ENGINE WORKSHOP MANUAL SECTION 6A

WORKSHOP MANUAL
2007MY N-SERIES
ENGINE 4HK1-TC
SECTION 6
Isuzu Motors Limited
Service Marketing Department

NOTICE
Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section-0A under the headings “GENERAL REPAIR
INSTRUCTIONS”.
All material contained in this Manual is based on latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model:
N-Series
This manual is applicable to 2007 year model.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTENTS

6A ENGINE MECHANICAL (4HK1-TC)
6B COOLING SYSTEM
6C FUEL SYSTEM
6D ENGINE ELECTRICAL
6F EXHAUST SYSTEM
Engine Mechanical (4HK1-TC) 6A-1
ENGINE
Engine Mechanical (4HK1-TC)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4HK1-TC) . . . . . . . . . . 6A-3 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-61
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-63
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-63
Main Data and Specifications. . . . . . . . . . . . . . 6A-15 Torque Specifications . . . . . . . . . . . . . . . . . . . .6A-65
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Valve Stem Seal and Valve Spring . . . . . . . . . . . 6A-66
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A-17 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-67
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-68
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-71
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-71
Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 6A-26 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-75
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-89
Tightening Torque Specifications . . . . . . . . . . . 6A-28 Torque Specifications . . . . . . . . . . . . . . . . . . . .6A-96
PCV Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Piston and Connecting Rod . . . . . . . . . . . . . . . .6A-98
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-98
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-98
Inlet Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-99
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-100
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .6A-105
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-107
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-32 Torque Specifications . . . . . . . . . . . . . . . . . . .6A-109
Turbocharger and Exhaust Manifold . . . . . . . . . . 6A-33 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-109
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-33 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-110
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-33 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-110
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-110
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-36 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-113
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-39 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-113
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-116
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-116
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-44 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-45 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-118
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-53 Torque Specifications . . . . . . . . . . . . . . . . . . .6A-120
Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . . 6A-54 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . .6A-121
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-121
Dismount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-123
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Torque Specifications . . . . . . . . . . . . . . . . . . .6A-127
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-127
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-58 Crankshaft Rear Oil Seal. . . . . . . . . . . . . . . . . .6A-128
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-59 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128
Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-128
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-60 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-129
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-60 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-132
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-61
6A-2 Engine Mechanical (4HK1-TC)
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-134
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-134
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-135
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139
Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-142
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-143
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-144
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-144
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-144
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-145
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-146
Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-148
Lubrication System . . . . . . . . . . . . . . . . . . . . . . 6A-149
Service Precautions . . . . . . . . . . . . . . . . . . . . 6A-149
Functional Check . . . . . . . . . . . . . . . . . . . . . . 6A-149
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-151
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-152
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-152
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-152
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-153
Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . 6A-154
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-154
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-154
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-154
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-155
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-156
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-156
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-156
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-157
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-157
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-158
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-160
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-160
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-160
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-160
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-163
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-163
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-164
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-165
Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 6A-170
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-170
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . 6A-171
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-171
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-171
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-171
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-171
ISUZU DIESEL ENGINE (4HK1-TC)

Service Precautions Matters that require attention in specifically dealing
with this engine
Matters that require attention in terms of
maintenance Holes or clearances in the fuel system which serve as a
passage of fuel, including the inside of injector, are
To prevent damage to the engine and ensure reliability
finished extremely precisely. For this reason, they are
of its performance, pay attention to the following in
highly sensitive to foreign matter. If it gets inside, it can
maintaining the engine:
lead to breakdown on the road. Be sure to prevent it
• When lifting up or supporting the engine, do not from getting inside.
apply a jack on the oil pan.
When taking down the engine on the ground, do Service Technical Information
not make the bearing surface of the oil pan touch How to use Plastigauge
directly the ground. Use a wood frame, for
example, to support the engine with the engine
foot and the flywheel housing. Type Measurable range (mm)
Because there is only a small clearance between
PG-1 (Green) 0.025 – 0.076
the oil pan and the oil pump strainer, it can damage
the oil pan and the oil strainer. PR-1 (Red) 0.051 – 0.152
• When the air duct or air cleaner is removed, cover PB-1 (Blue) 0.102 – 0.229
the air intake opening to prevent foreign matter
from getting into the cylinder. If it gets into it, it can
considerably damage the cylinder and others while <Example> Measurement of clearance between
the engine is operating. connecting rod bearing and crank pin.
• When maintaining the engine, never fail to remove • Clean the connecting rod and the bearing, and
the battery earth cable. If not, it may damage the assemble the bearing to the connecting rod.
wire harness or electrical parts. If you need • Cut the Plastigauge in the width of the crank pin,
electricity on for the purpose of inspection, for and place it parallel, away from the oil hole of the
instance, watch out for short circuits and others. pin.
• To protect and lubricate the rotational surface • Align the stamp mark of connecting rod with that of
during the initial operation, apply plenty of engine cap, and assemble them to the crank pin. Apply
oil to it. molybdenum disulfide to the threads and the
• When valve train parts, pistons, piston rings, seating surface of the tightening bolts, and tighten
connecting rods, connecting rod bearings or the bolts on the cap alternately to the specified
crankshaft journal bearings are removed, put them torque.
in order and keep them.
Caution:
• When installing them, put them back to the same Never move the connecting rod while using the
location as they were removed. Plastigauge.
• Parts, such as gaskets, oil seals and O-rings, have
to be replaced by brand-new ones every time the • Carefully remove the cap and the connecting rod,
engine is dismantled. and measure the width (clearance) of flattened
• As for parts where a liquid gasket is used, remove Plastigauge using the scale printed on the bag.
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust may be
clung to them. Then, apply the designated liquid
gasket to each place anew before assembly.
• Assemble it within 7 minutes after applying the
liquid gasket.
If 7minutes or longer passed, remove the liquid
gasket and apply it again.
• When assembling or installing parts, fasten them
with the prescribed tightening torque so that they
may be installed properly.
• Carefully remove the crankcase, and measure the
width (clearance) of the flattened Plastigauge
using the scale printed on the bag.
N6B6112E
N6B6114E
N6B6113E
<Example> Measurement of clearance between

crankshaft bearing and crankshaft journal.
• Clean the bearing installation surfaces on the N6B6115E
crankcase and on the cylinder block, and the
bearings. Then assemble each bearing to the
cylinder block and the crankcase.
• Put the crankshaft on the cylinder block carefully,
and rotate the crankshaft for approx. 30° to fit in.
• Cut the Plastigauge in the width of the crankshaft
journal, and place it parallel, away from the oil hole
of the journal.
• Put the crankcase on the cylinder block carefully,
and apply molybdenum disulfide to the threads
and the seating surface of the tightening bolts.
Then tighten them to the specified torque in the
specified order.
Caution:
Never rotate the crankshaft while using the
Plastigauge.
How To Read The Model
2 1
N6B6001E
Legend
1. Engine Model 2. Engine Selial Number
Explanation of Functions and Operations Cylinder Liner

Electronic Engine Control The cylinder liner is selected to match an internal
With the control unit, the range from injection to air diameter of a bore of the cylinder block and built, which
intake/exhaust, including fuel injection quantity, is imprinted on the left side of the cylinder.
injection timing, intake air restriction, EGR, and idling Piston
rpm, is controlled. The piston is aluminum-alloy and an autothermatic
Cylinder Block piston with a strut cast, while the combustion chamber
The cylinder block is cast-iron with the center distance is a round reentrant type.
of each bore being equal and is of the highly rigid, Cylinder Head
symmetrical structure with the crankshaft center being The cylinder head is cast-iron and there are 4 valves
the center. The bearing cap is of the ladder frame per cylinder. The angular tightening method of the
structure and tightened up under the plastic range cylinder head bolt further increases reliability and
rotation angle method. durability.
Crankshaft e. Rotate the crankshaft to make the No.1 cylinder
Tuftriding is given, while on the No. 1 balance weight meet the compression top dead center (TDC).
imprinted is the grade of each journal diameter.
EGR System
Based upon data, including water temperature, engine 1
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.
Connecting Rod Cap Bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.
Common Rail-type Electronic Control Injection
System
The common rail-type electronic control injection
system is composed of a fuel supply pump that sets the
target pressure of high-pressure fuel and supply it, a N6B6002E
fuel rail that measures such high-pressure fuel and an
fuel injector that turns it into a fine spray and injects it. Legend
Each is controlled via ECM based upon various 1. Timing Mark
signals, while injection timing or fuel injection quantity
is controlled under every possible driving condition. • Insert a 0.4 mm (0.016 in) thickness gauge into
a clearance between the rocker arm and the
Fuel Injector bridge to check it and adjust it if needed.
The fuel injector is a 7-hole nozzle that adjusts fuel
injection quantity or injection timing by opening or
closing an electromagnetic valve on the head of the Valve clearance mm (in)
fuel injector. Intake valve 0.4 (0.016)
ECM corrects the dispersion of fuel injection quantity
between fuel injectors according to ID code data in Exhaust valve 0.4 (0.016)
memory. At the replacement of fuel injectors, ID code
data should be stored in ECM. Caution:
Adjust while being cold.
Fuel Filter with Sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.
Preheating System
The preheating system consists the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and make the engine easy to start.
Lubrication System
It is an oil filter with full-flow bypass, which uses a
water-cool oil cooler and oil jet to cool the piston.
Functional Inspection
Inspection/adjustment of valve clearance
1. Inspection of valve clearance
N6B6003E
a. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”. 2. Adjustment of valve clearance
b. Remove the fuel injector harness assembly. Caution:
c. Loosen the terminal nuts alternately to remove. Adjust valve clearance carefully so that the bridge
d. Remove the leak-off pipe. contacts the end of the 2 valve stem.
a. Completely loosen all of the bridge and rocker Valve bridge clearance: ± 0.1 mm (0.0039
arm adjusting nuts and adjusting screws (8 nuts in) or less
and 8 screws). c. After making an adjustment so that the end
b. Place a 0.4 mm (0.016 in) thickness gauge of the valves on both sides may touch
between the No. 1 cylinder rocker arm end and properly, tighten up an adjusting screw nut
the bridge cap. of the bridge with a minus driver so that the
c. Tighten the rocker arm adjusting screw until the bridge adjusting screw may not rotate.
thickness gauge is snug (not tight) between the Tighten:
rocker arm end and the bridge cap. Adjusting screw nut to 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
d. Tighten the rocker arm lock nut.
e. Tighten the bridge adjusting screw until the Caution:
bridge contacts the valve head. If the adjusting screw of the bridge is poorly adjusted,
the bridge would tilt and be pushed down and seized,
f. Tighten the bridge lock nut. which may damage the bridge guide, for example.
g. Check that the thickness gauge is still held Thus, adjust it accurately.
snugly between the rocker arm end and the
bridge cap. If it is too tight, slightly loosen the
bridge adjusting screw and lock nut to restore
snugness.
h. Remove the thickness gauge.
i. Repeat Steps b through h for the remaining
cylinders.
Tighten:
Bridge lock nut to 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
N6A6005E
Tighten:
Rocker arm adjustment screw nut to 22 N⋅m (2.2 kgf⋅m/
16 lbf⋅ft)
Bridge adjustment screw nut to 22 N⋅m (2.2 kgf⋅m/16
lbf⋅ft)
Adjustment table
Cylinder No. 1 2 3 4
N6A6004E
Valve
Legend IN EX IN EX IN EX IN EX
arrangement
1. Rocker Arm
2. Bridge Cap No. 1 cylinder
3. Bridge Compression { { { {
TDC
a. With a thickness gauge kept inserted,
No. 4 cylinder
tighten an adjusting screw of the bridge
Compression × × × ×
lightly and make sure that the tip of the
TDC
adjusting screw touches the end of valve
stem and the movement of the thickness
gauge has become tight.
b. Then, check if the end of the valve stem on
the opposite side is unstable or hits
diagonally. If so, loosen the bridge adjusting
screw a little so that the end of the valves on
both sides may touch properly.
• If the No. 1 cylinder is the compression • Install the cylinder head cover.
TDC, adjust a valve clearance with { mark Refer to “Cylinder Head Cover.”
given on the table and if the No. 4 cylinder is
the compression top dead center, that with × Compression pressure inspection
mark. • Warm up the engine.
• Remove a minus terminal of the battery and
remove all the glow plugs.
• Remove the harness connector for the fuel injector
built on the lower head cover (no fuel will be
injected).
Caution:
When the harness connector is removed, ECM judges
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear memory
of ECM.
(For how to clear memory of ECM, refer to Section 6E)
N6A6006E
N6A6008E
Legend
1. Fuel Injector Harness Connector
• Install the minus terminal of the battery.

N6A6007E
• Turn on the starter to emit foreign matter within the
• Attach the harness assembly to the fuel cylinders.
injector.
Tighten the harness bracket with the
designated torque.
Tighten:
Harness bracket to 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
• Attach the terminal nuts to the fuel injector.
Tighten:
Terminal nuts to 2 N⋅m (0.2 kgf⋅m/17 lbf⋅in)
Notice:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
unified.
• Do not tighten the nuts too tightly because it leads to
damage to the terminal studs.
• Install an adapter and a gauge of a compression Judgment of time to overhaul
gauge of the special tool. Rate of increase in engine oil consumption
Overhaul is needed when the consumption rate (travel
distance of kilometers per liter) drops to less than 50%
of that of new vehicle (100%).
Rate of increase in fuel consumption
Overhaul is needed when the consumption rate (km/L)
drops to less than 60% of that of new vehicle (100%).
Noise in engine
If the noise is caused by internal parts of the engine,
carry out overhaul earlier.
* Many reasons are considered to cause noise.
However, noise is caused mainly by excessive wear of
engine parts, seizure, or pinched foreign objects.
A list of defective phenomena

• Engine does not turn over.
• Engine turns over but does not start.
N6B6297E
• Excessive black exhaust smoke.
Compression gauge set: 5-8840-2008-0 • Excessive white exhaust smoke.
(Compression gauge: J-26999-12, • Engine knocking.
Gauge adapter: EN-46722) • Abnormal engine rotation.
• Turn on the starter to inspect compression • Abnormal battery charging.
pressure.
Compression pressure MPa (kg/cm2 / psi) / rpm

Standard 2.60 – 2.90 (26.5 – 29.5 /
377 – 421) / 220
2.50 – 2.80 (25.5 – 28.6 /
363 – 406) / 185
2.40 – 2.70 (24.5 – 27.5 /
348 – 391) / 150
Limit 2.16 (22.0 / 313)
Differences among 294 kPa (3.0 kg/cm2 / 43
the cylinders psi)
• Measure each cylinder one by one.
Caution:
To keep engine speed at 220 rpm or more, use fully
charged batteries.
• Remove a compression gauge of the special tool.

• Remove a minus terminal of the batteries.
• Install a harness connector for the fuel injector built
on the lower head cover.
• Install all the glow plugs.
Tighten:
Glow plugs to 20 N⋅m (2.0 kgf⋅m/15 lbf⋅ft)
• Install a minus terminal of the batteries.
Trouble Shooting
Engine does not turn over
Condition Possible Cause Correction

Starter motor does not rotate Dead or weak battery Charge or
Replace battery
Incomplete circuit Connect
Repair
Starter relay Replace starter relay
Starter motor brushes stuck, worn, Replace brushes
or broken
Starter motor internal damage Repair motor
Starter motor not meshed with Ring gear abrasion Replace ring gear
flywheel Pinion gear abrasion Replace pinion gear
Magnetic switch (starter motor) not Adjust
properly adjusted
Starter motor pinion meshed with Dead or weak battery Charge battery
ring gear but does not rotate Replace battery
Insufficient contact pressure Adjust pressure
between starter motor brushes and
commutator
Armature (starter motor) stuck Repair armature
Engine internal damage (Seizure) Repair engine
Engine turns over but does not start

No fuel flows in the supply pump. Air in fuel system Air bleeding
Air suction from fuel pump Bleed air or replace.
Running out of fuel Add.
Clogged strainer at fuel suction part Clean or replace.
Clogged fuel pipe Clean or replace.
Malfunction of supply pump Replace.
Severe cold weather = fuel is not for Replace with appropriate fuel.
severe cold weather.
Clogged fuel filter Replace.
Defective engine control system Diagnose the engine control
system.
Fuel flows in the supply pump. Loose connection of injection pipe Further tighten each part.
Leakage in overflow valve Replace.
Supply pump internal failure Replace.
Poor connection or open circuit in Repair or replace.
wiring
system.

Shortage or instability of fuel Air in fuel system Air bleeding
injection amount Clogged fuel pipe Clean or replace.
Malfunction of supply pump Replace.
Stuck injector nozzle Replace.
Poor connection or open circuit in Repair or replace.
wiring
Clogged fuel filter Replace.
system.
Excessive black exhaust smoke

Bad injection timing Defective engine control system Diagnose the engine control
system.
Poor injection condition of injector Stuck nozzle Replace.
system.
Faulty compression pressure Excessive valve clearance Adjust.
Stuck valve stem (remains open) Overhaul.
Faulty valve spring Replace.
Worn valve seat Overhaul.
Poor compression due to faulty Overhaul.
piston rings etc.
Faulty gasket Overhaul.
Piston seizure Overhaul.
Bad fuel Water in fuel Replace.
Inferior fuel Replace.
Air intake failure Clogged air intake pipe Repair or replace.
Clogged air cleaner element Clean or replace.
Stuck throttle valve Overhaul.
Fault detection by engine control Fault in each sensor etc. Repair or replace.
system Defective engine control system Diagnose the engine control
system.
Throttle valve or EGR valve failure Stuck intake throttle valve Repair or replace.
Stuck EGR valve Repair or replace.
Stuck exhaust brake valve Replace.
system.
Turbocharger malfunction Deformed or damaged turbine fin Replace.
Nonsmooth or stuck turbine shaft Replace.
Air leakage from compressor Repair.
discharge side
Excessive white exhaust smoke

Bad injection timing Engine control system malfunction System diagnosis
Malfunction detected by engine Engine control system malfunction System diagnosis
control system Control unit malfunction Replace unit
Defective sensor Replace sensor
Insufficient compression pressure Excessive valve clearance Adjust clearance
Sticking valve stem (valve open) Repair or replace valve
Damaged valve spring Replace spring
Valve seat abrasion Repair valve seat
Compression leakage due to Replace piston ring
damaged piston ring
Damaged gasket Replace gasket
Piston scoring Replace piston
Fuel condition Water in fuel Drain existing fuel and replace with
new fuel
Excessive oil consumption Worn or damaged piston ring(s) Replace ring(s)
Defective valve stem oil seal Replace oil seal
Defective turbocharger oil seal Replace turbocharger
Clogged turbocharger oil return Repair pipe
pipe
Engine knocking

Bad timing Engine control system malfunction System diagnosis
Malfunction detected by engine Defective sensor Replace sensor
control system Control unit malfunction Replace unit
Engine control system malfunction System diagnosis
Fuel condition Poor quality fuel Drain existing fuel and replace with
new fuel
Poor engine aspiration Clogged intake pipes Clean or replace pipes
Engine control system malfunction System diagnosis
Engine break-down Foreign material in cylinders Engine overhaul
Scored pistons and/or bearings Replace pistons and/or bearings
Abnormal engine rotation

Engine speed does not rise. Control unit failure Replace.
system.
Unstable engine revolution Control unit failure Replace.
system.
Clogged fuel filter element Replace element
Injector failure Replace.
Water in fuel Replace.
Air in fuel system Air bleeding
Stuck exhaust brake valve Replace.
Stuck intake throttle valve Repair or replace.
Abnormal battery charging

No charging Open circuit, short circuit or poor Repair or replace.
contact
Generator internal malfunction Overhaul.
Insufficient charging Short circuit or poor connection Connect or repair.
Loose generator drive belt Replace.
Faulty battery Replace.
Excessive charging Shorted wiring Connect or repair.
Turbocharger Troubleshooting

Engine has less than normal power Air leakage from intake pipe rubber Repair
hose
Air leakage from inlet cover Repair
Clogged intercooler cooling section Clean
Clogged air cleaner element Clean or replace
Exhaust brake valve stuck Repair or replace
Turbine and housing contact Replace
(Interference)
Excessive carbon deposit near Clean or repair
turbine exhaust port that interferes
with turbine
Rough turbine shaft rotation Repair or replace
Damaged turbine fan Repair or replace

Blue exhaust smoke Oil leakage from turbocharger oil Repair or replace
seal
Clogged turbocharger oil return Repair
pipe
Clogged center housing oil Repair or replace
passages
Engine oil deterioration Change engine oil
Noisy turbocharger operation Gas leakage from intake or exhaust Repair
system
Turbine and housing contact Repair or replace
(Interference)
Damaged turbine fan Replace
Turbine shaft bearing abrasion or Repair or replace
scoring
Excessive rotating part wear Engine oil deterioration Change engine oil
Clogged turbocharger oil feed pipe Repair
Low engine oil pressure Repair
Main Data and Specifications
Item Engine model 4HK1-TCS Engine model 4HK1-TCN

Type Diesel/4-cycle/water cooling Diesel/4-cycle/water cooling
type in-line OHC type in-line OHC
Combustion chamber type Direct injection type Direct injection type
Cylinder liner type Dry type Dry type
Number of cylinders -cylinder mm (in) 4-115 (4.53) × 125 (4.92) 4-115 (4.53) × 125 (4.92)
bore × strokes
Displacement cc (cu.in) 5193(317) 5193(317)
Compression ratio 17.5 17.5
Compression pressure MPa (kg/cm2/ 2.60 – 2.90 (26.5 – 29.5/377 – 2.60 – 2.90 (26.5 – 29.5/377 –
psi)/rpm 421)/220 421)/220
Idling speed rpm 650 (Smoother) 650 (Smoother)
575 (MT) 575 (MT)
Valve clearance Intake 0.4 (0.016) (cold) 0.4 (0.016) (cold)
mm (in) Exhaust 0.4 (0.016) (cold) 0.4 (0.016) (cold)
Ignition type Compressed ignition Compressed ignition
Injection order 1-3-4-2 1-3-4-2
Injection timing (TDC) 0° 0°
Lubricating system
Lubricating type Pressure type Pressure type
Oil pump type Gear type Gear type
Volume of lubricating oil Liters (US/Imp 13.0 (3.43/2.86) 13.0 (3.43/2.86)
gal.)
Oil filter type Full flow filter (cartridge type) Full flow filter (cartridge type)
Oil cooling type Built-in-type, water cooling Built-in-type, water cooling
Cooling system
Cooling type Water cooling type Water cooling type
Radiator type Corrugated fin(pressure type) Corrugated fin(pressure type)
Water pump type Centrifugal, belt type Centrifugal, belt type
Thermostat type 2 wax-type units 2 wax-type units
Thermostat valve-opening °C (°F) 82 (180), 85 (185) 82 (180), 85 (185)
temperature
Volume of coolant Liters (US/Imp 18 (4.76/3.96) (incl. radiator) 18 (4.76/3.96) (incl. radiator)
gal.)
Fuel system
Injection pump type Electronic control common rail Electronic control common rail
type type
Governor type Electronic type Electronic type
Timer type Electronic type Electronic type
Item Engine model 4HK1-TCS Engine model 4HK1-TCN

Injection nozzle type Multi-hole type Multi-hole type
7-holes φ0.14 mm (0.0055 in) 7-holes φ0.14 mm (0.0055 in)
inside diameter inside diameter
Charging system
Generator type AC type AC type
Power output V-A 24 - 80, 24 - 50 24 - 80, 24 - 50
Regulator type IC IC
Starting system
Starter type Reduction type Reduction type
Power output V-kw 24 - 4.5 24 - 4.5
Preheat system type Glow plug Glow plug
Glow plug standard voltage/ V 24 24
electric current
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2008-0
Compression Gauge Set
(J-26999-12 /
Compression Gauge,
EN-46722 /
Gauge Adapter)
5884020080
Engine Assembly
Removal • Remove the connector of the boost pressure
sensor.
1. Remove a minus (-) terminal of the battery.
2. Drain the coolant.
3. Remove the starter motor.
• Disconnect the front frame harness connector
in the vicinity of the control box of the
transmission and remove each clip that fixes
the harness.
• Remove 2 bolts that fasten the starter and
remove the starter from the clutch housing.
• Fix the starter motor with wire, for instance, in a
place that does not get in the way in removing
the transmission.
4. Remove the transmission assembly.
Refer to “Transmission Assembly”.
5. Remove the charge air hose (between 2 1
turbocharger and inter cooler).
N6B6005E
Legend
1. Charge Air Hose
2 2. Boost Pressure Sensor
9. Remove the upper hose of the radiator.

1
N6B6201E
Legend
1. Inlet Hose
2. Charge Air Hose
6. Disconnect the IAT&MAF sensor connector.

7. Remove the inlet hose (between air cleaner and N6A6012E
turbocharger). 10. Remove the coolant reserve tank hose from the
• Remove the PCV hose. radiator side.
8. Remove the charge air hose (between intercooler 11. Remove a bracket of the fan guide.
and inlet pipe). 12. Remove the fan assembly.
• Remove the nuts and pull them out upward.
13. Remove the heater hoses.
• Remove 2 hoses on the engine side.
• Remove the terminal B cable and harness
connector from the generator.
17. Remove the vacuum hose on the vacuum pump
side.
18. To prevent oil from flowing out when the hydraulic
booster brake hose is removed, remove the
fastening bolts for the hydraulic booster brake tank
to lower the tank.
19. Remove one side of the hydraulic booster brake
hose on the high-pressure side.
20. To prevent oil from flowing out when the power
steering oil hose is removed, remove the fastening
bolts for the power steering reserve tank to lower
the tank.
21. Remove the power steering oil hose.
22. Remove the lower hose of the radiator on the
N6B6006E engine side.
14. Remove the engine harness. 23. Hang wire on the engine hanger and hoist to lift up
• Disconnect the VGS C/U and dropping resistor the engine slightly.
connectors. 24. Remove the front exhaust pipe.
• Remove the ECM and VGS C/U. • Remove the front exhaust pipe from the turbo
• Disconnect the two main harness connectors and exhaust brake.
from the ECM (For SLD equipped, disconnect 25. Remove the fuel hose on the feed and return
the unsealed connector.) sides.
• Remove the engine ground cable. 26. Remove the engine mount.
15. Remove the A/C compressor. • Remove the fastening bolts for the engine
• Remove the drive belt. mount on the chassis frame side.
• Remove the connector. 27. Remove the engine assembly.
• Remove the A/C compressor and fix it with • Remove the cab back cover.
wire, for example, to an appropriate place along
with hoses and others.
N6A6015E
Legend
N6B6007E 1. Screw
Legend 2. Cab Back Cover
1. Fixing Bolt 3. Nut
2. Connector
3. Bracket • Operate a hoist slowly and hoist the engine
4. A/C Compressor until it comes up to the surface of the chassis
frame.
16. Remove the AC generator harness.
• Turn the engine at an angle of 90 degrees to • Operate a hoist slowly to move the engine to
move from the surface of the chassis frame and the place where it is to be installed.
remove the engine assembly.
N6A6017E
N6A6016E
• Turn the engine at an angle of 90 degrees to
lower the engine slowly to the place it is to be
installed.
N6A6017E
N6A6016E
Installation
• Make the transmission side lower and operate
Notice: a hoist slowly, pulling it backward to the engine.
Be absolutely sure that each harness is reconnected to 2. Install the engine mount.
its original position.
• Install the engine mount to fit into the holes of
1. Install the engine assembly. the engine mounting cross member and tighten
it up with the specified torque.
• Hang wire on the engine hanger and hoist to lift
up the engine. Tighten:
To cross member : 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
3. Install the feed and return sides of the fuel hose.
4. Install the front exhaust pipe.
5. Install the lower hose of the radiator.
• Install the connector.
N6A6018E
N6B6007E
6. Install the power steering oil hose.
7. Install the power steering reserve tank. Legend
1. Fixing Bolt
8. Install the hydraulic booster brake hose on the
2. Connector
high-pressure side.
3. Bracket
9. Install the hydraulic booster brake tank. 4. A/C Compressor
10. Install a vacuum hose to the vacuum pump.
• Install the drive belt.
• Hang the drive belt to adjust its tension with an
adjusting bolt of the tension pulley.
• For further details for adjusting tension of the
belt, refer to “Drive Belt” in Section 6B.
• Check if a flexure is within the specified range
when the center part is pressed by the hand
with 98 N (22 lb) by using a scale, for instance.
In addition, check if it is not damaged as well.
• Flexure of the A/C compressor belt.
• 19 – 24 mm (0.748 – 0.945 in) (when the belt is
new)
• 24 – 28 mm (0.945 – 1.102 in) (when the belt is
reused)
N6B6008E
11. Install the AC generator harness.

• Install the terminal B cable and the harness
connector to the generator.
12. Install the A/C compressor.
• After adjusting tension of the belt, tighten up the • Install 2 hoses.
lock nut of the tension pulley.
N6B6006E
N6B6284E
16. Install the fan assembly.
13. Install the cab back cover. 17. Install a bracket for the fan guide.
18. Install the coolant reserve tank hose to the radiator
side.
19. Install an upper hose of the radiator.
• Install the upper hose with a band clip.
N6A6015E
Legend
1. Screw
2. Cab Back Cover
3. Nut
N6A6012E
14. Install the engine harness. 20. Install the charge air hose (between intercooler
15. Install the heater hoses. and inlet pipe).
• Install the connector of the boost pressure Refer to “Transmission Assembly”.
sensor. 25. Install the starter motor.
• Install 2 up and down bolts to fasten the starter.
• Connect the front frame harness connector and
install each clip which fixes the harness.
26. Replenish the coolant.
27. Install a minus (–) terminal of the battery.
2 1
N6B6005E
Legend
1. Charge Air Hose
2. Boost Pressure Sensor
21. Install the inlet hose (between air cleaner and

turbocharger).
• Hose is inserted until bumping to turbocharger.
• Clip assembled along the white line on hose.
Clip Tightening torque: 6.3 N⋅m (0.64 kgf⋅m / 5 lbf⋅ft)
• Install the PCV hose.
1 3 2
N6B6116E
Legend
1. Turbocharger
2. Clip
3. White Line
4. Hose
22. Connect the IAT&MAF sensor connector.

23. Install the charge air hose (between turbocharger
and intercooler).
24. Install the transmission assembly.
Engine Mount
Component
N6B6009E
Legend
1. Fan Guide 3. Engine Foot
2. Engine Mount
Removal
1. Remove the fan guide bracket.
2. Remove the engine mount.
• Remove the cab back cover. Installation
1. Install the engine mount and tighten up with the
specified torque.
Tighten:
The nuts on the chassis frame side to 48 N⋅m (4.9 kgf⋅m/
35 lbf⋅ft)
The bolts on the engine foot side to 82 N⋅m (8.4 kgf⋅m/
60 lbf⋅ft)
N6A6015E
Legend
1. Screw
2. Cab Back Cover
3. Nut
• Before removing the engine mount, hang the

engine with a hoist.
• Remove the nuts fastened to the engine foot N6A6022E
and engine mount. 2. Install the fan guide bracket.
• Remove the bolts fastened to the engine mount • Check if nothing is wrong with the engine
on the chassis frame side. mount by starting the engine.
• Hoist the engine assembly slightly to remove 3. Install the cab back cover.
the engine mount.
N6A6015E
N6A6016E
Legend
1. Screw
2. Cab Back Cover
3. Nut
Torque Specifications
N m (kgf m / lbf ft)
82 (8.4 / 60)
48 (4.9 / 35)
N6B6010E
Cylinder Head Cover

Components
3
5
N6A6024E
Legend
1. Head Cover 4. Gasket
2. Gasket 5. Head Lower Cover
3. Sound Insulation Cover
Removal
1. Remove the 6 bolts that fasten the EGR cooler
1
(2nd) and hang the EGR cooler (2nd) with wire, for
instance, in a place that does not get in the way in
removing the cylinder head cover.
2. Remove the sound insulation cover (1).
3. Remove the head cover (2)
4. Remove the gasket.
N6A6027E
5. Remove the fuel injector harness connector (2).

6. Remove the head lower cover (1).
7. Remove the gasket.
N6A6029E
N6A6028E
6. Install the sound insulation cover.
Tightening torque: 7 N⋅m (0.7 kgf⋅m/5 lbf⋅ft)
Installation
1. Install the gasket on the head lower cover (1).
2. Install the head lower cover (1). 1
Tighten:
Bolts to 18 N⋅m (1.8 kgf⋅m/13 lbf⋅ft)
3. Install the fuel injector harness connector (2).
Caution:
Push it in thoroughly until the claws of the lock raise.
N6A6027E
Legend
2. Head Cover
7. Install 6 bolts to fasten the EGR cooler (2nd).

Tighten:
N6A6028E
4. Install the gasket on the head cover.

5. Install the head cover and tighten up according to
the orders given on the figure.
Tighten:
Tightening Torque Specifications
18 (1.8 / 13)
7 (0.7 / 5)
18 (1.8 / 13)
N6B6011E
PCV Hose
Components
3
1
2
N6B6266E
Legend
1. Ventilator 3. PCV Rubber Hose
2. Bracket 4. Pipe Flange
Removal
1. Remove the PCV rubber hose (Ventilator — Pipe
flange).
2. Remove the bracket.
3. Remove the ventilator.
4. Remove the pipe flange.
Installation
1. Install the pipe flange.
Tighten:
8 N⋅m (0.8 kgf⋅m/6 lbf⋅ft)
2. Install the ventilator.
3. Install the bracket.
4. Install the PCV rubber hose (Ventilator — Pipe
flange).
Inlet Cover
Component
N6B6012E
Legend
1. Throttle Assembly 3. Inlet Pipe Gasket
2. Inlet Cover
Removal
•
1. Remove the fuel rail.

Refer to “Fuel Rail” in Section 6C.
2. Remove the EGR valve.
Refer to “EGR Valve and EGR Cooler” in Section
6F.
3. Remove the throttle assembly.
N6B6013E
4. Remove the inlet cover. • Tighten up the stud part together with the fuel rail.
• On the place where the throttle assembly is to
be installed inside the inlet cover (arrow) is a
bolt. Be careful not to forget to remove it.
• Peel the liquid gasket off carefully.
N6B6014E
2. Install the throttle assembly.

• Taking care with the direction (arrow) of gasket
(2), install the gasket, and tighten to the
N6A6033E specified torque.
• Install the mounting rubber securely.
Installation Tighten:
1. Install the inlet cover. Bolt and nut to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
• Apply the liquid gasket (ThreeBond 1207C or
equivalent) keeping a bead diameter of 2.5–5.5
mm (0.1–0.2 in) along the groove of the inlet
cover.
• Install it within 7 minutes after applying the
liquid gasket.
Tighten:
Bolt and nut to 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
Caution:
• Be careful not to forget to fasten the bolt indicated
with an arrow.
N6B6015E
3. Install the EGR valve.

Refer to “EGR Valve and EGR Cooler” in Section
6F.
4. Install the fuel rail.
22 (2.2 / 16)
22 (2.2 / 16)
24 (2.4 / 17)
N6B6016E
Turbocharger and Exhaust Manifold

Component
4
6
7
9 8
N6B6119E
Legend
1. Oil Feed Pipe 6. Exhaust Adapter
2. Water Return Pipe 7. Water Feed Pipe
3. Turbocharger Assembly 8. Oil Return Pipe
4. Heat Protector 9. Exhaust Manifold
5. Heat Protector
Removal 6. Remove the front exhaust pipe.

