N⋅m (0.04 kg⋅m / 3.47 lb in)6. After starting the engine, check each section for no

looseness.

MFW61DLH000101

1 2

7

4

3

6

5


Fuel InjectorComponents

Legend1. Cylinder Head Cover2. Fuel Injector Clamp3. Fuel Injector Clamp Bolt

4. Fuel Injector5. Fuel Injection Pipe6. Fuel Injection Pipe Clip

The fuel system consists of many tiny holes andspaces that allow the movement of fuel from one placeto another. These holes and spaces are milled toextremely high precision. This is especially true of thefuel injector.The fuel injector is very sensitive to foreign material.Foreign material will result in fuel system breakdown.Exercise great care not to allow the entry of foreignmaterial into the fuel system or fuel injector during theremoval and installation procedure.

NOTE:To avoid electric shock: Set the switch to the 'OFF'position and disconnect the battery negative cablebefore checking or repairing the fuel injector, wiring or/and connectors.

Removal1. Remove the cylinder head cover.

Refer to “Cylinder Head Cover” in ENGINEMECHANICAL section.

LNW76CLF000201

5

6

34

2

1


2. Remove the injection pipe sleeve nut (1) from theinjector.

3. Remove the injector.

NOTE:Do not reuse the clip, gasket and bolt.

Legend1. Fuel Injector2. Leak Off Pipe3. Clip4. Gasket5. Washer

NOTE:• Do not tamper with the electromagnetic portion of

the fuel injector. Reduced electromagnetic functionwill result in injector failure.

4. Mark each fuel injector with the number of thecylinder from which it was removed. Store the fuelinjector in a safe place. Position the fuel injector sothat the nozzle is protected.

NOTE:• If a fuel injector is replaced, cross off the replaced

injector ID codes on the label with a marking penetc.

• If all fuel injectors are replaced, remove the fuelinjector ID code label from the engine cover.

Legend1. 1st Cylinder Injector ID Code2. 2nd Cylinder Injector ID Code3. 3rd Cylinder Injector ID Code4. 4th Cylinder Injector ID Code5. Engine Cover6. Injector ID Code Label

LNW71DSH000101

1

RTW66CSH000101

1

4

5

2

3

LNW76CSH001701

4JJ1

51

51

51

51

16

19

39

19

1A

13

39

19

25

OF

2C

18

1A

OF

1C

00

24

OF

23

17

17

00

13

00

17

09

14

00

00

09

00

00

14

09

OF

00

00

00

00

00

52

54

57

44

1

2

3

4

56


Installation1. Install the new gasket and O-ring to each fuel

injector.

Legend1. Fuel Injector2. Leak Off Pipe3. Clip4. Gasket5. Washer

2. Install the fuel injector clamps. Refer to theillustration.• Apply Engine oil to the threads and seating

surfaces of the clamp bolts.

Legend1. Fuel Injector2. Fuel Injector Clamp Bolt3. Fuel Injector Clamp

3. Install the fuel injector clamps to the cylinder head.

4. Temporarily tighten the clamp bolts.5. Apply a thin coat of engine oil to the outer surface

of the fuel injector side sleeve nuts.6. Install the fuel injector pipes to the position shown

in the illustration.7. Use a spanner to carefully tighten the sleeve nuts

until the fuel injector pipes contact the fuel injectorand fuel rail.

8. Tighten the fuel injector pipe clips to the specifiedtorque.


Legend1. Fuel Injector2. Pipe Clip

9. Tighten the injection pipes to the specified torque.

Tightening torque⋅

Injector Side: 30 N⋅m (3.1 kg⋅m / 22 lb ft)

Fuel rail side: 25 N⋅m (2.5 kg⋅m / 18 lb ft)

RTW66CSH000101

1

4

5

2

3

RTW56CSH000601

1

2

3

LNW76CMH000101

1

2


Legend1. Clamp Bolt2. Sleeve Nut

10. Tighten the fuel injector clamp bolts to thespecified torque.Tightening torque: 26 N⋅m (2.7 kg⋅m / 20 lb ft)

11. Tighten the engine oil level gauge guide tube.

Tightening torque: 25 N⋅m (25 kg⋅m / 18 lb ft)12. Install the cylinder head cover.

Refer to “Cylinder Head Cover” in ENGINEMECHANICAL section.

13. Program the Fuel Injector ID Codes• Refer to “Programming” in ENGINE CONTROL

SYSTEM section.

Legend1. Fuel Injector ID Code2. Fuel Injector

LNW76CSH000501

1

2

2

RTW76ESH002601

5F 05 00

FB00 F7

SAMPLE

08 F5 19

FF04 49

2

1



LNW76CLF000101

26(2.7/20)

8(0.8kg m/69lb in)

30(3.1/22)

25(2.5/18)


Fuel Pressure SensorRemoval

1. Disconnect the fuel pressure sensor harnessconnector (1).

2. Remove the fuel pressure sensor.

NOTE:Cover the areas exposed during parts removal toprevent the entry of foreign material into the fuelsystem.

Legend1. Fuel Rail2. Fuel Rail Pressure Sensor3. Fuel Pressure Limiter

Installation1. Install the fuel pressure sensor.

Tightening torque: 98 N⋅m (10.0 kg⋅m/72 lb ft)2. Connect the fuel pressure sensor harness

connector.

LNW76CSH001601

1

RTW76CSH000101

1

3 2


Fuel Pressure LimiterRemoval

1. Remove the leak off pipe and hose (1).


2. Remove the fuel pressure limiter.



Installation1. Install the fuel pressure limiter.

Tightening torque: 172 N⋅m (17.5 kg⋅m/127 lb ft)2. Install the fuel leak off pipe and hose (1) using the

mounting eyebolt using the specified torque.

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

LNW76CSH000401

1

RTW76CSH000101

1

3 2

LNW76CSH000301

1


Fuel Rail AssemblyComponents

Legend1. Injection Pipe (#1 to #4)2. Fuel Feed Pipe Assembly3. Injection Pipe Clip4. Fuel Rail

5. Fuel Rail Bracket6. Space Rubber7. Fuel Leak Off Pipe

Parts of the fuel system such as the internal part of thefuel injector, holes and clearances that form passagesfor fuel are finished to a very high degree of accuracy. They are therefore highly sensitive to foreign matterand the entry of foreign matter could cause damage tothe fuel passage. Therefore, effective measures shouldbe taken to prevent the entry of foreign matter.

Removal1. Remove the air intake pipe with the hoses.




pipe.

LNW76CLF000301

2

1

3

7

5

6

4


2. Remove the noise cover left side.• Disconnect the dropping register connector and

remove the noise cover.3. Disconnect the fuel rail pressure sensor harness

connector (1).

4. Remove the engine oil level gage guide tube.5. Remove the fuel hose (1).


6. Remove the leak off pipe and hose (1).


7. Remove the fuel feed pipe assembly (1) for supplypump.


LNW76ASH000501

LNW76CSH001601

1

LNW76CSH000701

1

LNW76CSH000401

1


8. Disconnect the injection pipe sleeve nut (1).


9. Remove the fuel rail and fuel rail bracket.

NOTE:• Do not grasp the pressure sensor, during the fuel

rail removal procedure.• Take care not to damage the connector unit of the

pressure sensor.

Legend1. Fuel Rail2. Fuel Rail Bracket3. Space Rubber

Disassembly1. Remove the fuel pressure limiter.2. Remove the pressure sensor.


Reassembly1. Install the fuel pressure limiter.


LNW76CSH000801

1

LNW76CSH000601

1

LNW76CSH001201

2

3

1

RTW76CSH000101

1

3 2


2. Install the fuel pressure sensor.


Installation1. Tighten the space rubber, fuel rail bracket and fuel

rail using the specified mounting torque.


