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INDUSTRIAL

DIESEL ENGINE
4LE2
MODEL

WORKSHOP MANUAL

2003 ISUZU MOTORS LIMITED

FOREWORD
This Workshop Manual is designed to help you perform necessary
maintenance, service, and repair procedures on applicable Isuzu
industrial engines.
Information contained in this Workshop Manual is the latest
available at the time of publication.
Isuzu reserves the right to make changes at any time without prior
notice.

TABLE OF CONTENTS
SECTION 1.

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2.

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

SECTION 3.

LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79

SECTION 4.

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83

SECTION 5.

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89

SECTION 6.

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

SECTION 7.

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

SECTION 8.

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

GENERAL INFORMATION 1

SECTION 1

GENERAL INFORMATION
TABLE OF CONTENTS
CONTENTS

PAGE

GENERAL REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTES ON THE FORMAT OF THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN DATA AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ANGULAR NUT AND BOLT TIGHTENING METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE ON MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11


GASKET LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RECOMMENDED LUBRICATING OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2 GENERAL INFORMATION

GENERAL REPAIR INSTRUCTIONS


1. Before performing any service operation with the engine mounted, disconnect the grounding cable
from the battery.
This will reduce the chance of cable damage and burning due to short circuiting.
2. Always use the proper tool or tools for the job at hand.
Where specified, use the specially designed tool or tools.
3. Use genuine ISUZU parts referring ISUZU PARTS CATALOG for the engines.
4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you
remove them. Replace them with new ones.
5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation.
It is especially important to keep fastening parts separate. These parts vary in hardness and design,
depending on their installation position.
6. All parts should be carefully cleaned before inspection or reassembly.
Oil ports and other openings should be cleaned with compressed air to make sure that they are completely free of obstructions.
7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.
8. If necessary, use a sealer on gaskets to prevent leakage.
9. Nut and bolt torque specifications should be carefully followed.
10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine
or disconnecting pipes and hoses.
11. Always check and recheck your work. No service operation is complete until you have done this.
12. Information contained in the Main Data and Specifications of the Workshop Manual and the Instruction Book may differ. In this case, the information contained in the Instruction Book should be
considered applicable.

NOTES ON THE FORMAT OF THIS MANUAL


This Workshop Manual is applicable to the 4LE2 family of industrial diesel engines. Unless otherwise
specified, these engines have common parts and components as well as data and specifications.
Illustrations used in this Workshop Manual are based on the 4LE2 engines.
1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.
2. Common technical data such as general maintenance items, service specifications, and tightening
torques are included in the General Information section.
3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and
reassembly.
4. When the same servicing operation is applicable to several different units, the manual will direct you
to the appropriate page.
5. For the sake of brevity, self-explanatory removal and installation procedures are omitted.
More complex procedures are covered in detail.

GENERAL INFORMATION 3
6. Each service operation section in this Workshop Manual begins with an exploded view of the applicable area.
(Example)
Major components
Figures in parentheses (

) show the order of disassembling or reassembling.

Water Outlet Pipe (5)


Packing (6)
Thermostat (7)

Water pump ASM (8)

Pulley; Fan (4)


Spacer (2)
Fan; Cooling (1)

Belt; Fan (3)

Fig. 1

7. Measurement criteria are defined by the terms standard and limit.


A measurement falling within the standard range indicates that the applicable part or parts are serviceable.
Limit should be thought of as an absolute value.
A measurement which is outside the limit indicates that the applicable part or parts must be either
repaired or replaced.
8. Components and parts are listed in the singular form throughout the Manual.

4 GENERAL INFORMATION
9. The following symbols appear throughout this Worshop Manual. They tell you the type of service
operation or step to perform.

...

Remove

...

Adjustment

...

Installation

...

Cleaning

...

Disassembly

...

Important Operation Requiring Extra Care

...

Reassembly

...

Specified Torque (Tighten)

...

Alignment (Marks)

...

Special Tool Use Required for Recommended


(Isuzu Tool or Tools)

...

Directional Indication

...

Commercially Available Tool Use Required or


Recommended

...

Inspection

...

Lubrication (Oil)

...

Measurement

...

Lubrication (Grease)

...

Sealant

10. Direction used in this Manual are as follows:


Front
The cooling fan side of the engine viewed from the flywheel.
Right
The injection pump side of the engine.
Left
The exhaust manifold side of the engine.
Rear
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine.
The front most cylinder is No. 1 and rear most cylinder is No.
The engines direction of rotation is counterclockwise viewed from the flywheel.

GENERAL INFORMATION 5

APPEARANCE
1. MODEL 4LE2
(1) Left side view

Fig. 2

(2) Right side view

Fig. 3

6 GENERAL INFORMATION

MAIN DATA AND SPECIFICATIONS


1. MODEL 4LE2
Engine model(s)

4LE2

Item
Type

4-cycle, verlical in-line, water cooled, OHV

Timing drive system

Gear drive

No. of cylinders - bore stroke


Displacement

mm

4 85 92

L (cid)

2.179 (133)

Compression ratio

18.8 : 1

Type of combustion

Direct injection

Overall length width height

mm

691 449 616

kg (lb)

155 (342)

(when at stop)

14

Dry weight
Fuel injection timing (BTDC)
Firing order

1342

Fuel

Highspeed diesel fuel (SAE No.2)


min-1

Idling speed
Compression pressure
Valve clearance (cold)
mm (in)

Valve
operating
timing

MPa(kg/cm2/psi)

850
3 (31/440) or more/250 min-1

Intake

0.4 (0.0157)

Exhaust

0.4 (0.0157)

Open (BTDC)

15

Close (ABDC)

29

Open (BBDC)

40

Close (ATDC)

16

Intake valve

Exhaust valve

Injection pump

Bosch type

Governor

Mechanical type

Nozzle

Multi-hole type

Injection pressure

MPa(kg/cm2/psi)

17.7 (180/2560)

Oil pump

Trochoid type

Oil filter

Cartridge type

Lubricant capacity: In total

L (qts)

About 8.7 (9.2)

Generator output

(V A)

12 35

(V KW)

12 2.0

Starter output

(Note) These specifications may be subject to change without notice.


Figures in the column with an asterisk (*) are different for each machine. Refer to the specifications provided by machine manufacturers.

GENERAL INFORMATION 7

TIGHTENING TORQUE SPECIFICATIONS


The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.

STANDARD BOLT

Nm (kgfm)

Bolt
Identification

Bolt
Diameter
pitch (mm)
M 6 1.0

003.9007.8 {00.400.8}

004.9009.8 {00.501.0}

M 8 1.25

007.8017.7 {00.801.8}

011.8022.6 {01.202.3}

016.7030.4 {01.703.1}

M10 1.25

020.6034.3 {02.103.5}

027.5046.1 {02.804.7}

037.3062.8 {03.806.4}

019.6033.4 {02.003.4}

027.5045.1 {02.804.6}

036.3059.8 {03.706.1}

M12 1.25

049.1073.6 {05.007.5}

060.8091.2 {06.209.3}

075.5114.0 {07.711.6}

* M12 1.75

045.1068.7 {04.607.0}

056.9084.4 {05.808.6}

071.6107.0 {07.310.9}

M14 1.5

076.5115.0 {07.811.7}

093.2139.0 {09.514.2}

114.0171.0 {11.617.4}

* M14 2.0

071.6107.0 {07.310.9}

088.3131.0 {09.013.4}

107.0160.0 {10.916.3}

M16 1.5

104.0157.0 {10.616.0}

135.0204.0 {13.820.8}

160.0240.0 {16.324.5}

* M16 2.0

100.0149.0 {10.215.2}

129.0194.0 {13.219.8}

153.0230.0 {15.623.4}

M18 1.5

151.0226.0 {15.423.0}

195.0293.0 {19.929.9}

230.0345.0 {23.435.2}

* M18 2.5

151.0226.0 {15.423.0}

196.0294.0 {20.030.0}

231.0346.0 {23.635.3}

M20 1.5

206.0310.0 {21.031.6}

270.0405.0 {27.541.3}

317.0476.0 {32.348.5}

* M20 2.5

190.0286.0 {19.429.2}

249.0375.0 {25.438.2}

293.0440.0 {29.944.9}

M22 1.5

251.0414.0 {25.642.2}

363.0544.0 {37.055.5}

425.0637.0 {43.364.9}

* M22 2.5

218.0328.0 {22.233.4}

338.0507.0 {34.551.7}

394.0592.0 {40.260.4}

M24 2.0

359.0540.0 {36.655.0}

431.0711.0 {43.972.5}

554.0831.0 {56.584.7}

* M24 3.0

338.0507.0 {34.551.7}

406.0608.0 {41.462.0}

521.0782.0 {53.179.7}

* M10 1.5

An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting.

8 GENERAL INFORMATION

TIGHTENING TORQUE SPECIFICATIONS


The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.