1. Loosen the radiator drain cock to drain coolant. 7. Remove the EGR duct (EXH).
2. Remove the air intake duct from the turbocharger 8. Remove the EGR cooler (1st).
and the air cleaner. 9. Disconnect the VGS connector.
3. Remove the charge air hose from the turbocharger
and the inter cooler.
4. Remove the A/C compressor harness.
5. Remove the A/C compressor bracket.
• Without disconnecting the hose of the A/C 13. Remove the water return pipe.
compressor, remove the compressor from the
bracket and remove the compressor bracket
from the cylinder head.
N6A6039E
Legend
1. Water Return Pipe
N6B6007E 2. Rubber Hose
Legend
1. Fixing Bolt 14. Remove the turbocharger.
2. A/C Compressor Harness • Remove the heat protector on the turbocharger.
3. A/C Compressor Bracket
• Remove the exhaust adapter bolts.
4. A/C Compressor
• Remove the four turbocharger clamping nuts.
10. Remove the oil feed pipe. • Remove the turbocharger from the exhaust
11. Remove the oil return pipe. manifold.
12. Remove the water feed pipe.
1
4
6
5
2 3
2 1 4
N6B6019E
3
N6B6018E Legend
1. Fixing Nut
Legend
2. Exhaust Adapter
1. Oil Feed Pipe
3. Fixing Bolt
4. Fixing Nut
3. Heat Protector
4. Charge Air Hose 15. Remove the exhaust manifold.
5. Intake Duct
6. EGR Pipe
• Remove the 2 nuts and 6 bolts to remove the Wheel shaft axle play
exhaust manifold. Use a dial gauge to measure the wheel axle shaft play
when a fore of 12 N (2.6 lb) is alternately applied to
both sides of the compressor wheel.
Axle play mm (in)

Standard 0.03 – 0.08 (0.0011 – 0.0031)
Limit 0.09 (0.0035)
N6B6020E
Inspection
• Inspection of the exhaust manifold
Inspect the plane surface of the plane on which the
manifold and the cylinder head are to be installed.
Manifold installation plane surface mm (in) N6A6043E

Standard 0.3 (0.01) or lower
Wheel shaft and bearing clearance
Limit 0.5 (0.02)
Use a dial gauge to measure the clearance between
the wheel shaft and the bearing.
Caution:
If the plane surface exceeds the limit, replace it.
Clearance mm (in)
Standard 0.08 – 0.10 (0.0031 – 0.0039)
Limit 0.17 (0.0067)
N6A6042E
• Check a crack in the exhaust manifold visually.

Carefully inspect the turbocharger for abrasion and/or
excessive wear. Make any necessary adjustments,
repairs, and/or part replacements.
Tighten:
Nuts to 52 N⋅m (5.3 kgf⋅m/38 lbf⋅ft)
3. Tighten the adapter bolt (exhaust manifold side) to
the specified torque.
Tighten:
Bolt to 24 N⋅m (2.4 kgf⋅m/18 lbf⋅ft)
2 3
N6A6044E
Legend
1. Oil Outlet
2. Oil Inlet
Installation
4
1. Put the gasket in to install the exhaust manifold. N6B6019E
• Tighten up with the 2 nuts and 6 bolts according Legend

to the order given on the figure. 1. Fixing Nut
2. Exhaust Adapter
Tighten: 3. Fixing Bolt
Bolts (1), (2), (3), (4), (5), (6) and Nuts (7), (8) to 34 N⋅m 4. Fixing Nut
(3.5 kgf⋅m/25 lbf⋅ft)
4. Install the water feed pipe to the turbocharger.
Caution:
Do not tighten up too much because it hampers • Tighten the joint bolts to the specified torque.
expansion and contraction due to the heat from the Tighten:
manifold. Turbocharger side: 27 N⋅m (2.7 kgf⋅m/20 lbf⋅ft)
Cylinder block side: 41 N⋅m (4.2 kgf⋅m/30 lbf⋅ft)
• Install the pipe bracket and tighten the bolts to
Tighten:
6 8 Bolts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
4
5 3
2
1
7
N6B6212E
2. Install the gasket and turbocharger to the exhaust

manifold. Tighten the nuts to the specified torque.
• Install the pipe bracket and tighten the bolts to
Tighten:
4
6
5
N6B6021E
5. Install the water return pipe. Tighten the joint bolts

to the specified torque.
2 1
Tighten: 3
Joint bolts to 27 N⋅m (2.7 kgf⋅m/20 lbf⋅ft) N6B6018E
6. Install the water return pipe bracket. Tighten the Legend

bolts to the specified torque. 1. Oil Feed Pipe
Tighten: 3. Heat Protector
Bolts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft) 4. Charge Air Hose
• Install the rubber hose between the water 5. Intake Duct
return pipe and the thermostat housing. 6. EGR Duct (EGR cooler (1st) – EGR cooler
(2nd))
8. Tighten the oil return pipe bolts to the specified

torque.
Tighten:
Bolts to
Turbocharger side: 9 N⋅m (0.9 kgf⋅m/78 lbf⋅in)
Cylinder block side: 22 N⋅m (2.1 kgf⋅m/15 lbf⋅ft)
N6A6039E
Legend
2. Rubber Hose
7. Install the turbocharger oil feed pipe to the top of

the turbocharger. Tighten the joint bolts to the
specified torque.
Tighten: N6B6022E
Turbocharger side: 17 N⋅m (1.7 kgf⋅m/13 lbf⋅ft)
9. Install the heat protector and tighten the bolts to
Oil filter block side: 27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft) the specified torque.
Tighten:
Bolts to 8 N⋅m (0.8 kgf⋅m/86 lbf⋅in) 16. Install the A/C compressor bracket.
10. Connect tne VGS connector. • Install the A/C compressor bracket on the
cylinder head and tighten up with the
prescribed toque.
Tighten:
• Install the A/C compressor on the bracket and
tighten up with the prescribed torque.
Tighten:
N6B6023E
11. Install the air intake duct and tighten the bolts to
Tighten:
Bolts to 8 N⋅m (0.8 kgf⋅m/86 lbf⋅in)
12. Install the charge air pipe in the turbo charger and
the charge air cooler.
Tighten:
N6B6036E
Duct bolt to 21 N⋅m (2.1 kgf⋅m/15 lbf⋅ft)
Duct clip to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
13. Install the front exhaust pipe to the turbocharger
and tighten the nuts to the specified torque.
Tighten:
N6A6050E
14. Install the EGR cooler (1st) and the EGR duct
(EXH).
Refer to “EGR Valve and EGR Cooler.”
17 (1.7 / 13)
8 (0.8 / 86 lbf in)
24 (2.4 / 17) 24 (2.4 / 17)
27 (2.7 / 20)
32 (3.3 / 24)
24 (2.4 / 17)
52 (5.3 / 38) 8 (0.8 / 69 lbf in)
27 (2.8 / 19.9)
41 (4.2 / 30)
24 (2.4 / 17)
9 (0.9 / 78 lbf in)
34 (3.5 / 25) 22 (2.1 / 15)

N6B6120E
N6B6024E
Timing Gear Train

Component
2
1
4
12
13
6
11
14
10
18 8
9
19
7
20 15
16
17
N6B6117E
Legend
1. Power Steering Pump 11. Rear Oil Seal
2. Idle Gear B Shaft 12. Flywheel Housing
3. Idle Gear A 13. Slinger
4. Idle Gear B 14. Plug
5. Power Steering Pump Idle Gear 15. Crankshaft Position Sensor
6. Power Steering Pump Idle Gear Cover 16. Crankshaft End Spacer (Smoother)
7. Clutch Pressure Plate 17. Oil Pan
8. Driven Plate 18. Fuel Supply Pump
9. Flexible Plate (Smoother) 19. Fuel Supply Pump Bracket
10. Flywheel (M/T) 20. Vacuum Pump
Removal 2. Remove the rocker arm shaft assembly.

Refer to “Rocker Arm Shaft Assembly”.
1. Remove the cylinder head cover.
3. Remove the camshaft assembly.
Refer to “Cylinder Head Cover”. Refer to “Camshaft Assembly”.
4. Remove the cylinder head assembly.
Refer to “Cylinder Head”.
5. Remove the clutch pressure plate and the clutch
disc.
6. Remove the supply pump (1) and the coupling (3). 4
1
• Loosen the supply pump bracket tightening bolts, 3
and remove them from the vacuum pump(4). 2
• Remove the coupling (3).
7
3 4
2
1
N6B6027E
Legend
1. Supply Pump
2. Key
3. O-ring
4. Supply Pump Bracket
5. Nut
6. Coupling
7. Flange Bolt
N6B6026E
Legend 8. Remove the vacuum pump (1).

1. Supply Pump • Loosen the bolt and nut, and remove the vacuum
2. O-ring pump (1).
3. Coupling
9. Remove the gear (3) from the vacuum pump (1).
4. Vacuum Pump
7. Remove the supply pump bracket (4).

1
• Insert the two bolts into the thread holes (φ10,
P1.25) of the coupling (6) to prevent it from 2
restating, and then loosen the nut.
3
• Insert the two bolts into the thread holes of the
coupling (6), and then remove the coupling (6) 4
using a gear puller.
N6B6028E
Legend
1. Vacuum Pump
2. Key
3. Gear
4. Nut
5. O-ring
10. Remove the crankshaft position sensor.

• Remove the crankshaft position sensor before
removing flywheel. In the case of smoother vehicle, after loosening the
bolts to fasten the flexible plate, remove the
washer, the flexible plate, the spacer according to
this order.
N6B6025E
11. Remove the flywheel.

• Install the crankshaft stopper on the starter part N6A6504E
of the flywheel housing to stop the crankshaft
from rotating. Legend
1. Pilot Bearing
Caution: 2. Washer
Check if the stopper meshes with the ring gear without
fail and is installed properly. 12. Remove the rear oil seal and the slinger.
Refer to “Crankshaft Rear Oil Seal”.
13. Remove the oil pan.
Special tool
14. Remove the power steering pump.
Crankshaft stopper: 5-8840-2230-0 (EN-47680)
15. Remove the power steering pump idle gear cover.
16. Remove the power steering pump idle gear.
N6A6057E
• Loosen the fastening bolts of the flywheel little

N6A6058E
by little according to the order given on the
figure. 17. Remove the flywheel housing.
• After loosening all the bolts, remove the stopper
to remove the flywheel.
• Never fail to remove the bolt(s) given on the • Measure backlash of the idle gear before
figure. removing the idle gear A.
N6A6059E N6A6061E
18. Remove the idle gear A. 2. Measurement of end clearance of the idle gear.
19. Remove the idle gear B. • Insert a thickness gauge between the idle gear
20. Remove the idle gear B shaft. and the thrust collar to measure a clearance.
• If the measurement exceeds the limit, replace
either the idle gear or the thrust collar.
End clearance of the idle gear mm (in)

Standard 0.080 – 0.155 (0.003 – 0.006)
Limit 0.20 (0.008)
• Measure an end clearance of the idle gear

before removing the idle gear B.
N6A6060E
Inspection
1. Measurement of idle gear backlash.
• Apply a dial gauge on the teeth of the idle gear
to be measured and move the gear to right and
left lightly to read how much the dial gauge
shook (never fail to fix the gear).
the idle gear. N6A6062E
3. External diameter of the idle gear shaft.

Backlash of the timing gear mm(in) • Use a micrometer to measure an external
Standard 0.10 – 0.17 (0.004 – 0.006) diameter of each idle gear shaft.
Limit 0.30 (0.01) the shaft.
Installation
External diameter of the idle gear shaft mm (in) 1. Install the idle gear B shaft.
Standard 29.959 – 29.980 (1.179 – 1.180) • Tighten up the idle gear B shaft with the
prescribed torque.
Limit 29.80 (1.173)
Tighten:
• After installation, apply engine oil over the
shaft.
N6A6063E
4. Clearance between the idle gear and the idle gear

shaft.
N6A6065E
• Measure an inside diameter of the idle gear
bush to calculate a clearance between the idle 2. Install the idle gear B.
gear and the idle gear shaft. • Install the idle gear B in the direction given on
• If the measurement exceeds the limit, replace the figure and tighten up the fastening bolts
either the idle gear or the shaft. with the prescribed torque.
Tighten:
Clearance between the idle gear and the Bolts to 110 N⋅m (11.2 kgf⋅m/81 lbf⋅ft)
shaft mm (in)
Standard 0.020 – 0.062 (0.0007 – 0.0024)
Limit 0.200 (0.0079)
N6A6066E
Legend
1. Idle Gear
2. Thrust Collar
3. Bolt
N6A6064E
3. Install the idle gear A.
• Turn the crankshaft in the normal direction of
engine rotation until the No. 1 or No. 4 cylinder
is at TDC on the compression stroke.
N6B6003E
• Make the meeting marks of the crankshaft gear

and the idle gear A meet and install it on the
cylinder block.
• Tighten up the fastening bolts with the
prescribed torque.
Tighten:
N6A6067E
2
1
3
9
0 L 0
5
7 6
N6A6653E
Legend
1. Idle Gear C 6. Crankshaft Gear
2. Camshaft Gear 7. Oil Pump Drive Gear
3. Idle Gear B 8. Fuel Supply Pump Gear
4. Power Steering Pump Gear 9. Idle Gear A
5. Power Steering Pump Idle Gear
4. Install the flywheel housing. • As the figure shows, apply the liquid gasket
• Clean the rear side of the cylinder block. In (ThreeBond 1207C or equivalent) inside a hole
particular, remove overflow liquid gasket of the bolt (except the bolt holes indicated with
thoroughly when the crankcase is installed. arrows) evenly.
N6A6069E
• Along with the dowel pin of the cylinder block,

install the flywheel housing.
• Tighten up the Mark 3 from the cylinder block
Tighten:
side.
Bolts (1) to 96 N⋅m (9.8 kgf⋅m/71 lbf⋅ft)
N6A6070E
5. Install the power steering pump idle gear.

• Apply engine oil over the part where the gear of
the idle gear shaft is to be put together.
• Put the idle gear and the shaft together and
install it on the location given on the figure and
tighten up with the prescribed torque.
Tighten:
N6A6071E
Without HBB
N6A6072E
6. Install the power steering pump idle gear cover. N6A0775E
• Install the O-ring on the cover and install it on With HBB

the flywheel housing and tighten up the
tightening bolts with the prescribed torque.
Tighten:
N6A6074E
Legend
1. Flywheel Housing Fixing Bolt
2. Cylinder Block Fixing Bolt
N6A6073E 8. Install the oil pan

7. Install the power steering pump. • Apply the liquid gasket (ThreeBond1207C or
• Install the power steering pump and tighten up equivalent) on a joint between the cylinder
with the prescribed torque. block, the front cover and the flywheel housing
with a beat diameter of 3 mm (0.1 in).
Tighten:
Fixing bolts to
Flywheel housing side (1): 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
Cylinder block side (2): 44 N⋅m (4.5 kgf⋅m/32 lbf⋅ft)
• Install the oil pan within 7 minutes after applying • After fastening the oil pan at the respective
the liquid gasket. points of (1), (2), (3), and (4), fasten other parts.
Tighten:
Bolts and nuts to 11 N⋅m (1.1 kgf⋅m/95 lbf⋅in)
N6A6075E
• With the flywheel housing, the front cover and

the stud of the crankcase as a guide, put
N6A6077E
together the gasket and put the oil pan on it.
Then, put the rubber assembly on the oil pan 9. Install the rear slinger and the oil seal.
and fix it by fastening bolts and nuts. Refer to “Crankshaft Rear Oil Seal”.
10. Install the flywheel.
• Along with the knock pin of the crankshaft,
install the flywheel and tighten up with the
prescribed torque according to the order given
on the figure.
Tighten:
Bolts to
1st step: 78 N⋅m (8.0 kgf⋅m/57 lbf⋅ft)
2nd step: 120° – 150° (degrees)
N6A6076E
N6A6078E
Legend
1. Rubber Assembly 11. Install the crankshaft position sensor.
2. Oil Pan • Tighten up the fastening bolts with the prescribed
3. Gasket torque.
• Align the mark line (1) in the vacuum pump side
Tighten:
with the gear slit (2).
• Assemble the vacuum pump by referring the stud
12. Install the gear (3) to the vacuum pump (1). bolt of the cylinder block for guidance.
• Install the key (2) to the shaft of vacuum pump (1). • Check that the gear slit (2) is located near the
• Insert the gear (3) into the shaft, and tighten the center of the hole by looking through the plug hole
nut (4) to the specified torque. of the cylinder block.
Caution:
If the slit is out of the center, try again.
1
2
2
3 3
1
4
N6B6028E 6
4
Legend 5
1. Vacuum Pump
N6B6029E
2. Key
3. Gear Legend
4. Nut 1. Mark Line
5. O-ring 2. Slit
3. Slit position before insertion
13. Turn the crankshaft in the normal direction of 4. Slit position after insertion
engine rotation until the No. 1 or No. 4 cylinder is 5. Plug hole
at TDC on the compression stroke. 6. Air Compressor
Refer to illustration.
• Tighten the vacuum pump to the specified torque.
Caution:
Tighten in a diagonal order.
• M10 nut to 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
• M12 nut and bolt to 76 N⋅m (7.7 kgf⋅m/56 lbf⋅ft)
16. Apply a light coat of engine oil to the O-ring.
17. Install the oil drain adapter to the plug hole.
Tighten the bolt to the specified torque.
Tighten:
Bolt to 8 N⋅m (0.8 kgf⋅m/69 lbf⋅in)
N6B6003E
14. Remove the oil drain adapter.

15. Install the vacuum pump to the cylinder block.
• Install the O-ring to the vacuum pump.
20. Install the camshaft assembly.
Refer to “Camshaft Assembly”.
21. Install the rocker arm shaft assembly.
22. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
1
2
N6B6030E
Legend
1. Oil Drain Adapter
2. O-ring
18. Assemble the supply pump (1) and the supply

pump bracket (4) in a unit.
• Install the O-ring (3) to the supply pump (1), and
assemble them into the supply pump bracket (4).
• Tighten the TORX bolts (7) in a diagonal order.
Tighten:
19 N⋅m (1.9 kgf⋅m/14 lbf⋅ft)
• Insert the key (2) into the supply pump shaft, and
install the coupling (6).
• Insert the two studs into the thread holes (φ10,
P1.25) of the coupling (6) to fix it, and then tighten
the nut (5) to the specified torque.
Tighten:
64 N⋅m (6.5 kgf⋅m/47 lbf⋅ft)
4
1
3
2
N6B6027E
19. Install the cylinder head assembly.


24 (2.4 / 17.7)
48 (4.9 / 35)
31 (3.2 / 23)
44 (4.5 / 32)
110 (11.2 / 81)
133 (13.6 / 98)
134 (13.7 / 99)
19 (1.9 / 14)
40 (4.1 / 29.5)
176 (17.9 / 129.8)
1st 78 (8.0 / 58)

8 (0.8 / 69 lbf in)
2nd 120 150
76 (7.7 / 56)
8 (0.8 / 69lbf in)
11 (1.1 / 95 lbf in)
N6B6202E
Special Tool
Tool Number /
Illustration
5-8840-2230-0
(EN-47680)
Crankshaft Stopper
Rocker Arm Shaft Assembly

Component
N6A6083E
Legend
1. Camshaft Bracket 5. Rocker Arm Bracket
2. Rocker Arm 6. Camshaft Bracket
3. Wave Washer 7. Rocker Arm Shaft
4. Rocker Arm
Removal
2. Remove the rocker arm shaft assembly.
• Along with the camshaft bracket, remove the
rocker arm shaft assembly.
• Keep the 2-bolts (arrowed in the figure) fixing 6. Remove the camshaft bracket to take the shaft out.
the rocker arm shaft to the camshaft bracket,
before removal of all the rocker arm brackets
N6A6085E
Legend
N6A6084E 1. Camshaft Bracket
2. Rocker Arm
Caution: 3. Wave Washer
Pay full attention so as not to drop the bridge cap in the 4. Rocker Arm
gear case of the rear part of the cylinder head or the 5. Rocker Arm Bracket
hole into which oil pours back in the front. 6. Camshaft Bracket
7. Rocker Arm Shaft
Dismount
Inspection
1. Remove the camshaft bracket.
1. Check if the oil hole of the camshaft bracket (on
2. Remove the rocker arm.
the rear side) is clogged.
3. Remove the wave washer.
4. Remove the rocker arm.
5. Remove the rocker arm bracket.
• Repeat the procedure of (2) to (5).
N6A6086E
2. Check if the rocker arm shaft is warpage.

• Place the rocker arm shaft on a V block.
• Mesure the runout of the rocker arm shaft with
a dial gauge on the center of the shaft.
• As a result of measurement, if its bend is slight,
press it to rectify it (do not heat).
• If the warpage of the shaft exceeds the limit,
replace the shaft.
• Use a cylinder gauge to measure an inside
diameter of the bush of the rocker arm to
Bend of the rocker arm shaft mm (in)
measure a clearance between the external
Limit 0.3 (0.012) diameter of the shaft.
the rocker arm and the shaft.
Clearance between the rocker arm and

rocker arm shaft mm (in)
Standard 0.010 – 0.056 (0.0004 – 0.0022)
Limit 0.2 (0.0079 )
N6A6087E
3. Check if the rocker arm shaft is worn.

• Use a micrometer to measure 8 places rubbed
by the rocker arms.
• Replace the shaft if the diameter is less than
the limit.
External diameter of the rocker arm shaft mm (in) N6A6089E

Standard 21.979 – 22.000 (0.865 – 0.866) 5. Inspect a clearance between the roller of the
Limit 21.85 (0.860) rocker arm and the rocker arm pin.
a. Pass a string, through the opening between the
rocker arm and the roller, pull it strongly in the
direction indicated with arrows and measure
the gap between the rocker arm and the roller
with the roller being hulled out. (Figure 1)
b. After marking the measuring point, pull the
string out push the roller fully into the rocker
arm, and measure the gap of the marked place.
(Figure 2)
c. The gap between the measurement taken
under a. and that under b. Is the a clearance
between the roller and the rocker arm pin. If it
exceeds the limit, replace the rocker arm.
Clearance between the roller and the

rocker arm pin mm (in)
Standard 0.068 – 0.100 (0.0026 – 0.0039)
N6A6088E
Limit 0.2 (0.0079)
4. Inspect a clearance between the rocker arm and
the rocker arm shaft.
• Apply engine oil to the hole of the rocker arm,
the roller and the rocker arm pin.
N6A6090E
N6A6092E
Reassembly 3. Install the wave washer between the rocker arm.
1. Install the camshaft bracket to one side of the 4. Install the rocker arm bracket.
rocker arm shaft tentatively first. (Tighten them up,
• Paying attention to the direction of the rocker
after the rocker arm shaft assembly is installed on
arm bracket, repeat the step 2 to 4.
the cylinder head.)
5. Install the camshaft bracket.
• Assemble in the reverse order to dismounting.
• Install the camshaft bracket on the rocker arm
shaft with the bolts indicated with an arrow
tightened tentatively. (Tighten them up, after the
rocker arm shaft assembly is installed on the
cylinder head.)
N6A6091E
2. Install the rocker arm.
N6A6085E
Legend
1. Camshaft Bracket
2. Rocker Arm
3. Wave Washer
4. Rocker Arm
5. Rocker Arm Bracket
6. Camshaft Bracket
7. Rocker Arm Shaft
Installation • Apply engine oil on threads of the bolts and
nuts, and fix them tentatively (about tighten up).
• Tighten them up according to the order
• If the bridge cap comes off, apply engine oil
specified below gradually, taking care not to
over the inside of the bridge cap and put it
incline the entire rocker arm assembly.
together with the bridge.
Tightening order:
Caution: 1. Nuts (1) from near side of the rocker arm
Pay full attention so as not to drop the bridge cap in the shaft
gear case of the rear part of the cylinder head or the 2. Bolts (2)
hole into which oil pours back in the front. 3. Bolts (3) from out side
4. Bolts (4)
Tighten:
Bolt (3) to 56 N⋅m (5.7 kgf⋅m/41 lbf⋅ft)
Nut (1), Bolt (2), (4) to 27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft)
N6A6093E
Legend
1. Bridge Cap
2. Bridge
N6A6094E
1) Temporarily tighten the bolts marked with the Legend

arrow in the illustration. 1. Camshaft Bracket Fixing Nut
2) Loosen the rocker arm adjust screws and apply 2. Camshaft Bracket Fixing Bolt
engine oil to the rocker arm roller portions. 3. Rocker Arm Bracket Fixing Bolt
4. Rocker Arm Shaft Set Bolt
3) Install the rocker arm assembly on the cylinder
head.
• Adjust valve clearance.
Refer to “Functional Inspection”.
N6A6084E
N6B6213E
Camshaft Assembly
Component
N6B6262E
Legend
1. Bearing Cap 3. Knock Pin
2. Bearing 4. Camshaft Gear
Removal Caution:
Put the removed bearings in order with a tag, for
1. Rotate the crank shaft to make the No. 1 cylinder
example, by cylinder.
meet the compression TDC.
Refer to the “cylinder head cover.”
Refer to the “rocker arm shaft assembly.”
4. Remove the camshaft bearing cap.
5. Remove the bearing upper.
7. Remove the bearing lower.
• Check if the journal and cam parts of the
camshaft are worn or damaged, if so, replace it.
N6A6097E
N6A6101E
Disassembly 2. Inspect an end clearance of the camshaft.
1. Remove the camshaft gear. • Use a thickness gauge to measure an end
• Remove the fastening bolts of the camshaft clearance of the camshaft gear and the
gear and put the block of wood in a puller to camshaft bracket.
remove the camshaft gear. • If the measurement exceeds the limit, replace
the camshaft gear or the camshaft.
End clearance of the camshaft mm (in)

Standard 0.085 – 0.205 (0.033 – 0.008)
Limit 0.25 (0.009)
Caution:
Measure an end clearance of the camshaft before
disassembling.
N6A6100E
Legend
1. Wood
2. Remove the dowel pin.

Inspection
1. Inspect the camshaft visually.
N6A6102E
3. Check if the cam lobe is worn.

• Measure the height “H” of the cam lobe with a
micrometer.
• If the height of the cam lobe is the limit or less,
replace the camshaft.
Height of the cam lobe mm (in)

Inlet Exhaust
Standard 52.8 (2.08) 54.5 (2.15)
Limit 51.8 (2.04) 53.5 (2.11)
H
N6A6104E
5. Check if the camshaft is warpage.

• Place the camshaft on a V block to measure a
runout with a dial gauge.
• Rotate the camshaft slowly and measure the
range of fluctuation. If it exceeds the limit,
Warpage of the camshaft mm (in)

N6A6652E
Limit 0.05 (0.0019 )
4. 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,
External diameter of the camshaft journal

part mm (in)
Standard 39.950 – 39.975 (1.5728 – 1.5738)
Limit 39.850 (1.5688)
Partial wear of the camshaft journal part mm (in)

Limit 0.05 (0.0019)
N6A6105E
6. Measure camshaft journal oil clearance.

a. Measure the inside diameter of the camshaft
bearing with a dial gauge.
b. Read the difference between the inside
diameter of the camshaft bearing and the
diameter of the camshaft journal.
If the measured oil clearance exceeds the limit,
replace the camshaft bearing.
Installation
Clearance of the journal part mm (in) 1. Turn the crankshaft in the normal direction of
Standard 0.025 – 0.087 (0.0009 – 0.0034) engine rotation until the No. 1 or No. 4 cylinder is
at TDC on the compression stroke.
Limit 0.15 (0.0059)
N6B6003E
2. Install the camshaft bearing lower.

N6A6106E
• Apply engine oil over the camshaft bearing
lower and install it on the cylinder head.
Reassembly 3. Install the camshaft assembly.
1. Install the knock pin. • The camshaft assembly ‘B’ mark must be
facing the cylinder head upper face. If not,
2. Install the camshaft gear.
serious engine damage will result.
• With the side of the camshaft gear center boss
part stuck out being on the camshaft side,
install the camshaft gear along with the knock
pin.
Tighten:
Caution:
Be careful not to damage the cam and journal parts
when tightening up the gear.
N6A6651E
4. Install the bearing upper to the bearing cap.

5. Install the bearing cap.
• Apply engine oil on the bearing upper.
N6A6102E
• Direct the front mark of the bearing cap toward
the front of the engine and put it together with
the cylinder head in numerical order.
N6A6109E
• Apply engine oil to the thread and tighten up the

bearing cap with the prescribed torque.
Tighten:
Nut to 27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft)
N6A6110E

27 (2.8 / 20)
142 (14.5 / 105)
N6B6204E
Valve Stem Seal and Valve Spring

Component
N6A6112E
Legend
1. Camshaft Bearing Cap 6. Valve Spring
2. Camshaft Bearing 7. Spring Upper Seat
3. Camshaft Assembly 8. Split Collar
4. Rocker Arm Shaft Assembly 9. Bridge
5. Valve Stem Oil Seal
Removal 5. Remove the bridge cap (1).

1. Remove the cylinder head cover. 6. Remove the bridge (2).
Caution:
2. Remove the fuel injector. Keep the removed bridge and bridge cap properly so
Refer to “Fuel Injector”. that they may be put back to the original position.
• Remove the special tool to remove the upper
seat.
9. Remove the valve spring.
Put the removed valve springs in order by cylinder
number.
10. Remove the valve stem oil seal.
• Use pliers to remove the oil seal.
N6A6093E
Legend
1. Bridge Cap
2. Bridge
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or a hole N6A6114E
into which oil pours back in the front.
Caution:
7. Remove the split collar. Do not use the removed oil seal again.
• Apply compressed air over the cylinder from a
glow plug hole to keep the valve at the home
position (the piston top dead center is also
Inspection
acceptable). Inspect the valve spring
• Use a replacer to compress the valve spring to Caution:
remove the split collar. Check the valve spring visually and if there is clear
damage or wear-out, replace it.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263) 1. Free length
Pivot: 5-8840-2808-0 (EN-46721) • Measure free length of the spring and if it is
shorter than the prescribed limit, replace the
spring.
Free length of the valve spring mm (in)

Inlet Exhaust
Standard 59.9 (2.36) 70.3 (2.76)
Limit 56.9 (2.24) 67.3 (2.65)
N6A6113E
8. Remove the spring upper seat.

Tension of the valve spring

Inlet Exhaust
Installation
47.0 (1.85) 47.0 (1.85)
length mm (in)
Standard N (lb) 333 (74.9) 490 (110.2)
Limit N (lb) 315 (71.0) 463 (104.3)
N6A6115E
2. Valve spring squareness

• Use a surface plate and a square to measure
the valve spring squareness.
If the measured value exceeds the specified
limit, replace the valve spring.
Valve spring squareness mm (in)

Limit 1.0 (0.04)
N6A6117E
Installation
1. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a
valve stem seal installer.
Caution:
After installing the valve stem oil seal, check if it is
inserted deeply enough and the oil seal is not tilted or
the garter spring has not come off.
N6A6116E
3. Tension
• Use a spring tester to compress the spring to
the installation height. Measure tension of the
compressed spring. If the measurement is
lower than the limit, replace the spring.
Special tool • Apply compressed air over the cylinder from the
Valve stem seal installer: 5-8840-2833-0 glow plug holes to keep the valve at the home
(EN-47685) position.
• Use a replacer to compress the valve spring
and install the split collar.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 5-8840-2808-0 (EN-46721)
N6A6118E
2. Install the valve spring.

• Install it with the paint mark or the narrow side
of the spring pitch being the lower side (cylinder
head side).
N6A6113E
Paint mark
5. Apply engine oil over the bridge and install it.
Inlet Blue
Caution:
Exhaust Red Move it up and down to check if them moves smoothly.
6. Apply engine oil over the bridge cap and install it.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
N6A6119E
Legend
1. Spring Pitch
2. Paint Mark
3. Install the spring upper seat.

4. Install the split collar.
Tool Number /
Illustration
5-8840-2833-0
(EN-47685)
Valve Stem Seal Installer
EN47685
N6A6093E
Legend
1. Bridge Cap
2. Bridge

9. Install the fuel injector.
Refer to “Fuel Injector”.
Special Tool
Tool Number /
Illustration
5-8840-2621-0 (J-43263)
Valve Spring Replacer
5-8840-2808-0
(EN-46721)
Pivot Assembly
Cylinder Head
Component
1
4 2
16
5
6
3
7
8
9
10
15
11
14
12
13
N6B6031E
Legend
1. Bridge Cap 9. Idle Gear C Cover
2. Bridge 10. Idle Gear C
3. Bridge Guide 11. Glow Plug
4. Split Collar 12. Intake and Exhaust Valves
5. Spring Upper Sheet 13. Cylinder Head
6. Valve Spring 14. A/C Compressor Bracket
7. Valve Stem Oil Seal 15. Thermostat
8. Valve Guide 16. Water Outlet Pipe
Caution: Removal
To avoid electric shock;
1. Drain the coolant.
Set the switch to the ‘OFF’ position and disconnect
battery negative cable before checking or repairing the 2. Remove the engine harness.
fuel injector, wiring or/and connectors. 3. Remove the front exhaust pipe.
4. Remove the turbocharger.
Refer to “Turbocharger and Exhaust Manifold”.
5. Remove the charge air hose on the right and left • Loosen the tension pulley nut and the adjust
sides of the engine. bolt and remove the drive belt.
1
1
2
N6B6004E N6B6285E
Legend Legend
1. Inlet Hose 1. Tension Pulley Nut
2. Charge Air Hose 2. Adjust Bolt
6. Disconnect the radiator upper hose. 9. Remove the A/C compressor.

7. Remove the water rubber hose (2), EGR ducts (3, • Remove the A/C compressor harness
5), EGR cooler (1), and EGR valve (4). connector, remove the compressor from the
• Refer to “EGR Valve and EGR Cooler”. A/C compressor bracket, and fix it with wires
and others.
1 2
4 3
5
N6B6033E
N6A6123E
Legend
1. EGR Cooler 10. Remove the A/C compressor bracket.
2. Water Rubber Hose 11. Remove the cylinder head cover.
3. EGR Duct (EGR cooler (2nd) – EGR valve) Refer to “Cylinder Head Cover.”
4. EGR Valve 12. Loosen the fuel injector terminal nuts alternately to
5. EGR Duct (EXH) the same level, and remove the terminal.
8. Remove the A/C compressor drive belt. 13. Loosen the fuel injector harness bracket bolt,
remove the inside connector, and remove the
harness bracket.
Caution:
Injector ID code is used to identify each injector.
Do not remove the injector ID code.
14. Remove the nozzle leak-off pipe (4).
N6B6035E
18. Remove the camshaft position sensor connector.

N6A6124E
Legend Refer to “Camshaft Assembly”.
1. Harness Bracket
21. Remove the bridge cap carefully so that it does not
2. Harness Connector
fall into inside the engine.
3. Fuel Injector Terminal Nut
4. Nozzle Leak-off Pipe 22. Remove the bridge.
15. Remove the fuel leak-off hose. Caution:

Store the removed bridge and bridge cap so that they
16. Remove the fuel leak-off pipe (2).
can be placed in their original locations.
23. Remove the glow plug connector.

24. Remove the glow plug.
N6B6034E
Legend
1. High Pressure Pipe
2. Leak-off Pipe N6A6127E
17. Remove the water bypass hose from the cylinder

head side.
• Remove the engine coolant temperature sensor
connector.
25. Remove the injection pipe clip, and remove the
injection pipes. Special tool
Fuel injector remover: 5-8840-2826-0 (EN-46720)
1
Sliding hammer: 5-8840-0019-0 (J-23907)
29. Mark each fuel injector with the number of the
cylinder from which it was removed. Store the fuel
injectors in a safe place. Position the fuel injector
so that the nozzle is protected.
Caution:
• Do not tamper with the electromagnetic portion of
the fuel injector. Reduced electromagnetic function
will result in injector failure.
N6B6082E
Legend
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip

• Remove the fuel rail pressure sensor
connector.
27. Remove the fuel injector bracket.
28. Loosen the fuel injector clamp fixing bolts and
remove the fuel injectors. N6A6129E
If the fuel injectors are difficult to remove, use the fuel
injector remover. Install the fuel injector remover to the Legend
leak-off pipe attachment part on the fuel injector. Use a 1. Sliding Hammer
sliding hammer to force the fuel injector clamp off the 2. Fuel Injector Remover
fuel injector. 3. Fuel Injector Assembly
Caution: Caution:
• Injector ID code is used to identify each injector. Attach a cylinder number to the removed fuel injectors
Do not mix with other injector ID code plates. til re-install them.
• If the injector assembly has been replaced, write Be sure not to make the nozzle touch something.
the ID code in the ECM using a scan tool. Refer to
“Engine Control” chapter for how to write an
injector ID.
• When pulling out the injector using a special tool,
make sure that the injector sleeve will not come off
during the work.
• Remove liquid gasket adherent to the removed
inlet cover.
N6A6130E
30. Remove the lower head cover.