Legend1. Fuel Rail2. Fuel Rail Bracket3. Space Rubber

2. Tighten the fuel pipe using the mounting sleeve nut(1) and the specified torque.

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

3. Connect the fuel rail pressure sensor harnessconnector.

4. Install the fuel feed pipe assembly (1) for supplypump and tighten the bolts to the specified torque.


5. Tighten the fuel leak off pipe (1) using themounting eyebolt using the specified torque.Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)

LNW76CSH001201

2

3

1

LNW76CSH000601

1

LNW76CSH000801

1

LNW76CSH000401

1


6. Install the fuel hose (1).

7. Tighten the engine oil level gage guide tube andtighten the mounting bolt to the specified torque.

Tightening torque: 25N⋅m (2.5 kg⋅m/18 lb ft)8. Install the noise cover left side.9. Install the dropping register connector.

10. Fit the air intake pipe and hose.



marking.


11. Install the boost sensor connector.


LNW76CSH000701

1

LNW76ASH000501

LNW76CMF000101

25(2.5/18)

44(4.5/33)

25(2.5/18)


Fuel Supply PumpComponents

Legend1. Fuel Feed Pipe Assembly2. Injection Pipe Sleeve Nut3. Space Rubber A4. Bracket5. Space Rubber B6. Fuel Supply Pump

7. Noise Cover8. Timing Chain Cover Lower9. Nut

10. Sprocket11. Fuel Supply Pump Gear

The fuel system consists of many tiny holes andspaces that allow the movement of fuel from one placeto another. These holes and spaces are milled toextremely high precision. This is especially true of thefuel injector.The fuel injector is very sensitive to foreign material.Foreign material will result in fuel system breakdown.Exercise great care not to allow the entry of foreignmaterial into the fuel system or fuel injector during theremoval and installation procedure.

Removal1. Partially drain the engine coolant. Refer to drain

procedure for engine cooling in this manual.2. Remove the radiator upper hose.

LNW76CMF000201

11

10

9

8

7

6

1 2

5

4 3


3. Remove the fan guide.

Legend1. Fan Guide Bracket2. Fan Guide Bracket3. Bolt

4. Remove the cooling Fan.

5. Remove the A/C compressor drive belt.

6. Remove the A/C compressor adjust pulley.

Legend1. Bolt2. Nut

7. Disconnect the A/C compressor.8. Remove the A/C compressor bracket.9. Remove the fuel rail assembly. Refer to removal

procedure for Fuel rail assembly in this manual.10. Remove the cylinder head cover.

Refer to removal procedure for Fuel rail assemblyin this manual.

11. Disconnect the connector of supply pump.12. Remove the noise cover.

Legend1. Noise Cover

LNW76ASH000701

1

2

3

3

RTW56ASH025401

LNW76CSH001101

2 1

RTW56CSH001401

1


13. Remove the timing chain cover assembly. Upper &lower.

Legend1. Timing Chain Cover Upper 2. Timing Chain Cover Lower.

14. Align the timing marks at 3 locations as shown.


Legend1. Align mark on intake camshaft and exhaust

camshaft to mark of bearing cap

15. Loosen the nut.

Legend1. Nut

LNW76CSH001001

1

2

LNW76ASH001101

1

2

3

RTW56ASH006901

1

RTW56CSH001601

1


16. Remove the timing chain tennsioner.

Legend1. Timing Chain Tennsioner.2. Gasket

17. Remove the timing chain tension lever pivot.18. Remove the nut and sprocket.

Legend1. Tension Lever Pivot 2. Sprocket3. Nut

19. Timing chain in moved upwards.

20. Paint the alignment mark. Between idle gear A andsupply pump gear.

LNW71BSH001401

1

2

RTW56CSH004101

1

2

3

RTW56CSH003301

RTW56AMH000401


21. Use a gear puller to remove the fuel supply pumpgear.

22. Remove the supply pump and supply pumpbracket with spacer rubber.

NOTE:• Do not hold the high pressure pipe, during the

supply pump removal procedure.• Do not grasp the high pressure pipe, when moving

the supply pump from one location to another.

Legend1. Supply pump2. Space Rubber B3. Supply Pump Bracket4. Space Rubber A

23. Remove the supply pump and O-ring.

Legend1. O-ring2. Supply Pump

Installation1. Install the O-ring to the fuel supply pump.2. Install the fuel supply pump. Apply soapy water to

the O-rings before attaching.

NOTE:Take care not to twist the O-ring.

3. Install the fuel supply pump bracket.Temporarily tighten with the bolts and nuts (Gearcase side).Temporarily tighten with the bolts (Cylinder bodyside).Fully tighten the bolts and nuts (Gear case side).Fully tighten the bolts (Cylinder body side).

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

RTW56CSH002901

LNW76CSH001301

1

2

3 4

LNW76CSH000901

2

1


Legend1. Fuel Supply Pump2. Space Rubber B3. Fuel Supply Pump Bracket4. Space Rubber A

4. Confirm that the supply pump camshaft key isturned to the right and is horizontal.

5. Install the fuel supply pump to the pump shaft.a. Align the fuel pump gear timing mark (1) with

the idle gear A paint marks (2).b. Ensure that the pump must be bit with

maingear(3)of the idle gear A. Depress thepump gear when it is bitted with scissors gear(4) of the idle gear A.

6. Install the timing chain to the each sprocket andinstall the fuel supply pump sprocket to the pumpshaft.a. Align the camshaft sprocket timing mark (1)

with the bright plate timing chain link (2).b. Align the fuel supply pump sprocket timing

mark (3) with the yellow plate timing chain link(4).

c. Install the fuel supply pump sprocket to the fuelpump shaft by aligning the dowel pin that isattached to the gear.

d. Hand-tighten the fuel supply pump shaft nut.

Legend1. Timing Mark2. Dark Plate2. Timing Mark2. Yellow Plate

LNW71DSH000401

1

2

3 4

RTW56CSH004301

RTW56CSH005101

1

3

4

2

RTW56CSH005001

3

4

2

1


7. Install the timing chain tension lever pivot. Hand-tighten the pivot bolt.Confirm that the tension lever moves smoothly.

8. Attach the hook of the timing chain tensioner.• Hold the latch(3) depressed. Insert the

plunger(2). Attach the hook (4) to the pin (1) tohold the plunger in place.

9. Install the gasket (2) and the timing chain tensioner(1). Tighten the nut to the specified torque.

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

10. Unlock the tensioner hook.• Press the place of the arrow in the figure.• The hook is opened. The plunger pushes the

tension lever.

11. Tighten the nut (1) to the specified torque.


12. Tighten the timing chain tension lever pivot bolt tothe specified torque

Tightening torque: 27 N⋅m (2.8 kg⋅m / 20 lb ft)13. Turn the crank pulley two rotations (720°CA).

LNW71BSH001501

1

2

4

3

LNW71BSH001401

1

2

RTW56ASH020401

RTW56CSH001601

1


14. Check the mark (1) on the intake camshaft andexhaust camshaft to the mark of camshaft bearingcap.

15. Install the cylinder head cover.Refer to “Cylinder Head Cover”.

16. Apply liquid gasket (ThreeBond TB-1207C orequivalent) to the timing chain cover upper (1).• Attach the cover within 5 minutes of applying

the liquid gasket.

17. Install the timing chain cover upper (1).Tighten the bolt to the specified torque.• Apply Loctite #262 or equivalent to the bolt and

stud threads of cylinder head side (2).


18. Apply liquid gasket (ThreeBond TB-1207C orequivalent) to the timing chain cover lower (1).• Attach the cover within 5 minutes of applying

the liquid gasket.

19. Install the timing chain cover lower (1). Tighten thebolts (2) and nuts (3) to the specified torque.


RTW56ASH006901

1

RTW56CSH002101

1

RTW76CSH001201

1

2

2

RTW56CSH002301

1


20. Install the noise cover (1). Tighten the bolts to thespecified torque.


21. Install the connector of supply pump.22. Install the fuel rail assembly.

• Refer to the Install procedure for Fuel railassembly in this manual.

23. Install the A/C compressor bracket. Tighten thebolts to the specified torque.

Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)24. Install the A/C compressor.