FLANGED HEAD BOLT

Nm (kgfm)

Bolt
Identification

Bolt
Diameter
pitch (mm)
M 6 1.0

004.6008.5 {00.500.9}

006.6012.2 {00.601.2}

M 8 1.25

010.50196 {01.102.0}

015.3028.4 {01.602.9}

018.1033.6 {02.103.4}

M10 1.25

023.1038.5 {02.403.9}

035.4058.9 {03.606.1}

042.3070.5 {04.307.2}

022.3037.2 {02.303.8}

034.5057.5 {03.505.8}

040.1066.9 {04.106.8}

M12 1.25

054.9082.3 {05.608.4}

077.7117.0 {07.911.9}

085.0128.0 {08.713.0}

* M12 1.75

051.0076.5 {05.207.8}

071.4107.0 {07.310.9}

079.5119.0 {08.112.2}

M14 1.5

083.0125.0 {08.512.7}

115.0172.0 {11.717.6}

123.0185.0 {12.618.9}

* M14 2.0

077.2116.0 {07.911.8}

108.0162.0 {11.116.6}

116.0173.0 {11.817.7}

M16 1.5

116.0173.0 {11.817.7}

171.0257.0 {17.426.2}

177.0265.0 {18.027.1}

* M16 2.0

109.0164.0 {11.216.7}

163.0244.0 {16.624.9}

169.0253.0 {17.225.8}

* M10 1.5

A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.

GENERAL INFORMATION 9

ANGULAR NUT AND BOLT TIGHTENING METHOD

1. Carefully wash the nuts and bolts to remove all oil


and grease.

2. Apply a coat of molybdenum disulfide grease to the


threads and setting faces of the nuts and bolts.

Fig. 4

3. Tighten the nuts and bolts to the specified torque


(snug torque) with a torque wrench.

Snug torque

Fig. 5
Center line

Fig. 6

4. Draw a line [A-B] across the center of each bolt.

10 GENERAL INFORMATION
5. Draw another line [C-D] on the face of each of the
parts to be clamped. This line should be an extension of the line [A-B].

Line

Fig. 7

6. Draw another line [F-G] on the face of each of the


parts to be clamped. This line will be in the direction of the specified angle [Q] across the center [E]
of the nut or bolt.

E
Specified angle (Q)
F

Coinciding line

Fig. 8

7. Use a socket wrench to tighten each nut or bolt to


the point where the line [A-B] is aligned with the line
[F-G].

Tighten
A
C
B

G
Fig. 9

Example: Specified Angle and Tightening Rotation

Fig. 10

B C D E

30

1/12 of a turn

60

1/6 of a turn

90

1/4 of a turn

180

1/2 of a turn

360

One full turn

GENERAL INFORMATION 11

TIGHTENING TORQUE ON MAJOR COMPONENTS


1. COOLING FAN AND WATER PUMP
Nm (kgfm/ft. lb)
19 28
(1.9 2.9 / 14 21)

12 18
(1.2 1.8 / 9 13)

12 18
(1.2 1.8 / 9 13)

19 28
(1.9 2.9 / 14 21)
To cylinder head

19 28
(1.9 2.9 / 14 21)
To cylinder head

19 28
(1.9 2.9 / 14 21)
19 28
(1.9 2.9 / 14 21)
34 46
(3.5 4.7 / 25 34)
Fig. 11

12 GENERAL INFORMATION

2. CYLINDER HEAD AND CYLINDER HEAD COVER


Nm (kgfm/ft. lb)
8 12
(0.8 1.2 / 6 9)
8 12
(0.8 1.2 / 6 8)
24
(0.2 0.4 / 1.4 2.9)

8 12
(0.8 1.2 / 6 9)

(Apply sealant.)

83 93
(8.5 9.5 / 61 69)

60 90
15 20
(1.5 2.0 / 11 14)

(Apply engine oil.)

19 28
(1.9 2.9 / 14 21)

0.9 1.1
(0.09 0.11 / 0.6 0.8)

(Apply Locktite No.262 to this part.)

25 34
(2.5 3.5 / 18 25)
19 28
(1.9 2.9 / 14 21)

(Apply engine oil.)


Fig. 12

14 GENERAL INFORMATION

4. CYLINDER BLOCK AND OTHER COMPONENTS (2)


Nm (kgfm/ft. lb)
20 25
(2.0 2.5 / 15 18)
10 14
(1.0 1.4 / 7 10)

8 12
(0.8 1.2 / 6 9)

15 25
(1.5 2.5 / 11 18)

31 41
(3.2 4.2 / 23 30)
19 28
(1.9 2.9 / 14 21)

8 12
(0.8 1.2 / 5.8 8.7)

19 28
(1.9 2.9 / 14 21)

21 30
(2.1 3.1 / 15 22)

(Apply engine oil.)

Positioning
pin.

8 12
(0.8 1.2 / 6 9)

69 88
(7.0 9.0 / 51 65)

19 28
(1.9 2.9 / 14 21)

19 28
(1.9 2.9 / 14 21)
Fig. 14

GENERAL INFORMATION 15

5. CYLINDER BLOCK AND OTHER COMPONENTS (3)


Nm (kgfm/ft. lb)

Apply Locktite
No.262 (2 locations).

8 12
(0.8 1.2 / 6 9)
12 16
(1.2 1.6 / 9 12)

8 12
(0.8 1.2 / 6 9)

Rotate 3/4 turn after


contacted with
sealing surface.

1.5 25
(1.5 2.5 / 11 18)

(With PTO provided)

8 12
(0.8 1.2 / 6 9)

19 28
(1.9 2.9 / 14 21)

8 12
(0.8 1.2 / 6 9)

19 28
(1.9 2.9 / 14 21)

Fig. 15

41 55
(4.2 5.6 / 30 41)
8 12
(0.8 1.2 / 6 9)

16 GENERAL INFORMATION

6. TURBOCHARGER
Nm (kgfm/ft. lb)

19 28
(1.9 2.9 / 14 21)

Fig. 16

GENERAL INFORMATION 17

GASKET LOCATION
1. LOCATIONS WHERE GASKETS ARE USED

Packin; nozzle holder


Gasket; nozzle holder

Packin; joint bolt

O-ring

Packin; headcover
() Sealant should not be
applied.

Gasket

Seal; valve

Packin;
water outlet pipe

Gasket;
cylinder head

Packin;
idle spring set screw

O-ring;
fuel cut lever

Packin;
rear cover
(PTO)

Packin;
governor
cover

Gasket;
exhaust
manifold

Oil seal;
crankshaft
rear

O-ring;
control lever

O-ring;
Oil strainer

O-ring;
angleich cover
Oil seal;
crankshaft front

O-ring;
Oil pump
O-ring;
Oil drain plug

Fig. 17

Gasket;
exhaust silencer

18 GENERAL INFORMATION

2. LOCATIONS WHERE SEALANT IS APPLIED


Location
Name of part

Condition for use


Name of
mating part

Object to be
sealed

Groove to be
applied

Name of
sealant

Oil pan

Cylinder block

Engine oil
(10W-30)

Not provided

TB1207C

Rocker bracket

Cylinder head

Engine oil
(10W-30)

Provided

TB1207B

Air inlet pipe

Cylinder head cover

Air

Provided

TB1207C

Front plate
(with PTO provided)

Cylinder block

Engine oil
(10W-30)

Provided

TB1207B

Timing case (with


PTO provided)

Front plate

Engine oil
(10W-30)

Provided

TB1207B

Timing case (with


no PTO provided)

Cylinder block

Engine oil
(10W-30)

Provided

TB1207B

Water pump ASM

Cylinder block

Cooling water

Not provided

TB1207C

Rear cover;
water pump

Body; water pump

Cooling water

Provided

TB1207B

Housing cover;
injection pump

Cylinder block

Engine oil
(10W-30)

Provided

TB1207B

10

Solenoid; fuel cut

Cylinder block

Engine oil
(10W-30)

Provided

TB1207C

11

Retainer; oil seal

Cylinder block

Engine oil
(10W-30)

Provided

TB1207B

12

Indicator; air cleaner

Air cleaner

Air

Not provided

(Sealing tape)

Fig. 18

Cautions:
1. Always use the above brandnames or an equivalent as the sealant.
2. Since Loctite FMD127 and Three-Bond 1386 are anaerobic, do not use them in case a gap exceeding
0.25 mm is occurring between the metallic mating surfaces since satisfactory effects cannot be
expected.
3. Always use the optimum quantity of sealant. Observe the handling precautions designated for
respective products.
When applying a sealant :
(1) when applying a sealant over a surface where some other liquid gasket was used previously, thoroughly clean the reside sealant using a scraper and wipe the surface by waste cloth to remove oil,
moisture, dust, etc. from the surface.
(2) When using the gasket remover Bundo 391D made by Three-Bond (Isuzus Part No. 1-8840-0542-0)
to facilitate the cleaning work, apply the remover and leave it as is for about 10 minutes before
starting the removal work.
(3) Be careful not to apply too much or too little.
(4) How to use the TB1207C and TB1207B
Apply them with a line diameter of 3 mm or more and for a thickness of 1 ~ 2 mm.
Apply them along the gluing groove without interruptions and assemble the mating structures with 5
minutes.
Also, after finishing the assembly, leave the assembly as is for at least 2 hours and do not run the
engine during this period.

GENERAL INFORMATION 19

Bolt hole

Determina
tion

Dent

Dent

Apply onto the bore surface


of the bolt hole.
Specified bead width
(Reference)
Anaerobic : 2 ~ 3 mm
Others : 2 ~ 6 mm

Caution: When the application method is being designated in the repair manual, follow the designation.