N6A6034E
3. Remove the A/C compressor bracket.
• Loosen the cylinder head bolts in the described
order in the drawing. 4. Remove the EGR cooler bracket.
5. Remove the exhaust manifold.
Caution: Refer to “Turbocharger and Exhaust Manifold”.
Be sure not to overlook (1) and (2) because they are 6. Remove the exhaust gasket.
attached with the flywheel housing with M10 bolts.
7. Remove the water outlet pipe.
• Remove the cylinder head gasket. 8. Remove the thermostat.
Caution:
Replace the head gasket with a new one once it was
removed.
N6A6132E
9. Remove the idle gear C cover.
N6A6131E
Disassembly
1. Remove the throttle assembly.
• Remove the intake throttle valve connector.
2. Remove the inlet cover.
• Put the edge of a driver on the outer circle of • Remove the special tool, then remove the
the sealing cup as shown in the drawing, tap it upper sheet and springs.
lightly, reverse it, then pull it out with pliers or
other equipment. Sort the removed valve springs by cylinder
number.
N6A6133E
N6A6113E
10. Remove the idle gear C.
14. Remove the intake and exhaust valves.
• Sort the removed valves according to cylinders
by using tags and others.
N6A6134E
Legend
1. Idle Gear C
2. Idle Gear Shaft N6A6135E
15. Remove the valve stem oil seals.

11. Remove the split collar.
12. Remove the spring upper sheet.
13. Remove the valve spring.
• Use a replacer to compress the valve spring,
then remove the split collar.
Special tool
Pivot: 5-8840-2808-0 (EN-46721)
• Use pliers to remove the oil seals.
N6A6137E
N6A6114E Legend
16. Remove the valve guides. 1. Nozzle Sleeve
• Use the valve guide replacer to press out the
valve guides from the bottom side of the 18. Remove the bridge guide.
cylinder head. • Electrically weld the nut on the head of the
bridge guide, attach the sliding hammer and
Special tool pull it out.
Valve guide replacer: 5-8840-2628-0 (J-43272)
N6A6138E
N6A6136E Legend
17. Put the nozzle sleeve remover on the nozzle 1. Nut
sleeve from the bottom side of the cylinder head,
then pull out the nozzle sleeve. 19. Remove the oil seal.
Special tool
Nozzle sleeve remover: 5-8840-2623-0 (J-43265)
Caution:
• Be sure not to scratch the bottom side of the
cylinder head.
• Do not reuse the removed nozzle sleeve.
• Carefully remove sawdust in the screw groove.
• Press the tool against the oil seal. Strike the • Check whether there is a crack between the
tool to remove the seal from the inside of the valve sheets and in the cylinder head of the
cylinder head. exhaust port part, and replace the cylinder
head if there is serious damage or crack.
Check the collar if necessary.
N6A6139E
N6A6140E
Inspection c. Flatness of the under surface of the cylinder
1. Inspect the cylinder head assembly. head
• Remove varnish, soot and others adhered on • Use a straight edge ruler and thickness
the metal surface completely. Use metal brush gauge to measure the four sides and
and others so that the seal surface of the diagonal lines as shown in the drawing, and
surface where the gasket is installed is not replace if they exceed the limit.
damage.
• Check the following causes in the case of leak Distortion of the under surface of the
of the seal surface of the cylinder head, cylinder head mm (in)
corrosion, air leak and defective gasket.
- Defective installation. Standard 0.05 (0.002) or less
- Defective tightening of the cylinder head. Limit 0.20 (0.0079)
- Winding seal surface of the cylinder block.
a. Damage on the screw surface or extracted
cylinder head bolt due to extra tightening
torque.
Caution:
Replace suspicious bolt.
b. Inside the combustion chamber, glow plug hole.
N6A6141E
d. Flatness of the surface where the exhaust

manifold and inlet cover are installed
• Use a straight edge ruler and thickness 2. Bridge
gauge to measure the four sides and • Make sure the bridge moves smoothly along
diagonal lines as shown in the drawing, and the bridge guide.
replace if they exceed the limit.
• Measure the gap between the bridge and
bridge guide.
Distortion of the surface where the
manifold and cover are installed mm (in)
Gap between the bridge guide and bridge
Standard 0.05 (0.002) or less guide mm (in)
Limit 0.2 (0.0079) Assembly standard 0.020 (0.00079) –
0.056 (0.00220)
Usage limit 0.1 (0.0039)
N6A6142E
e. Flatness of the exhaust manifold

• Use a straight edge ruler and thickness N6A6145E
gauge to measure the flatness. If it exceeds Legend
the limit, replace the exhaust manifold. 1. Bridge
2. Bridge Guide
Distortion of the exhaust manifold mm (in)
3. Inspect the valve guide.
Standard 0.3 (0.0118)or less
Caution:
Limit 0.5 (0.0197)
If there is a scratch or abnormal abrasion in the valve
stem and the inner diameter part of the valve guide,
replace it with new one along with valve guide.
a. Measure the valve guide clearance.

• Measure the diameter of the valve stem with
a micro meter.
If the diameter of the valve stem is smaller
than the limit, replace the valve and valve
stem altogether.
The external diameter of the valve

stem mm (in)
Standard Limit
7.946 (0.3128) –
Intake valve 7.88 (0.3102)
7.961 (0.3134)
7.921 (0.3118) –
Exhaust valve 7.80 (0.3071)
N6A6143E 7.936 (0.3124)
• If the abrasion exceeds the limit, or there is an
abnormal abrasion (zonal abrasion), replace
the bridge cap.
Abrasion of the bridge cap mm (in)

Limit 0.1 (0.00394)
N6A6146E
• Measure the gap between the valve guide

and valve stem within 10 mm (0.39 in) from
the valve guide, using a dial gauge.
• If the measured value exceeds the limit,
replace the valve guide and valve
altogether.
N6A6148E
Gap between the valve guide and
valve stem mm (in) 5. Inspect the valve.
Thickness of the valve
Standard Limit • Measure the thickness of the valve.
0.039 (0.00153) – • If the measured value exceeds the limit, replace
0.054 (0.00213) the valve and valve guide altogether.
0.064 (0.00252) –
0.079 (0.00311) Thickness of the valve mm (in)
Standard Limit
Intake valve 1.71 (0.0673) 1.3 (0.0512)
Exhaust valve 1.75 (0.0689) 1.3 (0.0512)
N6A6147E
4. Inspect abrasion of the bridge gap.

• Measure the contact surface of bridge cap and
the rocker arm, using a dial gauge.
N6A6149E
Valve sheet
• Remove carbon, water stain and others on the
under surface of the cylinder head.
Install the valve in the cylinder head.
Measure the depth of the valve from the under
surface of the cylinder head, using a depth
gauge or straight edge ruler.
If it exceeds the limit, replace the valve insert or
cylinder head assembly.
Depth of the valve mm (in)

Standard Limit
2.5 (0.0984)
N6B6253E
Contact surface of the valve seat

• If the contact surface of the valve seat is
defective, modify it or replace the valve, valve
guide and valve seat altogether.
Angle of the contact surface: 45° (degrees)
N6B6251E
• Measure the contact width of the valve seat. If

the seat contact surface has a scratch or is
rough, or if the abrasion of the contact surface
exceeds the limit, modify or replace it.
N6B6252E
Contact width of the valve seat mm (in)
Repair of the seat surface
Standard Limit
• Remove carbon from the surface of the valve
Intake valve 1.5 (0.0591) 3.0 (0.1181) insert seat.
Exhaust valve 2.1 (0.0827) 2.5 (0.0984)
• Use a seat cutter to minimize the scratch and
other roughness (15/45/75 degree-blade),
thereby returning the contact width to the
standard value.
N6A6155E
Replace the valve seat insert

Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve
N6A6153E
seat insert.
Caution: • Cool the valve seat insert for two to three
Remove only scratches and roughness, and do not cut minutes. Contraction fur to cooling makes it
the surface too much. easier to remove the valve seat insert.
Use the free adjustment valve cutter pilot. • Remove the valve seat insert, using a screw
Do not let the valve cutter pilot waver inside the valve driver. Be sure not to damage the cylinder
guide. head.
N6A6156E
N6A6154E
Legend
• Attach abrasives in the valve insert seat. 1. Arc-weld
• Insert the valve into the valve guide. 2. Valve Seat Insert
• Attach abrasives on the valve seat surface, 3. Screw Driver
rotate the valve and hit it lightly to grind them, Install the valve seat insert
and confirm that it has even contact all round.
• Carefully place an attachment (the outer
Caution: diameter is smaller than the valve seat insert)
Remove abrasives completely after grinding. on the valve seat insert.
• Use the press to apply pressure gradually on
the washer, thereby pushing the valve seat
insert.
Caution:
Do not apply too much pressure with the press.
Attach compound on the valve seat surface, rotate the
valve and hit it lightly to grind them, and confirm that it
has even contact all round.
N6A6158E
Legend
1. Cylinder Head
2. Oil Seal Installer
2. Install the bridge guide.

N6A6157E
• Apply engine oil on the outer diameter of the
Legend guide, then use the installer to hammer it into
1. Attachment the depth of the finishing part of the hole of the
2. Valve Seat Insert cylinder head.
3. Press (Note: the height of the bridge guide is about
37.5 mm (1.48 in) from the upper surface of the
head)
Reassembly
Special tool
1. Install the oil seal.
Bridge guide installer: 5-8840-2626-0 (J-43268)
• Install on the surface of injection pipe insert.
• Hammer it in so that the seal does not incline.
Caution:
Be sure not to damage the rip.
Special tool
Oil seal installer: 5-8840-2627-0 (J-43269)
N6A6159E
Legend
1. 122.5 ± 0.5 mm (4.82 ± 0.02 in)
2. 37.5 mm (1.48 in)
3. Install the nozzle sleeve.

• Install the O-ring on the nozzle sleeve, apply
N6A6139E engine oil.
• Apply seal material on the taper section.
Special tool
Loctite No.TL290 Nozzle sleeve installer: 5-8840-2624-0
(J-43266)
N6A6650E
Legend N6A6161E
1. O-ring (White Paint) Legend

2. O-ring 1. Punch Bar
3. Apply the Loctite 2. Ball
4. Engine Oil 3. Guide Sleeve
4. Nozzle Sleeve
• Install the nozzle sleeve on the cylinder head, 5. Bracket
insert the guide sleeve. 6. Bolt
• Use the guide sleeve to push in so that the
nozzle sleeve fully contacts with the under 4. Install the valve guide.
surface of the cylinder head.
• Insert the sleeve and fix it with the tighten and
bolt.
• Insert the ball (bearing steel ball 9.525 mm
(0.375 in)) into the guide sleeve, attach the
punch bar and hammer out the ball.
Caution:
• Leave the cylinder head floating so that the ball
comes off from the under surface.
• Hammer in the valve guide from the upper Special tool
surface of the cylinder head, using the valve Valve stem seal installer: 5-8840-2833-0
guide replacer. (EN-47685)
Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272)
N6A6118E
6. Install the intake and exhaust valves.

N6A6162E
• Apply engine oil on the valve stem part and
install the valve.
Height from the upper surface of the cylinder Caution:

head to the edge surface of the valve guide: After assembling valve, make sure parts are assembled
18.75 – 19.25 mm (0.7381 – 0.7578 in) correctly.
Caution:
When replacing the valve guide, it must be replaced
together with the valve.
N6A6164E
7. Install the valve spring.

• Install the valve spring with the paint mark or
N6A6163E the narrower side of the spring pitch on the
under side (the cylinder head side).
5. Install the valve stem oil seal.
• Apply engine oil on the outer diameter of the
valve guide, use the valve stem seal installer to Paint mark
install the oil seal. Intake side Blue
Caution: Exhaust side Red
After installation of the valve stem seal, confirm that the
oil seal is not inclining and the garter spring is in place.
• Apply engine oil on the idle gear C shaft and
the inner diameter of the idle gear, install the
idle gear C so that the side with gear groove is
on the side of the rear surface of the engine.
• Tighten the idle gear C with the designated
torque.
• Do not use impact wrench and like.
Tighten:
N6A6119E
Legend
1. Spring Pitch
2. Paint Mark
8. Install the spring upper sheet.

9. Install the split collar.
• Use the replacer to compress the valve spring
and install the split collar.
• After installation, tap the head of the valve stem
N6A6134E
lightly with rubber hammer to stabilize the split
collar. Legend
1. Idle Gear C
Caution: 2. Shaft
Make sure that the split collar is securely inserted into
the valve stem groove. 11. Install the idle gear C cover.
Special tool
Pivot: 5-8840-2808-0 (EN-46721)
N6A6113E
10. Install the idle gear C.

• Apply liquid gasket (Loctite 262) on the outer • Tighten the water outlet pipe with the
diameter of the idle gear C cover, use the designated torque.
sealing cup setting tool to hammer it in so that
Tighten:
the measurements follow the drawing.
• After installation, tap the head of the valve stem
lightly with rubber hammer to stabilize the split
collar.
Caution:
Make sure that the split collar is securely inserted into
the valve stem groove.
Special tool
Sealing cup installer: 5-8840-2222-0
(EN-47690)
N6A6167E
14. Install the EGR cooler bracket.

Tighten:
24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
15. A/C compressor bracket.
Install the bracket, tighten the bolt with the
designated torque.
Tighten:
N6A6165E Bolts to 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
12. Install the thermostat.
• Install the thermostat on the position shown in
the drawing.
N6B6036E
16. Install the inlet cover.
N6A6166E
Legend
1. Thermostat
13. Install the water outlet pipe.

• Apply liquid gasket (ThreeBond1207C or • Install the intake throttle valve connector.
equivalent) in accordance with the groove of
the inlet cover, with the bead diameter of φ2.5 –
5.5 mm (0.0984 – 0.2165 in).
N6B6015E
18. Install the exhaust gasket.

N6A6169E
19. Install the exhaust manifold.
• Install the distance tube conical spring and the
• Tighten in the order described in the drawing.
nut on the stud of the cylinder head in this
• Tighten the stud bolts (6) and (9) jointly with the order.
fuel rail.
Tighten:
Stud bolts to 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
N6A6168E
Legend
1. Distance Tube
2. Conical Spring
N6A6170E
3. Nut
• Coat the liquid gasket and mount within 7 • Tighten the exhaust manifold in the order
minutes. described in the drawing.
Tighten: Tighten:
Bolt and nut to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft) Bolt (1),(2),(3),(4),(5),(6) and Nut (7), (8) to 34 N⋅m (3.5
kgf⋅m/25 lbf⋅ft)
Caution:
Do not tighten it too much so that it hinders extraction
and contraction of the manifold due to heat.
Measurement
Head of the piston (2) and (3)
points:
6
Standard point: Upper surface of the
8 (1)
4 cylinder block
3
Caution:
5
2 Note that there are three options for the head gasket
1 according to the amount of extrusion of piston shown in
7 the following table.
• Calculate the average piston extrusion amount

of each cylinder.
• Calculate the maximum amount of the average
amount of each cylinder.
• Select a gasket of an appropriate grade based
N6B6212E
on Timax.
• Install the heat protector.
Tighten:
Installation
1. Install the cylinder head gasket.
• Select the cylinder head gasket.
• Clean the head of the piston and the upper
surface of the cylinder block.
• Use a dial gauge to measure the extrusion of
the piston. Measure at two points of each
cylinder.
• The following drawing shows the measurement
points and the standard point of the cylinder
block.
N6A6172E
Gasket Recognized Piston extrusion

Grade by amount mm (in)
A (no hole) 0.439 (0.01728) –
0.519 (0.02043)
B (1 hole) 0.519 (0.02043) –
0.589 (0.02319)
C (2 holes) 0.589 (0.02319) –
0.669 (0.02633)
N6A6171E
• Install the cylinder head gasket with the parts
number upside, along with the cylinder head
rear gear case and dowel.
N6A6173E
Legend
1. Grade Recognition Hole
N6A6175E
• Apply liquid gasket 2. Install the cylinder head assembly.

• Apply liquid gasket (ThreeBond 1207C or • Install the cylinder head, adjusting the dowel of
equivalent) on the joint (1) of the cylinder block the cylinder block.
and the flywheel housing with the bead
diameter of 3 mm (0.118 in). Caution:
• Install the cylinder head within seven minutes Be sure not to damage the head gasket when installing
after applying liquid gasket. it.
N6A6174E
N6A6176E
• Install the cylinder head gasket.
• Apply molybdenum disulfide on the thread and
setting face of the head bolt of M14, and apply
engine oil on the thread and setting face of the
head bolt of M10.
• Use a torque wrench and angle gauge to
tighten the head bolts in the order described in
the drawing.
Tighten:
M14 bolts (1 – 18) to
2nd step: 147 N⋅m (15.0 kgf⋅m/108 lbf⋅ft)
3rd step: 30° – 60° (degrees)
M10 bolts (19, 20) to
4th step: 38 N⋅m (3.9 kgf⋅m/28 lbf⋅ft)
• Tighten bolts from 1-18 (M14) and confirm that
they are tightened to a torque of 167 N⋅m (17.0
kgf⋅m/123 lbf⋅ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
N6A6178E
Legend
1. Fuel Injector Assembly
2. Fuel Injector Tighten Bolt

Tighten:
Fuel rail to 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
• Install the fuel rail pressure sensor.
6. Install the injection pipe.
• Apply a thin coat of engine oil on the outer
diameter of the sleeve nut on the side of the
fuel injector and install the injection pipe.
N6A6177E • Use a spanner to tighten the sleeve nut until it
3. Install the fuel injector on the cylinder head. completely contacts both on the fuel injector
4. Apply molybdenum disulfide on the thread and and fuel rail.
setting face of the fuel injector tighten bolt and • Tighten the injection pipe clip with the
tighten it tentatively. designated torque.
Important: Tighten:
Reinstall each fuel injector to the original cylinder from Clip to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
which it was removed during the disassembly
procedure.
1
1
2
2
N6B6121E
Legend
1. Injection Clamp Bolt
2. Injection Pipe Sleeve Nut
9. Install the glow plug.

Tighten:
Glow plug to 20 N⋅m (2.0 kgf⋅m/15 lbf⋅ft)
10. Install and tighten the glow connector with the
N6B6082E
designated torque.
Legend
1. Fuel Injection Pipe Tighten:
2. Fuel Injection Pipe Clip Glow connector to 1.2 N⋅m (0.1 kgf⋅m/10.5 lbf⋅in)
11. Apply engine oil on the bridge, install it.
7. Final tighten the injection clamp bolts to the
specified torque. Caution:
Move it up and down to confirm that it moves smoothly.
Tighten:
Bolts to 30 N⋅m (3.0 kgf⋅m/22 lbf⋅ft) 12. Apply a thin coat of engine oil inside the bridge
8. Tighten the injection pipes to the specified torque. cap, install it.
Tighten:
Nuts to
Injector side: 30 N⋅m (3.1 kgf⋅m/22 lbf⋅ft)
Fuel rail side: 25 N⋅m (2.5 kgf⋅m/18 lbf⋅ft)
N6A6093E
Legend
1. Bridge Cap
2. Bridge
15. Install and tighten the camshaft position sensor
with the designated torque.
Tighten:
N6A6181E
21. Install the fuel injector harness connectors.

22. Install the harness bracket and tighten the bolts to
Tighten:
N6B6101E
16. Install the water bypass hose.

17. Install the engine coolant temperature sensor on
the thermostat housing.
Tighten:
Engine coolant temperature sensor to 25 N⋅m (2.5
kgf⋅m/18.4 lbf⋅ft)
18. Install the leak-off pipe.
Tighten:
Leak-off pipe to 12 N⋅m (1.2 kgf⋅m/104 lbf⋅in)
19. Install the fuel leak-off hose.
20. Clip a new gasket to the fuel nozzle leak-off pipe
and install the fuel leak-off pipe.
N6A6182E
Tighten: 23. Install the terminal nuts on the fuel injector.
Nozzle leak-off pipe (injector to cylinder head) to 12 N⋅m
(1.2 kgf⋅m/104 lbf⋅in) Tighten:
Fuel leak-off pipe (cylinder head side) 12 N⋅m (1.2 Terminal nuts to 2 N⋅m (0.2 kgf⋅m/17 lbf⋅in)
kgf⋅m/104 lbf⋅in)
Caution:
Fuel leak-off pipe (supply pump side) 18 N⋅m (1.8 kgf⋅m/
• Do not over tighten the nuts. Damage to the terminal
13.3 lbf⋅ft)
studs will result.
Caution: • The terminal nut with two wires is engine front side.
Use new gaskets.
• Use a scale or other equipment to inspect
whether the flexure of the belt when it was
3 pushed by hand with pressure of 98 N (22 lb) is
within the designated range.
A/C belt flexure mm (in)

New belt 19 (0.748) – 24 (0.945)
Reused belt 24 (0.945) – 28 (1.102)
1
• Tighten the locknut of the tension pulley with
the designated torque after adjusting the
tension of the belt.
Tighten:
2
Lock nut to 27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft)
N6A6627E
Legend
1. Fuel Injector 1
2. Fuel Injector Harness
3. Fuel Injector Terminal Nut
2

25. Install the radiator upper hose.
26. Install the A/C compressor.
• Install the A/C compressor bracket on the A/C
compressor and tighten it with the designated
torque.
Tighten:
• Install the A/C compressor harness connector. N6B6285E
Legend
1. Tension Pulley Lock Nut
2. Tension Pulley Adjusting Bolt
28. Install the turbo charger.

Refer to “Timing Gear Train.”
29. Install the EGR cooler (1), EGR ducts (3, 5), EGR
valve (4), and water rubber hose (2).
• Refer to “EGR Valve and EGR Cooler” in
Emission Control section, and follow the
installation procedure.
N6B6007E
27. Install the A/C compressor drive belt.

• Place the drive belt and adjust its tension with
the adjust bolt of the tension pulley.
•
Tighten:
Nuts to
Exhaust manifold side: 67 N⋅m (6.8 kgf⋅m/49 lbf⋅ft)
Exhaust brake side: 17 N⋅m (1.7 kgf⋅m/13 lbf⋅ft)
36. Install the engine harness.
2
1
4 3
5
N6B6033E
Legend
1. EGR Cooler
2. Water Rubber Hose
3. EGR Duct (EGR cooler (2nd) – EGR valve)
4. EGR Valve
5. EGR Duct (EXH)
30. Install the oil level gauge and the guide tube.
31. Connect the radiator upper hose.
32. Install the charge air hoses on the right and left
sides of the engine to the intercooler.
33. Install the Inlet hose.
• Install the bolt and the clip band, and tighten the
bolt to the specified torque.
2 1
N6B6005E
Legend
1. Inlet Hose
2. Charge Air Hose
3.
34. Install the oil level gauge and guide tube.

35. Install the exhaust pipe.
• Install the front exhaust pipe and tighten with
the designated torque.
N6B6037E
Special Tool
Tool Number / Tool Number /
Illustration Illustration
Description / Remarks Description / Remarks
5-8840-2833-0
5-8840-0019-0 (J-23907)
(EN-47685)
Sliding Hammer
Valve Stem Seal Installer
584000190 EN47685
5-8840-2628-0 (J-43272) 5-8840-0266-0 (J-45059)

Valve Guide Replacer Angle Gauge

5-8840-2808-0
5-8840-2624-0 (J-43266)
(EN-46721)
Nozzle Sleeve Installer
Pivot Assembly
5-8840-2222-0
5-8840-2626-0 (J-43268)
(EN-47690)
Bridge Guide Installer
Sealing Cup Installer
5-8840-2627-0 (J-43269)
Oil Seal Installer
5-8840-2623-0 (J-43265)
Nozzle Sleeve Remover
5-8840-2826-0
(EN-46720)
Fuel Injector Remover
EN46720
5-8840-2621-0 (J-43263)
Valve Spring Replacer
Piston and Connecting Rod

Component
7
1
1 2
N6B6038E
Legend
1. Snap Ring 5. Connecting Rod
2. Piston 6. Piston Pin
3. Bearing 7. Piston Ring
4. Connecting Rod Cap
Removal
Refer to “Oil Pan”.
5. Remove the cylinder head.
6. Remove the connecting rod cap.
Caution: Caution:
Sort the removed bearings according to cylinders by Sort the piston rings in the order of cylinders when
using tags. reusing them so that they will not be confused with the
pistons and piston rings of other cylinders.
N6A6186E
7. Remove the piston and connecting rod.

N6A6188E
• Remove carbon on the upper side of the
cylinder liner with a scraper. 2. Remove the snap ring.
• Pull out the piston and connecting rod towards 3. Remove the piston pin.
the cylinder head.
Caution:
Caution: Sort the disassembled piston pins, pistons and
Be sure not to damage the oil jet and cylinder liner connecting rods together in the order of cylinders.
when pushing out the connecting rod.
N6A6189E
N6A6187E
4. Remove the connecting rods from the piston.
8. Remove the connecting rod bearing.
5. Piston
Caution: • Clean carbon carefully that is adhered to the
Arrange the bearings in the order of cylinders. Be sure head of the piston and the groove of the piston
to put them back to the original cylinders. ring.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
Caution: • Use the bench press to replace the bush.
Do not use wire brush to clean the piston because it
scratches the piston. Special tool
Inspect the piston with eyes for cracks, burns and other Connecting rod bush replacer: 5-8840-2340-0
excessive wear, and replace it if there is any (EN-47682)
abnormality.
6. Remove the bush.

• Set the collar, connecting rod and collar on the
setting bar as shown in the drawing.
• Tighten the nut.
N6A6200E
Legend
1. Bolt
2. Connecting Rod Bush Replacer
Inspection
N6A6199E
1. Measure the gap between the piston and the inner
Legend diameter of the cylinder liner.
1. Setting Bar Inner diameter of the cylinder liner.
2. Connecting Rod
• Use a cylinder bore dial indicator to measure
3. Nut
the liner inner diameter both in the thrust and
4. Collar
radial directions in the designated position.
5. Bush
6. Collar • Measurement position (from the upper surface
of the cylinder block)
• Place the connecting rod bush replacer base on 1. 20 mm (0.79 in)
press, tighten the fixation bolt. 2. 110 mm (4.33 in)
3. 190 mm (7.48 in)
• Measure the liner inner diameter based on the
average value of the actual measurement
values on 6 positions.
Cylinder liner inner diameter mm (in)

115.021 – 115.050 (4.52838 – 4.52952)
N6A6190E N6A6191E
Legend 2. Piston replacement

1. 20 mm (0.79 in) • You do not need to select grades because there
2. 110 mm (4.33 in) is only one grade for each of the piston and the
3. 190 mm (7.48 in) cylinder liner inner diameter.
Piston outside diameter If you replace the cylinder liner, you must select
the cylinder block (1, 2, 3) because there are
• Use a micrometer to measure the outside two types of the liner outer diameter.
diameter of the piston in the right angle to the
piston pin in the designated position. • Refer to “Cylinder Block” if you replace the
cylinder liner.
• Measurement position (from the upper surface
of the piston) 82 mm (3.2 in). Caution:
The head of piston has a marking of grade B or C when
Piston diameter mm (in) it is shipped from the factory.
Standard 114.930 – 114.969

(4.52479 – 4.52632)
Gap between the piston and the inner

diameter of the cylinder liner mm (in)
Standard 0.052 – 0.120
(0.0020 – 0.0047)
Caution:
If it is found that the gap between the cylinder liner
inner diameter and the piston exceeds the standard
value, replace the piston or cylinder liner.
N6A6192E
Legend
1. Front Mark Cut
3. Inspect the piston ring.

Measure the joint of the piston ring (remove carbon
on the ring joint)
• Insert the piston ring into the cylinder liner.
• Use the piston to push the ring to reach the • Put the piston ring in the piston ring groove, use
under edge of the cylinder liner. a thickness gauge to measure the gap between
them.
• If the clearance between the piston ring groove
and the piston exceeds the limit, replace the
piston and the piston ring.
Piston ring and piston ring groove

clearance mm (in)
Piston ring Standard Limit
1st compression
— —
ring
2nd compression 0.02 – 0.07 0.15
ring (0.0008 – 0.0028) (0.0059)
Oil ring 0.03 – 0.07 0.15
(0.0012 – 0.0028) (0.0059)
N6A6193E
• Use a thickness gauge to measure the gap of

the ring joint.
N6A6195E
4. Inspect the piston pin.

N6A6194E • Inspect the piston pin with eyes for cracks,
• If the measurement exceeds the limit, replace scratches and other damages, replace it if
the piston ring. necessary.
• Use a micrometer to measure the outer
diameter of the piston pin. If the measured
Piston ring gap mm (in) value exceeds the limit, replace the piston pin.
Standard Limit
1st compression 0.27 – 0.46 1.20 Piston pin outer diameter mm (in)
ring (0.0106 – 0.0181) (0.047) Standard 39.995 – 40.000 (1.5746 – 1.5748)
2nd compression 0.36 – 0.61 1.20 Limit 39.970(1.5736)
ring (0.0141 – 0.0240) (0.047)
Oil ring 0.27 – 0.56 1.20
(0.0106 – 0.0220) (0.047)
Measure the clearance between the piston ring

groove and the piston.
• Remove carbon in the piston ring groove.
N6A6196E N6A6198E
• Inspect to make sure that there is a resistance 5. Measure the clearance between the piston and the
to the extent which the piston can push the piston pin.
piston pin lightly in normal temperatures. • Apply engine oil on the piston pin. Use your
• If it feels a large looseness or instability in finger to push it in hole of the piston and rotate
normal temperatures, replace the piston or it. If the pin smoothly rotates without instability,
piston pin. the clearance is normal. If there is instability,
measure the clearance. If the clearance
exceeds the limit, replace the piston and the
piston pin.
Piston pin and piston pin hole clearance mm (in)

Standard 0.009 – 0.022 (0.00035 – 0.00087)
Limit 0.04 (0.0016)
6. Measure the connecting rod alignment.

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

N6A6197E (par length of 100 mm (3.94 in)) mm (in)
• Measure the bush of the small edge of the Standard Limit
connecting rod. If the clearance of the bush
inner diameter and the pin diameter exceeds Distortion and 0.20
0.05 (0.002)
the limit, replace the bush or connecting rod Parallelism (0.008)
assembly, and the pin.
Piston pin and connecting rod small end

bushing clearance mm (in)
Standard 0.012 – 0.027
(0.0005 – 0.0011)
Limit 0.05(0.0020)
N6A6201E N6A6202E
7. Measure the bearing oil clearance. - Remove the cap.

• Measure the oil clearance between the - Measure the largest width of the plastigauge
connecting rod bearing and the crank pin with to calculate the oil clearance. If the
the following method. clearance exceeds the limit, replace the
- Remove the connecting rod cap. Sort the entire bearing.
removed caps according to the cylinder
number. Crankpin and bearing clearance mm (in)
- Clean the bearing and the shaft pin.
Standard 0.037 – 0.076 (0.0015 – 0.0030)
- Inspect the bearing. If it is damaged or worn
seriously, replace the entire bearing.
- Remove the plastigauge from the bearing
• Place the plastigauge on the crankshaft pin. and crankpin.
• Install the bearing cap and tighten the bolt with
the designated torque.
Apply molybdenum disulfide on the screw part
and the bearing surface.
Tighten:
Connecting rod bearing cap bolt to
2nd step: 60° (degrees)
3rd step: 30° (degrees)
Caution:
Do not rotate the crankshaft.
N6A6203E
8. Select the connecting rod bearing.

• Select bearings carefully by the grade of big
end hole diameter of the connecting rod
according to the selection table.
• Place the connecting rod bush replacer base on
a press, set the connecting rod and tighten the
fixation bolt.
Special tool
Connecting rod bush replacer: 5-8840-2340-0
(EN-47682)
2 3
N6A6648E
Legend
1. Top and Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
Bearing selection table

N6A6200E
Big end hole Bearing
Oil clearance Legend
diameter recognition
1. Bolt
Grade color mm (in) 2. Connecting Rod Bush Replacer
A Green 0.037 – 0.096
(0.0015 – 0.0038) • Set the collar, new bush and collar on the
setting bar as shown in the drawing.
B Yellow 0.037 – 0.076
• Tighten the nut.
(0.0015 – 0.0030)
N6A6205E
Legend
1. Grade Recognition Color
Reassembly
1. Install the bush
• Adjust the oil hole of the connecting rod and the • Use snap ring pliers to install the snap ring of
oil hole of the bush, and use the bench press to one side.
install the bush.
N6A6645E
N6A6199E Legend
Legend 1. Front Mark
1. Setting Bar 2. Forging Mark (Projecting)
2. Connecting Rod
3. Nut 4. Apply enough engine oil on the piston pin, push it
4. Collar in the piston and the connecting rod small edge.
5. Bush 5. Use snap ring pliers to install the snap ring.
6. Collar
Caution:
• After installing the new bush, use a grinder to Make sure that the snap ring is installed in the ring
machine the pin hole so that the pin clearance groove properly. Make sure that the connecting rod
equals the standard value. moves smoothly.
N6A6206E
N6B6239E
2. Install the piston.
3. Install the connecting rod. 6. Use ring pliers to install the piston ring.
• Install it so that the front mark of the head of the • Install the oil ring so that the joint angle of the
piston and the connecting rod forging mark ring and coil expander is in the opposite 180°
(projecting) on the connecting rod face the direction.
same direction.
• Install 2nd and 1st compression rings in this • Apply enough engine oil on the piston ring, ring
order so that the marks “2T” and “1T” face groove and piston side surface.
upward. • Dislocate the piston ring joint so that (1) is 1st
ring, (3) is 2nd ring and (2) is oil ring, as shown
in the drawing.
• Face the piston front mark cut to forward, use
the piston ring compressor to insert the piston
in the cylinder liner.
Caution:
• When pushing in the piston, attach the setting tool
tight to the cylinder liner. Insufficient tightness can
cause damage to the ring while pushing in.
• Be sure not to make the connecting rod touch the oil
jet when pushing in the piston.
• Be sure not to damage the inside of the liner when
pushing in the piston.
Special tool
Piston ring compressor: 5-8840-9018-0
N6A6209E
(J-8037)
Legend
1. Oil Ring
2. Compression Ring 2nd
3. Compression Ring 1st
Caution:
Note that the shapes of compression rings 1st and 2nd
are different.
Make sure that there is no gap in the position indicated
in the drawing when the oil ring coil expander was
installed.
N6B6250E
3. Install the connecting rod cap.

• Install the bearing on the connecting rod cap
and apply engine oil.
N6A6210E
Installation
1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, apply
engine oil on the bearing.
2. Install the piston and connecting rod assembly.
• Install the cap, matching the numbers (1, 2, 3,
4) of the caps and connecting rods.
2 3
N6A6212E
4. Install the cylinder head.