25. Install the A/C compressor adjust pulley.

Legend1. Bolt2. Nut

Tighten the bolt and nut to the specified torque.

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

Nut Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)26. Install the A/C compressor drive belt.

Refer to the drive belt tension check procedure forHeating and air conditioning in this manual.

27. Install the cooling fan.28. Install the fan guide.29. Install the radiator upper hose.30. Replenish the engine coolant.31. Start the engine and let idle.

IMPORTANT:In order for the ECM to learn the characteristics of thefuel supply pump, let the engine idle until warn-up. Iffuel system DTC's are stored in the meantime, clearthe DTC and warn-up the engine again.

LNW76CSH001401

1

3

2

3

2

2

RTW56CSH001401

1

LNW76CSH001101

2 1



LNW76CLF000401

25(2.5/18)

10(1.0/87lb in)

10(1.0/87lb in)

10(1.0/87lb in)

10(1.0/87lb in)

130(13.3/96)

27(2.8/20) 25(2.5/18)

25(2.5/18)

25(2.5/18)


Fuel Sedimenter SwitchInspection

1. Check that there is continuity between the switchconnector terminals when the float in the fuelsedimenter is above the water drain line.

2. Turn on the ignition switch, remove the fuelsedimenter connector, and connect the terminalsof the connectors on the harness side. Confirmthat the sedimenter warning lamp lights up.

If abnormalities are detected during the check, replacethe CASE – KIT (with switch) and carry out repairs incase of defective connections between circuits or shortcircuits.

Legend1. Sensor2. Connector on The Vehicle Side3. Harness4. Drain Plug

LNW76CSH000201

2

3

4

1


Fuel TankComponents

Legend1. Fuel gauge unit connector2. Breather hose3. Fuel feed hose

4. Fuel return hose5. Band6. Fuel tank

Removal1. Loosen the fuel filler cap.2. Drain the fuel through the drain plug.3. After draining the fuel tighten the drain plug to its

specified torque.

4. Remove the connector from the fuel gauge unit.5. Remove the breather hose.

6. Remove the fuel feed hose.7. Remove the fuel return hose.

• Use a stopcock to prevent fuel from spilling,point it upwards and tie it to the frame.

8. Remove the band for mounting the fuel tank andremove the tip of the band on the frame side.

9. Pull the fuel tank to the outside.

LNW21DLF000301

5

6

431

2



NOTE:If the fuel tank can not be removed, remove the bracketand lower the fuel tank downwards.

Mounting1. Mount the fuel tank.

NOTE:If you removed the bracket when removing the fueltank, attach the bracket to the frame and tighten it to itsspecified torque.

Also, when placing the fuel tank on the bracket, makesure the rubber that is attached to fuel tank contacts thebracket.

2. Mount the band onto the fuel tank and tighten themounting nut to its tightening torque.

3. Mount the fuel return hose.4. Mount the fuel feed hose.

• Put the hose onto the pipe at least 25 mm(0.9843 in).

5. Mount the breather hose.

• Put fuel into the fuel tank and tighten the fuelfiller cap.

• Connect the battery ground cable.• After starting the engine, check the hose

connections to make sure that there are not anyfuel leaks.

6. Connect the connector to the fuel gauge unit.

Tightening torque: 55 N⋅m (5.6 kg⋅m / 41lb ft)


LNW21DMH000501


Fuel Gauge UnitComponents

Legend1. Fuel gauge unit connector 2. Fuel gauge unit

Removal1. Remove the wiring connector from the fuel gauge

unit.2. Remove the mounting screw and remove the fuel

gauge unit.

NOTE:When removing and attaching the fuel gauge unit, takecaution with respect to interference with surroundingobjects; do not deform the arm.Also, after removing the fuel gauge unit, place a seal sothat foreign materials do not get into the tank.

1

2

LNW21DMF000101


InspectionThe fuel tank unit changes its internal resistance basedon the position of the float (height of liquid) and movesthe needle of the fuel meter.

1. While moving the float from E to F, inspect theresistance value between connector terminals 1 J-28 - 2 J-28.

2. Confirm that the low fuel light turns on when thefloat is in the "E" position.If there are any abnormalities found with theinspection, replace with a part that works correctly.

LNW21DSH002301

a 325.2mm / 12.80in (Fuel tank capacity 63L / 13.86Imp.gal)379.7mm / 14.95in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)

b 284.8mm / 11.21in (Fuel tank capacity 63L / 13.86Imp.gal)336.1mm / 13.23in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)

LNW76DMF000101

121/2

Warning lamp lighting point

F

a b c d

E

J-28


MountingPerform the removal process backwards for mounting.

1. Mount the fuel gauge unit.2. Connect the wiring connector to the fuel gauge

unit.


c 175.1mm / 6.89in (Fuel tank capacity 63L / 13.86Imp.gal)207.7mm / 8.18in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)

d 76.7mm / 3.02in (Fuel tank capacity 63L / 13.86Imp.gal)75.8mm / 2.98in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)

Float Position Standard resistance volume (Ω)

F (FULL stopper) 2.5

1/2 33.0

Warning lamp lighting point

87.0

E (EMPTY stopper) 98.3

LNW76DMF000201

55(5.6/41)

12(1.2/104lb in)

20(2.0/14)

MEMO................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

ENGINE ELECTRICAL (4JJ1) 6D-1

ENGINEENGINE ELECTRICAL


Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .6D-2Servicing Cautions . . . . . . . . . . . . . . . . . . . . . . .6D-2Important Generator Components and Function6D-2Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .6D-3Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-4

Unit Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6Inspection and Repair . . . . . . . . . . . . . . . . . . . .6D-8Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . .6D-8Stator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . .6D-10Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . 6D-11Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-12Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . .6D-12

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-14Starting Circuit Diagram . . . . . . . . . . . . . . . . . .6D-14Removal and Installation . . . . . . . . . . . . . . . . .6D-14Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6D-15Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-19Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-22Magnetic Switch. . . . . . . . . . . . . . . . . . . . . . . .6D-24

Pre-Heating System . . . . . . . . . . . . . . . . . . . . . .6D-26Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-26

6D-2 ENGINE ELECTRICAL (4JJ1)

Charging SystemServicing Cautions

• Battery polarity is important. If the battery cablesare reversed, the generator diodes will bedestroyed.

• Do not remove the battery cables or the chargingcircuit wiring when the engine is running.

• Confirm that the terminal wires are connected tothe proper terminals by checking the terminalnumbers (the number on the terminal wire and theterminal must be the same).

• Disconnect the battery negative cable (-) beforeinspecting the generator.

• Do not open or close the battery relay switch whenthe engine is running.

• Disconnect the battery negative cable (-) whenusing external equipment (Quick-Charge) tocharge the battery.

• When steam cleaning or washing the engine, donot allow steam or water to come in direct contactwith the battery and other electrical systemcomponents.

• Be sure to read the item on belt tension adjustmentbefore beginning the procedure.

Important Generator Components andFunction

• The generator uses a built-in solid-state IC voltageregulator. The regulator and other importantcomponents together with their connections areshown in the illustration.

• The voltage regulator is installed to the rear coverassembly of the generator together with the brushholder and the rectifier. The generator requires noadditional voltage regulation.

• 9 diodes are connected to the stator coil to convertAC to DC. The DC voltage is delivered to thegenerator output terminal.

AC Generator

RTW76DMF000101


Charging System

TroubleshootingSymptoms

• No charging

• Inadequate charging• Excessive charging• Unstable charging current• Abnormal generator noise

No charging

Inadequate charging

RTW56DMF000101

Stator coilR

otor

coi

l

Bat

tery

SW

IG-SW

IC Regulator

Charge lamp

Warnninglamp

Chargerelay

QOSC/U

E

B

B

S

L

S L

P

F

Possible problem Countermeasure

Dead battery Replace

Open or shorted wiring Repair

Open or shorted ammeter

Loose wiring connections

One or more generator coils open or shorted Replace

Bad diode

Bad regulator

Loose regulator connections Repair


Dead battery Replace


Excessive charging

Unstable charging current

Abnormal operating noise

DiagnosisOn-vehicle InspectionThe charging system warning light tells the vehicleoperator of possible problems with the system.When the ignition switch is moved to the ON position,the light turns on. The light turns off immediately afterthe engine is started. If the light turns on during engineoperation, there is a problem with the charging system.Perform the checks described below.