3. Locktite
Types

Colors

Loctite 242

Blue

Work procedures
1.

2.

Loctite 262

Loctite 271

Red

Red

Wipe the thoroughly remove oil, grease and moisture from


the mating surfaces such as the bolt surface, bolt hole,
thread surface of the nut.
Apply Locktite.
Apply over the tip end
surface, namely 1/3 of
the threaded section.

3. Tighten the bolt at the specified torque.


Caution: After tightening the bolt, do not apply excessive
torque or vibrations for about an hour until the
applied Loctite sets.

20 GENERAL INFORMATION

MAINTENANCE
1. VALVE CLEARANCE AND ADJUSTMENT

Note:
The cylinder head bolts were previously tightened with
the Angular Tightening Method. Therefore, it is not
necessary to retighten the cylinder head bolts before
adjusting the valve clearance.

Fig. 19

1. Bring the piston in either the No. 1 cylinder or the


No. 3 cylinder to Top Dead Center on the compression stroke by turning the crankshaft until the TDC
mark on the front cover aligns with the groove mark
on the crankshaft pulley.

Groove mark
TDC mark

2. Check to see if there is play in the No. 1 intake and


exhaust valve rocker arms.
gear
(Timing
case cover )

If the No. 1 cylinder intake and exhaust valve rocker


arms have play, the No. 1 piston is at TDC on the
compression stroke.

Crank
pulley
Fig. 20

If the No. 1 cylinder intake and exhaust valve rocker


arms are depressed, the No. 4 piston is at TDC on
the compression stroke.
Adjust the circle or double circle marked valves as
shown in Fig. 22, while the No. 1 or the No.4 cylinder is at TDC on compression stroke.
mm (in)
No.1 cylinder
exhaust

No.1 cylinder
intake

I ; Intake

1
I

2
E

0.40 0.05 (0.015 0.002)

3. Loosen each valve clearance adjusting screw as


shown in the illustration.

Fig. 21
Cylinder No.
Valve
arrangement
No. 1 cylinder
TDC for compression
No. 4 cylinder
TDC for compression

Intake and Exhaust


Valve Clearance (cold)

3
E

4
E

4. Insert a 0.40 mm (0.015 in) feeler gauge between the


rocker arm and the valve stem end.
5. Turn the valve clearance adjusting screw until a
slight drag can be belt on the feeler gauge.

6. Tighten the lock nut securely.



E ; Exhaust
Fig. 22

7. Rotate the crankshaft 360.


Realign the crankshaft pulley.
8. Adjust the clearances for the remaining valves as
shown in the illustration.

GENERAL INFORMATION 21

2. LUBRICATIN SYSTEM
Cartridge (Spin-On) Type
Cartridge

Removal
Remover and Installer: Filter Wrench
1. Loosen the used oil filter by turning it counterclockwise with the filter wrench.
2. Discard the used oil filter.
Installation
1. Wipe the oil filter mounting face with a clean rag.
Fig. 23

This will allow the new oil filter to seat properly.


2. Lightly oil the O-ring.
3. Turn in the new oil filter until the sealing face is fitted against the O-ring.
4. Use the filter wrench to turn in the oil filter an additional 3/4 of a turn or one turn.
5. Check the engine oil level and replenish to the specified level if required.
6. Start the engine and check for oil leakage from the
oil filter.

3. COOLING SYSTEM
Cooling Fan Drive Belt
Adjustment

Fan pulley 1

About 10 mm

1. Check the cooling fan drive belt for cracking and


other damage.

Generator pulley
2

2. Check the drive belt tension by exerting a force of 98


N (10 kg) midway between the Fan pulley 1 and the
Generator pulley 2.

Depress here
Cooling
fan drive
belt

Crank pulley
Fig. 24

3. Adjust the belt tension by loosening the Generator


mounting bolt and the Generator adjusting bolt and
pivoting the Generator.
Be sure to retighten the bolts after adjusting the belt
tension.
mm (in)
Cooling Fan Drive
Belt Deflection

7.5 8.5
(0.3 0.33)

22 GENERAL INFORMATION

4. INJECTION TIMING
Note:
Take care to avoid entry of dust or foreign particles into
the pump interior when the timing adjustment is made.
Delivery valve
holder

Injection pump

Delivery
spring

1.

Remove the injection pipe of the No. 1 cylinder.

2.

Remove the delivery valve holder of the injection


pump of the No. 1 cylinder, and then pull out the
delivery spring.

3.

With the spring left removed, install the delivery


valve holder.

4.

Slowly turn the crankshaft pulley clockwise, at the


same time, continue to feed the fuel.
When the fuel stop flowing out from the No. 1 delivery valve holder, stop turning the crankshaft.

Fig. 25

This crank angle position is the starting point of


injection.
5.
Groove mark
TDC mark

In the condition at Step (4) above, confirm what


degree the groove mark of the crank pulley is at,
when seen by the timing mark, provided in the
timing gear case.
When the value is out of the range of the normal
injection timing, adjust it accordingly.

Timing gear
case cover

* Injection timing

Crank
pulley

Injection pump
Cylinder block
Identification
mark

Note:
The injection timing varies according to the specifications of the machine.

Fig. 26

Shim

BTDC 14

6.

Adjust the injection timing with a shim between the


injection pump and the cylinder block.
Shim is available in the following 9 types, and identification mark is stamped (or imprinted) on the top
face.

Identification mark of shim and its thickness


Knock hole

Fig. 27

(mm)

Mark

Thickness

Mark

Thickness

Mark

Thickness

0.2

0.5

0.8

0.3

0.6

10

1.0

0.4

0.7

12

1.2

Note:
For each of the injection pumps of three cylinders, the
shim adjustment is made at the same time.
When a shim is missing while overhauling the engine
and the shim thickness is unknown, assemble the
engine with provisional shim inserted. After assembling
the engine, check the injection timing and adjust the
shim until the normal injection timing is obtained.
Reference:
To add the 0.1 mm shim thickness corresponds to the 1
degree of crankshaft angle advance.

GENERAL INFORMATION 23
Air bleeding from fuel (automatic air-bleeding system)
1.

For the automatic air-bleeding system


When the starter switch is set to OPERATION, the
electromagnetic pump is activated to force-feed fuel
to the fuel pipe and the leak-off pipe, and air in the
fuel system is automatically bled.

2.
Injection Pump

Fig. 28

For non-automatic air-bleeding system


While sending fuel by means of the force of the electromagnetic pump, the fall from the fuel tank or the
feed pump lever, bleed air out of the fuel pipe eye
bolt of the No. 1 cylinder injection pump, the leak-off
pipe eye bolt of the injection nozzle and the airbleeder plug of the fuel filter, starting with the one
installed the lower most and upward.

5. COMPRESSION PRESSURE MEASUREMENT


Compression gauge

1. Operate the engine to warm-up until the coolant


temperature reachs to 75C (167F).
2. Remove all of the glow plugs and the injection
pipes.

Adapter; gauge

3. Attach a compression gauge to the No. 1 cylinder


glow plug installation threads.
Note:
Compression pressure may be measured starting at any
cylinder and in no particular cylinder order. However, it
is very important that the compression pressure be
measured in each cylinder.
Therefore, start at the No. 1 cylinder and work back. In
this way, you will be sure to measure the compression
pressure in each cylinder.

Fig. 29

Compression Gauge

5-8840-2675-0

Compression Gauge Adapter 5-8840-9029-0

4. Crank the engine with the starter motor and take the
compression gauge reading.
MPa (kgf/cm2 /psi) at 250 min-1
Standard

Limit

3 (31/440)

2.5 (26/370)

5. Repeat the procedure (.Steps 3 and 4.) for the


remaining cylinders.
Fig. 30

Compression pressure should be approximately the


same for each cylinder. A variation exceeding 200
kPa (2.0 kg/cm2 /.28 psi.) is unacceptable.
If the measured value exceeds the specified limit,
the related parts must be checked.

24 GENERAL INFORMATION

6. FUEL SYSTEM
Fuel Filter Replacement
Cartridge (Spin-On) Type
Removal
1.

Loosen the fuel filter by turning it counterclockwise


with the filter wrench or your hand. Discard the
used filter.
Filter Wrench

2.

Wipe the fuel filter fitting face clean with a rag.


This will allow the new fuel filter to seat properly.

Fig. 31

Installation
1.

Apply a light coat of engine oil to the O-ring.

2.

Supply fuel to the new filter.


This will facilitate air bleeding.

3.

Turn in the new fuel filter until the filter O-ring is fitted against the sealing face.

4.

Use the filter wrench to turn in the fuel filter an additional 2/3 of a turn.