N6A6648E
Legend 5. Install the camshaft assembly.
1. Back and Top Recognition Boss Refer to “Camshaft Assembly”.
2. Big End Hole Diameter Grade Mark
3. Cylinder Number
• Apply molybdenum disulfide on the screw part 7. Install the cylinder head cover.
and the setting face of the tightening bolt and Refer to “Cylinder Head Cover”.
tighten it with the designated torque. 8. Install the oil pan.
• Tighten two bolts alternately in each step. Refer to “Oil Pan”.
Tighten:
Tightening bolt to
2nd step: 60° (degrees)
3rd step: 30° (degrees)
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
Caution:
Make sure that the crankshaft smoothly rotates.
1st 39 (4.0 / 29)

2nd 60
3rd 30
N6B6039E
Special Tool
5-8840-2340-0
(EN-47682) 5-8840-0266-0 (J-45059)
Connecting Rod Bush Angle Gauge
Replacer
5-8840-9018-0 (J-8037)
Piston Ring compressor
Flywheel
Component
N6B6040E
Legend
1. Flywheel Housing 6. Pilot Bearing (MT)
2. Flywheel Assembly (MT) 7. Crankshaft Position Sensor
3. Washer 8. Flexible Plate (Smoother)
4. Clutch Assembly (MT) 9. Crankshaft End Spacer (Smoother)
5. Clutch Pressure Plate Assembly (MT)
Removal
1. Remove the starter motor.
• Remove the earth cable of the starter motor.
• Disconnect the front frame harness connector • Remove the clutch pressure plate assembly
near the control box of the transmission, from the flywheel.
remove the clips that fix the harness.
N6A6217E
N6B6041E
4. Remove the clutch plate assembly.
• Remove the two bolts on the upper side and • Remove the clutch plate assembly from the
lower side that fix the starter, remove the starter flywheel along with the clutch aligner (1).
from the clutch housing.
• Use wire to secure the starter to the
transmission. Position the wire and starter so
that it does not interfere with the transmission
removal procedure.
N6A6218E
Legend
1. Clutch Aligner
• Install the crankshaft stopper in the starter

N6B6042E installation part of the flywheel housing.
Refer to “Transmission Assembly”. Caution:
Make sure that the stopper is applied with the ring gear
3. Remove the clutch pressure plate assembly.
and installed properly.
• Insert the clutch aligner on the spline of the
driven plate.
• Remove the clutch pressure plate assembly
installation bolts in the order shown in the
drawing.
Special tool • In the case of smoother vehicle, after loosening
Crankshaft stopper: 5-8840-2230-0 (EN-47680) the flexible plate installation bolts, remove the
washer, flexible plate, spacer in this order.
N6A6057E
N6A6078E
• Remove to prevent contact damage when the 8. Remove the pilot bearing.
flywheel is removed. • Remove the pilot bearing from the flywheel.
• Do not throw or drop because it is vulnerable to
shock.
N6A6219E
Legend
N6B6025E 1. Washer
6. Remove the washer. 2. Pilot Bearing
3. Flywheel
• Gradually loosen the flywheel installation bolts 9. Remove the ring gear.
in the order shown in the drawing so that the
flywheel does not rotate.
• After loosening the bolts, remove the stopper
and remove the flywheel.
• Put a bar on the ring gear and hit it with a Depth = From the pressure installation surface
hammer to remove it. to the friction surface.
N6A6220E N6A6221E
Inspection Installation
1. Inspection with eyes 1. Install the ring gear.
• Inspect the flywheel friction surface for cracks • After heating the ring gear with a gas burner
and damages, and replace it if it has equally, install it in the flywheel. Do not allow
abnormality. the temperature of the gas burner to exceed
• Inspect the tooth part of the ring gear, replace 200°C (390°F).
the ring gear if it has damage or serious wear. • During shrinkage cooling of the ring gear,
2. Measurement of the friction surface maintain the flatness by applying force of
68.6 kN (15,400 lbf).
• Measure the depth of the friction surface of the
flywheel. Caution:
• Adjust it if the measured value is between the • Install the ring gear in the direction within the
standard value and the limit. chamfered face comes to the side of pressure
• If the measured value exceeds the limit, replace installation surface.
the flywheel. • Shrink fit the ring gear to the flywheel.
Make sure that flywheel and ring gear adhesion is
Depth of the friction surface of the complete.
flywheel mm (in)
Standard 19 (0.75 )
Limit 20 (0.79)
N6A6222E
2. Install the flywheel. Smoother specification
3. Install the washer. 1) Align the knock pin on the crankshaft to install
M/T specification the spacer.
1) Align the flywheel with the crankshaft knock pin 2) Install the flexible plate and washer, also
and temporarily tighten the flywheel bolts. aligning to the knock pin on the crankshaft.
2) Use the crankshaft stopper to prevent the 1st step; 78.4 ± 5.0 N⋅m (8.0 ± 0.5 kgf⋅m/58 ±
crankshaft from turning. 3.6 lbf⋅ft)
Crankshaft stopper: 5-8840-2230-0 (EN-47680) 2nd step; 120° – 150° (degrees)
3) Install the washer and the flywheel bolts and
tighten to the specified torque in numerical order
show in the illustration.
Tighten:
Bolts to
1st step: 78.4 ± 5.0 N⋅m (8.0 ± 0.5 kgf⋅m/58 ± 3.6 lbf⋅ft)
2nd step: 120° – 150° (degrees)
Special tool
Crankshaft stopper: 5-8840-2230 (EN-47680)
Angle gauge: 5-8840-0266-0 (J-45059)
N6A6078E
4. Install and tighten the crankshaft position sensor

with the designated torque.
Tighten:
5. Hammer in the pilot bearing until it reaches the
edge surface of the crank.
6. Install the clutch plate assembly.
• Use a clutch aligner to install the clutch plate
assembly on the flywheel.
N6A6078E
N6A6218E
Legend
N6A6057E
1. Clutch Aligner
7. Install the clutch pressure plate assembly.

• Install the clutch pressure plate assembly on • Connect the front frame harness connector.
the flywheel so that the installation hole of the
clutch pressure plate assembly matches with
the dowel pins of the flywheel.
• Tighten the clutch pressure plate assembly in
the order shown in the drawing.
Tighten:
N6B6041E
N6A6217E

Refer to “Transmission Assembly”.
9. Install the starter motor on the clutch housing with
bolts.
Tighten:
N6B6042E
• Install the earth cable of the starter motor.

78.4 5.0 (8.0 0.5 / 58 3.6)
8 (0.8 / 69 lbf in)
78.4 5.0 (8.0 0.5 / 58 3.6)
N6B6044E
Special Tool
Tool Number /
Illustration
5-8840-2230-0
(EN-47680)
Crankshaft Stopper
5-8840-0266-0 (J-45059)
Angle Gauge
Front Cover
Component
N6B6045E
Legend
1. Adjust Plate 8. Front Oil Seal
2. Generator 9. Crankshaft Pulley
3. Front Cover 10. Water Pump Assembly
4. Oil Pan Gasket 11. Fan Belt
5. Oil Pan 12. Water Pump Pulley
6. Rubber Assembly 13. Fan Assembly
7. Front Slinger
Removal 4. Remove the front cover.

1. Remove the front oil seal.
Refer to “Crankshaft Front Oil Seal”.
2. Remove the oil pan
3. Remove the water pump.
Refer to “Water Pump” in Section 6B.
• Remove the generator adjust plate. • Pull out the oil cooler bypass valve from the
cylinder block.
N6B6264E
N6A6227E
• Remove the oil relief valve (arrowed), loosen
the front cover installation bolts and remove the
front cover.
Installation
1. Install the oil cooler bypass valve.
• Insert the oil cooler bypass valve into the
cylinder block. Be sure not to insert in a wrong
direction.
N6B6265E
5. Remove the oil cooler bypass valve.
N6A6228E
2. Install the front cover.

• Clean the cylinder block front surface. In
particular, remove liquid gasket leaked during
installation of the crankcase.
• Install two O-rings and apply liquid gasket
(ThreeBond 1207B, 1207C, 1207F or
equivalent) along with the groove of the front
cover installation surface.
Beat width: 1.5 – 5mm (0.059 – 0.20 in)

Beat height: 0.3 – 1.5mm (0.012 – 0.059 in) from
the joint surface
• Install within seven minutes after applying liquid
gasket.
Caution:
Apply liquid gasket so that it does not adhere to the O-
ring.
N6A6230E
Legend
1. BOLT : L = 35 mm (1.38 in)
2. BOLT : L = 25 mm (0.98 in)
3. BOLT : L = 65 mm (2.56 in)
4. BOLT : L = 30 mm (1.18 in)
N6A6229E
5. Oil Relief Valve
Legend 3. Install the water pump.

1. O-ring Refer to “Water Pump” in Section 6B.
4. Install the oil pan.
• Install the front cover to match with the dowel
Refer to the “Oil Pan”.
pins of the cylinder block.
5. Install the front oil seal.
Caution: Refer to the “Crankshaft Front Oil Seal”.
Along with the front cover, install the water pump
assembly (before liquid gasket becomes dry)
Tighten:
Front cover bolt to 24 N⋅m (2.4 kgf⋅m/18 lbf⋅ft)
• Tighten bolts with (*) mark together with the
adjust plate of the generator.
• Tighten the oil relief valve (5) with the
designated torque.
Tighten:
Oil relief valve to 39 N⋅m (4.0 kgf⋅m/29 lbf⋅ft)
N6B6046E
Crankshaft Front Oil Seal

Component
3
2
1
N6B6137E
Legend
1. Crankshaft Pulley 3. Crankshaft Front Slinger
2. Crankshaft Front Oil Seal
Removal • Fix the detached starter with a wire or the like at

a position where it will not be a hindrance to
1. Drain coolant.
removing the transmission.
2. Remove the starter.
• Disconnect the starter ground cable.
at a position near the transmission control box
and unlatch fixing clips from the harness.
N6B6042E
3. Disconnect the upper radiator hose on the engine

side.
4. Disconnect the coolant reserve tank hose on the
radiator side.
N6B6041E
5. Disconnect the lower radiator hose on the engine
• Remove two mounting bolts. side.
6. Remove the radiator (with the fan guide) detaching
right and left brackets.
7. Remove the fan assembly.
• Remove the fan assembly unscrewing four • Remove only the oil seal off with a screwdriver
mounting nuts. or the like avoiding damage to the oil seal
8. Remove the fan belt. contact surface on the front cover and the shaft.
N6B6047E N6A6235E
9. Remove the crankshaft pulley. Legend

1. Felt
• Loosen the pulley bolts blocking the crankshaft
2. Slinger
from turning by placing a crankshaft stopper on
3. Oil Seal
the starter mounting position on the flywheel
housing. 11. Remove the crankshaft front slinger.
Caution: • Pull out the slinger using a slinger puller.
Make sure that the stopper is properly fitted and (Fixing the circumference of the puller with a
engaged with the ring gear. clip band will make the procedure easier.)
Special tool Special tool

Crankshaft stopper: 5-8840-2230-0 (EN-47680) Slinger puller: 5-8840-2360-0 (J-43285)
N6A6234E N6B6048E
10. Remove the crankshaft front oil seal.

Installation • Put the sleeve over the adapter, place a washer
on the center bolt and tighten the bolt until the
1. Install the crankshaft front slinger.
sleeve touches the adapter to press fit the front
• Press-fit the slinger using an oil seal installer slinger.
kit.
N6A6238E
N6A6237E
• After you have pressed the front slinger, confirm
Legend the measurement shown (depth from the end
1. Front Slinger surface of the crankshaft to the flange of the
2. Adapter (Front) slinger) and check for deflection of the slinger.
3. Fixing Bolt
4. Sleeve (Front) Caution:
5. Washer (Front) Be careful not to put the slinger inside out or mistake
6. Center Bolt front side slinger for rear one, and vice versa. Rear side
slinger has four right-hand threads on it while front one
Special tool has four left-hand threads. Slinger and oil seal should
Oil seal installer kit: 5-8840-2703-0 (J-43282) always be replaced in pairs.
(Use the parts listed below for the front oil seal.)
No. Part Name Slinger Oil seal

1 Sleeve (front) { {
2 Adapter (front) { {
3 Adapter ring (front) — {
4 Washer (front) { {
5 Center bolt { {
6 Fixing bolt { {
Caution:
Oil seal installer kit includes the sleeve (5-8840-2712-
0) for engine of May in 1993 model before, but it is not
used for this engine.
N6A6239E
• Insert the front slinger into the end of the Legend
adapter and fit them on the crankshaft. 1. Adapter
2. Sleeve
3. Slinger
4. 40.5 ± 0.3 mm (1.594 ± 0.012 in)
5. 34 ± 0.1 mm (1.339 ± 0.004 in)
2. Install the crankshaft front oil seal. • Put the front side adapter ring in the sleeve and
• Press fit the oil seal using an oil seal installer fix the sleeve on the adapter with the center bolt
kit. and a washer.
• Tighten the bolt until the sleeve touches the
adapter to press fit the front oil seal.
N6A6240E
Legend
1. Oil Seal N6A6242E
2. Adapter (Front) Legend

3. Adapter Ring (Front) 1. Oil Seal
4. Fixing Bolt 2. Adapter Ring (Front)
5. Sleeve (Front) 3. Sleeve (Front)
6. Washer (Front) 4. Bolt and Washer
7. Center Bolt
• Mount the adapter onto the crankshaft with

fixing bolts.
N6A6238E
N6A6241E
Legend
1. Adapter (Front)
• Apply engine oil to the lip of the oil seal and

place it on the front side adapter.
Caution:
Be sure to apply oil to the oil seal lip.
• After you have press-fitted the front oil seal, 4. Install the fan belt.
confirm the measurement shown (depth from • When adjusting the fan belt, you should also
the end surface of the crankshaft to the oil seal) adjust ACG belt and air conditioner belt at the
and check for deflection of the oil seal. same time.
• Fit the fan belt and adjust the tension following
the below procedures.
• Refer to “Drive Belt” in Section 6B for details of
the belt tension adjustment.
a. Inspection of fan belt deflection
Refer to “Drive Belt.” in Section 6B.
5. Tighten the fan assembly to the specified
tightening torque.
Tighten:
N6A6243E
Legend
1. Adapter Ring
2. Sleeve
3. Adapter
4. Oil Seal
5. 31 ± 0.3 mm (1.220 ± 0.012 in)
3. Install the crankshaft pulley.

• Apply engine oil to the threads of the fastening
bolts.
• Install the crankshaft pulley aligning with the N6B6047E
dowel pins on the crankshaft.
6. Install the radiator.
• Tighten in the sequence shown.
• Attach right and left brackets of the radiator to
Tighten: the brackets on the frame as illustrated.
Tighten:
Brackets to 26 N⋅m (2.6 kgf⋅m/19 lbf⋅ft)
3 4
N6B6049E
Rigid suspension model
N6A6247E
Legend
1. Flange Nut
2. Rubber
3. Stud Bolt
4. Frame Side Bracket
5. Radiator Side Bracket
6. Washer
7. Connect the lower radiator hose.

8. Connect the coolant reserve tank hose.
9. Connect the upper radiator hose.
10. Connect the air charge pipe to the intercooler.
11. Install the starter in the clutch housing with bolts
and tighten to the specified tightening torque.
Tighten:
• Connect the starter ground cable.
• Connect the front frame harness connector.
N6B6042E
12. Refill the radiator with coolant.

200 40 (20.4 4.1 / 148 30)
N6B6205E
Special Tool
Tool Number /
Illustration
5-8840-2230-0
(EN-47680)
Crankshaft Stopper
8-8840-2360-0 (J-43285)
Slinger Puller
5-8840-2703-0 (J-43282)
Oil Seal Installer Kit
Crankshaft Rear Oil Seal

Component
N6B6286E
Legend
1. Starter 6. Crankshaft Rear Oil Seal
2. Transmission Assembly 7. Crankshaft Rear Slinger
3. Clutch Pressure Plate Assembly (MT) 8. Flexible Plate (Smoother)
4. Clutch Plate Assembly (MT) 9. Crankshaft End Spacer (Smoother)
5. Flywheel (MT)
Removal
Refer to "Transmission Assembly".
2. Remove the pressure plate and the clutch disc.
Refer to “Flywheel”.
5. Remove the crankshaft rear oil seal.
• Remove only the oil seal off with a screwdriver Installation
or the like avoiding damage to the oil seal
1. Install the crankshaft rear slinger.
contact surface on the flywheel housing and the
shaft. • Press fit the rear sling using the oil seal installer
kit.
N6A6235E
N6A6251E
Legend
1. Felt Legend
2. Slinger 1. Rear Slinger
3. Oil Seal 2. Fixing Bolt
3. Center Bolt
6. Remove the crankshaft slinger. 4. Sleeve (Rear)
5. Collar (Rear)
• Pull out the slinger using a slinger puller.
6. Adapter (Rear)
(Fixing the circumference of the puller with a
clip band will make the procedure easier.)
Special tool
Special tool Oil seal installer kit: 5-8840-2703-0 (J-43282)
Slinger puller: 5-8840-2360-0 (J-43285)
No. Part Name Slinger Oil seal
1 Sleeve (rear) { {
2 Adapter (rear) { {
3 Collar (rear) { {
4 Adapter ring (rear) — {
5 Center bolt { {
6 Fixing bolt { {
Caution:
Oil seal installer kit includes the sleeve (5-8840-2712-
0) for engine of May in 1993 model before, but it is not
used for this engine.
N6A6250E
• Insert the rear slinger into the end of the rear
side adapter and mount the adapter on the
crankshaft with the fixing bolt with a collar
placed on it.
3 N6A6254E
Legend
1. Rear Part of The Crankshaft
2. Adapter
N6A6252E 3. 17.3 ± 0.3 mm (0.681 ± 0.012 in)
Legend 4. 10.8 ± 0.1 mm (0.425 ± 0.004 in)
1. Collar 5. Slinger
2. Fixing Bolt 6. Sleeve
3. Adapter 7. Collar
• Put a sleeve over the adapter and tighten the 2. Install the crankshaft rear oil seal.
center bolt until the sleeve touches the adapter • Press-fit the rear oil seal using an oil seal
to press fit the rear slinger. installer kit.
N6A6253E N6A6255E
• After you have press-fitted the rear slinger, Legend
confirm the measurement shown (depth from 1. Adapter (Rear)
the end surface of the crankshaft to the slinger) 2. Fixing Bolt
and check for deflection of the slinger. 3. Center Bolt
4. Sleeve (Rear)
Caution: 5. Collar (Rear)
Be careful not to put the slinger inside out or mistake 6. Adapter Ring (Rear)
the front slinger for the rear one, and vice versa. Rear 7. Rear Oil Seal
side slinger has four right-hand threads on it while front
one has four left-hand threads. Slinger and oil seal
should always be replaced in pairs.
• Put a collar on the fixing bolt and mount the • Tightening the center bolt until the sleeve
adapter onto the crankshaft. touches the adapter to press fit the oil seal.
N6A6252E N6A6253E
Legend • After you have pressed in the rear oil seal,

1. Collar confirm the measurement shown (depth from
2. Fixing Bolt the end surface of the crankshaft to the oil
3. Adapter seal).
• Apply engine oil to the lip of the oil seal and

place it in the rear side adapter. Rear oil seal press-fit size mm (in)
Caution: Assembly standard 7.5 (0.295) — 8.1 (0.319)

Be sure to apply oil to the oil seal lip.
• Put the rear side adapter ring in the sleeve and

put the sleeve on the adapter and fix with the
center bolt.
N6A6257E
Legend
1. Rear Part of The Crankshaft
2. Oil Seal
N6A6256E
3. 7.8 ± 0.3 mm (0.31 ± 0.012 in)
Legend 4. Collar
1. Sleeve 5. Adapter Ring
2. Adapter Ring 6. Sleeve
7. Adapter

4. Install the crankshaft position sensor.
5. Install the driven plate and the pressure plate.
6. Install the starter.
Refer to " Transmission Assembly ".
Special Tool
Tool Number /
Illustration
5-8840-2703-0 (J-43282)
Oil Seal Installer Kit
5-8840-2360-0 (J-43285)
Slinger Puller
Crankshaft
Component
N6A6258E
Legend
1. Upper Bearing 5. Lower Bearing
2. Upper Thrust Bearing 6. Lower Thrust Bearing
3. Gear 7. Crankcase
4. Crankshaft
Removal 5. Remove the cylinder head.

1. Demount the engine assembly.
Refer to “Engine Assembly”. 6. Remove the fuel supply pump.
Refer to “Fuel Supply Pump” in Section 6C.
Refer to “Cylinder Head Cover”. 7. Remove the oil pan.
Refer to the “Oil Pan”.
3. Remove the rocker arm shaft.
Refer to “Rocker Arm Shaft Assembly”. 8. Remove the crankshaft front oil seal.
4. Remove the camshaft.
Refer to “Camshaft Assembly”. 9. Remove the water pump.
10. Remove the front cover. 20. Remove the upper crankshaft bearings.
Refer to “Front Cover”.
11. Remove the crankshaft rear oil seal.
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 Rod”.
15. Remove the crankcase.
• Gradually loosen crankcase mounting bolts in
the sequence shown and remove the
crankcase using the three replacer holes
(arrowed holes in the figure).
N6A6261E
Disassembly
1. Remove the gear.
• Remove the gear using a gear puller.
Special tool
Crankshaft gear puller: 8-9439-1097-0
(EN-47684)
N6A6259E
16. Remove the lower thrust bearing.

17. Remove the lower crankshaft bearings.
N6A6262E
Reassembly
1. Install the gear.
• Heat the gear to 170 – 250°C (338 – 482°F)
and install it aligning the groove on the gear
with the pin on the crankshaft.
N6A6260E
18. Remove the crankshaft assembly.

19. Remove the upper thrust bearing.
• Insert the gear at one push into the flange with
its end side with the alignment mark “S” facing
outward. If you are fitting the gear while it is
cold, beat the gear in until it impinges on the
end using the installer.
Special tool
Crankshaft gear installer: 5-8840-2667-0
(J-41222)
N6A6264E
2. Main bearing clearance

• Remove the crankshaft. Remove the main
bearings.
Set out disassembled main bearings in the
order of the numbers.
• Clean the crankshaft journal upper and lower
bearings and upper and lower thrust bearings.
N6A6263E • Check the bearings for damage or excessive
Legend wear. If you find damage or excessive wear in
1. Alignment Mark the check, replace the bearings in pairs.
• Place the upper bearings and the crankshaft on
the cylinder block. Install the crankshaft so that
it becomes horizontal.
Inspection
1. Thrust clearance Caution:
• Set a dial gauge as shown and measure the Turn the crankshaft about 30 degrees to allow the
crankshaft thrust clearance. bearings to settle in.
• If the thrust clearance exceeds the limit, replace
the thrust bearings in a pair.
Axial play of the crankshaft mm (in)

Standard 0.040 – 0.205 (0.0016 – 0.0081)
Caution:
Measure the thrust clearance before dismounting.
N6A6265E
• Place Plastigage on the crankshaft journal as

shown.
• Place the lower bearings at original positions on
the crankcase.
N6A6268E
N6A6266E Tighten:
M14 bolts (1 – 10) to
• Install the crankcase and tighten bolts to the
specified tightening torque. 1st step: 98 N⋅m (10.0 kgf⋅m/72 lbf⋅ft)
• Tighten the crankcase in the sequence shown
using a torque wrench and an angle gauge. 3rd step: 30° – 60° (degrees)
M10 bolts (11 – 27) to
• Tighten the bolts (M14) from 1-10 and confirm
that they are tightened to a torque of 167 N⋅m
(17.0 kgf⋅m/123 lbf⋅ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
Caution:
Do not turn the crankshaft after you have tightened the
crankcase.
• Loosen the bolts and gently remove the

crankcase.
• Measure the widest part of the Plastigage
flattened by tightening the crankcase to
N6A6267E determine the clearance.
Journal oil clearance mm (in)

Standard
No.1, 2, 4, 5 0.039 – 0.070 (0.0015 – 0.0028)
No.3 0.053 – 0.084 (0.0021 – 0.0033)
4. Measure the journal and the crankpin diameters
and uneven wear.
• Measure outer diameters of the journal and the
pin and calculate differences between the
maximum and the minimum values. Take
measurements at four positions for both the
journal and the pin.
N6A6269E
• If the journal oil clearance exceeds the limit,

replace the main bearings altogether or the
crankshaft.
• Remove the Plastigage from the bearings and
the crankshaft.
N6A6271E
Inspection of the crankshaft
• Check the crankshaft journal and crank pin
surfaces for wear and damage. Check the oil Crankshaft outside diameter mm (in)
seal contact surface for excessive wear and
damage. Standard
• Check the oil port for clogging. Journal #1, 2, 4, 5 81.905 – 81.925
3. Crankshaft run-out (3.22460 – 3.22538)
Carefully set the crankshaft on the V block. Slowly Journal #3 81.891 – 81.911
turn the crankshaft to measure the run-out. If the (3.22408 – 3.22483)
crankshaft run-out exceeds the standard, replace
the crankshaft. Pin 72.902 – 72.922
(2.87015 – 2.87094)
Crankshaft run-out mm (in)

Caution:
Standard 0.05 or less (0.0020 or less) Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, do not
polish the surface of the crankshaft.
Inspection of crankshaft tuftride layer

1. Thoroughly clean the crankshaft using organic
cleaner. Remove oil completely from the test area.
2. Prepare solution of 5 – 10 % copper (II)
ammonium chloride in dilution water.
3. Apply the solution to the test area using greaser.
Keep the test surface level so as not let the
solution run.
N6A6270E
• Journals are numbered from 1 to 5 from left to right
when viewed so that the numbers are in normal
reading orientation.
N6B6206E
Legend
1. Do not drop solution in this area.
2. Test area N6A6272E
3. Pin or journal sliding surface
Caution:
Do not let the solution contact the area around the oil
port.
Judgment
• Wait for 30 to 40 seconds.
• The crankshaft is usable if the color does not
change after 30 to 40 seconds. (This means the
tuftride layer still stays on.)
Replace the crankshaft if the color is changed (test
surface turns a copper color).
Caution:
• The test solution is strong corrosive. Wipe it off
immediately after the test, and thoroughly clean N6A6273E
with water, steam, etc.
• Do not allow the solution to contact eyes, hands, Caution:
cloth, etc. If it goes into an eye, immediately flush Be careful about difference in the shape of the bearings
with large amount of water and seek for medical when installing them.
attention.
Crankshaft bearing selection

• When installing new crankshaft bearings or
replacing bearings in use, make reference to the
Bearing Selection Table.
• Select and install new bearings paying close
attention to the cylinder block journal internal
diameter grade and the crankshaft journal
diameter grade.
N6A6274E
Legend
1. Upper Bearing
2. Oil Gallery
3. Grade Identification Color
4. Oil Groove
5. Lower Bearing
6. Grade Identification Color
Bearing Selection Table

Combination of grades Oil clearance mm (in)
Cylinder block Crank journal Bearing identification
#1, 2, 4, 5 #3
Grade Grade color
1 1 Black 0.041 – 0.068 0.055 – 0.082
(0.00161 – 0.00272) (0.00217 – 0.00322)
1 2 Brown 0.039 – 0.065 0.053 – 0.079
(0.00153 – 0.00260) (0.00209 – 0.00316)
2 1 Blue 0.043 – 0.070 0.057 – 0.084
(0.00172 – 0.00276) (0.00224 – 0.00331)
2 2 Black 0.041 – 0.067 0.055 – 0.081
(0.00161 – 0.00263) (0.00217 – 0.00319)
Installation
1. Install the crankshaft upper bearing.
• Install the upper bearing in the cylinder block
and apply oil.
Caution: • Press the crankshaft to the rear and insert the
When replacing the crankshaft bearings, select grades upper thrust bearing in the rear side of the
referring to the Bearing Selection table. Do not apply oil cylinder block journal No.5.
to the bearing installation surface on the cylinder block
and external surface of the bearing. Caution:
Install the thrust bearing so that the oil groove contacts
the crankshaft.
N6A6275E
2. Install the upper thrust bearing.

• Install the upper thrust bearing in the front side N6A6277E
of the cylinder block journal No.5. In doing this,
4. Install the lower crankshaft bearing.
you may attach the upper thrust bearing to the
cylinder block with grease. Then, be sure to 5. Install the lower thrust bearing.
wipe up excess grease. • Install the lower thrust bearing in the rear side
of the crankcase journal No.5.
Caution: • Install the thrust bearing so that the oil groove
Install the thrust bearing so that the oil groove contacts contacts the crankshaft.
the crankshaft.
N6A6278E
N6A6276E 6. Install the crankcase.

3. Install the crankshaft assembly. • Apply liquid gasket (ThreeBond 1207C or
equivalent) to the crankcase forming beads
• Apply engine oil to the crankshaft journal and
with diameters of 3 – 4 mm (0.12 – 0.16 in).
gently place the crankshaft on the cylinder
block. • Install the crankcase within 7 minutes after you
have applied the liquid gasket.
• Gently place the crankcase on the cylinder
block.
N6A6279E
• Apply Molybdenum Disulfide to M14 bolt’s

threads and setting faces and tighten them to
the specified tightening torque in the sequence
shown.
• Do not apply any oil to M10 bolts.
Tighten:
M14 bolts (1 – 10) to
3rd step: 30° – 60° (degrees)
M10 bolts (11 – 27) to
• Tighten bolts from 1-10 (M14) and confirm that
they are tightened to a torque of 167 N⋅m (17.0
kgf⋅m/123 lbf ft) or more.
N6A6268E
Special tool
Angle gauge: 5-8840-0266-0 (J-45059) 7. Install pistons and connecting rods.
Refer to “Piston and Connecting Rod”.
Caution: 8. Install the oil pump.
Confirm that the crankshaft turns smoothly. Refer to “Oil Pump”.
9. Install the timing gear train.
10. Install the crankshaft rear oil seal.
Refer to the “Front Cover”.
12. Install the crankshaft front oil seal. 17. Install the camshaft assembly.
Refer to “Crankshaft Front Oil Seal”. Refer to “Camshaft Assembly”.
13. Install the water pump. 18. Install the rocker arm shaft assembly.
Refer to “Water Pump” in Section 6B. Refer to “Rocker Arm Shaft Assembly”.
14. Install the oil pan. 19. Install the cylinder head cover.
Refer to “Oil Pan”. Refer to “Cylinder Head Cover”.
15. Install the fuel supply pump. 20. Mount the engine assembly on the chassis.
Refer to “Fuel Supply Pump” in Section 6C. Refer to “Engine Assembly”.
N6B6287E
Special Tool
Tool Number /
Illustration
8-9439-1097-0
(EN-47684)
Crankshaft Gear Puller
5-8840-2667-0 (J-41222)
Crankshaft Gear Installer
5-8840-0266-0 (J-45059)
Angle Gauge
Cylinder Block
Component
N6B6052E
Legend
1. Cylinder Liner 3. Cover
2. Cylinder Block
Removal 6. Remove the fuel supply pump.

1. Demount the engine assembly.
Refer to “Engine Assembly”. Refer to “Oil Pan”.
2. Remove the cylinder head cover. 8. Remove the water pump.
Refer to “Cylinder Head Cover”. Refer to “Water Pump” in Section 6B.
3. Remove the rocker arm shaft assembly. 9. Remove the crankshaft front oil seal.
Refer to “Rocker Arm Shaft Assembly”. Refer to “Crankshaft Front Oil Seal”.
4. Remove the camshaft assembly. 10. Remove the front cover.
Refer to “Camshaft Assembly”. Refer to the “Front Cover”.
5. Remove the cylinder head. 11. Remove the crankshaft rear oil seal.
Refer to “Cylinder Head”. Refer to “Crankshaft Rear Oil Seal”.
12. Remove the timing gear train. • Conduct color check and hydraulic (or
Refer to “Timing Gear Train”. pneumatic) test and if you find crack or other
13. Remove the oil pump. damage, replace the cylinder block.
14. Remove pistons and connecting rods.
15. Remove the crankshaft.
Refer to “Crankshaft”.
16. Remove piston oil jet.
N6A6283E
5. Cylinder liner wear measurement

• Check the internal surface of the liner for flaw or
damage.
• Measure the liner bore diameter at the most
worn part (it wears more in the rotation
N6A6282E direction) at 15 – 20 mm (0.59 – 0.79 in) from
the top end of the liner with the liner installed in
17. Remove the cylinder liner.
the cylinder block. If the wear is over the
If the cylinder liner cannot be pulled free by hand,
application limit, replace it.
tap around the lower side of the liner with a
hammer grip or similar object loosen it.
Inspection
1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
• Be careful not to damage the cylinder block.
2. Carefully remove the liquid gasket on the
crankcase mounting surface.
3. Clean up the cylinder block.
4. Visually inspect the cylinder block.
N6A6284E
Cylinder liner bore diameter mm (in)

Standard 115.021 – 115.050
(4.52837 – 4.52952)
Limit 115.20 (4.5354)
Caution:
You need not select piston grade since cylinder liner
bore is only available in one size against the liner grade
selection of its outer diameter.
6. Cylinder block upper face warpage

• Pull out the cylinder liners and remove water
stains on the cylinder block.
• Measure four sides and two diagonals of the
top surface of the cylinder block using a straight
edge and a thickness gauge.
• Replace the cylinder block if the measurements
exceed limit values.
Cylinder block upper face warpage mm (in)

Standard 0.05 or less (0.002 or less)
N6A6286E
Limit 0.20 (0.079)
Cylinder block bore and liner grade

(for reference) mm (in)
Grade (1,2)/(1X) (3)/(3X)
Cylinder
118.001 – 118.020 118.021 – 118.030
block
(4.64699 – (4.64649 –
Bore
4.64654) 4.64684)
diameter
Liner 117.991 – 118.000 118.001 – 118.010
outside (4.64531 – (4.64570 –
diameter 4.64566) 4.64605)
(Reference)
When replacing liners, a “liner set” let you
obtain a piston of proper grade for a given liner
bore diameter only by specifying a liner outside
diameter grade.
N6A6285E
2. Install the cylinder liners.
• Install the cylinder liners perpendicular to the
Installation cylinder block.
1. Cylinder liner grade selection • Do not hammer the liner or apply excessive
force to insert it.
• Select liner outer diameter grades according to
the cylinder block bore grades stamped on the Caution:
cylinder block at arrowed positions in the figure. Clean up and blow with compressed air the cylinder
block and the cylinder liners before installing them.
Grade matching of cylinder block and liner
Grade of Cylinder block (stamp) 1, 2 3
Grade of Liner outside diameter 1X 3X
Caution:
Be careful not to deform or damage the oil jet nozzle.
N6A6287E
3. Amount of the cylinder liner extrusion

Measure the amount of the cylinder liner extrusion
N6A6289E
using a dial gauge.
Difference of the amount of the extrusion between 5. Install the crankshaft.
adjacent two cylinders should be within 0.03 mm Refer to “Crankshaft”.
(0.0012 in). 6. Install pistons and connecting rods.
7. Install the oil pump.
Amount of the cylinder liner extrusion mm (in)
Standard 0.05 – 0.10 (0.0020 – 0.0039) 8. Install the timing gear train.
Caution: 9. Install the crankshaft rear oil seal.
Be sure to measure the cylinder liner extrusion Refer to “Crankshaft Rear Oil Seal”.
whenever you have replaced cylinder liners.
Refer to “Front Cover”.
11. Install the crankshaft front oil seal.
12. Install the water pump.
14. Install the fuel supply pump.
N6A6171E Refer to “Cylinder Head Cover”.
4. Install the piston oil jet. 19. Mount the engine assembly on the chassis.
• Align the dowel pin of the oil jet with the pin hole Refer to “Engine Assembly”.
on the cylinder block and tighten with the check
valve.
Tighten:
21 (2.1 / 15)
N6B6124E
Lubrication System
Service Precautions • Avoid excessive or insufficient coating amount.
Note that seizure may occur in case of excessive
• During each disassembly, remove the old gasket
coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely
and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid
is insufficient.
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton • Always, the starting and ending piston of
and apply the specified new fluid gasket at each application should be overlapped.
location.
Explanations on Functions and Operation
The lubrication system uses the filter element
combined with a full flow bypass, water-cooled oil
cooler, and oil jet for piston cooling.
Lubricating System Diagram
N6B6053E
Functional Check 5. Stop the engine.

Oil pressure check 6. Remove the oil pressure gauge.
1. Check the engine oil level. If engine oil level is 7. Install the oil pressure switch.
insufficient, replenish it. 8. Start the engine and check for oil leakage.
2. Install the oil pressure gauge. Caution:
Check engine oil for abnormal dirt or mixture of water. If
Special tool there is abnormal dirt or mixture of water, check the
Oil pressure gauge set: 5-8840-2843-0 cause and take proper action. After that, change the oil.
3. Warm the engine.
4. Measure to check if the oil pressure is 294 kPa
{3.0 kg/cm2} or more at 1700 rpm.
Use oil
• Grade (JASO) DH-2 grade
Viscosity (SAE) 10W-40 Besco clean super or
equivalent
(DPD compatible oil)
1
Caution:
Always use the oil described above for this engine. 7
Engine oil level 6 2

3
• Place the vehicle on level surface and check the
engine oil level with a dipstick before engine starts 5 4
or when 30 minutes or more has elapsed after the
engine stops.
• The vehicle equipped with this engine has the
DPD, which requires different method of checking
engine oil level.
The vehicle with DPD automatically performs N6B6208E
regeneration (burning) when a certain amount of
Legend
PM (particulate matter) accumulates in the DPD
1. Oil change is needed.
filter.
2. Can be used.
To do this regeneration, a small amount of fuel is
3. Oil can be added up to “MAX for Adding”.
injected after burst in the combustion chamber to
4. Adding oil is needed.
mixed with exhaust gas, and sent to the DPD filter.
5. MIN
Some of this fuel get into the engine oil, resulting in
6. MAX for Adding
more engine oil than when it was poured. But this
7. MAX for Check
is not failure.
• How to check oil level using a dipstick
- Take out the oil dipstick and wipe off oil on it. Engine oil leakage
- Put it back all the way, and slowly take it out • In the lift up condition, confirm that there are no
again. Oil level should be between “MAX for leaks from the cylinder head cover and oil pan.
Check” and “MIN”.
- If oil level is low, add oil up to “MAX for
Adding”. If oil level is above “MAX for Check”,
be sure to change oil.
• Check the engine oil for dirt.
N6B6207E
Legend
1. Oil dipstick
Special Tool
Tool Number /
Illustration
5-8840-2843-0
Oil Pressure Gauge Set
(J-43630-20 /
Oil Pressure Gauge,
J-43630 / Hose,
J-43630-14 / Connector,
EN-46333 / Oil Pressure
5884028430 Testing Adapter)
Oil Filter Assembly

Components
N6A6294E
Legend
1. Oil Pressure Switch 3. O-ring
2. Oil Filter Body
Removal
1. Place a tray under the oil filter cartridge.
2. Remove the oil pressure switch.
3. Remove the oil filter body.
4. Remove the O-ring.
Installation
1. Install the O-rings and on the oil filter body.
N6A6297E
N6B6055E
Legend
1. O-ring
2. O-ring
2. Install the oil filter on the cylinder block and tighten

it using the specified torque.
Tighten:
Nuts and bolts to 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
N6A6296E
3. Install the oil pressure switch on the oil filter body.