1. Check the belt (broken or loose).2. Check the harness connectors (loose or

disconnected).

3. With the engine off, turn the ignition switch to theON position. If the warning lamp does not light,remove the harness connector from the generator.Ground the connector L terminal. The lamp shouldlight. If it does not, the bulb is burned out. Replacethe bulb.

4. Start the engine. If the warning lamp remains on,the generator must be repaired or replaced.

Open or shorted wiring Repair

Loose wiring connections

Loose generator drive belt Adjust belt tension

Stator coil intermittent short Replace

Bad diode

Loose battery connections Repair

Bad regulator Replace

Loose regulator connections Repair




Open wiring connection or broken wire Repair


Open or shorted stator coil Replace

Loose terminal connections Repair


Loose regulator terminal connections Repair



Bad bearing Replace

Loose rotor core or stator core Repair

Bad diode Replace

Open or shorted stator coil Replace



Specifications

Battery power Volts 24

Generator output Amperes 45 / 50 / 80

Rotational direction (Viewed from pulley) — Clockwise

Rated speed rpm 5000

Maximum speed 12000


Unit ServicingComponents

Legend1. Pulley Nut2. Pulley 3. Front Cover Assembly4. Rotor Assembly5. Stator Assembly

6. Through Bolts7. Rear Cover Assembly8. Rectifier9. Ball Bearing

10. Ball Bearing

Disassembly1. Remove the through bolts.2. Insert a flat-blade screwdriver between the front

cover and the stator. Pry the parts apart.

LNW76DLF000101

6

8

1

2

5

10

9

7

3

4


3. Separate the front cover/rotor assembly from therear cover/stator assembly.

4. Place the front cover and rotor in a vise.5. Remove the pulley nut and the pulley.6. Remove the rotor from the front cover.

7. Remove the screw from the front cover.

8. Remove the bearing retainer and the bearing.

9. Remove the B-terminal nut and M5 nut.10. Remove the rear cover from the stator.

LNW76DSH000801

LNW76DSH000201

LNW71DSH000201

LNW71DSH000301


11. Remove the stator assembly.

12. Remove the rectifier assembly from the statorassembly.

Inspection and RepairRepair or replace any parts found to be excessivelyworn or damaged during the inspection procedure.

Rotor Assembly1. Check for dirty or rough slip ring surfaces. Remove

dirt from the surfaces with a clean rag. Use No.500 or No. 600 sandpaper to smooth the surfaces.

2. Measure the slip ring diameters. Replace the slipring if the diameter is less than the specified limit.

3. Measure the electrical resistance between the sliprings. If the resistance is greater than the specifiedlimit (open circuit), repair is required.

Slip ring diameter mm (in)Standard 31.7 (1.248)

RTW46DSH000401

LNW76DSH000601

Limit 30.7 (1.209)

Rotor coil resistance at 20°C (68°F) Ω

(45 A) 10.5(50 A) 8.2(80 A) 10.2

LNW76DSH000501

1

LNW76DSH000301


4. Check for conductivity between the slip rings andthe rotor core. If there is continuity, the rotorassembly must be replaced.

Stator Coil1. Measure the stator coil resistance. If the resistance

is less than the specified value, the stator coil mustbe replaced.

2. Measure the resistance between the stator coil andthe stator core. If the resistance is less than thespecified value, the stator coil must be replaced.

Stator coil/core resistance: MIN 1 MΩ

BrushesMeasure the brush height. If the height is less than thespecified limit, the brushes must be replaced.

Stator coil resistance at 20°C (68°F) Ω

45 A 0.1950 A 0.1980 A 0.07

LNW76DSH000401

1

LNW76DSH000701

1

2

Brush height mm (in)Standard 25 (0.984)

Limit 6.5 (0.260)

HCW31ESH004401

1

2


Rectifier AssemblyMeasure each of the diode resistances in bothdirections (anode/cathode and cathode/anode). If anyof the diodes have the same resistance in bothdirections, the rectifier must be replaced.

LNW76DMH000101

1

2

4

3

RTW46DSH001201

Tester Wire

E+ —

BAT+ —

U,V, and WN U,V, and WN

+ —— Conductivity + —— NO conductivity

— NO conductivity —— — Conductivity ——

Negative side diode check Positive side diode check


Rectifier Assembly(45A / 50A)

(80A)

Test circuitRefer to the judgment criteria shown in the Tablebelow.Carefully check Items 1 to 5.If all the items areOK, the IC regulator is normal.

Circuit components

LNW76DSF000101

V

+

-

DIRECT-CURRENT

STABILIZATION POWER SUPPLY

PULSE

GENERATOR

OUTPUT SIGNAL

5~30V

1kHz

VOLT METER

SWITCH 2

SWITCH 3LAMP 1LAMP 2

L

B

E

P

1

2

3 5

6

7

8

4

RTW46DSF000301

V

+

-

DIRECT-CURRENT

STABILIZATION POWER SUPPLY

PULSE

GENERATOR

OUTPUT SIGNAL

5~30V

1kHz

VOLT METER

SWITCH 1

SWITCH 2

SWITCH 3LAMP 1LAMP 2

S

L

B

E

P

1

2

3

4 6

7

8

9

5

1 DC regulated power supply 0 - 30 volts variable with output of 1 ampere or more2 Lamps (2) 24 volts, 1.8 watts3 Switches (3) ——4 DC voltmeter 0 to 60 volts, 0.5 grade5 Pulse generator (Oscillator) 5 to 30 volt output at a frequency of 1KHz


Judgment criteria

ReassemblyFollow the disassembly steps in reverse order toreassemble the generator. Pay close attention to theitems below.

• Be very careful not to reverse battery polarity.Reversed battery polarity will destroy the rectifierdiodes.

• Do not ground the generator B-terminal. Heat andfire damage to the harness will result.

• If using a fast charge procedure, be sure todisconnect the battery positive cable. If you do not,the rectifier diodes will be exposed to high positivevoltage that will destroy them.

• Be very careful to reassemble the parts to theiroriginal positions. Particular care must be takenwith insulated parts.

• Carefully clean all insulated parts so that they arecompletely free of oil and/or grease.

• Be sure that B-terminal twist-type stoppers (roundterminal) are securely inserted before tighteningthe nuts.

Final Assembly1. Pulley and rotor assembly.

• Install the pulley and rotor assemblya. Carefully clamp the rotor assembly in a vise.

b. Tighten the pulley nut.

Tightening torque: 110 N⋅m (11.2 kg⋅m / 81lb ft)

NO. Switch1

Switch2

Switch3

Voltmeterreading

Lamp conditionRemarks

Lamp 1 Lamp 2

1 ON OFF OFF24V

On(dim) ON Initial excitation check

2 ON ON OFF On orflashing

OFFFull excitation check

3 ON ON OFF 32V Off oron (dim)

Lamp 1 off or dimly lit when the voltmeter showsless than 24 volts or 32 volts

4 OFF ON OFF 24V On orflashing ON

Stator and brush separation check

5 ON ON ON 36V On Excess voltage check

RTW46DSH002101


c. The rear ball bearing is pressed into the wheeleccentric groove.The bearing ring projects fromthe groove.During installation, rotate thebearing to the point of minimum bearing ringprojection.

2. Rear cover and stator assembly.• Use a pair of long-nose pliers to connect the

stator coil leads and the rectifier leads.• Finish the work as quickly as possible to

prevent the rectifier from heat transferred by thesoldering.

• Insert the pin from the outside of the rear cover.Press the brushes into the holder. Complete theassembly procedure.

3. Use a bench press to install the rear coverassembly to the front cover assembly.

4. Through bolts.• place a guide bar through the holes in the front

cover and rear cover flange for properalignment.Install the through bolts.