Injection nozzle

Check to see if the spray condition and the injection


pressure are normal. Adjust them to the specified value
respectively when they dont meet the standard valve.
Spray Condition
(1) Correct
(2) Incorrect (Restrictions in orifice)
(3) Incorrect (Dipping)

Fig. 32

MPa (kgf/cm2 /psi)


Injection pressure

17.7 (180/2560)

Using a nozzle tester, adjust the injection pressure with a


shim.
Special tool: Nozzle tester

Fig. 33

GENERAL INFORMATION 25

RECOMMENDED LUBRICATING OIL


TYPE OF LUBRICANTS (API)

DIESEL ENGINE OIL; CC OR CD GRADE

ENGINE OIL VISCOSITY CHART


ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 5W20
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

[Single grade]

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 20, 20W
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 40
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;

;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W
SAE 30
;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

Ambient
temperature

[Multi grade]

25C 20C 15C


(13F) (4F) (5F)

0C
(32F)

15C
(59F)

25C 30C
(77F) (86F)

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 15W40, 20W40
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

Fig. 34

MEMO

ENGINE 27

SECTION 2

ENGINE
TABLE OF CONTENTS
CONTENTS

PAGE

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

28 ENGINE

DISASSEMBLY
1. EXTERNAL PARTS (Left-hand side)

(9)

(10)

(2)

(1)

(8)
(3)

(5)

(11)
(7)
(4)

(6)

Fig. 35

(1) Exhaust silencer


(2) Exhaust pipe
(3) Cooling fan and spacer
(4) Fan belt
(5) Fan pulley
(6) Generator
(7) Starter
(8) Exhaust manifold and gasket
(9) Cylinder head cover and air intake pipe
(10) Water outlet pipe and thermostat
(11) Water pump assembly

ENGINE 29

2. EXTERNAL PARTS (Right-hand side)

(15)

(14)

(13)

(12)

(18)

(16)

(19)

(17)

(20)

Fig. 36

(12) Injection pipe . . . . . . . . . 4 pcs.


(13) Fuel hose
(14) Fuel leak off pipe
(15) Fuel pipe
(16) Engine stop solenoid
(17) Injection pump housing cover
(18) Injection pump and shim . . . . . . . . . 4 set
(19) Oil filter
(20) Oil level gauge

30 ENGINE
Leak off pipe

Fuel pipe

Injection pipe
Leak off pipe
Fuel pipe

Eye bolt
Injection pipe

1.

Loosen the sleeve nuts on the nozzle holder side and


on the injection pump side, and then disconnect the
injection pipes.

2.

Disconnect the leak off pipe together with gaskets.

3.

Remove the eye bolt, and then disconnect the fuel


pipe.

Nozzle holder

Injection pump

Fig. 37

Solenoid ASM
Remove the solenoid ASM.

Solenoid ASM
Fig. 38

Injection pump housing cover


Stud bolt

1.

Remove the bolts and nut.

2.

Install the bolts (M8 x 1.25) to the replacer hole.

3.

Tighten the bolts, and then remove housing cover.

Housing cover

Fig. 39
Housing cover

Mark : M81.25 for replacer


Fig. 40
Fuel cut cover
Pin(6 )

Governor cover
Fig. 41

Injection pump
1.

Align the hole of the fuel cut lever with the hole of
the governor cover, and then insert a pin (6) into
this hole to hold the fuel cut lever.

2.

Check to see if the pin groove of the control link is at


the center of the injection pump.

3.

Remove the injection pump, and then take out the


shim.

ENGINE 31
NOTE:
Injection pump
center position

Control link

1.

Mark each injection pump as to which cylinder it


was removed from.

2.

Do not reuse the shim, replace it with the same


thickness that was removed.

Injection pump
rack pin
Fig. 42
Injection pump ASM

Shim

* Stud
Cylinder block
Fig. 43

Backlash of timing gear

mm (in)
STANDARD

LIMIT

CRANK GEAR/
IDLER GEAR

0.04
(0.0017)

0.2
(0.0079)

CAM GEAR/
IDLER GEAR

0.03
(0.0012)

0.2
(0.0079)

IDLER GEAR END PLAY

mm (in)

STANDARD

LIMIT

0.058 0.115 (0.0023 0.0045)

0.2 (0.0079)

CRANKSHAFT END PLAY

mm (in)

STANDARD

LIMIT

0.058 0.208 (0.0023 0.0082)

0.3 (0.0118)

32 ENGINE

3. INTERNAL PARTS
Disassembly Steps
(1) Rocker Bracket Assembly
(2) Push Rods
(3) Rear Hanger
(4) Front Hanger
(5) Cylinder Head Assembly
(6) Cylinder Head Gasket
(7) Tappets
(8) Oil Pan
(9) Oil Strainer
(10) Oil Pipe
(11) Crank Pulley
(12) Flywheel
(13) Flywheel Housing
(14) Timing Gear Case (without PTO)
(15) Oil Pump Assembly
(16) Idler Gear and Shaft
(17) Cam Gear
(18) Camshaft
(19) Rear Seal Retainer
(20) Piston Assemblies
(21) Crankshaft

ENGINE 33

Internal Parts (1/3)

(14)

(1)

(3)

(2)

(5)
(18)
(17)

(7)
(4)

(16)
(15)

(6)

Fig. 44

34 ENGINE

Internal Parts (2/3)

(20)

(13)

Do not pull out


this bolt.

(9)
(12)

(21)

(10)
Rear

(19)
(11)

(8)

Fig. 45

ENGINE 35

Internal Parts (3/3)


When provided with PTO

(14-2)

(14-1)

(15)

Fig. 46

36 ENGINE
Rocker bracket

Install of
nuts (6)

Push rod
Install of
bolts (5)

1.

Remove the rocker bracket assembly.


(M6 1 . . . . . 5 bolts and 6 nuts)

2.

Pull out the push rods (8 pcs.).

Marks : Thread hole (M8 x 1.25) for replacer of rocker


bracket assembly

Rocker Bracket

Fig. 47

Cylinder head assembly

Rear
hanger
Head bolt
(M12)

Cylinder head
ASM

(M8)

Fig. 48

Remove the rear and front hangers.

2.

When removing the cylinder head bolts, loosen


them slowly, a little at a time, starting with the
outside, working in a circular pattern inward.

3.

Remove the cylinder head assembly and the head


gasket.

4.

Pull out the tappet from the cylinder body.

Head gasket
Front hanger

1.

12

15

11

13

14

Fig. 49

10

7
6

ENGINE 37

Cylinder Head Assembly

Glow plug (2)


Connector (1)
Seal; valve
Split collar (4)
Guide; valve
Spring seat (5)
Studs are applied with
sealing agent.
Do not pull them out.
(5 locations)

Valve spring (6)

Nozzle holder (3)

Valve (7)

Hot plug

Seat; valve insert

Fig. 50

Valve mechanism
1.

Before disassembling the valve mechanism, remove


the connector, glow plug and nozzle holder assembly.

2.

Compressing the valve spring, remove the split collar, spring seat, valve spring and valve.

38 ENGINE

Timing Gear

Bearing
Wear ring

Cam shaft (8)


Pin
Bearing
Snap ring (7)
Cam gear (6)

Fly weight ASM (5)

Shaft; idle gear (3)


Lock nut
Idle gear (2)
Sleeve (4)
Thrust collar
Crankshaft
Key

Crank gear
Crank pulley (1)

Washer

Fig. 51

ENGINE 39
Timing gear
1.

Remove the idle gear and the idle gear shaft.

2.

Pull out the sleeve from the tip end of the cam shaft.

3.

Remove the lock nut of the cam shaft gear, and then
remove the flyweight assembly and the cam gear.

Camshaft
Crankshaft

Snap ring

Fig. 52

1.

Remove the snap ring which holds down the front


bearing of the cam shaft from the ring groove of the
cylinder block.

2.

Pull out the cam shaft from the cylinder block,


together with the bearing.

40 ENGINE

Piston and Connecting Rod

Piston ring (4)


Snap Pipe (5)
Piston

Piston pin (6)

Bush
(The drawing-out of the bush must
be limited to only when replaced.

Conrod bolt
(The drawing-out ot the conrod bolt
must be limited to only when replaced.)

Connecting rod (7)


Cap (6)

Cap nut (1)

Fig. 53

Piston and connecting rod


Piston

Connecting rod
cap

1.

Turning the crankshaft, position the piston to be


removed at the bottom dead center.

2.

Loosen the cap nut of the connecting rod, and then


remove it.

3.

Give another rotation to the crankshaft to position


the piston at the top dead center.

4.

With the handle of a hammer placed at the bottom


of the connecting rod, push the piston assembly
upward out of the cylinder block.

Fig. 54

Notes:
1.

Before removing the piston, scrape the carbon


deposit off the cylinder wall.

2.

When pushing out the piston assembly, care should


be taken not to damage the cylinder wall.

3.

Attach a tag with a cylinder number to the removed


caps and bearings to keep them in order.

ENGINE 41
Piston ring
Remove the piston ring with a ring pliers.
Pliers: piston ring 1-85221-029-0

Fig. 55
Brass bar

Piston pin
1.

Remove the snap rings with a commercially available tool.

2.

With a brass bar attached to the piston pin, push it


out by hammering it lightly.

Note:
Keep the pistons, piston pins and connecting rods in
order for each cylinder.

Piston pin

Fig. 56

42 ENGINE

INSPECTION AND REPAIR


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

1. CYLINDER BLOCK
Cylinder block
Check the cylinder block for wear, damage or any other
defects.
Use the hydraulic gauge to check the water jacket water
pressure.
Apply water pressure to the water jacket at 5 kg/cm2
(71.1 psi) for three minutes.