• Apply the liquid gasket (Loctite 262) on 2 to 3
peaks from the tip of the threaded part of the oil
pressure switch and install it at the position
shown in the figure.
Tighten:
Oil pressure switch to 13 N⋅m (1.3 kgf⋅m/113 lbf⋅in)
Oil Filter Cartridge

Components
N6A6298E
Legend
1. Oil Filter Cartridge
Removal • Tighten the cartridge using the specified torque.

1. Place a tray under the oil filter cartridge. Tighten:
2. Remove the oil filter cartridge using the oil filter Cartridge to 64 N⋅m (6.5 kgf⋅m/47 lbf⋅ft)
wrench. Or after it comes in contact with the oil seal, tighten it
through an additional turn of 1 and 1/4.
Special tool
Oil filter wrench: 1-8522-1097-0 (EN-47683) Special tool
Oil filter wrench: 1-8522-1097-0 (EN-47683)
Caution:
Be careful not to pinch the rotary sensor harness while
installing / removing the cartridge.
N6A6299E
Installation
1. Install the oil filter cartridge.
• Apply grease or engine oil to the seal in the
cartridge and install it using the oil filter wrench.
Special Tool
Tool Number /
Illustration
1-8522-1097-0
(EN-47683)
Oil Filter Wrench
Oil Cooler
Components
N6B6056E
Legend
1. Bypass Hose 5. Fuel Supply Pump
2. EGR Cooler Water Return Pipe 6. EGR Cooler Water Feed Pipe
3. Oil Cooler 7. Suction Pipe
4. Fuel Rail
Removal
2. Remove the fuel supply pump.
3. Remove the vacuum pump.
4. Remove the A/C drive belt.
5. Remove the idling pulley bracket.
• Remove the drive belt for A/C and the bracket
fixing bolts, and then remove the bracket along
with tensioner and idling pulley.
N6A6301E
6. Remove the EGR cooler water return pipe.

• Remove the brackets to the water pipe at three Disassembly
locations to make the pipe unsupported.
1. Remove the element mounting bolts.
7. Remove the EGR cooler water feed pipe.
2. Remove the element.
8. Remove the clip on the head side of the water
3. Remove the O-ring.
bypass hose and remove the hose from the
suction pipe and assembly.
N6A6304E
N6B6057E Legend
1. Element
Legend
2. O-ring
1. Bypass Hose
2. EGR Cooler Water Return Pipe
3. EGR Cooler Water Feed Pipe
4. Suction Pipe Reassembly
1. Install the O-ring on the oil cooler case.
9. Remove the oil cooler assembly.
2. Install the element.
• Screw the removed fixing bolt of the oil cooler
into the replacer hole at the location 1 of the 3. Tighten the element fixing bolts using the specified
figure and remove the oil cooler. torque.
Tighten:
N6A6303E
Legend
1. Oil Cooler Assembly N6A6304E
10. Remove the O-ring. Legend

1. Element
2. O-ring
Installation • Liquid gasket quickly hardens.
Make it complete within 7 minutes after
1. Install the oil cooler assembly.
applying the liquid gasket.
• Apply liquid gasket (ThreeBond1207C or
equivalent) to the flange surface groove
(cylinder block). Bead diameter must be
between 2 and 4 mm (0.08 and 0.16 in).
Refer to the illustration for the offset position
(no more than 1 mm (0.04 in)).
• Install the O-rings (1) and (2) to the oil passage
inlet and outlet. Do not allow the liquid gasket to
contact the O-ring.
N6A6306E
Legend
1. Oil Cooler Assembly
2. Install the water suction pipe.

• Apply liquid gasket (ThreeBond 1207C) to the
flange of the water suction pipe. Bead diameter
must be between 2 and 5 mm (0.008 and 0.20
in). Refer to the illustration for the offset
N6A6305E
position (no more than 1 mm (0.04 in)).
Legend
• Install the water suction pipe to the oil cooler.
1. O-ring
Refer to the illustration.
2. O-ring
3. Liquid Gasket • Tighten the bolts to the specified torque.
Tighten:
- Align the oil cooler holes with the cylinder Bolts to 24 N⋅m (2.4 kgf⋅m/18 lbf⋅ft)
block studs.
- Install the oil cooler and glow plug controller
bracket to the cylinder block.
- Tighten the bolts to the specified torque in
the order shown in the illustration.
Tighten:
N6A6307E
Legend
1. Liquid Gasket
Caution: 6. Install the idling pulley bracket and tighten it using
The water suction pipe must be installed immediately the specified torque.
after the oil cooler (the pipe and cooler use the same
Tighten:
liquid gasket).
Idling pulley bracket to 24 N⋅m (2.4 kgf⋅m/18 lbf⋅ft)
7. Install the A/C drive belt.
Refer to “Drive Belt” in Section 6B.
N6A6308E
3. Install the EGR cooler water feed pipe.

N6B6125E
• Install the O-ring on the EGR cooler water feed
pipe. 8. Remove the oil drain adapter.
• Install at the position shown in the figure and 9. Install the vacuum pump.
tighten using the specified torque. Refer to “Timing Gear Train”.
Tighten: 10. Install the fuel supply pump.
Bolts to 24 N⋅m (2.4 kgf⋅m/18 lbf⋅ft) • Refer to “Fuel Supply Pump” in Section 6C.
• Refer to “Fuel Rail” in Section 6C.
N6A6308E
4. Install the EGR cooler water return pipe.

Tighten:
5. Install the body cover assembly LH on the surface
of the oil cooler and cylinder block and tighten it
using the specified torque.
Tighten:
Body cover assembly LH to 13 N⋅m (1.3 kgf⋅m/10 lbf⋅ft)
Oil Pan
Components
N6B6058E
Legend
1. Oil Pan Gasket 3. Oil Pan Rubber
2. Oil Pan
Removal Installation
1. Drain out the engine oil. 1. Install the oil pan.
• After draining oil, tighten the drain plug to the • At the seam between the cylinder block and the
specified torque. front cover with the flywheel housing, apply the
liquid gasket (ThreeBond 1207C or equivalent)
Tighten:
to a bead diameter of 3 mm (0.12 in).
Drain plug to 83 N⋅m (8.5 kgf⋅m/61 lbf⋅ft)
Caution:
Do not forget tighten the drain plug.

• Apply the liquid gasket and install the oil pan • Tighten the locations (1), (2), (3), and (4) as
within 7 minutes. shown in the figure and then tighten others. (In
any sequence)
N6A6075E
N6A6077E
• Install the gasket using the studs of the
crankcase, flywheel housing, and front cover as
Tighten:
guide and mount the oil pan.
Nuts and bolts to 11 N⋅m (1.1 kgf⋅m/95 lbf⋅in)
Install the rubber assembly on the oil pan and
secure it using nuts and bolts. 2. Replenish the engine oil.
N6A6076E
Legend
1. Rubber Assembly
2. Oil Pan
3. Gasket
Oil Pump
Components
N6A6312E
Legend
1. Oil Pump Assembly 5. Driven Gear and Shaft
2. Spring 6. Oil Pump Body
3. Ball 7. Slinger
4. Split Pin
Removal 10. Remove the vacuum pump.

1. Drain out the engine oil.
2. Drain out the cooling water.
12. Remove the rear oil seal of the crankshaft.
14. Remove the power steering pump.
Refer to “Camshaft Assembly”. 15. Remove the idle gear cover of the power steering
pump.
7. Remove the clutch pressure plate assembly.
8. Remove the driven plate.
9. Remove the fuel supply pump assembly.
16. Remove the idle gear of the power steering pump. 18. Remove the idle gear A.
N6A6058E N6A6313E
17. Remove the flywheel housing. 19. Remove the oil pump assembly.
• Make sure you remove the bolts shown in the
figure.
N6A6314E
N6A6059E
Disassembly
1. Remove the driven gear and shaft.
2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Reassembly
1. Install the ball.
2. Install the spring.
3. Install the split pin and fold it according to (1).
N6B6059E
N6A6315E
2. Measure the clearance between the gear side
4. Apply engine oil on the driven gear and shaft and surface and the upper surface of the oil pump
mount them on the oil pump body. body.
• Measure the clearance between the gear
surface and the upper surface of the oil pump
body using the thickness gauge and square.
• If the clearance between the gear and inner
wall of the body exceeds the limit, replace the
gear assembly or the driven gear assembly.
Clearance between the gear side surface

and the upper surface of the oil pump
body mm (in)
Standard 0.065 – 0.109 (0.0025 – 0.0043)
Limit 0.20 (0.0079)
N6A6316E
Inspection
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
• Measure the clearance between the gear and
oil pump body using a thickness gauge.
• If the clearance between the gear and inner
wall of the body exceeds the limit, replace the
gear assembly or the driven gear assembly.
Clearance between the gear and inner

wall of the body mm (in)
N6A6318E
Standard 0.125 – 0.221 (0.0049 – 0.0087)
3. Measure the clearance between the driven gear
Limit 0.30 (0.0118) shaft and the bush.
• Measure the outside diameter of the driven
gear shaft using a micrometer.
Installation
Outside diameter of the driven gear shaft mm (in) 1. Install the oil pump assembly.
Standard 15.989 – 16.000 (0.62949 – 0.62992) • Apply the liquid gasket (ThreeBond 1141E or
equivalent) as shown in the figure, mount it on
Limit 15.900 (0.62598) the cylinder block within one hour, and tighten it
Tighten:
Oil pump assembly to 31 N⋅m (3.2 kgf⋅m/23 lbf⋅ft)
Caution:
Apply the fluid gasket such that it does not enter the
holes shown by arrows in the figure, gear, and the oil
pump body.
N6A6319E
• Measure the inside diameter of the bushes of

the oil pump body and cylinder block using the
dial gauge.
• If the clearance between the driven gear shaft
and bush exceeds the limit, replace the driven
gear assembly.
N6A6321E
2. Install the idling gear A.

Clearance between the driven gear shaft
and bush mm (in) • Install the idling gear shaft at the position
shown in the figure and apply engine oil on the
Standard 0.04 – 0.07 (0.0016 – 0.0028) shaft.
Limit 0.20 (0.0079) • Rotate the crankshaft clockwise and bring the
piston of the No.1 cylinder to the top dead
center.
N6A6320E
N6A6067E
• Match the coincidence marks of the crankshaft
Tighten:
gear and the idle gear A, and install them on
the cylinder block.
• The seal is tightened from the cylinder block
side.
N6A6322E
• Tighten the mounting bolts using the specified

torque.
Tighten:
3. Install the flywheel housing.
• Clean properly the rear surface of the cylinder
block. Remove the protruding fluid gasket
thoroughly, especially, when mounting the
crankcase.
• Apply the liquid gasket (ThreeBond1207C)
uniformly on the inside surface of the bolt holes
(excluding the bolt holes indicated by arrows)
as shown in the figure.
• After applying the liquid gasket, quickly install it.
N6A6069E
• Match the dowel pin of the cylinder block and

then install the flywheel housing.
N6A6070E
4. Install the power steering pump idling gear.

• Apply the engine oil on the gear assembly unit
of the idling gear shaft.
• Assemble the idling gear and the shaft in the
direction shown in the figure, mount it on the
flywheel housing, and tighten it using the
specified torque.
Tighten:
N6A6071E
5. Install the idling gear cover of the power steering

pump.
• Install the O-ring on the cover and on the
flywheel housing, and tighten the fixing bolts
Tighten:
N6A6072E
With HBB
N6A6073E
6. Install the power steering pump and tighten it using N6A6074E
the specified torque. Legend

1. Flywheel Housing Bolt
Tighten:
2. Cylinder Block Bolt
Flywheel housing fixing bolt (1) to 48 N⋅m (4.9 kgf⋅m/35
lbf⋅ft)
Cylinder block fixing bolts (2) to 44 N⋅m (4.5 kgf⋅m/33 Refer to “Oil Pan”.
lbf⋅ft)
8. Install the rear seal of the crankshaft.
Without HBB Refer to “Crankshaft Rear Oil Seal”.
10. Install the vacuum pump.
11. Install the fuel supply pump assembly.
12. Install the clutch plate assembly.
13. Install the clutch pressure plate assembly.
• Insert the clutch aligner in the spline of the
clutch plate assembly.
• Install the clutch plate assembly on the
flywheel.
• Match the mounting hole of the clutch pressure
plate assembly with the dowel pin of the
flywheel, and install the clutch pressure plate
N6A0775E assembly on the flywheel.
N6A6218E
Legend
1. Clutch Aligner
• Tighten the clutch pressure plate assembly in

the sequence shown in the figure using the
specified torque.
Tighten:
N6A6217E
14. Install the cylinder head assembly.

17. Tighten the cylinder head cover.
18. Replenish the cooling water.
19. Replenish the engine oil.
Oil Pressure Switch

Inspection
Check the continuity between the switch terminal and
the body grounding in the no-load condition.
If there is no connectivity, replace with normal parts.
(Refer to “Oil Filter Assembly”)
N6A6323E
Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and
confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the
circuit between the meter and the oil pressure
switch, and repair the disconnected locations.
N6A6324E
Air Cleaner Element

Removal
1. Remove the air cleaner cover fixing bolt.
2. Remove the air cleaner element assembly.
Inspection
• Check for damage to the element or clogging due
to dirt. If the element is damaged, then replace it. If
clogged, then clean it.
• The viscous-type (wet type) element cannot be
cleaned; therefore, it has to be replaced if it is very
dirty.
Replacement period Every 40,000 km (24,000

miles) or every two years
Installation
1. Install the air cleaner element assembly.
2. Tighten the air cleaner cover fixing bolt.
Cleaning
Dry type element
• While rotating the element, blow air under 690 kPa
(7.0 kg/cm2 / 100 psi) and remove the dust.
N6A6325E
• Dissolve neutral detergent in water and soak the

element for approximately 30 minutes. Then wash
it properly with water and allow it to dry in natural
conditions (two to three days.)
Notice:
It advises on not using wet type element by any means
in order to give a damage to a sensor strongly.
Cooling System 6B-1
ENGINE
Cooling System
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6B-2
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
A List of Defective Phenomena . . . . . . . . . . . . . 6B-7
Main Data and Specifications. . . . . . . . . . . . . . . 6B-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6B-12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14
Engine Coolant Temperature Sensor . . . . . . . . . 6B-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-17
Radiator and Intercooler . . . . . . . . . . . . . . . . . . . 6B-18
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-20
Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-22
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-22
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-22
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-23
6B-2 Cooling System
Cooling System
Service Precautions Explanations on Functions and Operation

WARNING: Cooling Water System
Do not remove the radiator cap when the cooling water The cooling water system, which is the forced
is at high temperature. Steam or boiling water will gush circulation system, consists of a water pump,
out and you may be burnt. To open the radiator cap, thermostat, and radiator as its main components.
cover the cap with a thick cloth when the cooling water
is cool, release the pressure by slowly turning the cap,
and then remove the cap.
10
11
12
9 15
8
13
16
14
7
1
3
2
5
N6B6060E
Legend
1. Water Jacket 9. Reserve Tank
2. Oil Cooler 10. Air Bleeding Plug
3. Water Pump 11. Water Outlet Pipe
4. Heater Core 12. Thermostat (2 nos.)
5. Drain Cock 13. Thermometer Unit
6. Radiator 14. Bypass Route
7. Cooling Fan 15. Turbo Charger
8. Radiator Cap 16. EGR Cooler
Cooling System 6B-3
Water Pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.
N6B6126E
Legend
1. Fan Center 4. Seal Unit
2. Fan Pulley 5. Impeller
3. Bearing 6. Groove
6B-4 Cooling System
Thermostat
The thermostat is a wax pellet type and consists of two
units, in which one unit (bottom bypass type) has an
valve initial opening temperature of 82 °C (180 °F) and
the second (inline type) has an valve initial opening
temperature of 85 °C (185 °F). It is designed such that
the water temperature can be adjusted finely and it is
mounted within the thermostat-housing unit.
N6A6328E
Legend
1. Jiggle Valve 4. Gasket
2. Stamp Mark (Valve Initial Opening Temperature) 5. Piston
3. Valve
Cooling System 6B-5
Radiator
The radiator is a tube with corrugated fins. To increase
the boiling point of the cooling water, a radiator cap of
injection valve opening pressure of 108 ± 14.7 kPa (1.1
± 0.15 kg/cm2 / 15.7 ± 2.1 psi) is attached.
N6A6330E
Legend
1. Reserve Tank
2. MAX Line (Upper Limit)
3. MIN Line (Lower Limit)
N6A6329E
Inspection
Functional Check Cooling water leak check
1. Cooling water level check • Use the radiator cap tester and apply a pressure of
• Check the cooling water level within the reserve 196 kPa (2.0 kg/cm2 / 28.4 psi) and check for leaks
tank and the level is appropriate when the in the locations given below. Check that the
cooling water level is within the MAX (upper radiator hose and heater hose are not damaged or
limit) and MIN (lower limit) range. In case the degraded and the hose clamp is not loose.
volume of the cooling water is deficient, remove
the reserve tank cap and replenish with a Inspection locations
mixture of tap water and engine coolant in the • Radiator assembly, water pump assembly, radiator
ratio of 1:1 until the level comes close to the hose, and heater hose.
MAX line.
Standard value
Cooling water level 18 liters (4.76 US gal. / 3.96
Imp gal.)
(between MIN and MAX level)
Replacement period Every two years or 40,000
kilometers (24,000 miles)
N6A6331E
Coolant
1. About the engine coolant concentration
6B-6 Cooling System
• Take the concentration corresponding to the • Use a deep container to suit the height of the
minimum temperature because the freezing specific gravity meter.
temperature varies according to the
concentration 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 to
occur if the ratio is greater than 60% and
corrosion prevention is inadequate if the ratio is
less than 30%.
N6A6333E
Legend
1. Anti-Freeze Specific Gravity Meter
2. Radiator
• Fix the temperature of the cooling water being

measured in the range of 0 to 50 °C (32 to
122 °F).
N6A6332E • Measure the temperature and specific gravity
and determine the concentration from the table
given below.
Mix ratio
Freezing Liter (qts) Concentration
temperature of engine
guideline Engine coolant
Tap water
coolant
-18°C(-0.4°F) 6.3 (6.7) 11.7 (12.4) 35%
-25°C (-13°F) 7.6 (8.0) 10.4 (11.0) 42%
-35°C (-31°F) 9.0 (9.5) 9.0 (9.5) 50%
-40°C (-40°F) 9.5 (10.0) 8.5 (9.0) 53%
2. Engine coolant density measurement

Methods for measuring specific gravity
• Measure the specific gravity and the
temperature of the cooling water using an anti-
freeze specific gravity meter and thermometer.
Take precautionary measures as the boiled

cooling water may gush out at high
temperatures if the cap is removed.
N6A6334E
Cooling System 6B-7
Coolant scooping method
• Measure the concentration using the coolant
scoop.
A List of Defective Phenomena
• Engine overheats
• Engine overcools
Engine overheats

Engine overheats. Low coolant level Add.
Engine oil shortage or use of Add or change engine oil.
improper oil
Loose fan belt Adjust or replace fan belt.
Too much fuel injection quantity. Diagnose the engine control
system.
Defective radiator cap Replace.
Clogging of radiator Clean or replace.
Clogging of exhaust system Clean or replace.
Defective thermostat Replace.
Defective water pump Replace.
Defective cylinder head gasket Replace.
Engine overcools

Engine overcools Thermostat is defective. Replace.

Cooling methods Forced circulation system

Radiator Tubes with corrugated fins
Radiation capacity kW (kcal/h) 127 (109200)
Radiation area m2 (ft2) 18.15 (195.4)
Frontal area m2 (ft2) 0.365 (3.93)
Dry mass N (lb) 177 (39.7)
Radiator cap
Valve opening pressure kPa (kg/cm2 / psi) 108 ± 14.7 (1.1 ± 0.15 / 15.7 ± 2.1)
Cooling water capacity Liters (US / Imp gal.) 3.2 (0.85 / 0.70)
Water pump Centrifugal impeller system
Pulley ratio 1.190
Thermostat Wax pellet system
Valve opening temperature °C (°F) With jiggle valve 85 (185)
Without jiggle valve 82 (180)
Temperature when fully open °C (°F) With jiggle valve 100 (212)
Without jiggle valve 95 (203)
Cooling water total capacity Liters (US / Imp gal.) 18 (4.76 / 3.96)
6B-8 Cooling System
Water Pump
Components
N6B6061E
Legend
1. Radiator Lower Hose 5. Setting Plate
2. Fan Guide 6. Water Pump Pulley
3. Fan 7. Fan Belt
4. Cooling Fan Clutch 8. Water Pump Assembly
Cooling System 6B-9
Removal 4. Remove the four mounting nuts and then the fan
assembly. Also, loosen the four bolts for tightening
1. Drain the coolant water.
the setting plate and water pump pulley together.
1 4
5
1
3
N6B6062E
N6B6128E
Legend
Legend
1. Radiator Drain Cock
1. Fan
2. Nut
3. Setting Plate
4. Water Pump Pulley
5. Bolt
5. (2) and (3) that tighten the setting plate and water
pump together. Loosen the adjusting bolts (1) in
the generator and remove the fan belt.
N6A6337E
Legend
1. Power Steering Pump
2. Drain Plug
2. Remove the radiator lower hose on the radiator

side.
3. Take out the fan guide from below. N6B6050E
Legend
1. Adjusting Bolt (With A/C)
2. Lock Nut
3. Bolt
6. Remove the setting plate and water pump pulley.

6B-10 Cooling System
7. Remove the water pump assembly while inserting • If you find abnormalities, replace with the water
and scraping with the driver at the position shown pump assembly.
in the figure.
3
N6A6342E
N6B6127E
Legend
1. Water Pump Installation
2. Water Pump Pulley 1. Mount the water pump assembly.
3. Setting Plate • Coat the fluid gasket (ThreeBond 1207C or
equivalent) to a bead diameter 3 to 5 mm (0.12
to 0.20 in) in the groove of the mounting surface
Inspection of the water pump.
1. External check • Mount the water pump to match with the studs
of the front cover within 7 minutes after coating
• Check for cracks or damage in the pump body. the fluid gasket.
• Check for cracks and corrosion in the impeller. • Refer to the figure for the offset in position of
• Check for water leakage from the seal unit. the fluid gasket.
• If you find abnormalities, replace with the water
Tighten:
pump assembly.
Bolts and nuts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
N6A6341E
N6A6343E
2. Bearing unit check
• Rotate the fan center while pushing it along the
radial direction. Confirm that there is no
abnormal noise and no excessive play.
Cooling System 6B-11
2. Temporarily fit the bolts until the water pump pulley 5. After the fan belt adjustments, tighten the
and the setting plate are properly seated in the temporarily fitted fan pulley and setting plate using
water pump assembly. the specified torque.
Tighten:
Bolt to 24 N⋅m (2.4 kgf⋅m / 17 lbf⋅ft)
6. Tighten the fan assembly using the specified
torque for mounting.
Tighten:
Nut to 24 N⋅m (2.4 kgf⋅m / 17 lbf⋅ft)
1 4
N6B6066E
Legend
1. Fan Pulley
2. Setting Plate
5
3. Mount the fan belt, tighten the adjusting bolts of

the generator, and adjust the tension. 3
• Refer to “Drive Belt” in Section 6B.
N6B6128E
4. After fan belt adjustments, tighten the generator
Legend
1. Fan Assembly
Tighten: 2. Nut
Nut and bolt to 2 members: 24 N⋅m (2.4 kgf⋅m / 17 lbf⋅ft) 3. Setting Plate
Nut and bolt to 3 members: 40 N⋅m (4.1 kgf⋅m / 30 lbf⋅ft) 4. Fan Pulley
5. Bolt
7. Mount the fan guide.

8. Mount the radiator lower hose.
9. Fill the cooling water.
N6B6050E
Legend
1. Adjusting Bolt (With A/C)
2. Lock Nut
3. Bolt
N6B6065E
Thermostat
Components
N6B6067E
Legend
1. Radiator Upper Hose 3. Thermostat
2. Water Outlet Pipe 4. Gasket
Removal • Measure the temperature when the valve is just

opened and when it is fully open.
1. Drain the cooling water. Prepare the container for
discharging and use it for replenishment when
mounting the thermostat. Set the discharge of
cooling water such that the water does not flow out
of the thermostat housing.
2. Remove the radiator upper hose from the radiator
side.
3. Remove the water outlet pipe.
4. Remove the thermostat.
5. Remove the gasket from the thermostat.
Inspection
• Place the thermostat in water and increase the
temperature while stirring it sufficiently.
N6A6347E
Installation 4. Replenish the cooling water stored during the
discharge, and check the volume of the cooling
1. Mount the gasket on the thermostat and mount it at
water.
the position shown in the figure.
• Mount the thermostat at the position shown in
the figure, as there are two types of thermostats
with different shapes.
• Fit the thermostat gasket ensuring that it does
not come out of and on top of the external
housing on the cylinder head side.
N6A6330E
Legend
1. Reserve Tank
N6A6348E
Legend
1. Thermostat
2. Cylinder Head
2. Mount the water outlet pipe.
Tighten:
Bolt to 24 N⋅m (2.4 kgf⋅m / 17 lbf⋅ft)
3. Mount the radiator upper hose.
N6A6349E
N6B6288E
Engine Coolant Temperature Sensor
Removal
1. Disconnect the wire connector.
2. Remove the engine coolant temperature sensor.
Inspection
This thermo-sensor works for the ECM and the
thermometer unit. It is thermistor type which has
characteristic that electrical resistance decreases
according to increase in temperature.
1 3
Example: Method for measuring thermistor characteristic for ECM

N6B6249E
Caution:
4 2 Take care not to allow water to get into the terminal.
1 3 2
Also wipe off the water splash on the sensor after
inspection.
Resistance value relative to temperature (approximate
value):
Terminal No. Resistance Remarks
5
Approx. 2.55(kΩ) 20°C
1←→3 (For ECM)
N6B6129E
Approx. 0.33(kΩ) 80°C
Legend 2←→Body (for meter) 142.6 to173.1(Ω) 60°C
1. This indicates wire connection.
2. This indicates wire connection.
3. This indicates wire connection. Thermistor characteristic
30
4. Thermistor for ECM
5. Thermistor for thermometer 20
10
1. Immerse the thermo-sensor into water, and check
Resistance value
7.0
if the resistance value matches with a value in the 5.0
graph of thermistor characteristic while changing 3.0
the water temperature. 2.0
1.0
0.7
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100 120
Engine coolant temperature
N6B6130E
• If the result of the inspection is unsatisfactory,

replace with a new part.
Installation
1. Apply Loctite 262 or 962 to the threads (2) of the
engine coolant temperature sensor, and tighten to
Tighten:
25 N⋅m (2.5 kgf⋅m/18 lbf⋅ft)
N6B6131E
Legend
1. Engine coolant temperature sensor
2. Loctite applied area
2. Install the wiring connector.

Radiator and Intercooler

Components
N6B6068E
Legend
1. Coolant Reserve Tank Hose 4. Fan Guide
2. Radiator Upper Hose 5. Radiator Lower Hose
3. Radiator and Intercooler
Removal
1. Loosen the water drain plug (on the rear of right
side) and radiator drain plug, and discharge the
cooling water completely.
• After discharging the water, tighten the drain 9. Take care to avoid damage to the radiator core
cock. from the fan blade, and remove the brackets on
the right and left sides of the radiator.
Simultaneously remove the radiator and inter-
cooler.
N6B6062E
Legend
1. Radiator Drain Cock
N6A6351E
Inspection
Radiator cap
1. Check the valve opening pressure using the
radiator cap tester. If the valve opening pressure
deviates from the standard value, replace the
radiator cap.
Valve opening pressure =
108 ± 14.7 kPa (1.1 ± 0.15 kg/cm2 / 15.7 ± 2.1 psi)
N6A6337E
Legend
1. Power Steering Pump
2. Drain Plug
2. Remove the intake pipe from the intake manifold

and inter-cooler (right side).
3. Remove the intake pipe from the turbo charger and
inter-cooler (left side).
4. Remove the 2 transmission oil pipes on the
underside of the radiator. N6A6352E
5. Remove the upper hose on the radiator side. 2. Check the state of the negative pressure valve
6. Remove the lower hose on the radiator side. situated at the center on the valve seat side of the
cap. If the valve seat does not function smoothly
7. Remove the coolant reserve tank hose from the
due to rust or dirt, clean or replace the radiator
radiator side.
cap.
8. Remove the fan guide from the lower side.
Radiator core 8. Install the intake pipe from the intake manifold and
1. If the radiator fin is deformed, the radiation effect inter-cooler (right side).
deteriorates causing overheating. Therefore, 9. Fill the cooling water.
modify the fin. Make sure that the root base of the Cooling water injection procedure (in case of changing
fin is not damaged during modification. the cooling water completely)
• Eliminate dust or other foreign matter. • Confirm that the engine has cooled.
• Open the radiator cap and the reserve tank cap.
Washing the radiator • Loosen the air bleeding bolt on the engine outlet.
1. Wash the internal parts of the radiator and cooling • Pour the cooling water up to the filler neck.
water passage using water. Eliminate scale and
• After filling the system to the full, push the radiator
rust completely.
upper hose two or three times. In doing so, if air in
the hose comes out and the coolant level goes
Installation down, add the coolant to the original level.
1. Ensure that no damage occurs to the radiator core • Pour the cooling water up to the “MAX” line in the
reserve tank.
because of the fan blade. Mount the brackets on
the left and right sides of the radiator on the frame • Bleeding air from the EGR cooler.
according to the figure. - Disconnect the out side hose (located at the top
of the EGR on the head cover) of the EGR
Tighten: cooler (2nd) to let air come out. Then,
Bolts to 26 N⋅m (2.6 kgf⋅m / 19 lbf⋅ft)
reconnect the hose back to the original position.
- In doing so, if air in the EGR comes out and the
coolant level goes down, add the coolant to the
original level.
N6A6247E
Legend
1. Flange Nut
2. Rubber N6B6294E
3. Stud Bolt • Tighten the air bleeding bolt on the engine outlet
4. Frame securely.
5. Bracket on The Radiator Side
6. Washer • Close the radiator cap and the reserve tank cap
and start the engine. Stop the engine after running
2. Install the fan guide. for about 2 to 3 minutes at the idling rpm. Open the
radiator cap again and replenish if the water level
3. Mount the reserve tank hose of the coolant on the
is low.
radiator.
4. Mount the radiator lower hose.
5. Mount the radiator upper hose.
6. Install the 2 transmission oil pipes on the
underside of the radiator.
7. Install the intake pipe from the turbocharger and
inter-cooler (left side).
WARNING: • Pour the cooling water up to the “MAX” line in the
DO NOT LOOSEN OR REMOVE THE RADIATOR reserve tank again.
CAP WHEN THE TEMPERATURE OF THE COOLING
WATER IS HIGH. STEAM OR BOILING WATER WILL
GUSH OUT AND YOU MAY BE BURNT. TO OPEN
THE RADIATOR CAP, COVER THE CAP WITH A
THICK CLOTH WHEN THE COOLING WATER IS
COOL, RELEASE THE PRESSURE BY SLOWLY
TURNING THE CAP, AND THEN REMOVE THE CAP.
• After tightening the radiator cap, warm up the

engine by running it at about 1600 rpm.
• When the pointer of the thermometer crosses the
median and the thermostat has activated, run at
idling rpm for another 5 minutes, then stop the
engine and leave it as-is.
• After the engine has cooled down sufficiently,
check the water level in the filler neck part and
replenish if necessary. If the level is extremely low,
check for leaks in the cooling water conduit system N6A6330E
and reserve tank hose. Legend
1. Reserve Tank
N6B6132E
Drive Belt
Components
6 9
10
11
8
12
13
5
2 9 3
2 9
N6B6241E
Legend
1. Crank Pulley 8. Adjusting Plate
2. Generator Drive Belt 9. A/C Compressor Drive Belt
3. Bolt 10. Water Pump Pulley
4. Generator 11. Lock Nut
5. Adjusting Bolt 12. Tension Pulley
6. A/C Compressor 13. Adjusting Bolt
7. Lock Nut
Inspection Deflection of generator drive belt