Tightening torque:4N⋅m(0.4 kg⋅m / 35 lb ⋅ in)

RTW46DSH004901

Ring

Projection part

(0.65mm blow)

eccentric groove

RTW46DSH000401

RTW46DSH005301

Pin

RTW56DSH000201


Starter MotorStarting Circuit Diagram

Removal and InstallationRead this Section carefully before performing anyremoval and installation procedure. This Section givesyou important points as well as the order of operation.Be sure that you understand everything in this Sectionbefore you begin.

Important Operations - RemovalStarter Motor1. Disconnect the battery cable and the ground cable

at the battery terminals.2. Remove the A/T oil level gage.3. Remove the E/G oil level gage.4. Disconnect the magnetic switch cable at the

terminal bolts.5. Disconnect the battery cable at the starter motor

and the ground cable at the cylinder body.6. Remove the starter motor from the engine.

Important Operations - InstallationFollow the removal procedure in the reverse order toperform the installation procedure. Pay careful attentionto the important points during the installationprocedure.

Starter Motor1. Install the starter motor to the rear plate.2. Tighten the starter motor bolts to the specified

torque.

3. Install the E/G oil level gage.4. Install the A/T oil level gage.5. Reconnect the battery cable at the starter motor

and the ground cable at the cylinder body.6. Reconnect the battery cable and the ground cable

at the battery terminals.

Motor Bolt Torque: N⋅m (kg⋅m / lb ft)85 (8.7 / 63)

RTW46DSH005501

M

Type : S13-555A

Starter switch

Battery

B

M

S


Components24 V 4.0 kW

Legend1. Plunger2. Dust Cover3. Magnetic Switch4. Terminal Cover5. Gear Case6. T0rsion Spring7. Dust Cover8. Shift Lever9. Through Bolt

10. Rear Cover11. Brush Holder12. O Ring13. Yoke

14. Ball Bearing15. Armature16. Ball Bearing17. Bearing Retainer18. Pinion Shaft19. Ball Bearing20. Clutch21. Ball Bearing22. Return Spring23. Stopper24. Clip25. Ball Bearing26. Bearing Holder

LNW76DLF000201

1

2

3

4

5

7

8

9

10

6

11

12

13

14

15

16

17

18

19

22

23

2425

26

21

20


24 V 4.5 kW

Legend1. Plunger2. Dust Cover3. Magnetic Switch4. Terminal Cover5. Torsion Spring6. Shift Lever7. Dust Cover8. Gear Case9. Through Bolt

10. Rear Cover11. Drain Pipe12. Brush Holder13. O Ring14. Yoke15. O Ring16. Ball Bearing17. Armature

18. Ball Bearing19. Bearing Retainer20. Clip21. Pinion Stopper22. Pinion23. Cushion Spring24. Sleeve Cover25. Stopper Washer26. Pinion Shaft27. Ball Bearing28. Clutch29. Ball Bearing30. Return Spring31. Stopper32. Clip33. Ball Bearing34. Bearing Holder

LNW76DLF000301

1

2

3

4

9

10

1211

13

14

16

17

15

18

27

26

19 20

21

22

23

2425

30

31

3233

34

5

29

28

6

7

8


Important Operations 1. Lead Wire

Disconnect the lead wire at the magnetic switch.

2. Magnetic Switch AssemblyRemove the magnetic switch bolts, then removethe switch from the shift lever.

Remove the torsion spring from the magneticswitch.

3. Through Bolt4. Screw5. Rear Cover

Remove the through bolts, then remove the rearcover.

RTW46DSH002601

RTW46DSH002701

RTW46DSH002801

RTW46DSH002901


6. Motor AssemblyRemove the four brushes from the brush holders.

Remove the yoke along with the armature and thebrush holder from the gear case.Remove the brushes and commutator carefully soas not to allow them in contact with the adjacentparts.

7. Brush Holder8. Yoke

9. ArmatureRemove the brush holder and pull out the armatureassembly free from the yoke.

10. Bearing Retainer11. Pinion Assembly12. Dust Cover13. Shift Lever (4.0kW only)14. Shift Lever and Lever pin (4.5kW only)15. Gear Case

a. Remove the bearing retainer.b. Remove the pinion from the gear case.

RTW46DSH003001

Brush

RTW46DSH003101

RTW46DSH003201

LNW76DSH000901


c. Use a screwdriver to remove the stopper clip.Then disassemble the pinion assembly.

Inspection and RepairMake the necessary adjustments, repairs, and partreplacement if excessive wear or damage is discoveredduring inspection.

Armature1. Measure the commutator run-out.

Replace the commutator if the measured run-outexceeds the specified limit.

2. Check the commutator mica segments forexcessive wear.

3. Measure the mica segment depth.

If the mica segment depth is less than the standardbut more than the limit, the commutator may bereground.If the mica segment depth is less than the limit, thecommutator must be replaced.

Legend1. Insulator2. 0.5 to 0.8 mm (0.020 to 0.030 in)3. Commutator Segments4. Correct5. Incorrect

4. Measure the commutator outside diameter.

Commutator Run-Out mm (in)Standard 0.05 (0.002)

Limit 0.20 (0.079)

RTW46DSH003401

RTW46DSH003501

Mica Segment Depth mm (in)Standard 0.5 – 0.8 (0.020 – 0.030)

Limit 0.2 (0.008)

Commutator Outside Diameter mm (in)Standard 36.5 (1.44)

Limit 35.5 (1.40)

RTW56DSH000701

1 2

3

4

5


If the measured outside diameter is less than thespecified limit, the commutator must be replaced.

5. Use a circuit tester to check the armature forgrounding.a. Hold one probe of the circuit tester against the

commutator segment.b. Hold the other circuit tester probe against the

armature core.If the circuit tester indicates continuity, thearmature is grounded.The armature must be replaced.

6. Use the circuit tester to check the armature forcontinuity.a. Hold the circuit tester probes against two

commutator segments.

b. Repair Step 1 at different segments of thearmature core.There should be continuity between allsegments of the commutator.If there is not, the armature must be replaced.

Yoke1. Use a circuit tester to check the field winding

ground.a. Hold one circuit tester probe against the field

winding end or brush.b. Hold the other circuit tester probe against the

bare surface of the yoke body.There should be no continuity. If there iscontinuity, the field coil is grounded. The yokemust be replaced.

2. Use the circuit tester to check the field windingcontinuity.a. Hold one circuit tester probe against the "M"

terminal lead wire.

HCW51ESH000901

RTW46DSH003601

RTW46DSH003701

RTW46DSH003801


b. Hold the other circuit tester probe against thefield winding brush.There should be continuity.If there is nocontinuity, the yoke must be replaced.

Brush and Brush Holder1. Use a vernier caliper to measure the brush length

(four brushes).Replace the brushes as a set if one or more of thebrush lengths is less than the specified limit.

2. Use a circuit tester to check the brush holderinsulation.Touch one probe to the holder plate and the otherprobe to the positive brush holder.There should be no continuity.

Inspect the brushes for excessive wear.If the negative brushes have excessive wear, the entirebrush holder assembly must be replaced.If the positive brushes have excessive wear, the entireyoke must be replaced.

Overrunning Clutch1. Inspect the overrunning clutch gear teeth for

excessive wear and damage.Replace the overrunning clutch if necessary.

2. Rotate the pinion clockwise.It should turn smoothly.

3. Try to rotate the pinion in the opposite direction.The pinion should lock.

Brush Length mm (in)Standard 15.5 (0.61)

Limit 12 (0.47)

RTW46DSH003901

RTW46DSH004001

RTW46DSH004101

LNW61DSH002701


BearingInspect the bearings for excessive wear anddamage.Replace the bearings if necessary.

ReassemblyImportant Operations

1. Magnetic Switch Assemblya. Attach the torsion spring to the hole in the

magnetic switch as illustrated.b. Insert the shift lever into the plunger hole of the

magnetic switch.