Fig. 57

Cylinder bore
Y
X

Measurement position: 13mm below the top


(Measure in X-X and
Y-Y directions.)
(Near the No. 1
compression ring)
mm (in)

Fig. 58

Standard

Limit

85

85.2

Repair method
Perform boring and
honing of the inner
diameter.

Cylinder bore diameter and grade mark


Bore grade mark
(Stamp position)

Fig. 59

The grade mark is stamped on the top surface of the


cylinder block (on the mating face with the cylinder
head).

ENGINE 43
mm (in)
Engine

4LE2

Bore Diameter

Grade

85.000 85.010
(3.3464 3.3468)

85.011 85.020
(3.3468 3.3472)

85.021 85.030
(3.3472 3.3476)

Cylinder Body Upper Face Warpage


1

Use a straight edge 1 and a feeler gauge 2 to measure


the four sides and the two diagonals of the cylinder
body upper face.
Regrind the cylinder body upper face if the measured
values are greater than the specified limit but less than
the maximum grinding allowance.
2
Fig. 60

If the measured values exceed the maximum grinding


allowance, the cylinder body must be replaced.
Cylinder Body Upper Face Warpage
A

Standard

Limit

Maximum Grinding
Allowance

0.075 (0.0029)

0.15 (0.0059)

0.3 (0.0118)

E
C

mm (in)

If the measured value is less than the limit, the cylinder


body may be reground.
Fig. 61

Cylinder Body Height H (Reference)

Fig. 62

Engine

Standard

4LE2

307.94 308.06
(12.123 12.128)

mm (in)

44 ENGINE

2. CYLINDER HEAD
Cylinder head inspection
Remove carbon deposit on the bottom surface of the
head with care not to damage the valve seat.
Leakage: Water pressure test 5kg/cm2 (for 3 minutes)

Fig. 63

Cylinder Head Lower Face Warpage


1.

Use a straight edge and a feeler gauge to measure


the four sides and the two diagonals of the cylinder
head lower face.

2.

Regrind the cylinder head lower face if the measured values are greater than the specified limit but
less than the maximum grinding allowance.

Fig. 64

If the measured values exceed the maximum grinding


allowance, the cylinder head must be replaced.
Cylinder Head Lower Face Warpage
A
F

E
C

mm (in)

Standard

Limit

Maximum Grinding
Allwance

0.075 (0.0029)

0.15 (0.0059)

0.3 (0.0118)

Fig. 65

Cylinder Head Height H (Reference)


Engine

Standard

4LE2

63.90 64.10
(2.515 2.523)

mm (in)

Note:
If the cylinder head lower face is reground, valve
depression must be checked.
Fig. 66

ENGINE 45

3. VALVE, VALVE SEAT INSERT AND VALVE SEAL


Inspection of valve seat
Cylinder head
Valve

1.

A Contact width

2.

B Valve depression

mm (in)
Standard

Limit

2.0 (0.0787)

2.5 (0.0984)

IN

0.7 (0.0276)

1.2 (0.0427)

EX

0.9 (0.0354)

1.5 (0.0591)

Contact width
B

Valve depression
45
Fig. 67

Valve thickness
Nominal

Limit

IN

1.0
(0.03937)

0.7
(0.0276)

EX

0.8
(0.0315)

0.5
(0.0197)

Repair method

Replace

Fig. 68

Valve Stem Outside Diameter


Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the
valve must be replaced.
Valve Stem Outside Diameter

Fig. 69

mm (in)

Standard

Limit

Intake Valve

7.0
(0.2756)

6.85
(0.2697)

Exhaust Valve

7.0
(0.2756)

6.80
(0.2677)

46 ENGINE
Valve Seat Insert Replacement
2

Valve Seat Insert Removal

1.

Arc weld the entire inside circumference 1 of the


valve seat insert 2.

2.

Allow the valve seat insert to cool for a few minutes.


This will invite contraction and make removal of the
valve seat insert easier.

3.
Fig. 70

Use a screwdriver 3 to pry the valve seat insert


free.
Take care not to damage the cylinder head 4.

4.

Carefully remove carbon and other foreign material


from the cylinder head insert bore.

Valve Seat Insert Installation


3

1.

Carefully place the attachment 1 (having a smaller


outside diameter than the valve seat insert) on the
valve seat insert 2.

Note:
2

The smooth side of the attachment must contact the


valve seat insert.
2.

Fig. 71

Use a bench press 3 to gradually apply pressure to


the attachment and press the valve seat insert into
place. 4,000 kg (8,819 lbs.)

Note:
Do not apply an excessive amount of pressure with the
bench press. Damage to the valve seat insert will
result.
Valve Seat Insert Correction

2
(0 .0 m
.0 m
8
in
.)

150
90
30

1.

Remove the carbon from the valve seat insert surface.

2.

Use a valve cutter (15, 45, and 75 blades) to minimize scratches and other rough areas. This will
bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do not
cut away too much. Take care not to cut away
unblemished areas of the valve seat surface.

Fig. 72

Valve Seat Angle

degree
45

Note:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.

Fig. 73

ENGINE 47

Fig. 74

3.

Apply abrasive compound to the valve seat insert


surface.

4.

Insert the valve into the valve guide.

5.

Apply light pressure to the valve while turning it to


fit the valve seat insert.

6.

Check that the valve contact width is correct.

7.

Check that the valve seat insert surface is in contact


with the entire circumference of the valve.

8.

Clean the head and valves to remove the abrasive


compound and metal particles.

4. VALVE SPRING
Valve Spring Inclination
Use a surface plate and a square to measure the valve
spring inclination.
If the measured value exceeds the specified limit, the
valve spring must be replaced.
mm (in)
Valve Spring
Inclination

Standard

Limit

1.8
(0.0709)

2.5
(0.0984)

Fig. 75

Valve Spring Tension


Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the
valve spring must be replaced.
mm (in)
Valve Spring
Tension at 29.9 mm
Set Length

Standard

Limit

17.0
(37.479)

15.0
(33.069)

Fig. 76

Valve Spring Free Length


Use a vernier caliper to measure the valve spring free
length.
If the measured value is less than the specified limit, the
valve spring must be replaced.
mm (in)

Fig. 77

Exhaust and Intake


Valve Spring Free
Length

Standard

Limit

42.1
(1.6575)

40.0
(1.5748)

48 ENGINE

5. TAPPET (Cam Follower or Valve Lifter) AND PUSH ROD


TAPPET
Inspect the tappets for excessive wear, damage and any
abnormalities.
Use a micrometer to measure the tappet diameter.
mm (in)
Standard
Tappet Diameter

20.967 20.980
(0.82547 0.82598)

Fig. 78

Use a dial indicator to measure the clearance between


the tappet and cylinder body tappet travelling bore.
mm (in)
Tappet and Tappet
Travelling Bore
Clearance

Standard

Limit

0.020 0.054
(0.00079 0.00213)

0.08
(0.00315)

Fig. 79

PUSH ROD
Use a filler gauge to measure the valve push rod runout.
Roll the push rod along a smooth flat surface (illustration).
mm (in)
Limit
Push Rod Run-Out
Fig. 80

0.3 (0.0118)

ENGINE 49

6. CAM SHAFT
Inspection of cam shaft
Check the journal and the cam for evidence of wear,
damage or any other defect.

Camshaft

Note:
With the front and rear parts of camshaft pressed in
with ball bearings, and with the cylinder block pressed
in with roller bearings as the center bearing, check to
see if the camshaft rotates smoothly with no play at
each bearing.
Fig. 81

Measurement of journal and cam


1.

Cam height (A B)

mm (in)

Standard

Limit

Repair method

Intake

6.13
5.83
(0.2413) (0.2295)

Replace

Exhaust

6.43
6.13
(0.2531) (0.2413)

Replace

Fig. 82

2.

I II
I II
A'
A

B'
B

B'

3.

Center journal diameter

mm (in)

Nominal

Limit

Repair method

52
(2.0472)

51.92
(2.0441)

Replace

Uneven wear of journal

mm (in)

A'

Fig. 83

4.

Fig. 84

Nominal

Limit

Repair method

52
(2.0472)

0.05 (0.002)

Replace

Runout of cam shaft

mm (in)

Nominal

Limit

Repair method

0.02
(0.008)

0.1 (0.004)

Replace

50 ENGINE

7. ROCKER ARM SHAFT AND ROCKER ARM


Inspect all disassembled parts for wear, damage and any
abnormalities.

Fig. 85

Rocker Arm Shaft Outside Diameter


Use a micrometer to measure the rocker arm outside
diameter.
If the measured value is less than the specified limit, the
shaft must be replaced.
mm (in)
Standard

Limit

Rocker Arm Shaft 11.935 11.955


Diameter
(0.4699 0.4707)

Fig. 86

11.85
(0.4665)

Rocker Arm Shaft and Rocker Arm Clearance


1.

Use a vernier caliper to measure the rocker arm


bushing inside diameter.
mm (in)
Standard
Rocker Arm Bushing
Inside Diameter

Fig. 87

2.

11.960 11.980
(0.4709 0.4717)

Measure the rocker arm shaft outside diameter.