Check for the presence of wear or damage in the drive For 50 A
belt and renew the parts if necessary. When the belt is new
Check the tension of the belt and adjust if necessary. 5 to 6 mm (0.197 to 0.236 in)
When the belt is reused
Deflection Standard 7 to 8 mm (0.276 to 0.315 in)
Apply a pressure of 98 N (22 lb) at the center of the For 80 A
long span of each belt and check the deflection of the When the belt is new
belt. 6 to 7 mm (0.236 to 0.276 in)
7 to 9 mm (0.276 to 0.354 in)
Deflection of A/C compressor drive belt
When the belt is new
19 to 24 mm (0.748 to 0.945 in)
When the belt is reused
24 to 28 mm (0.945 to 1.102 in)
Without A/C
FOR 50 A Fan belt tension is adjusted by moving the generator.
1
Tighten:
Nuts and bolts to 6 members: 24 N⋅m (2.4 kgf⋅m / 17
2 lbf⋅ft)
Nuts and bolts to 2 members: 40 N⋅m (4.1 kgf⋅m / 30
lbf⋅ft)
• Finally, adjust the tension of A/C compressor
drive belt.
Caution:
You must adjust the tension of A/C compressor drive
belt after adjusting generator belt.
FOR 80 A a. Rotate the tension pulley adjusting bolt of the

tension pulley and adjust the belt (remove and
1
fit).
b. After adjustments, tighten the tension pulley
2
lock nut using the specified torque.
Tighten:
Lock nut to 27 N⋅m (2.8 kgf⋅m / 20 lbf⋅ft)
Caution:
When replacing the belt, be sure to replace two belts
together.
N6B6260E
Legend
1. A/C Compressor Drive Belt 5 12
2. Generator Drive Belt 7
8
9
10
Adjustment 4
Adjust simultaneously the generator drive belt and A/C 6

compressor drive belt for adjustment of belt.
3
For 50 A
2
With A/C
1. Loosen the tension pulley lock nut and tension 11
pulley adjusting bolt of the tension pulley of the
A/C compressor drive belt and bring the belt to 1
free state.
N6B6258E
2. Loosen the adjusting plate lock nuts and the
mounting bolts of generator on the underside of Legend
the generator. 1. Crank Pulley
3. Rotate the adjusting bolts of generator and adjust 2. Bolt
the belt (remove and fit). 3. Generator
4. Adjusting Bolt
• When replacing the belt, you must always 5. A/C Compressor
replace both the belts. 6. Lock Nut
4. After adjustments, tighten the adjusting plate lock 7. Water Pump Pulley
nuts and the mounting bolts of generator on the 8. Lock Nut
underside of the generator using the specified 9. Tension Pulley
torque. 10. Adjusting Bolt
11. Generator Drive Belt
12. A/C Compressor Drive Belt
For 80 A Without A/C
With A/C Fan belt tension is adjusted by rotate the tension pulley
1. Loosen the tension pulley lock nut and tension adjusting bolt of the tension pulley.
pulley adjusting bolt of the tension pulley of the Tighten:
A/C compressor drive belt and bring the belt to Lock nut to 41 N⋅m (4.2 kgf⋅m / 30 lbf⋅ft)
free state.
2. Loosen the tension pulley lock nut and tension Caution:
pulley bolt of tension pulley of the generator drive You must adjust the tension of A/C compressor drive
belt and bring the belt to free state. belt after adjusting generator belt.
3. Rotate the tension pulley adjusting bolt of the a. Rotate the tension pulley adjusting bolt of the
tension pulley and adjust the belt (remove and fit). tension pulley and adjust the belt (remove and
• When replacing the belt, you must always fit).
replace both the belts. b. After adjustments, tighten the tension pulley
4. After adjustment, tighten the tension pulley lock lock nut using the specified torque.
nut using the specified torque.
Tighten:
Lock nut to 27 N⋅m (2.8 kgf⋅m / 20 lbf⋅ft)
Caution:
When replacing the belt, be sure to replace two belts
together.
5 12
7
8
9
11 10
6 4
2
14
13
N6B6295E
Legend
1. Crank Pulley
2. Bolt
3. Generator
4. Adjusting Bolt
5. A/C Compressor
6. Lock Nut
7. Water Pump Pulley
8. Lock Nut
9. Tension Pulley
10. Adjusting Bolt
11. Generator Drive Belt
12. A/C Compressor Drive Belt
13. Lock Nut
14. Tension Pulley
For 50 A
24 (2.4 / 17)
24 (2.4 / 17)
27 (2.8 / 20)
40 (4.1 / 30)
N6B6259E
For 80 A
24 (2.4 / 17)
24 (2.4 / 17)
40 (4.1 / 30)
50 (5.1 / 37) 27 (2.8 / 20)
41 (4.2 / 30)
N6B6261E
Fuel System 6C-1
ENGINE
Fuel System
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . .6C-2
A List of Defective Phenomena . . . . . . . . . . . . .6C-7
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-7
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . .6C-8
Fuel System Check . . . . . . . . . . . . . . . . . . . . . .6C-9
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-14
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .6C-15
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . .6C-16
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . .6C-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-25
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-25
Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .6C-26
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-27
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-32
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-32
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-34
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35
Fuel Sedimenter Switch . . . . . . . . . . . . . . . . . . .6C-38
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-40
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . .6C-41
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-41
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-42
Tightening Torque Specifications . . . . . . . . . . .6C-42
6C-2 Fuel System
Fuel System
Service Precautions Do not use water removal agent in the fuel tank. It
helps light oil to absorbs moisture that may cause rust.
Parts of the fuel system such as the internal part of the
If water removal agent is used in the fuel then it will
fuel injector, holes and clearances that form passages
absorb moisture in the light oil and may cause rust.
for fuel are finished to a very high degree of accuracy.
Therefore, do not use water removal agent in the fuel
They are therefore highly sensitive to foreign matter
tank.
and the entry of foreign matter could cause damage to
the fuel passage. Therefore, effective measures should
Work Procedure
be taken to prevent the entry of foreign matter.
Holes and clearances in the fuel system which serve as • The fuel opening must be quickly sealed when
a passage of fuel, including the inside of injector, are removing the fuel pipe, injection pipe, fuel injector,
finished extremely precisely. For this reason, they are fuel supply pump, and fuel rail.
highly sensitive to foreign matter. If it gets inside, it can • The eyebolts and gasket must be stored in a clean
lead to breakdown on the road. Be sure to prevent it parts box with a lid to prevent adhesion of foreign
from getting inside. matter.
Injector ID code plate is unique to each injector. Do not • Fuel leakage could cause fires. Therefore, after
mix with other injector ID code plates. finishing the work, wipe off the fuel that has leaked
If the injector ASM has been replaced, write the ID out and make sure there is no fuel leakage after
code in the ECU using a scan tool. Refer to “Engine starting the engine.
Control” chapter for how to write an injector ID.
Fuel System Diagram
8
5
N6A6661E
Fuel System 6C-3
Legend
1. Fuel Rail 7. Ventilation Hose
2. Leak-off Pipe 8. Fuel Filler Cap
3. Fuel Injector 9. Fuel Level Sensor
4. Fuel Return Pipe 10. Fuel Filter With Sedimenter
5. Fuel Feed Pipe 11. Fuel Supply Pump
6. Fuel Tank
Caution:
• Do not let foreign matter such as sand or dust get
into fuel.
• Use gas oil for fuel, not others.
Fuel Rail
2
1
N6B6133E
Legend
1. Pressure Limiter 2. Pressure Sensor
6C-4 Fuel System
Fuel Supply Pump
N6A6359E
Legend
1. Fuel Temperature Sensor 4. Camshaft Key
2. Fuel Rail Pressure Regulator 5. Camshaft Nut
3. High Pressure Piping
Fuel System 6C-5
Fuel Injector Fuel Filter
2 3
N6B6070E
Legend
1. Cartridge
2. Sensor
3. Drain Plug
Functional check
Air bleeding
N6A6360E
Legend
1. Terminal Stud
2. Fuel Leak-off Port
3. O-ring
4. Fuel Inlet Port 2
5. Injector Parts Number Marking
6. Fuel Injector ID Plate
N6B6071E
Legend
1. Priming Pump
2. Air Bleed Plug
Bleeding of fuel system

If the fuel filter has been replaced, air has got into the
fuel system. This makes it hard to start the engine.
Bleed air from the fuel system by using the air bleed
plug on the side of the priming pump.
1. Before starting engine
6C-6 Fuel System
a. Loosen the air bleed plug on the side of the • Loosen the drain plug.
priming pump sufficiently, and attach a vinyl • Operate the priming pump several times to
hose to prevent fuel from splattering. discharge the water.
b. Operate the priming pump up and down 20 • Tighten the drain plug after discharging the water.
times or more until no fuel that contains air
• Operate the priming pump several times and
comes out from the air bleed plug on the side of
check for fuel leakage.
the priming pump. (The number of times is the
reference value.) • Check that the warning lamp in the meter is off.
Fuel system vacuum check

Use this procedure to measure the vacuum (negative
pressure) discharge side the fuel system.
Important:
Vinyl hose
The fuel pressure/vacuum gauge assembly (gauge (1))
and the fuel pressure/vacuum gauge adapter (adapter
(5)) must be cleaned before connect to the fuel line.
Air bleed plug Otherwise, foreign material adherent to the tools may
damage the fuel supply pump.
1. Disconnect the fuel hose from the fuel filter

housing. (fuel supply pump side).
2. Install the adapter.
Special tool
N6B6209E
Fuel Pressure/Vacuum Gauge Set:
5-8840-2844-0
c. Tighten the plug securely, and wipe off fuel (Fuel pressure/vacuum gauge adapter:
around the plug completely. EN-47667)
d. Operate the priming pump up and down 3. Connect the gauge (1) with hose to the adapter
another 10 times or more to feed air from the (5).
fuel system to the fuel injection pump.
e. Turn the starter to start the engine. Special tool
2. After starting engine Fuel Pressure/Vacuum Gauge Set:
5-8840-2844-0
a. Without depressing the accelerator pedal, turn
(Fuel pressure/vacuum gauge assembly:
the starter to start the engine.
J-44638)
b. After the engine start-up, keep idling for five
4. Loosen the air bleeding plug on the supply pump.
seconds.
5. Use your hand to operate the fuel filter priming
c. Slowly turn the idling control knob fully
pump. Operate the pump until all the air has been
clockwise, and hold it for three minutes.
bled from the system.
d. Fully depress the accelerator pedal to rev up to
6. Start the engine and allow it to idle.
the maximum speed. (Repeat this operation
several times.) 7. Note the gauge (1) reading. If the reading is
normal, go to Step 8. If the fuel vacuum is greater
e. Turn the idling control knob counterclockwise to
than the specified value, there is a problem in the
return to the idle speed.
fuel system. Perform the procedures outlined
Caution: below.
• Insufficient air bleeding may cause engine Standard fuel vacuum: Less than 5 inHg
malfunction. Be sure to perform this procedure after
starting the engine. • Replace the cartridge fuel filter element.
• It is strongly advisable to use an Isuzu genuine fuel • Check the fuel delivery pipe. If it is clogged, it
filter assembly for replacement. must be replaced.
• Remove the fuel pipe at the fuel filter inlet. Use
Water drain high-pressure air forced through the fuel pipe to
A warning lamp will light up if water is collected more clean the fuel system.
than fixed quantity in the sedimenter. If the warning
lights up, drain out the water by following operations:
• Fit a tray below the fuel filter.
Fuel System 6C-7
Caution: 11. Use your hand to operate the fuel filter priming
• Remove the fuel filler cap before applying high- pump. Operate the pump until all the air has been
pressure air. bled from the system.
• Do not perform this procedure if the fuel tank is 12. Start the engine and allow it to idle.
nearly full (fuel approaching or flowing into the fuel 13. Inspect the fuel system for fuel leakage.
filler neck). The forced air will spray fuel from the
fuel filler neck.
8. Remove the gauge (1) and hose from the adapter • Problems with starting
(5).
• Hunting during idling
9. Remove the adapter (5).
• Insufficient horsepower
10. Connect the fuel hose.
• Maximum engine speed is too low
• Engine does not stop
• Exhaust gas is blue or black.
Special Tool
Tool Number /
Illustration
5-8840-2844-0
Fuel Pressure / Vacuum
Gauge Set
(J-44638 [Fuel Pressure /
Vacuum Gauge
Assembly]
EN-47667 [Suction Side
5884028440 Fuel Pressure / Vacuum
Gauge Adapter])
6C-8 Fuel System
Trouble Shooting
Problems with starting

Starting trouble Empty fuel tank Fill the tank.
Clogged fuel tank breather Clean the fuel tank breather.
Air in fuel system Bleed air.
Fuel line is clogged or damaged. Repair or replace the fuel line.
Loose connection of fuel line Retighten the connection.
Clogged fuel filter element Replace the cartridge.
Feed pump malfunction Replace the supply pump.
Open regulating valve Replace the regulating valve.
Stuck injector nozzle Replace the injector.
system.
Unstable idling

Hunting during idling Air in fuel system Bleed air from the fuel system.
Leakage or clogging in fuel system Repair or replace the fuel system.
Water in fuel system Change fuel.
Reduction in pressure to open Replace the injector.
injector valve, or poor injecting
condition
Supply pump malfunction Replace the supply pump.
system.
Insufficient power

Output shortage Clogged fuel tank or breather Clean up the fuel tank or breather.
Air in fuel system Bleed air from the fuel system.
Leakage or clogging in fuel system Repair or replace the fuel system.
Water in fuel system Change fuel.
system.
Maximum engine speed is too low

Maximum engine speed is too low Fuel line is clogged or damaged. Repair or replace the fuel line.
system.
Fuel System 6C-9
Engine does not stop

Engine does not stop. Defective engine control system Diagnose the engine control
system.
Exhaust gas is blue or black

Exhaust smoke is blue or black. Reduction in pressure to open Replace the injector.
injector valve, or poor injecting
condition
system.
Fuel System Check • The battery is completely charged and terminals

are cleaned and tight.
Description
• The engine cranking speed is normal.
The common rail fuel system is comprised of two fuel
pressure sections: a suction side between the fuel tank • There is adequate fuel in the fuel tank.
and the fuel supply pump and a high-pressure side • There is no air in the fuel line.
between the fuel supply pump and the fuel injectors. • Fuse and slow blow fuse are normal.
Fuel is drawn from the fuel tank via a feed pump and
then pumped into the fuel rail by two plungers, all of Diagnostic Aids
which are internal to the fuel supply pump. This high
• The fuel system from the fuel tank(s) to the fuel
pressure is regulated by the ECM using the fuel rail
supply pump is under a slight vacuum with the
pressure (FRP) regulator dependant upon values from
engine running. As a result, air can enter the fuel
the FRP sensor attached to the fuel rail. In case of fuel
system if these connections are not tight. Air in the
rail overpressure, a pressure limiter valve threaded into
fuel system will cause fuel rail pressure
the fuel rail will open to release overpressure and
fluctuations especially at high engine speed and
return fuel back to the fuel tank.
load.
The Fuel System Check diagnostic table directs the
service technician to the appropriate fuel system • If the fuel tank is empty or near empty, air might be
diagnosis. The diagnostic table assumes the following allowed to go into the fuel system. With air in the
conditions are met: fuel system, smooth flow of fuel into the supply
pump is interrupted and this DTC may set. Perform
bleeding of fuel system after refilling.
Schematic Reference: Fuel System Routing Diagram
Circuit / System Testing Fuel System Check
Step Action Value(s) Yes No

1. Install a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Turn ON the ignition, with the engine OFF.
1 — Refer to
4. Monitor the DTC Information with a scan tool.
Applicable DTC
Does the scan tool display any DTCs that failed in Engine
this ignition? Control Section Go to Step 2
1. Perform the Injector Force Drive with a scan
tool.
2. Command each injector ON and verify clicking
nose (solenoid operating noise).
2 —
Is there an injector that does not create a clicking
noise (solenoid operating noise), contains an
interrupted noise or abnormal noise when
commanded ON? Go to Step 17 Go to Step 3
6C-10 Fuel System

1. Inspect the high pressure side between the
fuel supply pump and the fuel injectors for fuel
leakage. The following components may
contain an external leak.
• Fuel supply pump
• Fuel rail
• Pressure limiter valve
• Fuel rail pressure (FRP) sensor
• Fuel pipe between the fuel supply pump
and fuel rail
3 • Fuel pipe between the fuel rail and fuel —
injectors
• Each fuel pipe sleeve nuts
Notice:
Fuel may leak under the cylinder head cover from
the inlet high pressure line. In such case, the
engine oil level will rise. Inspect for fuel leakage
into the engine oil.
2. Repair any fuel system leaks as necessary.
Did you find and correct the condition? Go to Step 20 Go to Step 4

1. Inspect the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
Notice:
The fuel system from the fuel tank(s) to the fuel
supply pump is under a slight vacuum with the
engine running. As a result, air can enter the fuel
system if these connections are not tight. Air in the
fuel system will cause fuel rail pressure
fluctuations especially at high engine speed and
load, which may set this DTC.
2. Pump the priming pump until it becomes firm.
If there is a leak on the suction side of the fuel
4 system between the priming pump and the —
fuel supply pump, the priming pump will not
build up sufficient firmness and fuel leakage
may occur.
3. Start the engine and check for high side fuel
system leaks at the fuel supply pump and fuel
rail.
Notice:
Fuel may leak under the cylinder head cover from
the inlet high pressure line. In such case, the
engine oil level will rise. Inspect for fuel leakage
into the engine oil
4. Repair any fuel system leaks as necessary.
Fuel System 6C-11

1. Make sure the fuel tank(s) have adequate fuel
and the fuel quality is good (take a sample).
2. Bleed the air from the fuel system as
necessary.
3. Start the engine and let idle. If the engine does
not start, continue to crank. ±5 MPa
5
4. Observe the Actual Fuel Rail Pressure and (±725 psi)
Desired Fuel Rail Pressure parameter with a
scan tool while cranking over the engine or
running the engine.
Is the differential pressure within the specified

value? System OK Go to Step 6
1. Turn OFF the ignition.
2. Disconnect the fuel injector in-line harness
connector (H-125) from the cylinder head
cover case in order to disable injection.
3. Remove the rubber fuel hose from the fuel
filter housing (fuel supply pump side). Use a
pan to catch the fuel from the removed fuel
line.
Important:
The fuel pressure/ vacuum gauge connector and
the adapter hose must be cleaned before
connecting to the fuel line. Otherwise, foreign
material internal to the tools line may damage the
fuel supply pump.
4. Connect the gauge adapter (5-8840-2844-0/
EN-47667) with fuel pressure/ vacuum gauge
assembly (5-8840-2844-0/ J-44638) in series
with the filter housing and the disconnected
6 fuel hose. Ensure the service tool and fuel line 8 inHg
connections are tight.
5. Bleed the fuel system by priming the priming
pump until it becomes firm, then crank over
the engine for a maximum of 5 seconds.
Perform procedure three times.
6. Fully clamp off a fuel hose as close to the fuel
tank as possible (this will draw vacuum on the
fuel system). You can also disconnect a fuel
line and plug it.
7. Crank over the engine (for no longer than 15
seconds) while monitoring the fuel pressure/
vacuum gauge.
Notice:
Release the clamp or open the plug when the
gauge is likely to be more than 8 inHg during the
test.
Can a vacuum of at least the specified amount be

pulled on the fuel system? Go to Step 9 Go to Step 7
6C-12 Fuel System

1. Inspect the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
2. Draw fuel from the fuel tank at the fuel line
going to the fuel pickup tube to verify a clean
7 stream of fuel comes out (use the hand-held —
vacuum pump 5-8840-0279-0/ J-23738-A)
with a clear hose or equivalent). This will
ensure the fuel pickup tube is not cracked
drawing air into the fuel line.
3. Repair or replace as necessary.

1. Replace the fuel filter cartridge. Refer to Fuel
Filter Cartridge Replacement.
2. Retest the fuel system vacuum test described
8 in Step 5. 8 inHg
Can a vacuum of at least the specified amount be

pulled on the fuel system? Go to Step 20 Go to Step 19
1. Unclamp or unplug the fuel line from Step 5
and reconnect the fuel line.
2. Prime the priming pump until firmness is felt.
3. Crank over the engine for 5 seconds.
4. Repeat steps 2 and 3 three times to bleed the
9 fuel system. 5 inHg
5. Crank over the engine (for no longer than 15
seconds at a time) while monitoring the fuel
pressure/ vacuum gauge.
Does the pressure/ vacuum gauge ever indicate

larger than the specified value? Go to Step 10 Go to Step 11
1. Inspect the fuel lines between the fuel supply
pump and fuel tank for being crushed or
kinked.
2. Inspect the fuel tank vent hose for a plugged
or kinked condition.
3. Inspect the fuel cap for a plugged or kinked
10 condition. —
4. Inspect inside the fuel tank (if possible) for any
foreign material that may be getting drawn into
the fuel line pickup causing a blocked
condition.
5. Repair the condition as necessary.

Fuel System 6C-13

1. Turn OFF the ignition.
2. Make sure the fuel injector in-line harness
connector (H-125) is disconnected from the
cylinder head cover case.
3. Remove the eyebolt from the cylinder head
that connects to the leak-off pipe.
4. Connect the fuel adapter 5-8840-2845-0 (J-
45873-103) with hose assembly to the
cylinder head. Install the hose into a
graduated cylinder from the 5-8840-2845-0 (J-
45873-100) kit.
5. Remove the eyebolt from the pressure limiter
11 valve that connects to the leak-off pipe. —
6. Connect the fuel adapter 5-8840-2845-0 (J-
45873-105) with hose assembly to the
pressure limiter valve.
9. Perform 7 and 8 three times to take the
average of the fuel return amount coming from
the cylinder head. Make sure the batteries are
fully charged and the engine is cranking at
normal speed for each test.
Is fuel leaking from the pressure limiter valve? Go to Step 16 Go to Step 12

Is the average fuel return coming from the cylinder
12 15ml
head less than the specified value? Go to Step 13 Go to Step 14
1. Remove each glow plug from the cylinder
head.
2. Inspect for fuel leakage into the combustion
13 chamber. —
Is there a cylinder that fuel leakage into the

combustion chamber? Go to Step 18 Go to Step 19
1. Remove the cylinder head cover and injector
harness in order to connect the fuel adapter 5-
8840-2845-0 (J-45873-101) with hose
assembly to each injector leak-off port. Refer
to Fuel Injector Replacement.
Important:
14 3ml
Replacement injector must be programmed.
3. Replace the injector(s) that return fuel more
than the specified value. Refer to Fuel Injector
Replacement/ Fuel Injector ID Code Data
Programming.
4. Retest after replacement of the fuel injector(s).
Did you complete the replacement? Go to Step 20 —

Replace the fuel filter cartridge. Refer to Fuel Filter
15 Cartridge Replacement. —
6C-14 Fuel System

Replace the pressure limiter valve. Refer to Fuel
16 Rail Replacement. —
Important:
Replacement fuel injector must be programmed.
Replace the appropriate fuel injector that does not
create a clicking noise (solenoid operating noise),
17 contains an interrupted noise or abnormal noise at —
Step 2. Refer to Fuel Injector Replacement/ Fuel
Injector ID Code Data Programming.

Important:
Replacement fuel injector must be programmed.
Replace the appropriate fuel injector that was
leaking fuel found at Step 13 and inspect the
18 engine mechanical for any damage or poor engine —
compression. Refer to Fuel Injector Replacement/
Fuel Injector ID Code Data Programming and
engine mechanical section.

Important:
The fuel supply pump must be timed to the engine
and adjustment value must be learned to the ECM.
19 Replace the fuel supply pump. Refer to Fuel —
Supply Pump Replacement.

1. Reconnect all previously disconnected
harness connector(s) or components.
3. Bleed the air from the fuel system.
4. Start the engine and let idle. ±5 MPa
20
5. Observe the Actual Fuel Rail Pressure and (±725 psi)
Desired Fuel Rail Pressure parameter with a
scan tool.
Is the differential pressure within the specified

value? System OK Go to Step 1
Special Tool
Description Description
5-8840-2844-0
Fuel Pressure / Vacuum
Gauge Set
(J-44638 [Fuel Pressure / 5-8840-0279-0
Vacuum Gauge (J-23738-A)
Assembly] Vacuum Pump
EN-47667 [Suction Side
5884028440 Fuel Pressure / Vacuum
5884002790
Gauge Adapter])
Fuel System 6C-15
Tool Number /
Illustration
Description
5-8840-2845-0
Fuel Test Adapter Set
(J-45873 / Fuel Test
Adapter Kit,
J-45873-100 / Fuel Test
Adapters)
5884028450
Specifications
Fuel pump specifications
Engine type 4HK1-TC

Items
Fuel injection pump type Electronic control fuel injection system
(Common rail type)
Supply pump model HP-3 (Denso)
Revolution direction Counterclockwise (viewed from drive-end)
Plunger diameter φ 8.5 × 2
2
Regulating valve opening pressure MPa {kgf/cm } 0.5 {5.1}
Feed pump Trochoid-type
Injector specifications
Items Specifications
Injector model DX1534
Nozzle hole (mm) × number of pieces φ 0.14 × 7
6C-16 Fuel System
Fuel Filter Assembly

Components
N6B6072E
Legend
1. Filler Cap 3. Fuel Sedimenter Connector
2. Fuel Hose 4. Fuel Filter Assembly
Removal
1. Remove the filler cap.
2. Remove the fuel sedimenter connector.
3. Remove the feed hose and the return hose from
the fuel filter and plug it so that the fuel does not
flow out.
4. Remove the bolts for mounting the fuel filter.
5. Remove the fuel filter assembly.
6. Remove the fuel filter bracket.
Installation
1. Install the fuel filter bracket.
2. Install the fuel filter assembly.
3. Install the bolts for mounting the fuel filter.
4. Install the inlet hose and the outlet hose.
5. Install the fuel sedimenter and clip the cable to the
bracket.
6. Install the filler cap.
7. Bleed out the air.
• Refer to “Fuel System/Air bleeding”.
Fuel System 6C-17
Fuel Filter Element

Removal 2. Insert the O-ring that the element comes with into
the groove on the outer circumference of the
1. Drain fuel from the element case.
aluminum body. Be careful not to damage the O-
a. Loosen the drain plug (cock) on the bottom of ring by the threaded portion of the body side.
the element case.
3. Apply new diesel fuel lightly to the packing inside
b. Loosen the air bleeder on the aluminum body to and outside the element, and then insert the
drain fuel from the drain cock. element until it contacts.
2. Remove the harness of water warning switch.
3. Using a socket wrench (29 mm) or a filter wrench, Caution:
loosen the element case counterclockwise to Be careful not to let foreign matter get into the four
remove it from the aluminum body. At this time, holes (clean-side) adjacent to the inside packing.
make sure that the float at the bottom inside the
4. Apply new diesel fuel lightly to the inner
removed case moves up and down smoothly. In
circumference of the element case (or to the O-ring
addition, clean the bottom if foreign matter or
on the body side), and rotate the case clockwise
sludge accumulates on it.
until it contacts the aluminum body, taking care not
4. Pull out the element downward, and remove the O- to let the O-ring bitten. If the case does not contact,
ring at the aluminum body. this means the element is not inserted sufficiently.
Push into the case again while rotating the
element.
5. Tighten the element case using a torque wrench. :
Tightening torque = 33.0 ± 3.0 N⋅m
6. Tighten the drain plug on the element case, and
4 connect the connector of the water warning switch
again.
1 7. Bleed out the air.
Refer to “Fuel System/Air bleeding”.
2
8. Make sure that there is no looseness on each part
after starting the engine.
N6B6073E
Legend
1. O-Ring
2. Filter Element
3. Case
4. Body
Installation
1. If foreign matter accumulates on the inner
circumference of the body, wipe it with a clean
cloth. N6B6134E
Caution:
To remove foreign matter, be sure to wipe it with a
cloth. Do not use an air blower etc.
If blown foreign matter gets into the clean-side
passage, the supply pump will malfunction.
6C-18 Fuel System
Fuel Injector
Components
13
10 8
12
1
2
N6B6074E
Legend
1. Fuel Injection Pipe Clip 8. EGR Valve Gasket
2. Fuel Injection Pipe 9. EGR Valve
3. Fuel Injector Leak-off Pipe 10. EGR Valve Gasket
4. Fuel Injector 11. Cylinder Head Cover
5. Fuel Injector Clamp 12. Fuel Injector Harness Bracket
6. Fuel Injector Clamp Bolt 13. Fuel Injector Terminal
7. EGR Adapter
The fuel system consists of many tiny holes and removal and installation procedure.
spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to Caution:
extremely high precision. This is especially true of the To avoid electric shock;
fuel injectors. Set the switch to the ‘OFF’ position and disconnect
The fuel injector is very sensitive to foreign material. battery negative cable before checking or repairing the
Foreign material will result in fuel system breakdown. fuel injector, wiring or/and connectors.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
Fuel System 6C-19
Important: 6. Remove the head cover.
The Fuel Injector ID Code Data Programming MUST be
done when the fuel injector is being replaced. The Fuel
Injector ID Code information MUST be recorded before 1
assembling the cylinder head cover.
Removal
1. Remove the fuel filter assembly and fuel filter
bracket. Refer to “Fuel Filter Assembly”.
2. Remove the engine harness, the throttle position
sensor, the EGR valve, the pressure sensor, and
all of the fuel injector connectors.
3. Remove the EGR valve and the EGR adapter.
4. Tape the EGR case holes shut to prevent the entry
of foreign material. 2
N6A6027E
Legend
1
2. Head Cover
7. Loosen the fuel injector terminal nuts.

8. Loosen the fuel injector harness bracket bolts.
2 Remove the inside connector and the harness
bracket.
9. Remove the fuel injector leak-off pipe.
10. Remove the lower cover.
N6B6075E
Legend
2. EGR Valve
5. Remove the sound insulation cover.
N6A6124E
Legend
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal
4. Fuel Leak-off Pipe
6C-20 Fuel System
11. Remove the fuel injection pipe clips and the Special tools
injection pipes. Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-0 (J-23907)
1
N6B6082E
N6A6129E
Legend
1. Fuel Injection Pipe Legend
2. Pipe Clip 1. Sliding Hammer
2. Remover
12. Loosen the fuel injector clamp fixing bolts and 3. Fuel Injector Assembly
remove the fuel injectors.
If the fuel injectors are difficult to remove, use the fuel 13. Mark each fuel injector with the number of the
injector remover. Install the fuel injector remover to the cylinder from which it was removed. Store the fuel
leak-off pipe attachment part on the fuel injector. Use a injectors in a safe place. Position the fuel injector
sliding hammer to force the fuel injector clamp off the so that the nozzle is protected.
fuel injector.
Caution:
Caution: • Do not tamper with the electromagnetic portion of
Do not remove the fuel injector sleeve. the fuel injector. Reduced electromagnetic function
will result in injector failure.
Fuel System 6C-21
Recording from the each fuel injector ID plate
Record 24 figures of each fuel injector ID plate. The
correct order for the fuel injector ID code for the
following illustration is as follows:
56 00 D1 CA 00 00 EC 00 23 14 21 B7
2 1
5600 D1CA
0000 EC00
2314 2100
0000 B7
3
N6A6370E
Legend
1. Gasket
2. Fuel Injector
3. Bolt
N6A6524E 4. Fuel Injector Clamp
Legend
1. Fuel Injector ID Plate 2. Apply molybdenum to the threads and seating
2. Fuel Injector ID Code surfaces of the clamp bolts.
3. Fuel Injector 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
Installation of the fuel injector side sleeve nuts.
Important: 6. Install the fuel injection pipes to the position shown
Install each of the fuel injectors on its original position. in the illustration.
(the cylinder from which it was removed) 7. Use a spanner to carefully the sleeve nuts until the
fuel injection pipes contact the fuel injector and
1. Install a new gasket and O-ring to each of the fuel common rail.
injector clamps. Refer to the illustration. 8. Tighten the fuel injection pipe clips to the specified
torque.
Tighten:
Clips to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
6C-22 Fuel System
1
1
2
2
N6B6121E
Legend
1. Clamp Bolt
2. Sleeve Nut
11. Install the nozzle leak-off pipes together with the

new gaskets. Tighten the pipes to the specified
torque.
Tighten:
N6B6082E Pipes to 12 N⋅m (1.2 kgf⋅m/104 lbf⋅in)
Legend
2. Pipe Clip
9. Final tighten the injection clamp bolts to the

specified torque.
Tighten:
10. Tighten the injection pipes to the specified torque.
Tighten:
Injection pipes to
Fuel rail side: 25 N⋅m (2.5 kgf⋅m/18 lbf⋅ft)
N6A6181E
12. Install the fuel injector harness connectors. Work

from the inside out.
13. Install the harness bracket and tighten the bolts to
Tighten:
Fuel System 6C-23
N6A6182E N6A6029E
14. Install the fuel injector terminal nuts to the injector. 17. Install the sound insulation cover.
Tighten: Tighten:
Nut to 2 N⋅m (0.2 kgf⋅m/17 lbf⋅in) Bolts to 7 N⋅m (0.7 kgf⋅m/5 lbf⋅ft)
Caution:
• Do not overtighten the nuts. Damage to the
1
terminal studs will result.
• The terminal nut with two wires is engine front
side.
2
1
N6A6027E
Legend
2 2. Head Cover
18. Install the gasket to the EGR valve and tighten the
N6A6627E
bolts to the specified torque.
Legend
1. Fuel Injector Tighten:
2. Harness Bolts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
3. Terminal Nut 19. Install the gasket to the EGR duct (EGR cooler
(2nd) – EGR valve) and tighten the bolts to the
15. Install the gasket to the cylinder head cover. specified torque.
16. Install the cylinder head cover and tighten up
Tighten:
according to the order. Bolts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
Tighten:
6C-24 Fuel System
2 1
5600 D1CA
0000 EC00
2314 2100
0000 B7
3
3
4
2
N6B6214E
Legend Legend
1. EGR Duct (EGR cooler (2nd) – EGR valve) 1. Fuel Injector ID Plate
2. EGR Valve Gasket 2. Fuel Injector ID Code
3. EGR Valve 3. Fuel Injector
4. EGR Valve Gasket
5. After complete the registration, turn OFF the
20. Attach the engine harness connectors. Each ignition for 30 second.
composite connector should make a loud click 6. Turn ON the ignition.
when it is securely attached.
7. Select Diagnostics > appropriate vehicle
21. Install the fuel filter bracket. identification > 4HK1 (Common Rail) >
Refer to “Fuel Filter Assembly”. Programming > Injector ID Code > Injector ID
22. Install the fuel filter assembly. Code. At this point, all registered fuel injector ID
Refer to “Fuel Filter Assembly”. code data can be verified. Compare the ID code
values registered into the ECM and each fuel
Fuel Injector ID Code Data Programming Procedure injector including the last 2 figures. If the registered
1. Install the Tech 2. ID code is incorrect, go back to Step 4 ID Code
Registration.
2. Turn ON the ignition, with the engine OFF.
8. Start the engine and let idle.
3. Select Diagnostics > appropriate vehicle
identification > 4HK1 (Common Rail) > 9. Inspect for a proper engine running condition and
Programming > Injector ID Code > ID Code for no DTC’s. Refer to the Diagnostic System
Registration. Check-Engine Controls if needed.
4. Select replaced cylinder and press Change. Input Notice:
22 figures. Then, input in order from the left edge After replacement of the fuel injector, perform the
of upper sequence to the right sequence. The following procedure.
correct order for the fuel injector ID code for the All fuel injectors are replaced:
following illustration is as follows: Remove the fuel injector ID code label on the cylinder
56 00 D1 CA 00 00 EC 00 23 14 21 head cover.
Any fuel injector(s) is replaced:
Important:
Blackout the replaced cylinder fuel injector ID code on
The number of places required for input is 22 figures
the cylinder head cover with a marking pen or
except last 2 figures.
equivalent.
Fuel System 6C-25
2 (0.2 / 17 lbf in)

7 (0.7 / 5)
12 (1.2 / 104 lbf in)
24 (2.4 / 17)
6 (0.6 / 52 lbf in)

30 (3.1 / 22)
N6B6210E
Special Tool
5-8840-2826-0
5-8840-0019-0 (J-23907)
(EN-46720)
Sliding Hammer
Fuel Injector Remover
5884000190 EN46720
6C-26 Fuel System
Fuel Supply Pump

Components
10
9
8
7
4 5 6
3
N6B6076E
Legend
1. Fuel Leak-off Pipe 6. Bracket O-ring
2. Fuel Pipe 7. Coupling
3. Fuel Supply Pump 8. Vacuum Pump
4. O-ring 9. Vacuum Gear
5. Bracket 10. Oil Drain Adapter
The fuel system consists of many tiny holes and 3. Remove the intake pipe and the intake throttle
spaces that allow the movement of fuel from one place valve.
to another. These holes and spaces are milled to 4. Remove the fuel pipe and fuel leak-off pipe.
extremely high precision. This is especially true of the
5. Remove the Vacuum pipe.
fuel injectors.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
removal and installation procedure.
Important:
The Fuel supply pump must be timed to the engine.
Removal
1. Remove the fuel filter assembly.
Refer to “Fuel Filter Assembly”.
Fuel System 6C-27
N6B6013E N6A6376E
6. Remove the fuel feed hose. 11. Loosen the 3 bolts holding the fuel supply pump
7. Disconnect the fuel temperature sensor and the bracket. Remove the bracket and the O-ring.
fuel rail pressure regulator harness connector from
the fuel supply pump.
8. Remove the fuel supply pump attachment bolts
and nuts, then remove the fuel supply pump and
coupling. 4
1
9. Remove the vacuum pump. 3
2
Notice:
One of the attachment bolt (5) secures the vacuum
pump to the flywheel housing as denoted in the picture 5
below. 6
4 5 N6B6027E
2 3
1
Legend
1. Fuel Supply Pump
2. Key
3. O-ring
4. Supply Pump Bracket
5. Nut
6. Coupling
7. Flange Bolt
Installation
N6B6299E
1. Install the O-ring to the fuel supply pump.
Legend
1. Supply Pump 2. Install the pump to the bracket and tighten the 3
2. O-ring bolts to the specified torque.
3. Coupling Tighten:
4. Vacuum Pump Bolts to 19 N⋅m (1.9 kgf⋅m/14 lbf⋅ft)
10. Use a gear puller to remove the vacuum pump Caution:

gear and the O-ring. Take care not to twist the O-ring.
6C-28 Fuel System
2
4
1 3
3
2
4
N6B6027E N6B6028E
Legend Legend
1. Fuel Supply Pump 1. Vacuum Pump
2. Key 2. Key
3. O-ring 3. Vacuum Pump Gear
4. Supply Pump Bracket 4. Nut
5. Nut 5. O-ring
6. Coupling
7. Flange Bolt 4. Turn the crankshaft in the normal direction of
engine rotation until the No. 1 or No. 4 cylinder is
3. Align the fuel supply pump shaft key and gear. at TDC on the compression stroke.
Install the gear and tighten the nut to the specified Refer to the illustration.
torque.
There is a round alignment mark on the gear
(white paint).
Tighten:
Nut to 137 N⋅m (14 kgf⋅m/101 lbf⋅ft)
N6B6003E
5. Remove the oil drain adapter.