2. Gear Case3. Dust Cover

a. Install the magnetic switch assembly in the gearcase.

b. Install the dust cover.

4. Pinion AssemblyApply a coat of grease to the reduction gear andinstall the pinion assembly to the armature shaft.

5. Brush Holdersa. Install the brushes into the brush holder with

raising the spring end of the brush spring.Take care not to damage the commutator face.

RTW46DSH004401

RTW46DSH005601

Dust Cover Bolt Torque: N⋅m (kg⋅m/lb in)10.6 (1.08 / 78)

RTW46DSH005701

LNW61DSH002801


b. Install the brush holder with aligning theperipheries of the yoke and the brush holder.

6. Through BoltInstall the through bolts in the rear cover andtighten them to the specified torque.

7. Lead WireConnect the lead wire in the magnetic switch andtighten the terminal nut to the specified torque.

Inspection After AssemblyUse a vernier caliper to measure the pinion shaft thrustplay.The pinion shaft thrust play is equal to the pinion shaftend and pinion stopper clearance.

Through Bolt Torque: N⋅m (kg⋅m/lb in)8.1 (0.83 / 69.7)

Lead Wire Terminal Nut Torque: N⋅m (kg⋅m/lb in) 8.6 (0.88 / 74.9)

RTW46DSH004501

LNW61DSH002901

Pinion Shaft Thrust Play: mm (in) 0.3 - 1.0 (0.012 - 0.039)

RTW46DSH002601

LNW76DSH001001

0.3-1.0mm


Magnetic SwitchThe following tests must be performed with the startermotor fully assembled.The yoke lead wire must be disconnected from the "M"terminal.To prevent coil burning, complete each test as quicklyas possible (within three to five seconds).Temporarily connect the solenoid switch between theclutch and the housing and run the following test.Complete each test within three to five seconds.

1. Pull-in TestConnect the battery negative terminal with thesolenoid switch body and the M terminal. Whencurrent is applied to the S terminal from the batterypositive terminal, the pinion should flutter.

2. Hold-in Maintenance TestDisconnect the lead at the M terminal. The pinionshould continue to flutter.

3. Return TestDisconnect the battery positive lead at the Sterminal.The pinion should return to its home position.

RTW46DSH004601

S

RTW46DSH005901

S

RTW46DSH004701

S


LNW76DLF000401

8.1 (0.83/6.0)

8.6 (0.88/6.4)


Pre-Heating SystemInspection and RepairMake the necessary adjustments, repairs, and partreplacement if excessive wear of damage is discoveredduring inspection.

Visual CheckCheck the main fuses and glow indicator for damage.Replace the part(s) if required.

Glow RelayThe glow relay is located in the relay box the enginecompartment.Use an ohmmeter to measure the resistance betweenterminals No.2 and No.3.If the measured value is outside the specified range,the glow relay must be replaced.

Glow PlugUse a circuit tester to test the glow plugs for continuity.

Glow Relay Resistance: Ω

94 - 114

Glow Plug Resistance (Reference): Ω

Approximately 0.9

LNW61DSH003001

3

14

2

2

1

3

4

LNW21KSH001401

EXHAUST SYSTEM (4JJ1) 6F-1

ENGINEEXHAUST SYSTEM


Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6F-2Explanations on functions and operation . . . . . . 6F-2Functional check . . . . . . . . . . . . . . . . . . . . . . . . 6F-3List of abnormal phenomena . . . . . . . . . . . . . . . 6F-3Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6F-3

Exhaust Silencer and Exhaust Pipe . . . . . . . . . . . 6F-4Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4DPD Disassembly . . . . . . . . . . . . . . . . . . . . . . . 6F-5DPD Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6F-6DPD Reassembly. . . . . . . . . . . . . . . . . . . . . . . . 6F-6Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-8Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-10

Exhaust Brake System . . . . . . . . . . . . . . . . . . . . 6F-11Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-11Explanations on functions and operation . . . . . 6F-11Functional check . . . . . . . . . . . . . . . . . . . . . . . 6F-11

Exhaust Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-14

Exhaust Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-18

EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-19Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-19Explanations on functions and operation . . . . . 6F-19

EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . 6F-20Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-21Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-22

6F-2 EXHAUST SYSTEM (4JJ1)

Exhaust SystemService PrecautionsOffset in position of the exhaust system duringassembly may sometimes cause vibrations or rattlingnoise. Therefore, temporarily tighten the bolt until allthe parts have been positioned, and sequentiallytighten from the engine side to the rear pipe side.

Explanations on functions and operationThe exhaust brake assembly operates the auxiliarybrakes by adjusting the exhaust pressure. The silencerhas a built-in catalytic converter and the catalyst is aceramic monolith (honeycomb). This reduces the COand HC in the exhaust gas. The rear exhaust pipe hasa built-in post silencer. This improves the silencingeffect.The main parts consist of the front exhaust pipe, centerexhaust pipe, exhaust brake unit, silencer with built-incatalyst, and rear exhaust pipe.

Legend1. Front Exhaust Pipe A2. Exhaust Brake Assembly3. Front Exhaust Pipe B4. DPD(Diesel Particulate Defuser, EURO 4

Specification)

5. Exhaust Silencer(EURO 3 Specification)6. Exhaust Throttle Assembly7. Exhaust Silencer8. Center Exhaust Pipe9. Rear Exhaust Pipe

LNW76FLF000201

1

2

3

4

6

7

5

8

9


Functional check• During check or repairs of the exhaust system,

confirm that the clearance between the body andthe floor is adequate.

• Adequate care should be taken to prevent damagedue to heating or vibrations in the body panel as itmay lead to exhaust gas entering the cabin.

• Check for loose or damaged connectors andleakage of exhaust gas.

• Check for degradation, cracks or damage to theclamp or rubber.

• If the pipe or silencer is damaged or has a dentthen repair or replace it.

• Check for dents, damage holes or cracks due tocorrosion, and abnormal noise during operation.

• If CO or HC value in the exhaust gas increaseswhen measuring the exhaust gas (vehicleinspection, etc.), replace the silencer (built-incatalyst).

List of abnormal phenomena• Vibration or rattling noise from the exhaust system.• Clogging of the exhaust system.• Exhaust leakage or noise.

Trouble ShootingVibration or rattling noise from the exhaust system

Clogging of the exhaust system

Exhaust leakage or noise


Vibration or rattling noise from theexhaust system

Loose or misaligned components Match the joints and then re-tighten.Or,check for damage in the hanger,mounting brackets and clamps.


Clogging of the exhaust system The exhaust brake is in the ONstatus.

Refer to the Engine Control Systemsin 6E section, check the electricsystem and repair if there areabnormalities.Check if the shaft movement in theexhaust brake throttle valve movesis jerky and replace if there is anabnormality.

Clogging or deformation of theexhaust piping.

Repair or replace the exhaust piping.


Exhaust leakage or noise Defect or misalignment in mounting Match the joints and then re-tighten.

Damage or burn-out of exhaustpiping or silencer

Replace the damaged parts.

Defective components in theexhaust system (clamps, pipes,silencer)

Replace the defective parts.

Internal damage to silencer Replace the silencer


Exhaust Silencer and Exhaust PipeRemoval

1. Remove the rear exhaust pipe.• Remove the clamp and rear exhaust pipe.

2. Remove the center exhaust pipe.3. Remove the exhaust silencer.4. Remove the exhaust throttle air pipe.5. Remove the exhaust throttle assembly.6. Remove the exhaust silencer(EURO 3

Specification).7. Remove the DPD assembly (EURO 4

Specification).• Remove the 2 connectors on the DPD exhaust

temperature sensor.• Remove the clip that secures the connectors on

the DPD exhaust temperature sensor.• Remove the 2 DPD differential pressure hoses.• Remove the DPD assembly from the front pipe.

Legend1. Differential Pressure Pipe (F)2. Exhaust Temperature Sensor (R)3. Differential Pressure Sensor4. Differential Pressure Hose (F) 5. Differential Pressure Hose (R) 6. Differential Pressure Pipe (R) 7. Exhaust Temperature Sensor (F)

NOTE:In the event that the differential pressure sensorassembly must be removed, pay attention to thefollowing points.