Replace either the rocker arm or the rocker arm shaft
if the clearance exceeds the specified limit.
mm (in)
Rocker Arm Bushing
and Rocker Arm
Shaft Clearance

3.

Fig. 88

Standard

Limit

0.005 0.045
(0.0002 0.0018)

0.2
(0.0079)

Check that the rocker arm oil port is free of obstructions.


If necessary, use compressed air to clean the rocker
arm oil port.

ENGINE 51

8. PISTON, PISTON PIN AND PISTON RING


Clearance between piston and cylinder bore

About 64

1.

Measure the outside diameter of the piston at about


64 mm from the top in a right angle to the piston pin
(in the unit of 1/1,000 mm).

2.

Calculate the clearance based on the measurements


of the cylinder bore and the outside diameter of the
piston.
mm (in)
Clearance

0.040 0.085 (0.0015 0.0033)

Fig. 89

Outside diameter of piston and grade mark


The grade mark is stamped on the top surface of the
piston installed at the factory.
The piston for service part doesnt have the grade.
mm (in)
Model

Outside diameter of piston

Grade

4LE2

84.945 84.960
(3.3443 3.3449)

NON

Fig. 90

Wear of piston pin (outside diameter)


mm (in)

Fig. 91

Nominal

Limit

25.0
(0.9843)

24.97
(0.9831)

Remarks
Replace if worn
beyond limit

52 ENGINE
Clearance between piston pin and piston pin hole
mm (in)
Standard
4LE2

0.007 0.017
(0.00027 0.00067)

Piston ring gap


With the ring inserted into the cylinder bore, push it in
with the piston head so that it becomes a right angle to
the cylinder, and then measure the gap of the piston
ring.
If worn beyond the limit, replace the rings.
mm (in)
Standard
Fig. 92

1st
compression ring

0.2 0.35
(0.0079 0.0138)

2nd compression
ring

0.35 0.5
(0.0138 0.0197)

Oil ring

0.2 0.4
(0.0079 0.0157)

Limit
1.5
(0.0590)
1.0
(0.03937)

Clearance between piston ring groove and ring


Measure clearance at several places on the circumference.
If worn beyond the limit, replace the rings or piston.
4LE2

Fig. 93

mm (in)
Standard

Limit

1st
compression ring

0.085 0.105
(0.0033 0.0041)

0.2
(0.0078)

2nd
compression ring

0.050 0.085
(0.0020 0.0033)

0.15

Oil ring

0.030 0.070
(0.0011 0.0027)

(0.0059)

ENGINE 53

9. CONNECTING ROD AND CONNECTING ROD BEARING


Torsion and parallelism of connecting rod
If worn beyond the limit-repair or replace.
mm (in)
Per 100 mm (3.94)

Standard

Limit

Torsion

0.05
(0.002)

0.2
(0.0079)

Parallelism

0.05
(0.002)

0.15
(0.0059)

Fig. 94

Clearance between small end pin hole of connecting rod


and piston pin, inside diameter of bushing
mm (in)

Clearance
Inside diameter

Standard

Limit

0.008 0.020
(0.0003 0.0008)

0.05
(0.0020)

25 (0.9843)

Fig. 95

Connecting Rod Bearing Inspection


1.

Fit the connecting rod bearing lower half into the


connecting rod bearing cap.

2.

Check the connecting rod bearing lower half tension.


If the tension is insufficient, the bearing must be
replaced.

3.

Tighten the connecting rod and the bearing cap to


the specified torque.
Nm (kgfm/ft. lb)

Fig. 96

Tightening torque

74 - 83 (7.5 - 8.5 / 54 - 61)

Clearance between bearing and crank pin, inside diameter with bearing installed and without.
mm (in)

Clearance

Fig. 97

Standard

Limit

0.035 0.073
(0.0014 0.0029)

0.10
(0.0039)

54 ENGINE

10.CRANKSHAFT AND CRANKSHAFT BEARING


Outside diameters of journal and pin
If worn beyond the limits-replace
Crank journal
4LE2

mm (in)
Standard

Limit

60.0 (2.3622)

59.86 (2.3567)

Crank pin
Fig. 98

mm (in)

4LE2

Standard

Limit

49.0 (1.9291)

48.87 (1.9240)

Note:
When there occurs an uneven wear to the crankshaft,
replace it with a new one without grinding it for reuse.
Clearance between journal and bearing inside diameter
with bearing installed and without
mm (in)

Clearance

Standard

Limit

0.029 0.072
(0.0011 0.0028)

0.11
(0.0043)

Fig. 99

Runout of crankshaft
Replace if beyond limit
mm (in)
Standard

Limit

0.025 (0.001)

0.05 (0.002)

Fig. 100

Crankshaft gear
Check the crankshaft gear visually for damage and any
other defects.

Fig. 101

ENGINE 55
Oil seal
Timing gear case

When the lip of an oil seal is found defective, replace it


with a new one.
Installation
Use the crankshaft front oil seal installer to install the
crankshaft front oil seal.

Front oil seal

Fig. 102

11.FLYWHEEL AND RING GEAR


Ring Gear Replacement
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the
ring gear must be replaced.
Ring Gear Removal
Strike around the edges of the ring gear with a hammer
and chisel to remove it.
Fig. 103

Ring Gear Installation


1.

Heat the ring gear evenly with a gas burner to invite


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

2.

Use a hammer to install the ring gear when it is sufficiently heated.

Fig. 104

12.TIMING GEAR
Uneven wear of idle gear shaft
mm (in)
Nominal

Limit

45.0 (1.7717)

0.1 (0.0039)

Fig. 105

Clearance between idle gear bushing and shaft


mm (in)

Fig. 106

Standard

Limit

0.025 0.085 (0.001 0.0033)

0.2 (0.0079)

56 ENGINE

REASSEMBLY
1. CYLINDER HEAD ASSEMBLY
Glow plug (7)
Connector (8)
Seal; valve (1)
Split collar (5)
Guide; valve
Spring seat (4)
Apply Locktite No.262
to this portion.
(5 locations)

Valve spring (3)

Nozzle holder (6)

Valve (2)

Hot plug

Seat; valve insert


Fig. 107

Important Operations
Valve Stem Oil Seal
1.

Lubricate the oil seals and valve stem sealing area


with engine oil.

2.

Use a valve stem oil seal installer to install the oil


seal.
Valve Stem Oil Seal Installer: 5-8840-9033-0

Fig. 108

Intake and Exhaust Valves


1.

Place the cylinder head on a flat wooden surface.

2.

Lubricate valve stems with engine oil.

3.

Install the valves to the intake or exhaust guides.


Install the valves to their original lapped valve seats.

Fig. 109

ENGINE 57
Intake and Exhaust Valve Springs
Install the valve springs with their painted end (the close
pitched end) facing down.

Painted potion
Fig. 110
Spring compressor
Split collar

Spring Seat Split Collar


1.

Use a spring compressor to push the valve spring


into position.

2.

Install the spring seat split collar.

3.

Set the spring seat split collar by tapping lightly


around the head of the collar with a rubber hammer.
Spring Compressor: 5-8840-9030-0

Fig. 111

Nozzle holder assembly


Bolt
Eye bolt

Before assembling the nozzle holder assembly, check to


see if the spray condition and the spray pressure of the
injection nozzle are appropriate, (Refer to INSPECTION
AND SERVICE.)

Bracket

Assemble to the cylinder head the gasket.

Nozzle holder ASM

Install the nozzle holder assembly, and then tighten it to


the specified torque.

Gasket
Fig. 112

Nm (kgfm/ft. lb)
Tightening torque

31 - 41 (3.2 4.2 / 23 - 30)

Glow plug and connector


Glow plug

Assemble the glow plug to the cylinder head, and then


tighten it to the specified torque.
Install the connector to the glow plug, and then tighten
until snug.
Nm (kgfm/ft. lb)

Connector

Fig. 113

Parts

Tightening torque

Glow plug

15 - 20 (1.5 2.0 / 11 - 14)

58 ENGINE

2. PISTON AND CONNECTING ROD

Piston ring (5)


Snap Pipe (4)
Piston (1)

Piston pin (3)

Bush (2)

bolt removed
* Rod
for clarity.

*
Connecting rod (2)
Cap (7)

Cap nut (8)

Bearing (6)

Fig. 114

Important Operations
Conventional
piston heater

Piston
Use a piston heater to heat the pistons to approximately
100C (212F).
Connecting Rod

Fig. 115
(Hot plug side)

Front mark

Engine
front
direction

Isuzu mark
Cylinder number
stamped side

Fig. 116

1.

Install the connecting rod to the piston with setting


the marks as illustrated.

2.

Install the piston pin into the piston and the connecting rod bushing.

ENGINE 59
Piston Pin Snap Ring
1.

Use a pair of snap ring pliers to install the piston pin


snap ring.

2.

Check that the piston moves smoothly on the piston


pin.

Fig. 117

Piston Ring
1st

1.

Use a piston ring installer to install the three piston


rings.
Piston Ring Installer

2nd

Install the piston rings in the following order.


(1) Oil ring
(2) 2nd compression ring

Oil

(3) 1st compression ring


The marked side of the two compression rings must
be facing up.