6. Install the vacuum pump to the cylinder block.
• Install the O-ring to the fuel supply pump.
• Align the slits as shown in the illustration.
• Insert the stud bolts into the guides and
temporarily tighten them.
Fuel System 6C-29
Caution:
Tighten:
• If the stud bolts (cylinder block side) have been Nut to 40 N⋅m (4.1 kgf⋅m/30 lbf⋅ft)
loosened or replaced, apply Loctite 262 to the
Bolt to 76 N⋅m (7.7 kgf⋅m/56 lbf⋅ft), 48 N⋅m (4.9 kgf⋅m/35
recessed portion of the bolts.
lbf⋅ft)
2
3
1
6
4
5
N6B6029E
N6B6298E
Legend
1. Mark Line 7. Apply a light coat of engine oil to the O-ring.
2. Slit 8. Install the oil drain adapter to the plug hole.
3. Slit position before insertion Tighten the bolt to the specified torque.
4. Slit position after insertion
5. Plug hole Tighten:
6. Vacuum Pump
• Check that the round alignment mark (white paint)

is positioned as shown in the illustration when
viewed from the plug hole. If necessary, reposition
the gear.
1
2
N6B6030E
Legend
1. Oil Drain Adapter
2. O-ring
N6A6080E 9. Connect the fuel temperature sensor and the

Legend suction control valve connectors to the fuel supply
1. Plug Hole pump.
2. Alignment Mark 10. Install the fuel feed hose.
• Tighten the bolts and the nuts to the specified
• Coat the fluid gasket and mount within 7
torque.
minutes.
6C-30 Fuel System
Tighten:
Throttle assembly to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
• Install the intake throttle valve chamber hose.
N6B6015E
Legend
1. Intake Throttle Valve Chamber
12. Install the vacuum pipe.

13. Install the fuel pipe and fuel leak-off pipe.
Important:
In order to make the fuel supply pump characteristic
learn into the ECM, let the engine idle until warm-up. If
the fuel system DTC’s stored in the meantime, once
clear DTC and warm-up the engine again.
16. Inspect for a proper engine running condition and

for no DTC’s. Refer to the Diagnostic System
Check-Engine Controls if needed.
Fuel System 6C-31
19 (1.9 / 14) 48 (4.9 / 35)
137 (14 / 101)

40 (4.1 / 30) 76 (7.7 / 56)
6 (0.6 / 52 lbf in) 12 (1.2 / 104 lbf in)
48 (4.9 / 35) 48 (4.9 / 35)

8 (0.8 / 69 lbf in)
44 (4.5 / 33) 18 (1.8 / 13)
N6B6086E
6C-32 Fuel System
Fuel Rail
Components
5
7
9 6 4
8
N6B6081E
Legend
1. Fuel Leak-off Pipe 6. Injection Pipe Clip
2. Fuel Pipe 7. Injection Pipe (#1 to #4)
3. EGR Valve 8. Fuel Rail
4. EGR Valve Gasket 9. Fuel Rail Bracket
5. EGR Duct (EGR cooler (2nd) — EGR valve)
Parts of the fuel system such as the internal part of the Removal
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy. WARNING:
They are therefore highly sensitive to foreign matter TO PREVENT LEAKED FUEL FROM CATCHING
and the entry of foreign matter could cause damage to FIRE, DO NOT WORK WHILE THE ENGINE IS HOT.
the fuel passage. Therefore, effective measures should
be taken to prevent the entry of foreign matter. Preparation:
• Pour detergent into a steam cleaner, and throughly
wash around the sensor and the fuel rail.
• Remove water completely using air blow.
Fuel System 6C-33
Notice: 8. Remove the injection pipe clip and remove the
Make sure that foreign matter will be prevented from injection pipes.
getting in.
Important:
1. Remove the air intake pipe. Loosen the injection pipes gradually not to scatter high
• Disconnect the connector for the intake air pressure fuel.
temperature sensor.
2. Remove the fuel filter assembly. 1
4. Remove the fuel pipe and fuel leak-off hose from
the leak-off pipe.
• Cover the removed fuel hose, keep it facing
upward and secure it using wire, etc.
5. Disconnect the fuel rail pressure sensor harness
connectors.
6. Remove the EGR valve and the EGR duct (EGR
cooler (2nd) – EGR valve).
7. Tape the EGR case holes shut to prevent the entry 2
of foreign material.
N6B6082E
Legend
9. Remove the fuel pipe.

N6B6075E
Important:
Legend Loosen the fuel pipe gradually not to scatter high
1. EGR Duct (EGR cooler (2nd) – EGR valve) pressure fuel.
2. EGR Valve
6C-34 Fuel System
10. Remove the clips and the fuel leak-off pipe. Disassembly
1. Remove the fuel pressure limiter.
2. Remove the fuel rail pressure sensor.
3 2
N6B6106E
Legend
1. Fuel Pipe
N6B6108E
2. Fuel Leak-off Pipe
Legend
11. Remove the fuel rail and the fuel rail bracket. 1. Fuel Rail
2. Fuel Rail Pressure Sensor
• Do not remove the flow damper.
3. Fuel Pressure Limiter
The dampers should always remain in the fuel
rail.
• Take care not to damage the connector unit of
the pressure sensor. Reassembly
1. Install the fuel pressure limiter.
Tighten:
Fuel pressure limiter to 172 N⋅m (17.5 kgf⋅m/127 lbf⋅ft)
2. Install the fuel rail pressure sensor.
Tighten:
Fuel rail pressure sensor to 98 N⋅m (10 kgf⋅m/72 lbf⋅ft)
N6B6107E
Legend
1. Fuel Rail Bracket
2. Fuel Rail
Fuel System 6C-35
3. Tighten the fuel leak-off pipe (1) using the
mounting eyebolt and the clips using the specified
torque.
Tighten:
(2) to 18 N⋅m (1.8 kgf⋅m/13 lbf⋅ft)
(3) to 12 N⋅m (1.2 kgf⋅m/104 lbf⋅in)
1
(4) to 8 N⋅m (0.8 kgf⋅m/69 lbf⋅in)
4. Tighten the fuel pipe (5) using the mounting sleeve
nut and the clip using the specified torque.
Tighten:
(6) to 44 N⋅m (4.5 kgf⋅m/33 lbf⋅ft)
(7) to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
3 2
(8) to 44 N⋅m (4.5 kgf⋅m/33 lbf⋅ft)
N6B6108E
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter
Installation
8
1. Tighten the fuel rail bracket using the specified
mounting torque.
2
6
Tighten: 5
7
Bolts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft) 2
2. Tighten the fuel rail using the specified mounting
torque.
Tighten:
N6B6219E
5. Install the fuel leak-off hose to the fuel leak-off

N6B6107E pipe.
Legend 6. Tighten the injection pipe and the clip using the
1. Fuel Rail Bracket specified mounting torque.
2. Fuel Rail
6C-36 Fuel System
Tighten:
Injection pipe sleeve nut to
1
Fuel rall side: 25 N⋅m (2.5 kgf⋅m/18 lbf⋅ft)
Tighten:
Injection pipe clip to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
• Apply a thin coat of engine oil on the periphery
of the sleeve nut on the fuel injector side and 3
assemble.
1
4
2
N6B6214E
Legend
2. EGR Valve Gasket
3. EGR Valve
4. EGR Valve Gasket
12. Install the air intake duct.

2
• Connect the connector for the intake air
temperature sensor.
N6B6082E
Legend
7. Connect the fuel rail pressure (FRP) sensor 2 1

connector.
8. Install the gasket to the EGR valve and tighten the N6B6005E
Tighten:
9. Install the gasket to the EGR duct and tighten the
Tighten:
10. Install the fuel filter bracket. Refer to “Fuel Filter
Assembly”.
11. Install the fuel filter assembly. Refer to “Fuel Filter
Assembly”.
Fuel System 6C-37
30 (3.1 / 22)
6 (0.6 / 52 lbf in)

22 (2.2 / 16)
22 (2.2 / 16.2)
24 (2.4 / 17)
172 (17.5 / 127)
24 (2.4 / 17) 12 (1.2 / 104 lbf in)

6 (0.6 / 52 lbf in)
24 (2.4 / 17)
8 (0.8 / 69 lbf in)

44 (4.5 / 33) 18 (1.8 / 13)
N6B6109E
6C-38 Fuel System
Fuel Sedimenter Switch

Inspection
1. Check that there is continuity between the switch
connector terminals when the float in the water
sedimenter is above the water drain line (reverse
the filter element case).
2. Turn on the ignition switch, disconnect the fuel
sedimenter connector, and connect the terminals
of the connectors on the vehicle side. Confirm that
the sedimenter warning lamp lights up.
If abnormalities are detected during the check, replace
the switch parts and carry out repairs in case of
defective connection between circuits or short circuits.
4
1
Sedimenter Sedimenter
Switch Switch
N6B6083E
Legend
1. Float
2. Connector on Engine Harness Side
3. Harness
4. Filter Element Case Assembly
5. Sedimenter Switch Connector
Fuel System 6C-39
Fuel Tank
Components
3
1
2 4
N6A6389E
Legend
1. Fuel Gauge Unit Connector 4. Fuel Return Hose
2. Evaporated Fuel Hose 5. Band
3. Fuel Feed Hose 6. Fuel Tank
Removal 6. Remove the fuel feed hose.

1. Loosen the fuel filler cap. 7. Remove the fuel return hose.
2. Drain the fuel from the drain plug. • Plug the hose so that fuel does not flow out,
and tie it to the frame-side with the opening
3. After draining, tighten the drain plug with the
faced up.
specified torque.
8. Remove the nut of band which installs fuel tank,
Tighten: and remove the band tip in the frame-side.
20 N⋅m (2.0 kgf⋅m/15 lbf⋅ft)
9. Pull out the fuel tank to the outside.
4. Remove the fuel gauge unit connector.
5. Remove the evaporated fuel hose.
6C-40 Fuel System
Caution: 6. Connect the fuel gauge unit connector.
If the fuel tank cannot be pulled out, remove the bracket
and pull out the fuel tank downward.
2
3
N6A6390E
Legend
1. Fuel Gauge Unit Connector
2. Fuel Gauge Unit
3. Cross-member
4. Fuel Tank
Installation
1. Install the fuel tank.
Caution:
When the bracket has been removed while taking out
the fuel tank, attach the bracket to the frame and
tighten it to the specified torque.
Tighten:
55 N⋅m (5.6 kgf⋅m/41 lbf⋅ft)
Also, when placing the fuel tank on the bracket, make
sure that the rubber part attached on the fuel tank is put
onto the bracket.
2. Install the band to the fuel tank and tighten up the
nuts with the specified torque.
Tighten:
12 N⋅m (1.2 kgf⋅m/9 lbf⋅ft)
3. Install the fuel return hose.
4. Install the fuel feed hose.
• Insert the hose into the pipe for more than 25
mm (1.0 in).
5. Install the evaporated fuel hose.
• Fill the fuel tank with fuel, and tighten the fuel
filler cap.
• Connect the battery earth cable.
• Make sure there is no fuel leakage from the
connector parts of hoses after starting the
engine.
Fuel System 6C-41
Fuel Gauge Unit

Components
N6A6391E
Legend
1. Fuel Gauge Unit Connector 2. Fuel Gauge Unit
Removal Inspection
1. Remove the wiring connector from the fuel gauge The fuel tank unit changes the internal resistance
unit. according to the float position (fluid level) to operate the
2. Remove the installed screw and remove the fuel indicator of the fuel meter.
gauge unit.
Caution:
When removing/installing the fuel gauge unit, take care
not to interfere with adjacent parts and not to let the F
arm etc. deformed. Also, after removing the fuel gauge
unit, cover the tank with a cloth to prevent the entry of
dust.
E
N6A6392E
6C-42 Fuel System
1. While moving the float from “E” to “F”, measure the Installation
resistance between the connector terminals 1J-28
Assemble in the reverse order of disassembly.
and 2J-28.
1. Install the fuel gauge unit.
2. Check that the fuel level warning lamp comes on
when the float is at “E” position. If the result of the 2. Connect the wiring connector to the fuel gauge
inspection is unsatisfactory, replace with a new unit.
part.
Tightening Torque Specifications

55 (5.6 / 41)
12 (1.2 / 9)
20 (2.0 / 15)
N6B6292E
Engine Electrical 6D-1
ENGINE
Engine Electrical
TABLE OF CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . . . . .6D-2
General Procedure. . . . . . . . . . . . . . . . . . . . . . .6D-2
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-3
General Description . . . . . . . . . . . . . . . . . . . . . .6D-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-3
On-vehicle Service . . . . . . . . . . . . . . . . . . . . . . .6D-3
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .6D-6
General Description . . . . . . . . . . . . . . . . . . . . . .6D-6
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-8
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-8
Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . .6D-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Inspection and Repair . . . . . . . . . . . . . . . . . . . 6D-11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-17
Main Data and Specifications. . . . . . . . . . . . . .6D-18
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . .6D-19
General Description . . . . . . . . . . . . . . . . . . . . .6D-19
On-vehicle Service: Starter System . . . . . . . . .6D-21
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-22
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6D-22
On-vehicle Service . . . . . . . . . . . . . . . . . . . . . . .6D-23
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-24
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-25
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-25
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6D-26
Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-28
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-31
Torque Specifications . . . . . . . . . . . . . . . . . . . .6D-34
Preheating System . . . . . . . . . . . . . . . . . . . . . . .6D-35
Glow Plug Replacement. . . . . . . . . . . . . . . . . .6D-35
Service Precautions . . . . . . . . . . . . . . . . . . . . .6D-36
A List of Defective Phenomena . . . . . . . . . . . .6D-37
Main Data and Specifications. . . . . . . . . . . . . .6D-37
6D-2 Engine Electrical
Service Precautions
General Procedure
When fasteners are removed, always reinstall them at
the same location from which they were removed. If a
fastener needs to be replaced, use the correct part
number fastener for that application. If the correct part
number fastener is not available, a fastener of equal
size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking
compound will be called out. The correct torque value
must be used when installing fasteners that require it. If
the above conditions are not followed, parts or system
damage could result.
Battery
General Description b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE - Drop charging voltage to
There are six battery fluid caps at the top of the battery.
15V and charge for 10 — 15 hours.
Diagnosis Then go to “Load test”.
c. VOLTAGE IS BETWEEN 12V AND 16V
Visual Inspection - Continue charging at the same rate for an
Inspect the battery for obvious physical damage, such additional 3-1/2 hours. Then go to “Load test”.
as a cracked or broken case, which would permit d. VOLTAGE IS BELOW 12V - Replace battery.
electrolyte loss.
Replace the battery if obvious physical damage is Load Test
discovered during inspection. 1. Connect a voltmeter and a battery load tester
Check for any other physical damage and correct it as across the battery terminals.
necessary. 2. Apply 300 ampere load for 15 seconds to remove
surface charge from the battery.
Fluid Level Check
Remove load.
The fluid level should be between the upper level line
3. Wait 15 seconds to let battery recover. Then apply
and lower level line on side of the battery.
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
1) VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN FOLLOWING TABLE
- The battery is good and should be returned to
service.
2) VOLTAGE IS LESS THAN MINIMUM LISTED
- Replace battery.
ESTIMATED
TEMPERATURE MINIMUM VOLTAGE
°F °C
70 21 9.6
60 16 9.5
50 10 9.4
N6A0983E 40 4 9.3
30 −1 9.1
Legend
1. Battery 20 −7 8.9
2. Upper Level 10 − 12 8.7
3. Lower Level
0 − 18 8.5
Voltage Check The battery temperature must be estimated by feel

and by the temperature the battery has been
1. Put voltmeter test leads to battery terminals.
exposed to for the preceding few hours.
a. VOLTAGE IS 12.4V OR ABOVE - Go to “Load
Test”. On-vehicle Service
b. VOLTAGE IS UNDER 12.4V - Go to procedure
2 below. Battery Charging
2. Determine fast charge amperage from Observe the following safety precautions when charging
specification. the battery:
Fast charge battery for 30 minutes at amperage 1. Never attempt to charge the battery when the fluid
rate no higher than specified value. level is below the lower level line on the side of the
Take voltage and amperage readings after charge. battery.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF In this case, the battery must be replaced.
AMPERAGE RATE - Replace battery.
2. Pay close attention to the battery during the Always keep batteries out of the reach of young
charging procedure. children.
Battery charging should be discontinued or the Jump Starting Procedure
rate of charge reduced if the battery feels hot to the 1. Set the vehicle parking brake.
touch. If the vehicle is equipped with an automatic
Battery charging should be discontinued or the transmission, place the selector lever in the
rate of charge reduced if the battery begins to gas “PARK” position.
or spew electrolyte from the vent holes. If the vehicle is equipped with a manual
3. Battery temperature can have a great effect on transmission, place the shift lever in the
battery charging capacity. “NEUTRAL” position.
4. The sealed battery used on this vehicle may be Turn “OFF” the ignition.
either quick-charged or slow-charged in the same Turn “OFF” all lights and any other accessory
manner as other batteries. requiring electrical power.
Whichever method you decide to use, be sure that 2. Look at the built-in hydrometer. (If equipped)
you completely charge the battery. Never partially If the indication area of the built-in hydrometer is
charge the battery. completely clear, do not try to jump start.
Jump Starting 3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Jump Starting With An Auxiliary (Booster) Battery
Attach the other end of the same cable to the
Caution: positive terminal of the discharged battery.
Never push or to the vehicle in an attempt to start it. Do not allow the vehicles to touch each other.
Serious damage to the emission system as well as This will cause a ground connection, effectively
other vehicle parts will result. neutralizing the charging procedure.
Treat both the discharged battery and the booster Be sure that the booster battery has a 12 volt
battery with great care when using jumper cables. rating.
Carefully follow the jump starting procedure, being 4. Attach one end of the remaining cable to the
careful at all times to avoid sparking. negative terminal of the booster battery.
Attach the other end of the same cable to a solid
WARNING:
engine ground (such as the A/C compressor
FAILURE TO CAREFULLY FOLLOW THE JUMP
bracket or the generator mounting bracket) of the
STARTING PROCEDURE COULD RESULT IN THE
vehicle with the discharged battery.
FOLLOWING:
This ground connection must be at least 450 mm
1. SERIOUS PERSONAL INJURY, PARTICULARLY
(18 in) from the battery of the vehicle whose
TO YOUR EYES.
battery is being charged.
2. PROPERTY DAMAGE FROM A BATTERY
EXPLOSION, BATTERY ACID, OR AN WARNING:
ELECTRICAL FIRE. NEVER ATTACH THE END OF THE JUMPER CABLE
3. DAMAGE TO THE ELECTRONIC COMPONENTS DIRECTLY TO THE NEGATIVE TERMINAL OF THE
OF ONE OR BOTH VEHICLES PARTICULARLY. DEAD BATTERY.
Never expose the battery to an open flame or electrical 5. Start the engine of the vehicle with the good
spark. Gas generated by the battery may catch fire or battery.
explode. Make sure that all unnecessary electrical
Remove any rings, watches, or other jewelry before accessories have been turned “OFF”.
working around the battery. Protect your eyes by 6. Start the engine of the vehicle with the dead
wearing an approved set of goggles. battery.
Never allow battery fluid to come in contact with your 7. To remove the jumper cables, follow the above
eyes or skin. directions in the reverse order.
Never allow battery fluid to come in contact with fabrics Be sure to first disconnect the negative cable from
or painted surfaces. the vehicle with the discharged battery.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Removal
1. Negative cable
2. Positive cable
3. Retainer screw and rods
4. Retainer
5. Battery
N6A0984E
Installation
To install the battery, follow the removal procedure in
the reverse order, noting the following points:
1. Make sure that the rod is hooked on the body side.
Charging System
General Description
The main charging system components are the
batteries, the generator and the battery discharge
indicator light circuit. The generator is a 110-amp,
selfrectifying type with a built-in regulator. The battery
discharge indicator light is mounted in the instrument
panel. For more details on this circuit, refer to “Meter
and Warning/Indicator Lights” in Section 8.
Circuit Diagram
N6B6296E
Legend
1. Engine Control Switch 8. Glow Plug Indicator Light
2. Generator (Integral Regulator) 9. ECM
3. Charge Relay 10. Starter Cut Relay
4. To Heater and A/C Relay 11. To Exhaust Brake Solenoid Valve
5. Low Charge Indicator Light 12. Starter Relay
6. Glow Plug Relay 13. Starter
7. Glow Plugs 14. ECM Main Relay
Maintenance Electrical Tests
The most common indication of charging system Before performing the following generator electrical
troubles is an undercharged or overcharged battery. tests on the vehicle, be certain that the system wiring is
Since the battery itself may be defective, the first step not defective and generator belts are not slipping. Also,
should be to check its condition as described under the battery must be fully charged for a valid test of the
“Diagnosis of Battery.” In the case of an undercharged charging system.
battery, check for battery drain caused by grounds or
by accessories left turned on. Notice:
Keep the generator and all other electrical system To avoid damage to the vehicle electrical system,
terminals clean and tight. A loose or badly corroded always observe the following precautions:
terminal connection will create excessive resistance in • Do not polarize the generator.
the system and result in hard starting, dim lights etc. • Do not short across or ground any of the terminals
Inspect the generator system at regular intervals and in the charging circuit except as specifically
correct any potential causes of trouble before vehicle instructed herein.
performance is affected.
• NEVER operate the generator with the output
terminal open-circuited.
Diagnosis of Charging System
• Be sure the generator and battery have the same
Trouble in the charging system will be evidenced as
ground polarity.
one or more of the following three conditions:
• When connecting a charger or booster battery to
1. The battery discharge warning light will stay on.
the vehicle battery, connect negative to negative
2. An undercharged battery as evidenced by slow and positive to positive.
cranking.
3. An overcharge, or overvoltage, condition. 1. With the engine control switch “ON” and engine not
running, connect a voltmeter from terminal “E” to
Undercharged Battery ground. The voltmeter should read zero volts.
Inspection 2. With the engine control switch “ON” and engine not
1. Accessories to be sure none were left on for running, connect a voltmeter from terminal “B” to
extended periods. ground. The voltmeter should read at least 24
2. Drive belt for proper tension. Refer to “Drive Belt” volts.
in Section 6B. 3. With the engine control switch “ON” and the engine
3. The ECM main relay has been ON stuck at the not running, connect a voltmeter from white wire
ignition switch OFF position. (Battery voltage is side of the connector to ground. The voltmeter
consumed.) should show 24 volts.
4. Battery. Refer to “Diagnosis of Battery” earlier in 4. With the engine control switch “ON” and the engine
this section. not running, the “charge” light should be on. This
5. Wiring and connections for corrosion or looseness. shows that the other circuit in the connection is
Overcharge (or Overvoltage) condition working.
A charging rate in excess of 29.5-volts for a prolonged 5. With the engine running and the headlight high
period may cause early electrical system failure. beams turned on, read the voltage at the “B” post
Blown fuses, light bulbs burned out, and even battery on the generator. The voltage should be at least 24
failure may result. If this condition exists, test the volts.
generator as described under “Generator Output Tests” 6. If steps 1 through 4 are not OK, check connectors
later in this section. in the harness for looseness or corrosion and
retest.
Noisy Generator 7. If step 5 voltage is low, substitute a known good
Inspection regulator and test again. If the voltage is still low,
1. Drive pulley for looseness. bench test the generator.
2. Mounting bolts for looseness.
3. Bearings for dirt, damage, or wear.
Generator noise may also be caused by worn or
damaged diodes and/or starter.
Generator
Component 1. Connect an ammeter from the positive (+) battery
side to the generator output wire. This is 8 mm
(0.032 in) (black) wire. Leave the carbon pile
disconnected.
2. Slowly increase the generator speed and observe
the voltage meter. If voltage is uncontrolled with
speed and increases above 30 volts on a 24-volt
system, replace the regulator and check the rotor
winding. If the voltage is below 30 volts, connect
the carbon pile across the battery.
3. Run the generator at 5,000 RPM and adjust the
carbon pile to obtain maximum current output,
which should be more than 42A (50A) or 75A (80A)
at 28 to 29 volts.
4. If the output is not within 10 amperes of the rated
output, check the rotor winding, rectifier bridge,
and stator as described later under “Inspection”
and “Electrical Bench Tests.”
N6B6211E
50A Model
Legend
1. Generator Adjusting Bracket
2. Bracket Mounting Bolt
3. Generator Adjusting Nut
4. Generator Bracket
5. Generator Bracket Mounting Bolt
6. Generator
7. Generator Adjusting Bolt (Model equipped with
A/C only)
Repair Instruction
Description of Generator
The generator is a 24 volt, 50A or 80A, model with a
solid state regulator mounted to the brush holder. The
generator must be disassembled to remove the
regulator or brush holder assembly. The generator rotor N6A6402E
bearings contain enough grease to eliminate periodic 80A Model

lubrication. Two brushes carry current through two slip
rings to the field coil.
The stator windings are assembled on the inside of a
laminated core that forms part of the generator frame.
A rectifier bridge connected to the stator windings
contains six diodes that change the stator AC voltages
to a DC voltage.
The vacuum pump is attached to the rear of the
generator.
Generator Output Tests

To check the generator in a test stand, proceed as
follows:
Important:
• Use a fully charged battery when performing these
tests.
N6A6587E
Disassembly
1 1. Remove the through bolts.
2. Insert a flat-blade screwdriver between the front
2
3 cover and the stator. Pry the parts apart.
3. Separate the front cover/rotor assembly from the
rear cover/stator assembly.
N6B6110E
Legend
1. Ball Bearings
2. Brush Holder
3. Voltage Regulator
4. Generator
N6B6272E
Notice: 4. Place the front cover and rotor in a vise.
• Before performing the generator output test,
5. Remove the pulley nut and the pulley.
inspect all charging system components, wires
and terminals for wear or damage. Repair or 6. Remove the rotor from the front cover.
replace any parts found defective.
Removal
• Disconnect the battery negative cable.
• Remove the A/C compressor. (Refer to “Engine
Assembly” in Section 6A)
1. Electrical wiring at the generator.
2. Loosen the lower mounting bolts.
3. Loosen the adjusting nut.
4. Drive belts.
5. Adjusting bolts.
6. Generator.
Inspection
N6B6273E
• Mount brackets for damage.
• Drive belts for wear or damage. 7. Remove the screw from the front cover.
8. Remove the bearing retainer and the bearing.
12. Remove the rectifier assembly from the stator
assembly.
N6B6274E
9. Remove the B-terminal nut and M5 nut.

N6B6276E
10. Remove the rear cover from the stator.
N6B6275E
11. Remove the stator assembly.
N6A6605E
5
4
3
10
9
1
8
7
N6B6271E
Legend
1. Pulley Nut 6. Through Bolt
2. Pulley 7. Rear Cover Assembly
3. Front Cover Assembly 8. Rectifier Assembly
4. Rotor Assembly 9. Ball Bearing
5. Stator Assembly 10. Ball Bearing
Important: Rotor Assembly

• Separate the stator and rear cover. Be sure you 1. Check for dirty or rough slip ring surfaces. Remove
identify the proper position of the insulated dirt from the surfaces with a clean rag. Use No. 500
washers to prevent improper installation. or No. 600 sandpaper to smooth the surfaces.
2. Measure the slip ring diameters. Replace the slip
ring if the diameter is less than the specified limit.
Inspection and Repair
Repair or replace any parts found to be excessively
worn or damaged during the inspection procedure. Slip ring diameter mm (in)
Standard 31.7 (1.248)
Limit 30.7 (1.209)
slip rings
N6A6596E N6B6279E
3. Measure the electrical resistance between the slip

Stator Coil Assembly
rings. If the resistance is greater than the specified
limit (open circuit), repair is required. 1. Check for continuity across the stator coils
If there is no continuity, the stator coils must be
replaced.
Rotor Coil Resistance at 20°C (68°F) ohms
50A 8.2
Standard Resistance Between Stator coil neutral
80A 10.2 mm (in)
point and the Coil Ends (Reference)
50A 0.19
Standard
80A 0.07
stator coil end
stator coil
neutral point
N6B6278E
4. Check for continuity between the slip rings and the

rotor core. N6A6601E
If there is continuity, the rotor assembly must be
replaced. 2. Check for continuity between each stator coil end
and the stator core.
If there is continuity, the stator coils must be
replaced.
stator coil end
stator core
2
6.5 (0.253)
N6A6602E
Brushes
Measure the brush height. If the height is less than the
25 (0.984)
specified limit, the brushes must be replaced.
Brush height mm (in)

Standard 25 (0.984)
Limit 6.5 (0.253) N6B6280E
Legend
1. Brush
2. Limit Line
Rectifier Assembly
Measure each of the diode resistances in both
directions (anodeacathode and cathodeaanode). If any
of the diodes have the same resistance in both
directions, the rectifier must be replaced.
N6A6603E
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
50 A
L
E
8
B +
6
5~30V
3
4
5 -
1kHz
1
V 2
N6B6281E
Legend
1. Voltmeter 5. Switch 3
2. DC Regulated Power Supply 6. Switch 2
3. Lamp 2 7. Pulse Generator
4. Lamp 1 8. Output Signal
80 A
L
E
S
9
B +
7
5~30V
4
5
2 6 -
1kHz
1
V 3
N6A6604E
Legend
1. Voltmeter 6. Switch 3
2. Switch 1 7. Switch 2
3. DC Regulated Power Supply 8. Pulse Generator
4. Lamp 2 9. Output Signal
5. Lamp 1
Test circuit
Refer to the judgment criteria shown in the Table below.
Carefully check Items 1 − 5. If all the items are OK, the
IC regulator is normal.
Circuit components
1 DC regulated power supply 0 − 30 volts variable with output of 1 ampere or more
2 Lamps (2) 24 volts, 1.8 watts
3 Switches (3) -----
4 DC voltmeter 0 − 60 volts, 0.5 grade
5 Pulse generator (Oscillator) 5 − 30 volts output at a frequency of 1kHz
Judgment criteria
Switch Switch Switch Voltmeter Lamp condition
No. Remarks
1 2 3 reading Lamp 1 Lamp 2
1 ON OFF OFF On (dim) ON Initial excitation check
24V On or
2 ON ON OFF Full excitation check
flashing
OFF
Off or Lamp 1 off or dimly lit when the voltmeter
3 ON ON OFF 32V
on (dim) shows less than 24 volts or 32 volts
On or
4 OFF ON OFF 24V Stator and brush separation check
flashing ON
5 ON ON ON 36V On Excess voltage check
Reassembly 3) The rear ball bearing is pressed into the wheel

eccentric groove. The bearing ring projects
Follow the disassembly steps in reverse order to
from the groove.
reassemble the generator. Pay close attention to the
items below. During installation, rotate the bearing to the
point of minimum bearing ring projection.
• Be very careful not to reverse battery polarity.
Reversed battery polarity will destroy the rectifier
diodes.
• Do not ground the generator B-terminal. Heat and
fire damage to the harness will result.
• If using a fast charge procedure, be sure to
Ring
disconnect the battery positive cable. If you do not,
the rectifier diodes will be exposed to high positive
voltage that will destroy them.
Projection part
• Be very careful to reassemble the parts to their (0.65mm blow)
original positions. Particular care must be taken
with insulated parts.
• Carefully clean all insulated parts so that they are
completely free of oil and/or grease. eccentric groove
• Be sure that B-terminal twist-type stoppers (round

terminal) are securely inserted before tightening
the nuts.
N6A6607E
Final Assembly 2. Rear cover and stator assembly.
1. Pulley and rotor assembly. Use a pair of long-nose plier to connect the stator
• Install the pulley and rotor assembly. coil leads and the rectifier leads.
1) Carefully clamp the rotor assembly in a vice. Finish the work as quickly as possible to prevent
2) Tighten the pulley nut. the rectifier from heat transferred by the soldering.
Tighten:
Pulley nut to 110 N⋅m(11.2 kgf⋅m/81 lbf⋅ft)
N6A6605E N6B6283E
Insert the pin from the outside of the rear cover. 4. Through bolts.
Press the brushes into the brush holder. Complete • Place a guide bar through the holes in the front
the assembly procedure. cover and rear cover flange for proper
alignment. Install the through bolts.
Tighten:
Pin
Through bolts to 4 N⋅m (0.4 kgf⋅m/35 lbf⋅in)
Installation
1. Generator.
Tighten:
Bracket Mount Bolt to 48 N⋅m (4.9 kgf⋅m/35.4 lbf⋅ft)
2. Adjusting bolts.
Tighten:
Adjusting Nut to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
3. Drive belts.
Tighten:
Lower mount bolt to 40 N⋅m (4.1 kgf⋅m/30 lbf⋅ft)
N6B6282E 4. Vacuum and oil hoses at the vacuum pump.
3. Use a bench press to install the rear cover 5. Electrical wiring at the generator.
assembly to the cover assembly. • Battery negative cable.
6. Install the A/C compressor. (Refer to “Engine
Assembly” in Section 6A.)
Rated Voltage 24 V
Rated Output 50/80 amp
Rated Output at 5000 RPM More than 42/75 amp
Regulated Voltage 28.0 – 29.0 V
Brush Length
Standard 25 mm (0.984 in)
Limit 6.5 mm (0.256 in)
Slip Ring Diameter
Standard 31.7 mm (1.248 in)
Limit 30.6 mm (1.205 in)
Generator Pulley Direction (Viewed From Pulley Side) Clockwise Pulley
Pulley Diameter 82 mm (3.23 in)
Generator Weight (With Vacuum Pump) 50A: 7.4 kg (16.3 lb)
80A: 9.6 kg (21.2 lb)
Maximum Vacuum Pump Output 90.7 kPa (0.29 kg/cm2 / 13.2 psi)
Vacuum Pump Vane
Standard Length 17.0 – 18.0 mm (0.669 – 0.709 in)
Vacuum Pump Housing Inside Diameter
Standard 69.5 – 69.6 mm (2.736 – 2.740 in)
Starting System
General Description
Circuit Diagram
N6B6296E
Legend
Starter and Glow Plug Relays Diagnosis of Starting System
The starter is a 4.5 kilowatt, reduction drive model. 1. No Cranking, No Sound
The gear housing and armature end bearing housings • Discharged batteries. Turn on the headlights and
are aluminum. The brush assembly has replaceable check the brightness. If the headlights are dim,
brushes. The commutator bars are mica insulated and charge the batteries. Check for the cause of the
are undercut. discharged batteries.
The starter circuit starts at the batteries. The battery
• Sulfated battery terminals. Turn on the headlights.
cable goes to the large terminal on the starter.
The headlights will be bright. Attempt to start the
From that terminal wires lead to the engine control
engine. The headlights will be very dim or go out.
switch and the starter relay.
Clean all the battery terminals and cable ends.
From the engine control switch the starter circuit goes
through Fuse #3 and the transmission neutral switch to • A starter that draws too much current.
the starter relay. When the engine control switch is • Starter relay won’t work. Attempt to start and listen
turned to start and the transmission neutral switch is for a “click” at the starter relay. If there is no “click,”
closed, the starter relay closes to complete the circuit check the starter relay control terminals with a test
from the batteries to the starter solenoid. The starter light. If the test light shows that power is getting to
circuit is also connected to the Engine Control Module the starter relay, check the ground circuit with the
(ECM). The Engine Control Module (ECM) operates test light. If the ground circuit is OK, replace the
when the engine control switch is turned to the “ON” starter relay.
position. • Engine control switch start circuit won’t close.
The starter and glow plug relays are located on the
With the engine control switch turned to start,
frame at the left rear side of the cab.
check the starter relay with a test light. If the test
light doesn’t come on, check the starter circuit at
the engine control switch with the test light. If the
test light comes on, check the harness for an open
and repair. If the test light does not come on,
replace the engine control switch.
• Starter relay power circuit isn’t closing. Attempt to
start. The starter relay “clicks.” Check the
secondary terminals with a test light. If the test light
lights on the battery side only, replace the starter
relay. If the test light lights on both terminals, check
for an open at the starter.
• Starter clicks when start is attempted. Check all
power connections for corrosion. Clean
2 connections if corrosion is present. Terminal on
starter should have at least 18 volts on it when
1
cranking the engine. If voltage is OK, replace the
starter.
• Starter cut relay
If the problem found, repair the following circuit as
necessary.
- Starter cut relay ground circuit. (Between starter
cut relay and ECM.)
- ECM power supply circuit. (Between fuse 10 A
and starter cut relay circuit.)
• Neutral switch or inhibitor switch
N6A6412E
If the problem found, repair the following circuit as
Legend necessary.
1. Starter Relay
- Neutral switch or inhibitor switch ground circuit.
2. Glow Plug Relay
(Between Frame-LH and neutral switch.)
- Starter relay power supply circuit. (Between
Maintenance fuse 10 A and starter relay.)
Keep the starter’s exterior clean. Remove corrosion - Starter relay ground circuit. (Between starter cut
from the terminals, leads, and connectors. relay and diode.)
Tighten the starter to engine mounting bolts and the 2. Slow Cranking, Solenoid Clicks or Chatters
electrical cable retaining nuts.
• Discharged batteries. Turn on the headlights and
check the brightness. If the headlights are dim,
charge the batteries. Check for cause of
discharged batteries.
• Corrosion on the battery terminals. Check for
corrosion. Hint: Test for warm terminals. Clean all
the battery terminals and connectors.
• Loose or dirty connections. Measure the cranking
voltage at the battery terminals. If the voltage is
less than 18 volts, load test the battery. If the
battery is bad, replace the battery. If the battery is
good, repair the starter.
If the voltage is 18 volts or more, measure the voltage
from the battery NEGATIVE terminal to the engine
block. If the voltage is 0.5 volt or more, repair the
ground cable and connections.
If the voltage is less than 0.5 volt, measure the voltage
at the battery cable terminal on the starter. If the
voltage is 18 volts or more, repair the starter. If the
voltage is less than 18 volts, clean and tighten the
positive cable connections. If the voltage is still less
than 18 volts, replace the positive cable.
On-vehicle Service: Starter System