• Do not loosen the 4 screws used to tighten thedifferential pressure sensor. If these screws havebeen loosened, replace the differential pressuresensor assembly.

• If the differential sensor assembly is dropped, itcannot be reused.

LNW76FSH000501

LNW76FSH000101

6

5

4

1

7

2

3


Legend1. Sensor Assembly2. Tightening Screw

8. Remove the front exhaust pipe (B).9. Remove the exhaust brake.

• Remove the air hose and the exhaust brakeassembly.

10. Remove the front pipe (A).• Remove the clamp and front pipe.

DPD Disassembly1. Loosen the clip (1) from the hose connecting to the

differential pressure pipe and remove the hose.2. Loosen the sleeve nuts (2) and (4) that secure the

differential pressure pipe.3. Remove the clip (3) that secure the differential

pressure pipe.4. Remove the differential pressure pipe.

Legend1. Hose Clip2. Sleeve Nut (Rr)3. Clip4. Sleeve Nut (Ft)

5. Disassemble the DPD assembly.• Loosen the nuts used for mounting the

oxidation catalyst section, and detach theoxidation catalyst section.

• Loosen the nuts used for mounting the filter anddetach the filter and rear case.

NOTE:Do not submit the DPD assembly to high impact or dropthe assembly.

LNW76FSH000201

1

2

LNW76FSH000301

2

3

1

4


Legend1. Oxidation Catalyst Section2. Gasket3. Filter Section4. Gasket5. Rear Case

DPD Inspection1. Perform an external appearance inspection on

exhaust pipe related components.• Damage to a body panel caused by heating or

vibration can lead to exhaust gas intruding intothe cabin.

• Inspect the connections for looseness,damage, and exhaust gas leaks.

• Inspect the clamps and rubber for deterioration,cracks, and damage.

• Inspect the pipe and silencer for dents andcorrosion induced cracks, and if damaged,repair or replace the damaged part(s).

2. Perform an DPD related inspection.• Visually inspect the filter for erosion, damage,

or blocking.• Light shines through the filter from the opposite

side. If light is transmitted and is visible, replacethe filter section.

NOTE:Before DPD disassemble, be sure to use a scan tool tocheck the DPD differential pressure, status, andinspection and servicing details. Refer to the "Enginecontrol" section for details.

Legend1. Filter2. Filter Case

3. If the differential pressure sensor assembly hasbeen replaced, carry out the following steps (onthe vehicle).• Without turning the engine on, turn the key from

"OFF" to "ON".• The DPD lamp is turned on, and then after 30

seconds turned off.• After confirming that the DPD lamp has gone

off, turn the key to the "OFF" position and leavefor 15 seconds.

4. Check the oxidation catalyst.• Visually inspect the catalyst for erosion,

damage, or plugging.

DPD Reassembly1. Insert gaskets in the filter section and the rear case

and tighten temporarily with bolts and nuts.2. Insert gaskets in the filter section and oxidation

catalyst and tighten temporarily with bolts andnuts.

NOTE:Check the mounting location of the filter section andrear case, and the filter section and oxidation catalyst,and tighten each pipe bracket in 2 places by tighteningthe bolts alternatively.

3. Tighten the bolts and nuts to the specified torque.• Tighten all of the bolts and nuts twice.

LNW41GSH000201

1

2

4

3

5

Torque : 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)

LNW41GSH000601

1

2


NOTE:After tightening all of the bolts and all of the nuts,tighten them all to the same torque (tightening twice)

Legend1. Oxidation Catalyst Section2. Gasket3. Filter Section4. Gasket5. Rear Case

4. Insert the protruded section of the differentialpressure pipe (only Ft side) into DPF and tightenthe sleeve nut (4) by hand. Then, tighten thesleeve nut (Rr) (2) by hand.

NOTE:Clean the old anti-seize compound from the sleeve nutand apply new anti-seize compound.

5. Fix the pipe in place using a clip (3).

6. Fully tighten the sleeve nuts.

7. Insert the hose for the differential pressure pipeuntil it reaches the spool and secure with a clip.

Legend1. Hose Clip2. Sleeve Nut (Rr)3. Clip4. Sleeve Nut (Ft)

NOTE:If the procedures described above are not followed, thesleeve nut may become loose.

Air-tightness check• Once the engine is warmed up, run at maximum

non-load RPM.• To ensure there are no gas leakages, with the

engine revved up, spray soapy water on thepressure hose (1) and sleeve nuts (2) (4)connecting parts.

Torque: 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)

Torque (Ft): 45 N⋅m (4.6 kg⋅m / 33 lb⋅ft)

Torque (Rr): 35 N⋅m (3.6 kg⋅m / 26 lb⋅ft)

LNW41GSH000201

1

2

4

3

5

LNW76FSH000301

2

3

1

4


Legend1. Hose clip2. Sleeve Nut (Rr)3. Clip4. Sleeve Nut (Ft)

InstallationNOTE:

• A possible cause of vibration or looseness is themisspositioning of the exhaust system duringassembly. Therefore, do not fully tighten the boltsuntil all the components are positioned, and whenpositioned, tighten the bolts starting at the engineand working outwards.

• Do not re-use gaskets or nuts that were removed.

1. Install the front exhaust pipe A.

NOTE:Tighten the front exhaust pipe so that it is balanced,and make sure there are not any gas leaks.

2. Install the exhaust brake and front exhaust pipe B.• Install the air hose.

3. Install the DPD assembly to the front pipe (EURO4 Specification).

4. Install the DPD differential pressure hose to thedifferential pressure pipe (EURO 4 Specification).• Insert the front side of the differential pressure

hose into the port of the differential pressuresensor that is marked "F" (white).

• Attach the hose clips (4 locations) securely toprevent gas leakage.

NOTE:• Do not confuse the front/rear directions.• Do not use hoses that are cracked.• Do not overtighten or remove the differential sensor

assembly's tightening screws.• If there is a gas leak in the coupling section, a

sensor malfunction may occur.Ensure to check for gas leakage after starting theengine.

Legend1. Differential Pressure Sensor2. Clip3. Differential Pressure Hose4. Properly Fitted Hoses5. Reversely Fitted Hoses6. Differential Pressure Hose7. Clip8. Differential Pressure Sensor




LNW76FSH000301

2

3

1

4

LNW41GSH000901

8

77

65

1

22

3

4


Legend1. Nut2. F; Front Mark3. Rear Side Differential Pressure Hose Spigot4. Front Side Differential Pressure Hose Spigot5. Bracket

5. Connect the DPD temperature sensor connectors(EURO 4 Specification).

NOTE:Do not confuse the front/rear directions.

Legend1. Differential pressure pipe (F)2. Exhaust temperature sensor 1 (filter inlet)3. Differential pressure sensor 4. Differential pressure hose (F) 5. Differential pressure hose (R) 6. Differential pressure pipe (R) 7. Exhaust temperature sensor 2 (catalyst inlet)

6. Fix the DPD temperature sensor harness with clips(EURO 4 Specification).

7. Install the exhaust silencer to the front pipe (EURO3 Specification).

8. Install the exhaust throttle assembly and extensionpipe.

9. Install the exhaust throttle air hose.10. Install the center exhaust pipe.11. Install the rear exhaust pipe.

• Tighten the clamp.

LNW41GSH000801

F

4

2

5

1 1

3

LNW76FSH000101

6

5

4

1

7

2

3




LNW76FSH000501



LNW76FLF000401

22(2.2/16)

27(2.8/20)

67(6.8/49)

50(5.1/37)

27(2.8/20)

50(5.1/37)


Exhaust Brake SystemService PrecautionsDuring assembly and mounting, mount the partsappropriately at the specified tightening torque value.

Explanations on functions and operation

Functional checkOperational check

• Confirm the sound of the valve touching thestopper when the exhaust brake is operated in theidling condition.