Fig. 118

The undercut side of the second compression ring


will be facing down.
As the oil ring has no any facing mark, it may face in
either direction.
2.

Lubricate the piston ring surfaces with engine oil.

3.

Check that the piston rings rotate smoothly in the


piston ring grooves.

60 ENGINE

3. INTERNAL PARTS
Reassembly Steps
(1) Crankshaft
(2) Piston Assembly
(3) Rear Seal Retainer
(4) Camshaft
(5) Cam Gear
(6) Idler gear and Shaft
(7) Oil Pump Assembly
(8) Timing Gear Case (Without PTO)
(9) Flywheel Housing
(10) Flywheel
(11) Crank Pulley
(12) Oil Pipe
(13) Oil Strainer
(14) Oil Pan
(15) Tappets
(16) Cylinder Head Gasket
(17) Cylinder Head Assembly
(18) Push Rods
(19) Rocker Bracket Assembly
(20) Engine Hangers

ENGINE 61

Internal Parts (1/3)

(2)

(9)

(13)

(10)

(1)

(12)
Rear

(3)
(11)

(14)

Fig. 119

62 ENGINE

Internal Parts (2/3)

(8)

(19)

(20)

(18)

(17)

(4)

(5)

(15)
(20)

(6)
(7)

(16)

Fig. 120

ENGINE 63

Internal Parts (3/3)

(8-1)
(8-2)

(7)

Fig. 121

64 ENGINE
Crankshaft bearing

With oil hole


and groove
(Upper)

Fit correctry

Note that there is an oil hole and an oil groove in the


upper bearing (on the block side), but not in the lower
bearing (on the bearing cap side).
Fit the bearing tang firmly into the slot machined on the
cylinder body bearing arches.
No oil groove and hole
(Lower)
Fig. 122

Crankshaft and bearing


Lubricate the bearings with engine oil, install the crankshaft, install the thrust bearings with the groove facing
the crankshaft.

Thrust Bearing

Crankshaft

Bearing

Fig. 123
Arrow mark
10

2 3

Crankshaft Bearing Cap

1.

Lubricate the bearing cap bolts with engine oil.

2.

Install the bearing caps to the crankshaft.


The arrow mark must be pointing to the front of the
engine.

8
Front

3.

Tighten the bearing cap bolts to the specified torque


a little at a time in the numerical order shown in the
illustration.
Nm (kgfm/ft. lb)

Fig. 124

Crankshaft Bearing Cap


Bolt Torque
4.

83 - 93 (8.5 - 9.5 / 61 69)

Check that the crankshaft turns smoothly by manually rotating it.

ENGINE 65
Position the rings as shown making sure the ring gaps
are away from the thrust side.
1st

2nd

Oil

Fig. 125

Piston and Connecting Rod


Special tool

Lubricate the piston, the piston rings, and the connecting rod bearings with engine oil.
Front mark

Position the piston front mark towards the front of the


engine.
Use the piston ring compressor to compress the piston
rings.
Use a hammer grip to push the piston in until it makes
contact with the crank pin.
At the same time, rotate the crankshaft until the crankpin
reaches its highest point.

Fig. 126

Set the bearing cap cylinder number marks and the connecting rod cylinder number marks.
The marks must be facing the injection pump side.
Nm (kgfm/ft. lb)
Cylinder
No.

Tightening torque

74 - 83 (7.5 8.5 / 54 - 61)

Note:
After installation, confirm that the crankshaft rotates
smoothly.
Fig. 127
6

Installation of retainer

After applying engine oil to the lip of the oil seal, install
the retainer. Apply sealant TB1207B to the retainer.

Tighten bolts on the retainer to the specified torque in


the order as shown in the figure left.
Nm (kgfm/ft. lb)
Tightening torque

5
Fig. 128

8 - 12 (0.8 - 1.2 / 6 - 9)

66 ENGINE
Camshaft assembly
1.

Apply engine oil to the inside of the bearing of


the cylinder block, and then install the camshaft
assembly.

Note:
When installing the assembly, care should be taken not
to damage the bearing.
2.
Fig. 129

After installation of the snap ring to the outside of


the front bearing, check to see if the camshaft
rotates smoothly.

Cam gear and sleeve


Cam gear

1.

Install the cam gear to the camshaft so that the timing point (a dot mark ) comes to the front side.

2.

With the flyweight installed, tighten the cam gear


with a lock nut.
Nm (kgfm/ft. lb)

Timing point
Sleeve

Tightening torque
Lock nut

Fly weight

69 - 88 (7.0 - 9.0 / 51 - 65)

3.

Apply engine oil to the shaft of the sleeve and the


slide of the flyweight.

4.

With the lip of the sleeve placed in the cavity of the


flyweight, insert the shaft of the sleeve into the tip
end of the camshaft.

Fig. 130

Note:
Check to see if the sleeve moves smoothly.
Idle Gear
Idle gear

Install the idler gear shaft with the oil hole facing upward.

Timing point

Lubricate the shaft with oil.

Thrust collar

Install the idler gear.


Idle gear shaft

Timing point

Align the timing marks as shown in the illustration.


Install the thrust collar and tighten the bolts to the
specified torque.
Nm (kgfm/ft. lb)

Fig. 131

Tightening torque
Cam gear
Timing point

Idle gear

Crank gear
Fig. 132

21 - 30 (2.1 3.1 / 15 22)

ENGINE 67
Oil pump assembly
1.

Cylinder block

When PTO is not provided, install the oil pump


assembly to the cylinder block.

PTO not provided


Tightening torque

Nm (kgfm/ft. lb)
19 - 28 (1.9 2.9 / 14 21)

Fig. 133

2.

When PTO is provided, install the oil pump to the


front plate.

PTO provided

Front plate

Tightening torque

Nm (kgfm/ft. lb)
8 - 12 (0.8 1.2 / 6 9)

Fig. 134

Front plate (only for those provided with PTO)


Front plate

Apply sealant to the front plate incorporated with the oil


pump before installing it to the cylinder block.
Nm (kgfm/ft. lb)
Tightening torque

19 - 28 (1.9 2.9 / 14 21)

(with PTO)
Fig. 135

Front oil seal


Timing gear case

Front oil seal

Install the front oil seal to the timing gear case.


Installation is made according to the L dimension
shown in the figure.
mm (in)
L dimension

Fig. 136

PTO not provided

60.2 60.8 (2.370 2.384)

PTO provided

40.2 40.8 (1.582 1.606)

68 ENGINE
Timing gear case (with governor)
Governor cover

Timing gear case

When not provided with PTO, install the timing gear


case to the cylinder block. When provided with PTO,
install it to the front plate.
1.

Put the link plate of the governor incorporated in


the gear case through the connecting hole of the
injection pump in advance.

2.

Apply engine oil to the bushes provided on both


ends of the main spring lever of the governor.

3.

Apply sealant to the gear case, and then install it to


the cylinder block or the front plate.

Front oil seal

Nm (kgfm/ft. lb)
Case tightening torque
4.
Fig. 137

19 - 28 (1.9 2.9 / 14 21)

Assemble the gasket and the governor cover to the


top of the gear case, and then tighten them to the
specified torque.
Nm (kgfm/ft. lb)
Cover tightening torque

8 - 12 (0.8 1.2 / 6 9)

Flywheel housing
Install the flywheel housing to the cylinder body.
Nm (kgfm/ft. lb)
Tightening torque

41 - 55 (4.2 5.6 / 30 40)

Fig. 138

Flywheel
Lubricate bolts with engine oil.
Tighten a little at a time in the sequence shown in the
illustration.
Nm (kgfm/ft. lb)
Tightening torque
Apply
engine oil
Fig. 139

88 - 108 (9 11 / 65 80)

ENGINE 69
Crank pulley
Lubricate the lip of the front, seal with oil
Crankshaft

Install the crank pulley, lock the crankshaft and tighten


the front bolt.
Nm (kgfm/ft. lb)

Crank pulley

Tightening torque

167 - 186 (17 19 /123 137)

Washer

Front oil seal


Fig. 140

Oil pipe and oil strainer


To 2nd bearing cap

Oil strainer

1.

Install the oil pipe from the oil pump assembly to


the cylinder block and tighten the sleeve nuts.

2.

Install the oil strainer to the oil pump, and then


tighten the bracket of the strainer to the No. 2 bearing cap.
Nm (kgfm/ft. lb)
Tightening torque

Oil pipe

19 - 28 (1.9 2.9 / 14 21)

Fig. 141

Oil pan
1.

Apply sealant to the oil pan.

2.

Install the oil pan to the cylinder block and tighten


fixing bolts evenly.
Nm (kgfm/ft. lb)
Tightening torque

8 - 12 (0.8 1.2 / 6 9)

Fig. 142

Tappet and head gasket


1.

Install the tappet to the cylinder block.

2.

When installing the head gasket, face up the UP


mark.
Install the head gasket over the cylinder head locating dowels.

Fig. 143

70 ENGINE
Cylinder head assembly
11

12

14

13

8
4

15

Lubricate the bolts with oil.