Maintenance
Keep starter terminals and all other terminals in the
electrical system clean and tight. A loose or corroded
connection or terminal will cause excessive resistance
in the system that will result in hard starting.
At regular intervals, inspect the starting system to
locate and correct potential causes of trouble before
the system performance is affected.
Starting motors do not require lubrication except during
overhaul.
Starter
Components
Starting Motor
N6B6293E
Legend
1. Magnetic Switch 7. Rear Cover
2. Gear Case 8. Armature
3. Torsion Spring 9. Yoke
4. Clutch 10. Brush
5. Pinion 11. Through Bolt
6. Dust Cover
On-vehicle Service
Component
Starter
N6A0988E
Legend
1. Starter Earth Cable 3. Starter Wiring Connector
2. Starter Assembly
Removal
Preparation
• Disconnect the battery ground cable (both
batteries).
1. Starter Earth Cable
N6A0989E
• Disconnect the starter earth cable at the starter

motor.
somewhere near the control box of the
transmission, remove each clip that fastens the
harness.
2. Starter Wiring Connector
3. Starter Assembly
N6A0990E
• Install the starter to the flywheel housing.
Tighten:
Starter bolt to 76 N⋅m (7.7 kgf⋅m / 56.1 lbf⋅ft)
3. Starter Earth Cable
N6A0990E
• Connect the earth cable to the starter motor.
• Remove the starter assembly from flywheel • Connect the battery ground cable.
housing.
Installation
1. Starter Assembly
2. Starter Wiring Connector
N6A0991E
Legend
1. Terminal B
2. Terminal S
Unit Repair
Component
S25-501B
24
25 22 23
20 28 26 27
14 15
16 13 17 18 19
21 12
3 2 5 6 10 11
1 4 9 8
N6B6237E
Legend
1. Armature 15. Ball Bearing
2. Ball Bearing 16. Pinion Shaft
3. Ball Bearing 17. Pinion Stopper Set
4. Field Coil Assembly 18. Ball Bearing
5. Pole Core Set Screw 19. Bearing Holder
6. Brush (+) 20. Magnetic Switch Assembly
7. O-ring 21. Bearing Retainer
8. Rear Cover 22. Gear Case
9. Brush Holder 23. Shift Lever
10. Brush Spring 24. Dust Cover Set
11. Brush (-) 25. Bolt
12. Pinion Assembly 26. Through Bolt
13. Clutch 27. Screw
14. Ball Bearing 28. M Terminal Cover
Disassembly
1. Lead Wire
Disconnect the lead wire at the magnetic switch.
N6B6242E
3. Through Bolt
4. Screw
N6B6221E
5. Rear Cover
2. Magnetic Switch Assembly Remove the through bolts, then remove the rear
Remove the magnetic switch bolts, then remove cover.
the switch from the shift lever.
N6B6223E
N6B6222E
Remove the torsion spring from the magnetic

switch.
6. Motor Assembly
Remove the four brushes from the brush holders.
N6B6226E
N6B6224E
10. Bearing Retainer
11. Pinion Assembly
Remove the yoke along with the armature and the 12. Dust Cover
brush holder from the gear case. 13. Shift Lever
Remove the brushes and commutator carefully so 14. Gear Case
as not to allow them in contact with the adjacent
1) Remove the bearing retainer.
parts.
2) Remove the pinion from the gear case.
N6B6225E
N6B6227E
7. Brush Holder
8. Yoke 3) Use a screwdriver to remove the stopper clip.
9. Armature Then disassemble the pinion assembly.
Remove the brush holder and pull out the armature
assembly free from the yoke.
Mica Segment Depth mm (in)

Standard Limit
0.5 — 0.8 (0.020 — 0.031) 0.2 (0.008)
If the mica segment depth is less than the standard

but more than the limit, the commutator may be
reground.
If the mica segment depth is less than the limit, the
commutator must be replaced.
N6B6263E
Inspection and Repair

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Armature
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
N6B6229E
Commutator Run-Out mm (in)
Standard Limit Legend
0.05 (0.002) or less 0.20 (0.008) 1. Insulator
2. 0.5 — 0.8 mm (0.020 — 0.03 in)
3. Commutator Segments
4. Correct
5. Incorrect
4. Measure the commutator outside diameter.
Commutator Outside Diameter mm (in)

Standard Limit
36.5 (1.437) 35.5 (1.398)
If the measured outside diameter is less than the

specified limit, the commutator must be replaced.
N6B6228E
2. Check the commutator mica segments for

excessive wear.
3. Measure the mica segment depth.
N6A1006E N6B6231E
5. Use a circuit tester to check the armature for Yoke

grounding. 1. Use a circuit tester to check the field winding
1) Hold one probe of the circuit tester against the ground.
commutator segment. 1) Hold one circuit tester probe against the field
2) Hold the other circuit tester probe against the winding end or brush.
armature core. 2) Hold the other circuit tester probe against the
If the circuit tester indicates continuity, the bare surface of the yoke body.
armature is grounded. There should be no continuity.
The armature must be replaced. If there is continuity, the field coil is grounded.
The yoke must be replaced.
N6B6230E
6. Use the circuit tester to check the armature for N6B6243E
continuity.
2. Use the circuit tester to check the field winding
1) Hold the circuit tester probes against two continuity.
commutator segments.
1) Hold one circuit tester probe against the “M”
2) Repeat Step 1 at different segments of the terminal lead wire.
armature core.
2) Hold the other circuit tester probe against the
There should be continuity between all segments
field winding brush.
of the commutator.
There should be continuity.
If there is not, the armature must be replaced.
If there is no continuity, the yoke must be replaced.
N6B6244E N6A1013E
Brush and Brush Holder 3. Inspect the brushes for excessive wear.
1. Use a vernier caliper to measure the brush length If the negative brushes have excessive wear, the
(four brushes). entire brush holder assembly must be replaced.
Replace the brushes as a set if one or more of the If the positive brushes have excessive wear, the
brush length is less than the specified limit. entire yoke must be replaced.
1) Use a pair of side cutters to cut the lead wire
Brush Length mm (in) from the brush.
Standard Limit Overrunning Clutch

15.5 (0.61) 10.5 (0.41) 1. 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.
N6B6245E
2. Use a circuit tester to check the brush holder

insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
N6A1017E
There should be no continuity.
Ball Bearing
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.
N6A6508E
4. Pinion Assembly
Apply a coat of grease to the reduction gear and
N6B6232E install the pinion assembly to the armature shaft.
Reassembly
1. Magnetic Switch Assembly
1) Attach the torsion spring to the hole in the
magnetic switch as illustrated.
2) Insert the shift lever into the plunger hole of the
magnetic switch.
N6A1025E
5. Brush Holders
1) Install the brushes into the brush holder with
raising the spring end of the brush spring.
Take care not to damage the commutator face.
2) Install the brush holder with aligning the
N6A1023E peripheries of the yoke and the brush holder.
2. Gear Case
3. Dust Cover
1) Install the magnetic switch assembly in the
gear case.
2) Install the dust cover.
Tighten:
Dust cover bolt to 10.6 N⋅m (1.08 kgf⋅m / 93.8 lbf⋅in)
N6B6247E N6B6221E
6. Through Bolt Inspection After Assembly

Install the through bolts in the rear cover and Use a vernier caliper to measure the pinion shaft thrust
tighten them to the specified torque. play.
The pinion shaft thrust play is equal to the pinion shaft
Tighten:
Through bolt to 6 N⋅m (0.6 kgf⋅m / 52 lbf⋅in) end and pinion stopper clearance.
Pinion Shaft Thrust Play mm (in)

0.3 — 1.0 (0.012 — 0.039)
0.3~1.0
N6A1028E
7. Lead Wire Nut

Connect the lead wire in the magnetic switch and
tighten the terminal nut to the specified torque. N6B6233E
Tighten:
Lead wire terminal nut to 10 N⋅m (1.0 kgf⋅m / 87 lbf⋅in)
Magnetic Switch The pinion should return to its home position.
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M”
terminal.
To prevent coil burning, complete each test as quickly
as possible (within three to five seconds).
Temporarily connect the solenoid switch between the

clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the
solenoid switch body and the M terminal. When
current is applied to the S terminal from the battery
positive terminal, the pinion should flutter.
N6B6236E
N6B6234E
2. Hold-in Maintenance Test

Disconnect the lead at the M terminal. The pinion
should continue to flutter.
N6B6235E
3. Return Test
Disconnect the battery positive lead at the S
terminal.

8.6 (0.9 / 76)
8.1 (0.8 / 71)
N6B6248E
Preheating System
Glow Plug Replacement
Circuit Diagram
N6B6296E
Legend
Precautions during maintenance Removal

Adequate care should be taken as over-tightening the 1. Remove the engine harness, the throttle position
glow plug could lead to damage. sensor, the EGR valve, the pressure sensor, and
all of the fuel injector connectors.
2. Remove the EGR valve and the EGR adapter.
3. Tape the EGR case holes shut to prevent the entry
of foreign material.
1 1
2 3
4
2
N6B6075E N6B6214E
Legend Legend
1. EGR Duct (EGR cooler (2nd) — EGR valve) 1. EGR Duct (EGR cooler (2nd) — EGR valve)
2. EGR Valve 2. EGR Valve Gasket
3. EGR Valve
4. Remove the glow connector. 4. EGR Valve Gasket
5. Remove the glow plug.
4. Attach the engine harness connectors. Each
composite connector should make a loud click
when it is securely attached.
Service Precautions
Adequate care should be taken as over-tightening the
glow plug could lead to damage.

The preheating system consists the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and make the engine easy to start.
Functional check
Refer to Section 6E (Glow Control System Check).
N6A6127E
Except the glow plug.
Glow plug check

Installation
• Use the circuit tester and measure the resistance
1. Install the glow plug.
of the glow plug.
Tighten: • If the measured value deviates from the specified
Glow plug to 20 N⋅m (2.0 kgf⋅m/15 lbf⋅ft) value, then replace the glow plug.
2. Install and tighten the glow connector with the
designated torque. Resistance value of glow plug is approximately
less than 6Ω.
Tighten:
Glow connector to 12 N⋅m (1.2 kgf⋅m/10 lbf⋅ft) Caution:
3. Install the EGR valve and the EGR adapter. Use a set of four glow plugs from the same
manufacturer.
Tighten:
EGR valve and adapter to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
N6A6429E

• The glow indicator lamp does not light up.
• Preheating does not work.
• The preheating time is too long or too short.
Trouble Shooting
1. The glow indicator lamp does not light up.

The glow indicator lamp does not Slow blow fuse has blown. Replace the slow blow fuse.
light up. Fuse is unavailable. Replace the fuse.
Indicator valve is burnt out. Replace the indicator valve.
Engine control system is faulty. Refer to Section 6E.
2. Preheating does not work.

Preheating does not work. Slow blow fuse has blown. Replace the slow blow fuse.
Defective or faulty glow plug relay Re-mount or replace the glow plug
connector contact. relay.
3. Preheating time is too long or too short.

The Preheating time is too long or Thermosensor fault and break in Replace the thermosensor. Repair
too short. circuit or short circuit. the circuit.
Fault in glow plug. Replace or tighten the glow plug.
Preheating device model Glow plug

Glow plug rated voltage (V) 24
Exhaust System 6F-1
ENGINE
Exhaust System
TABLE OF CONTENTS
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6F-2
Explanations on Functions and Operation . . . . . 6F-2
EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . . 6F-3
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 6F-6
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-7
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6F-7
Description of function and operation. . . . . . . . . 6F-7
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 6F-7
List of Abnormal Phenomena. . . . . . . . . . . . . . . 6F-7
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6F-8
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-10
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-15
Exhaust Brake System . . . . . . . . . . . . . . . . . . . . 6F-16
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-16
Explanations on Functions and Operation . . . . 6F-16
Functional Check . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Exhaust Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-18
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-19
6F-2 Exhaust System
EGR System
Service Precautions The EGR control starts when the conditions for engine
speed, engine coolant temperature and barometric
Perform EGR related assembly according to the usual
pressure are satisfied. Then, the valve opening is
procedure of temporarily fitting and then permanently
calculated according to the engine speed, and target
tightening the parts so that unnecessary stresses are
fuel injection quantity. Based on this valve opening, the
not applied on the parts.
drive duty of the motor is determined and the motor is
Explanations on Functions and Operation driven accordingly.
The EGR system recirculates a part of exhaust gas A potentiometer type EGR valve position sensor is
back into the intake manifold, which results in reducing employed and installed on the EGR valve body. The
nitrogen oxide (NOx) emissions. The EGR control EGR valve position sensor is supplied with reference
system uses an electronic control system to ensure voltage (5V) and ground at all times from the ECM. The
both driveability and low emission. The control current ECM reads the EGR position sensor voltage input and
from the engine control module (ECM) operates the determines the EGR lift position.
motor to control the lift amount of EGR valve. Also, an
EGR position sensor is provided at the rear of the
motor to feed actual valve lift amount back to the ECM
for more precision control of the EGR amount.
10
7
8 9
8
7
4
6
5
1
3
N6B6111E
Legend
1. Crankshaft Position Sensor 6. EGR Valve
2. Accelerator Pedal Position Sensor 7. EGR Cooler
3. ECM 8. Water Inlet
4. Intake Throttle Valve 9. Water Outlet
5. Intake Air 10. Exhaust Gas
Exhaust System 6F-3
EGR Valve and EGR Cooler

Components
1 2
4 3
N6B6085E
Legend
1. EGR Cooler 5. EGR Duct (EXH)
2. Water Rubber Hose 6. EGR Duct (EGR cooler (1st) – EGR cooler
3. EGR Duct (EGR cooler (2nd) – EGR valve) (2nd))
4. EGR Valve
Removal
1. Drain engine coolant. Refer to Engine Cooling
System section.
2. Remove the fuel filter assembly. Refer to “Fuel
Filter Assembly”.
3. Remove the fuel filter Bracket.
4. Remove the EGR valve connector.
6F-4 Exhaust System
5. Remove the cooling water pipes. Inspection
6. Remove the EGR duct. (EXH) • Gas leak check
7. Remove the EGR cooler. (1st) - Check for gas leak in various parts of the EGR
8. Remove the EGR duct. (EGR cooler (1st) – EGR gas line.
(2nd)) If the results of the check show abnormalities,
9. Remove the cooler. (2nd) repair or replace the defective parts.
10. Remove the EGR duct. (EGR cooler (2nd) – EGR • EGR valve check
valve)
11. Remove the EGR valve. Installation
1. Mount the EGR valve.
2 • Insert the gasket and temporarily fit the EGR
valve.
Notice:
Temporarily tighten the bolts.
5
3 2. Install the EGR duct. (EGR cooler (2nd) – EGR
valve)
• Insert the gasket between the two ends of the
4
EGR duct (EGR cooler (2nd) – EGR valve) and
1
temporarily fit it.
Notice:
3. Install the EGR cooler. (2nd)

N6B6135E
• Temporarily fit the EGR cooler to the bracket.
Legend
1. EGR Duct (EGR cooler (2nd) – EGR valve) Notice:
2. Water Return Pipe Temporarily tighten the bolts.
3. EGR Cooler
4. EGR Duct (EGR cooler (1st) – EGR cooler 4. Install the EGR duct. (EGR cooler (1st) – EGR
(2nd)) cooler (2nd))
5. Water Feed Pipe • Insert the gasket between the two ends of the
EGR duct (EGR cooler (1st) – EGR cooler
(2nd)) and temporarily fit it.
Caution:
After removing the EGR valve and EGR duct, seal the Notice:
opening so that foreign matter does not enter. Temporarily tighten the bolts.
5. Install the EGR cooler. (1st)

• Temporarily fit the EGR cooler (1st) to the EGR
duct (EGR cooler (1st) – EGR cooler (2nd)).
Notice:
Temporarily tighten the bolts
6. Install the EGR duct. (EXH)

• Insert the gasket between the two ends of the
EGR duct (EXH) and temporarily fit it.
Notice:
N6B6240E
Exhaust System 6F-5
During temporary assembly, tighten the nuts
and bolts to the specified torque in the order
shown in the illustration.
11 7
4
10
6
2
12
13
N6B6136E
Tighten:
Bolts and nuts to
(1): 104 N⋅m (10.6 kgf⋅m/78 lbf⋅ft)
(2), (3), (4): 28 N⋅m (2.9 kgf⋅m/21 lbf⋅ft)
(5), (6), (7), (8): 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
(9), (10), (11): 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
7. Install the cooling water pipes.
8. Install the EGR valve connector.
11. Replenish the engine coolant.
6F-6 Exhaust System
48 (4.9 / 35)
24 (2.4 / 17)
28 (2.9 / 21)
48 (4.9 / 35)
48 (4.9 / 35)
28 (2.9 / 21)
24 (2.4 / 17)
28 (2.9 / 21)
24 (2.4 / 17)
24 (2.4 / 17)
24 (2.4 / 17)
104 (10.6 / 78)

N6B6088E
Exhaust System 6F-7
Exhaust System
Service Precautions Description of function and operation
Offset in position of the exhaust system during The exhaust brake assembly adjusts exhaust pressure
assembly may sometimes cause vibrations or rattling to serve as supplement brake, Quick Warm-up System
noise. Therefore, temporarily tighten the bolts until all (QWS) for engine, etc. The DPD (diesel particulate
the parts have been positioned, and sequentially diffuser) body consists of a filter and oxidation catalyst,
tighten from the engine side to the rear pipe side. and serves to purify exhaust gas. The tail pipe has the
built-in post silencer that provides silencing effect. The
main components are exhaust brake assembly, front
exhaust pipes A and B, DPD, exhaust throttle
assembly, silencer, and tail pipe.
1 6
2
9
5 7 8
3
4
N6B6089E
Legend
1. Front Exhaust Pipe A 6. Exhaust Throttle Assembly
2. Exhaust Brake Assembly 7. Adapter Pipe
3. Front Exhaust Pipe B 8. Silencer
4. DPD 9. Tail Pipe
5. Extension Pipe
Functional Check Function check:

• During check or repairs of the exhaust system, • When DTC related to DPD is detected, check and
confirm that the clearance between the body and repair according to “Troubleshooting” related to
the floor is adequate. DPD in “Engine Control” section.
• Adequate care should be taken to prevent damage Caution:
due to heating or vibrations in the body panel as it Before disassembling the DPD assembly, always check
may lead to exhaust gas entering the cabin. the differential pressure of DPD and its status using a
scan tool, and confirm the procedure of check and
• Check for loose or damaged connectors and service. Refer to “Engine Control” chapter for details.
leakage of exhaust gas.
• Check for degradation, cracks or damage to the
clamp or rubber. List of Abnormal Phenomena
• If the pipe, DPD or silencer is damaged or has a • Vibration or rattling noise from the exhaust system
dent then repair or replace it. • Clogging of the exhaust system
• Check for dents, damage, holes or cracks due to • Exhaust leakage or noise
corrosion, and abnormal noise during operation.
6F-8 Exhaust System
Trouble Shooting
Vibration or rattling noise from the exhaust system

Vibration or rattling noise from the Loose or misaligned components Match the joints and then re-tighten.
exhaust system Or, check for damage in the hanger,
mounting brackets and clamps.
Clogging of the exhaust system
Symptom Possible cause Action to be taken

Clogging in exhaust system The exhaust brake and exhaust Refer to the Engine Control System
throttle are in the ON status. section for check of the electrical
system, and repair if there are
abnormalities. Check the shafts of
the exhaust brake and exhaust
throttle for roughness, and replace
if there is an abnormality.
Clogged exhaust pipe Repair or replace the exhaust pipe.
DPD-related DTC is detected. Check and repair according to
“Troubleshooting” related to DPD in
“Engine Control” section.
Exhaust leakage or noise
Symptom Possible cause Action to be taken

Exhaust leakage or noise Improper installation or Align the joints and tighten again.
misalignment
Breakage or burnout of exhaust Replace the damaged part.
pipe or silencer or DPD
Defective exhaust system Replace the defective part.
component (clamp, pipe, silencer)
Internal breakage of silencer Replace the silencer.
Internal breakage of DPD Replace the broken part (oxidation
catalyst/filter).
Exhaust System 6F-9
Exhaust Pipe
Removal • Remove the two exhaust temperature sensor
connectors of DPD.
1. Disconnect the tail pipe.
• Remove the clips of the exhaust temperature
sensor connector of DPD.
• Disconnect the two DPD differential pressure
hoses.
• Remove the DPD assembly from the front pipe.
1
2
4
4HK1-TCN
5
2
1
N6B6090E
Legend
1. Tail Pipe 6
2. Post Silencer 7
2. Disconnect the air pipe of the exhaust throttle.

3. Remove the silencer bracket.
4. Remove the silencer.
5 4
5. Remove the exhaust throttle assembly. 4HK1-TCS
2
6. Remove the exhaust pipe adapter.
1
2
6
3
1
3 4
5 7
N6B6091E
Legend
1. Exhaust Temperature Sensor 2 (catalyst inlet)
2. Exhaust Temperature Sensor 1 (filter inlet)
N6B6215E 3. DPD Assembly
Legend 4. Differential Pressure Hose (F)
1. Extension Pipe 5. Differential Pressure Hose (R)
2. Exhaust Throttle Assembly 6. Differential Pressure Pipe (R)
3. Adapter Pipe 7. Differential Pressure Pipe (F)
4. Silencer
5. DPD Caution:
If you need to remove the differential pressure sensor
7. Remove the DPD.
assembly, take care with the followings.
6F-10 Exhaust System
• Never loosen the four screws (2) that tighten the Disassembly
sensor. If loosened, replace the sensor assembly.
1. Loosen the sleeve nut that secure the differential
• If you drop the sensor assembly, do not reuse it. pressure pipe.
• Never use tools that cause vibrations such as an 2. Remove the clips of the differential pressure pipe.
impact wrench when installing or removing the 3. Disconnect the differential pressure pipe.
differential pressure sensor.
2
1
1
2
N6B6267E
Legend
N6B6092E
1. Hose Clip
Legend 2. Sleeve Nut (R)
1. Differential Pressure Sensor Assembly 3. Clip
2. Tightening Screw 4. Sleeve Nut (F)
8. Disconnect the front exhaust pipes A and B. 4. Disassemble the DPD assembly.
• Remove the clamp and disconnect the front • Loosen the tightening nut on the oxidation
exhaust pipes. catalyst part to remove the oxidation catalyst part.
• Remove the exhaust brake assembly. • Loosen the tightening nut of the filter part to
remove the filter part and the rear case.
Caution:
Do not have a strong impact on or drop the DPD
assembly.
1
3
N6B6093E
Legend
1. Front Exhaust Pipe A
2. Exhaust brake Assembly
3. Front Exhaust Pipe B
Exhaust System 6F-11
4 5
3
1
2
N6B6216E N6B6217E
Legend Legend
1. Oxidation Catalyst Part 1. Filter
2. Gasket 2. Filter Case
3. Filter Part
4. Gasket 3. If the differential pressure sensor assembly has
5. Rear Case been replaced, do the followings (on the vehicle):
• Turn the starter switch from key OFF to key ON
(do not start the engine).
Inspection • The DPD lamp comes on then goes off in
approx. 30 seconds.
1. Check the appearance of the exhaust pipe-related
parts. • After checking the DPD lamp is OFF, leave it for
more than 15 seconds with key OFF.
• Take care that damage due to heat or vibration
of the body panel may cause exhaust gas to Caution:
enter into the room.
• Check the connection for looseness, damage 4. Check the oxidation catalyst.
or exhaust gas leakage.
• Visually check the oxidation catalyst for melt,
• Check the clamp and the rubber for damage or clogging.
deterioration, crack or damage.
• Check the pipe and the silencer for dent or Assembly
crack due to corrosion, and repair or replace if Assemble the DPD assembly.
damaged. 1. Insert the gaskets between the filter part and the
2. Check the parts related to the DPD. rear case, and temporarily tighten the nut.
• Visually check the filter for melt, damage or 2. Insert the gaskets between the filter part and the
clogging. oxidation catalyst, and temporarily tighten with the
• Shine a light on the backside of the filter. If the bolt and nut.
light penetrates through the filter, replace the
Caution:
filter part.
• Check the assembled portions between the filter
Caution: part and the rear case, and between the filter part
Before disassembling the DPD assembly, always check and the oxidation catalyst part, and tighten
the differential pressure of DPD and its status using a together with the pipe brackets at the two portions.
scan tool, and confirm the procedure of check and 3. Tighten the bolts and nuts to the specified torque.
service. Refer to “Engine Control” chapter for details.
• Tighten all the blots and nuts twice.
Tighten:
Bolts and nuts to 25 N⋅m (2.5 kgf⋅m/18 lbf⋅ft)
Caution:
After tightening all the bolts and nuts, tighten again to
the same torque (double tightening).
3
4
4 5
3 1
2
1
N6B6094E
Legend
1. Differential Pressure Pipe (F)
N6B6216E 2. Differential Pressure Pipe (R)
Legend 3. Sleeve Nut (R)
1. Oxidation Catalyst Part 4. Clip
2. Gasket 5. Sleeve Nut (F)
3. Filter Part
4. Gasket Installation
5. Rear Case
Caution:
4. Insert the differential pressure pipes (F), (R), and • Vibration or play in the exhaust system may be
tighten the sleeve nut by hand. caused by misalignment at assembly. Tighten the
5. Secure the differential pressure pipes with clips. bolts temporarily until the positioning of all parts
are finished and then fully tighten them from the
Tighten:
engine side to the tail pipe side in order.
Clips to 10 N⋅m (1.0 kgf⋅m/87 lbf⋅in)
• Do not reuse the removed gasket and nut.
6. Tighten the sleeve nuts of differential pressure
pipes to the specified torque. 1. Install the front exhaust pipe A.
• Install the front exhaust pipe A to the exhaust
Tighten: manifold, and tighten to the specified torque.
Sleeve nut to 35 N⋅m (3.6 kgf⋅m/26 lbf⋅ft)
Tighten:
Caution: 67 N⋅m (6.8 kgf⋅m/49 lbf⋅ft)
• Clean off the old anti-seize compound on the
sleeve nuts, and apply new one. Caution:
Tighten the front exhaust pipe A evenly to prevent gas
• Make sure to install the differential pressure pipes leakage.
according to the procedure. Failure to follow the
procedure may cause the nut to be loose. 2. Install the exhaust brake assembly.
• When the DPD has been disassembled, do not • Install the exhaust brake assembly and the
reuse the old gasket, bolt and nut (use gasket, front exhaust pipe B to the front exhaust pipe A,
fixing kit). and tighten to the specified torque.
Tighten:
27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft)
8 1
2 2 2
7 7
6 3
1 5 4
3
N6B6093E N6B6268E
Legend Legend
1. Front Exhaust Pipe A 1. Differential Pressure Sensor
2. Exhaust Brake Assembly 2. Clip
3. Front Exhaust Pipe B 3. Differential Pressure Hose
4. The Normal Hose Assembly
3. Install the DPD assembly to the front pipe. 5. The Revers Hose Assembly
6. Differential Pressure Hose
Tighten:
7. Clip
S spec: 85 N⋅m (8.7 kgf⋅m/63 lbf⋅ft)
8. Differential Pressure Sensor
N spec: 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
4. Install the differential pressure hose to the DPD 5. Connect the DPD exhaust temperature sensor
differential pressure pipe. connector.
• Insert the differential pressure hose securely till
it reaches the bulge of the pipe. Caution:
Do not confuse its front and rear directions.
• Attach the hose clip properly.
Caution:
• Do not confuse its front and rear directions.
• Do not use the hose that have cracks.
• Do not further tighten nor remove the tightening
screw of the differential pressure sensor assembly.
• Gas leakage from the joint can cause malfunction
of the sensor.
Be sure to check for gas leakage after starting the
engine.
4
4HK1-TCN
5
2
1 2
1
3 4
5
6
7
N6B6215E
Legend
1. Extension Pipe
5 4 2. Exhaust Throttle Assembly
4HK1-TCS
2 3. Adapter Pipe
1 4. Silencer
5. DPD
10. Connect the tail pipe which has a post silencer.

• Tighten the clamp.
Tighten:
50 N⋅m (5.1 kgf⋅m/37 lbf⋅ft)
6
7
1
N6B6091E
2
Legend
1. Exhaust temperature sensor 2 (catalyst inlet)
2. Exhaust temperature sensor 1 (filter inlet)
3. DPD assembly
4. Differential pressure hose (F)
5. Differential pressure hose (R)
6. Differential pressure pipe (R)
7. Differential pressure pipe (F)
6. Fix the clip of the exhaust temperature sensor

harness of DPD. N6B6090E
7. Install the extension pipe to the DPD. Legend
Tighten: 1. Tail Pipe
50 N⋅m (5.1 kgf⋅m/37 lbf⋅ft) 2. Post Silencer
8. Attach the exhaust throttle assembly into the
adapter pipe, and install the silencer.
Tighten:
27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft)
9. Connect the air pipe to the air cylinder of the
exhaust throttle.
Caution:
After assembling each part, start the engine and make
sure that there is no gas leakage or vibration at each
connection. If the DPD assembly has been
disassembled, carefully check for gas leakage as
follows:
• Fully warm-up the engine.
• Blow up the engine to the maximum speed. At this
time, spray soap water to the differential pressure
hose joint and the tightening part of sleeve nut to
check gas leakage.
67 (6.8 / 49)
27 (2.8 / 20)
50 (5.1 / 37) 50 (5.1 / 37)

27 (2.8 / 20)
S spec 85 (8.7 / 63)

N spec 22 (2.2 / 16)
N6B6098E
Exhaust Brake System

Service Precautions
During assembly and mounting, mount the parts
appropriately at the specified tightening torque value.
N6A6439E
Functional Check
Operational check
• Confirm the sound of the valve touching the
stopper when the exhaust brake is operated in the
idling condition.
Exhaust Brake
Components
7 N6B6099E
Legend
1. Power Chamber, Insulator, Gasket and Bearing 5. Front Exhaust Pipe B
2. Lock Nuts and Clevis Joint 6. Exhaust Brake Assembly
3. Split Pin and Washer 7. Front Exhaust Pipe A
4. Exhaust Brake Valve
Removal
1. Remove the vacuum hose and clips.
2. Remove the nut.
3. Remove the exhaust pipe.
4. Remove the exhaust brake assembly.
Disassembly
1. Remove the split pin.
2. Remove the lock nuts.
3. Remove the clevis joint.
4. Remove the power chamber.
Reassembly
1. Mount the power chamber.
N6A6441E
Tighten:
2. Mount the lock nuts.
Nut to 14 N⋅m (1.4 kgf⋅m/122 lbf⋅in)
3. After mounting the clevis joint, tighten the lock nuts Unit check
to the specified torque. • Negative pressure in the power chamber caused
Tighten: by the vacuum pump
Lock nut to 13 N⋅m (1.3 kgf⋅m/113 lbf⋅in) When a pressure of 53.3 - 93.3 kPa (0.54 - 0.95
kg/cm2 / 7.7 - 13.5 psi) is applied, the exhaust
brake valve should open or close smoothly.
Special tool
Vacuum pump: 5-8840-0279-0 (J-23738-A)
N6A6442E
4. Mount the split pin.
Inspection
N6A6443E
Check for damage or degradation in the parts
mentioned below.
• Exhaust brake valve
Installation
• Exhaust brake shaft 1. Mount the exhaust brake assembly.
• Butterfly valve Tighten:
• Bush Bolt and nut to 27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft)
• Power chamber
N6B6218E
2. Mount the exhaust pipe. 3. Mount the nuts.
Tighten:
Nut to 67 N⋅m (6.8 kgf⋅m/49 lbf⋅ft)
4. Mount the vacuum hose and the clips.
N6A6445E
N6B6100E
Tool Number /
Illustration
Description
5-8840-0279-0
(J-23738-A)
Vacuum Pump
5884002790
LG4HK-WE-0761
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all

countries except the USA, Canada and Mexico.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
SERVICE MARKETING DEPARTMENT
Tokyo, Japan
First edition August, 2006

No.LG4HK-WE-0761

ENGINE WORKSHOP MANUAL SECTION 6A

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ENGINE WORKSHOP MANUAL SECTION 6A

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WORKSHOP MANUAL

Isuzu Motors Limited

Service Marketing Department

Before using this Workshop Manual to assist you in performing

All material contained in this Manual is based on latest product

This manual is applicable to 2007 year model.

SECTION No. CONTENTS

ISUZU DIESEL ENGINE (4HK1-TC)

<Example> Measurement of clearance between

Explanation of Functions and Operations Cylinder Liner

• Install the minus terminal of the battery.

A list of defective phenomena

Compression pressure MPa (kg/cm2 / psi) / rpm

• Measure each cylinder one by one.

• Remove a compression gauge of the special tool.

Condition Possible Cause Correction

Engine turns over but does not start

Condition Possible Cause Correction

Condition Possible Cause Correction

Excessive black exhaust smoke

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Abnormal battery charging

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Item Engine model 4HK1-TCS Engine model 4HK1-TCN

Item Engine model 4HK1-TCS Engine model 4HK1-TCN

9. Remove the upper hose of the radiator.

6. Disconnect the IAT&MAF sensor connector.

11. Install the AC generator harness.

21. Install the inlet hose (between air cleaner and

22. Connect the IAT&MAF sensor connector.

• Before removing the engine mount, hang the

N m (kgf m / lbf ft)

Cylinder Head Cover

5. Remove the fuel injector harness connector (2).

7. Install 6 bolts to fasten the EGR cooler (2nd).

4. Install the gasket on the head cover.

N m (kgf m / lbf ft)

1. Remove the fuel rail.

2. Install the throttle assembly.

3. Install the EGR valve.

N m (kgf m / lbf ft)

Turbocharger and Exhaust Manifold

Removal 6. Remove the front exhaust pipe.

Axle play mm (in)

Manifold installation plane surface mm (in) N6A6043E

• Check a crack in the exhaust manifold visually.

• Tighten up with the 2 nuts and 6 bolts according Legend

2. Install the gasket and turbocharger to the exhaust

5. Install the water return pipe. Tighten the joint bolts

6. Install the water return pipe bracket. Tighten the Legend

8. Tighten the oil return pipe bolts to the specified

7. Install the turbocharger oil feed pipe to the top of

N m (kgf m / lbf ft)

52 (5.3 / 38) 8 (0.8 / 69 lbf in)

34 (3.5 / 25) 22 (2.1 / 15)

Timing Gear Train

Removal 2. Remove the rocker arm shaft assembly.