LNW21GMF001401


Exhaust BrakeComponents

Legend1. Power Chamber, Insulator, Gasket and Bearing2. Lock Nuts and Clevis Joint3. Split Pin and washer4. Exhaust Brake Valve

5. Front Exhaust Pipe B6. Exhaust Brake Assembly7. Front Exhaust Pipe A

Removal1. Remove the vacuum and clips.2. Remove the nut.3. Remove the exhaust pipe.4. Remove the exhaust brake assembly.

Disassembly1. Remove the split pin.2. Remove the lock nuts.3. Remove the clevis joint.4. Remove the power chamber.

Reassembly1. Mount the power chamber.

LNW76FMF000101

7

6

5

8

9

2

1

103

4


Tightening torque : 14 N⋅m (1.4kg⋅m / 122lb⋅in)

2. Mount the lock nuts.3. After mounting the clevis joint, tighten the lock nuts

to the specified torque.Tightening torque : 13N⋅m (1.3kg⋅m / 113lb⋅in)

4. Mount the split pin.

InspectionCheck for damage or degradation in the partsmentioned below.

• Exhaust brake valve• Exhaust brake shaft• Butterfly valve• Bush• Power chamber

Unit check• Negative pressure in the power chamber caused

by the vacuum pump.When a pressure of 53.3 to 93.3 kPa (400 to 700mmHg) is applied, the exhaust brake valve shouldopen or close smoothly.

Installation1. Mount the exhaust brake assembly.

Tightening torque : 17N⋅m (1.7 kg⋅m / 12 lb⋅ft)

LNW21GSH001601

LNW21GSH002201

LNW21GSH001401

LNW46FSH000101


2. Mount the exhaust pipe. 3. Mount the nuts.Tightening torque : 67 N⋅m (6.8kg⋅m / 49lb⋅ft)

4. Mount the vacuum hose and the clips.


LNW76FSH000401

LNW76FMF000201

M6

67 (6.8/49)

41 (4.2/30)27 (2.8/20)


Exhaust ThrottleComponents

Legend1. Power Chamber2. Gasket3. Insulator4. Bearing5. Lock Nuts and Clevis Joint6. Pin and Split Pin

7. Cover8. Extension Silencer9. Exhaust Center Pipe

10. DPD (Diesel Particulate Defuser)11. Exhaust Throttle Body12. Exhaust Throttle Asembly

Removal1. Remove the vacuum hose and clip.2. Remove the nut.3. Remove the rear exhaust pipe.4. Remove the center exhaust pipe.5. Remove the exhaust silencer.

LNW76GMF000101

7

6

5

9

10

2

1

12

8

11

3

4


6. Remove the exhaust throttle assembly.

Disassembly 1. Remove the split pin.2. Remove the lock nut.3. Remove the clevis joint.4. Remove the power chamber.

Inspection Inspect the following parts for damage anddeterioration, etc.

• Exhaust throttle valve• Exhaust throttle shaft• Butterfly valve• Power chamber

Unit inspection • Apply vacuum pressure to the power chamber

using a vacuum pump.The exhaust throttle valve should open and closesmoothly when pressure of 75 - 93.3kPa 560 -700mmHg is applied.

NOTE:Do not change the exhaust throttle's adjustment as itmay have an affect on DPD performance.

Reassembly 1. Install the power chamber.

2. Install the lock nut.3. After mounting the clevis joint, tighten the lock nut

to specified tightening torque.

LNW76FSH000601

Tightening torque 14 N⋅m (1.4 kg⋅m / 122 lb⋅in)


LNW21GSH001401

LNW41GSH001101


NOTE:Do not adjust or remove the adjusting bolt.Do not remove the lever.

Legend1. Lever 2. Adjusting bolt

4. Install the split pin.

Installation1. Install the exhaust throttle assembly.

2. Install the exhaust silencer.3. Install the exhaust center pipe.

4. Install the rear exhaust pipe.

5. Install the vacuum hose and clip.

Tightening torque 20N⋅m (2.0kg⋅m / 14 lb⋅in)

LNW41GSH001201

1

2

LNW21GSH002301


LNW76FSH000601



LNW76GLF000101

13 (1.3/113lb in)

14 (1.4/122lb in)

27 (2.8/20)

50 (5.1/37)


EGR SystemService PrecautionsPerform EGR related assembly according to the usualprocedure of temporarily fitting and then permanentlytightening the parts so that unnecessary stresses arenot applied on the parts.

Explanations on functions and operationRe-circulate a part of the exhaust gas of the EGRsystem in the intake manifold.Reduce the combustiontemperature and inhibit NOx generation since inertgases may be mixed up in the intake sir.An electronic control system is used in this EGR tobalance the requirements of operability and lowemissions.A DC motor is operated using the controlcurrent of the Engine Control Module (ECM) to controlthe EGR.Refer to the chapter on Engine Control System fordetails on fault diagnosis of the EGR system.

Legend1. EGR cooler2. Engine Control Module (ECM)

3. EGR Valve DC Motor

LNW46FMF000501

2

1

3


EGR Valve and EGR CoolerComponents

Legend1. EGR Valve2. EGR Valve Gasket3. EGR Cooler

4. Heat Protector5. EGR Cooler Gasket6. EGR Cooler Gasket

Removal1. Drain the coolant.2. Remove the turbocharger.

Refer to “Turbocharger” in ENGINE MECHANICALsection.

LNW71FLF000101

1

2 3

6

4

5


3. Remove the heat protector.

4. Remove the EGR cooler.• Disconnect the Water pipe rubber hose (IN ,

OUT) and remove the EGR cooler and gasket.5. Remove the EGR valve.

Installation1. Install the EGR valve.

2. Install the EGR Cooler.a. Install the gaskets and the EGR cooler.

Temporarily tighten the bolts and the nuts.

b. Tighten the bolt and nuts by final tighteningorder.

3. Connect the water pipe rubber hose (IN,OUT).4. Install the heat protector

5. Install the turbocharger.Refer to “Turbocharger” in ENGINE MECHANICALsection.

6. Replenish the coolant.

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

Temporary tightening order : 1→2→3→4→5→6

LNW71FSH000101

LNW71FSH000301

Final tightening order : 3→4→5→1→2→6

Tightening torque : Bolt, Nut 1 to 5 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)Bolt 6 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)

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

LNW71FSH000201

6

4

53

2

1



LNW76FLF000101

27 (2.8/20)

27 (2.8/20) 25 (2.5/18)

27 (2.8/20)

52 (5.3/38)

ACCELERATOR CONTROL SYSYEM (4JJ1) 6H-1

ENGINEACCELERATOR CONTROL SYSYEM


Accelerator Pedal Assembly . . . . . . . . . . . . . . . . .6H-2Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2

6H-2 ACCELERATOR CONTROL SYSYEM (4JJ1)

Accelerator Pedal AssemblyComponents

Legend1. Nut2. Connector3. Control Link and Bracket Assembly

4. Accelerator Pedal5. Bolt

Removal1. Nut to Contorol Link and Bracket Assembly2. Bolt to Accelerator Pedal3. Harness Connector to Accelerator Switch

Connector and Accelerator Position Sensor

NOTE:Disconnect the battery ground cable when the harnessconnector is disconnected.

Installation1. Install the Harness Connector2. Instal the Accelerator Pedal Bolt3. Install the Control Link and Bracket Assembly

LNW41ILF000101

1

2

4

5

3

LG4JJ-WE-0761

You are requested to order this manual using themanual number that is shown above.

This manual is applicable for vehicles in allcountries except the USA, Canada and Mexico.

All rights reserved. This manual may not bereproduced in whole or in part, without thepermission in writing of ISUZU MOTORS LIMITED.

First edition August. 2006

Issued by

ISUZU MOTORS LIMITED

SERVICE MARKETING DEPARTMENT

Tokyo, Japan

No. LG4JJ-WE-0761

engine.pdf

Documents

torque specifications

special tools6a

oil cooler

oil pan

oil pump

oil seal6a

oil filter assembly

engine assembly