9

Tighten the bolts in the sequence shown in the illustration to the specified torque.
Nm (kgfm/ft. lb)

10

Bolt size
M12 1.5
(8 each)

Tightening torque
83 93
(8.5 - 9.5 / 61 69)

M8 1.25
(4 each)

Fig. 144

6090

24 34
(2.5 - 3.5 / 8 25)

Push rod
Install the push rods.
Rocker arm bracket assembly
Rocker arm

Apply liquid gasket to the the bottom of the rocker arm


bracket assembly, being careful not to get any in the
groove around the oil galley as shown in the illustration.

Rocker spring

Install the rocker arm bracket assembly making sure the


push rods align with the rocker arms and tighten to the
specified torque.
Nm (kgfm/ft. lb)
Tightening torque
Rocker arm
bracket

Fig. 145
(Rocker bracket bottom surface)
Apply stem of sealant

the application
Avoid
of sealant to this groove.
Oil gallery
Fig. 146

8 - 12 (0.8 1.2 / 6 9)

ENGINE 71
Adjustment of valve clearance

Refer to Section General


Information Maintenance
(on page 20).

Front hanger and rear hanger


Rear hanger

Tighten them to the specified torque shown below.


Nm (kgfm/ft. lb)
Tightening torque

Front hanger

Fig. 147

19 - 28 (1.9 2.9 / 14 21)

72 ENGINE

4. EXTERNAL PARTS (Right-hand Side)

(6)

(5)

(7)

(8)

(3)

(2)

(4)

(1)

Fig. 148

(1) Dipstick
(2) Oil Filter
(3) Injection Pump
(4) Injection Pump Housing Cover
(5) Fuel Pipe
(6) Leak Off Pipe
(7) Fuel Hose
(8) Injection Pipe

ENGINE 73

5. EXTERNAL PARTS (Left-hand Side)

(18)

(10)

(11)

(19)

(12)
(17)

(15)

(9)
(13)
(16)

(14)

Fig. 149

(9) Water Pump


(10) Thermostat and Water Outlet Pipe
(11) Cylinder Head Cover
(12) Exhaust Manifold
(13) Starter
(14) Generator
(15) Fan Pulley
(16) Fan Belt
(17) Cooling Fan
(18) Exhaust Pipe
(19) Exhaust Silencer

74 ENGINE
Dipstick
Dipstick

Cartridge

Oil filter (cartridge)


1.

Insert the dipstick.

2.

Install the cartridge with a filter wrench (commercially available).

(1) Apply engine oil thinly to the gasket of the cartridge.


(2) Screw in the cartridge until the gasket comes into
contact with the seal, and then tighten it by giving it
about 3/4 turns.
Fig. 150

Injection pump
center position
Control link

(Reference: Tightening torque

12 to 16 Nm
(1.2 1.6 kgfm))

Injection pump
Fuel cut lever
Pin
(6)

Align the two (2) holes in the fuel cut lever and the governor and lock into place with a pin.
This will center and hold the control link for the installation of the injection pumps.

Fig. 151
Injection pump ASM

Install a new shim with the same thickness as the one


that was removed. (Refer to the maintenance section on
shim selection).

Shim

Cylinder block
Fig. 152

Injection pump
center position

Install the injection pump making sure the rack pin is in


the groove of the control rack before tightening the
injection pump to the specified torque.
Nm (kgfm/ft. lb)

Control link
Rack pin

Tightening torque

19 - 28 (1.9 2.9 / 14 21)

Remove the rack pin (6) which is inserted into the fuel
cut lever, and then confirm that the fuel cut lever moves
smoothly.
Fig. 153

ENGINE 75
Injection pump housing cover
Housing cover

After applying sealant (TB1207B) to the housing cover,


install it to the cylinder block by the side of the injection
pump.
Nm (kgfm/ft. lb)
Tightening torque

8 - 12 (0.8 1.2 / 6 9)

Note:
The areas of the housing cover to which liquid gasket is
applied are about 4 mm in width from the cover edge
and about 2 mm around the bolts.

Fig. 154
Housing cover

Apply potion of sealant

About 4mm in width


from the cover edge
About 2mm
around the bolt hole
Fig. 155

Solenoid assembly
1.
Solenoid ASM

Apply sealant (TB1207C) to the surface (bite groove)


in which the solenoid is installed.

Note:
Avoid the application of sealant to the screw thread.
2.

Fig. 156

Tightening torque

Solenoid ASM
Installed surface
Apply surface
of sealant

Screw thread
Avoid the application
of sealant
Fig. 157

Screw in the solenoid from the rear of the cylinder


block (the rear of the No. 3 injection pump rack), and
then tighten it to the specified torque.
Nm (kgfm/ft. lb)
15 - 25 (1.5 2.5 / 11 18)

76 ENGINE
Fuel pipe

Leak off pipe

Fuel pipe
Leak off pipe

Fuel hose

Nozzle holder

1.

Install the fuel pipe to the injection pump and then


tighten it to the specified torque.

2.

Install the leak off pipe to the nozzle holder and then
tighten it to the specified torque.
Nm (kgfm/ft. lb)

Injection pump

Tightening torque
Fig. 158

Fuel pipe

20 - 25 (2.0 2.5 / 14 18)

Leak off pipe

10 - 14 (1.0 1.4 / 7 10)

Note:
When tightening it, hold the pipe securely by hand so
that it will not rotate.
3.

Connect the fuel pipe and the leak off pipe with the
fuel hose and fix them with clips.

Injection pipe

Injection pipe

Nozzle holder

Install the injection pipe to the injection pump and the


nozzle holder and tighten them up with sleeve nuts.
Nm (kgfm/ft. lb)
Tightening torque

Injection pump

15 - 25 (1.5 2.5 / 11 18)

Note:
Set the thread of the sleeve nut securely before tightening it up.
Fig. 159

Water pump assembly


1.

Put sealant on the water pump where it contacts the


block and head.

2.

Tighten to the specified torque.

(L=60)

Nm (kgfm/ft. lb)
Tightening torque

(L=40)

19 - 28 (1.9 2.9 / 14 21)

Tighten together with


adjusting plate
Fig. 160

Thermostat
Water outlet pipe

Thermostat

Gasket

Water outlet pipe


Assemble the thermostat, install the gasket and the
water outlet pipe, and then tighten it to the specified
torque.
Nm (kgfm/ft. lb)

Water pump

Fig. 161

Tightening torque

19 - 28 (1.9 2.9 / 14 21)

ENGINE 77
Adjustment of valve clearance
(Refer to Section GENERAL INFORMATION MAINTENANCE.)
Cylinder head cover
Cylinder cover

1.
Gasket

Install the gasket to the cylinder head cover.

Notes:
1.

Much care should be taken for the gasket not to get


dislocated or twisted when installing the head
cover.

2.

Avoid the application of sealant to the rubber gasket.

2.

Install the cylinder head cover to the rocker arm


bracket, and tighten it to the specified torque.

Rocker arm
bracket
Fig. 162

Nm (kgfm/ft. lb)
Tightening torque

2 - 4 (0.2 0.4 / 1.4 2.9)

Air inlet pipe


Cylinder head
cover

Air inlet pipe

1.

Apply sealant (TB1207C) to the surface in which the


air inlet pipe is installed.

2.

Install the air inlet pipe to the cylinder head cover,


and tighten it to the specified torque.
Nm (kgfm/ft. lb)
Tightening torque

8 - 12 (0.8 1.2 / 6 9)

Fig. 163

Exhaust manifold
Gasket
Exhaust
manifold

Assemble the gasket to the cylinder head, install the


exhaust manifold along the stud bolts and tighten it to
the specified torque.
Nm (kgfm/ft. lb)
Tightening torque

19 - 28 (1.9 2.9 / 14 21)

Cylinder head
Fig. 164

Starter
Install the starter to the flywheel housing, and tighten it
to the specified torque.
Nm (kgfm/ft. lb)
Tightening torque
Starter

Fig. 165

93 - 113 (9.5 11.5 / 69 83)

78 ENGINE
Generator
Water pump

1.

Tighten the adjust plate together with the water


pump, and then install them temporarily.

2.

Install the bottom of the alternator to the timing gear


case, and then tighten it temporarily with bolts and
nuts.

3.

Install the fixing bolts onto the top of the alternator


through the adjusting plate. (Temporary tightening)

Adjusting plate

Alternator
Fig. 166

Fan pulley and fan belt


Fan pulley

1.

Install the fan pulley to the water pump and then


tighten it up. (2 locations)

2.

Set the fan belt to each pulley.

Water pump

Fan belt
Fig. 167

Fan belt tension


Adjust the alternator as specified and tighten to the
specified torque.
mm (in)
Deflection amount (Press the belt
at its center between the pulleys
with 98 N (10kg / 22 lbs.) force.)

7.5 to 8.5
(0.29 0.33)
mm (in)

Fig. 168

Generator upper

1.9 2.9 (14.0 21.0)

Generator lower

3.5 4.7 (25.0 34.0)

Adjust plate

1.9 2.9 (14.0 21.0)

Cooling fan
Cooling fan

Spacer

Fig. 169

1.

Assemble the spacer before tightening the cooling


fan.

2.

Tighten it to the specified torque. (4 locations)

LUBRICATING SYSTEM 79

SECTION 3

LUBRICATING SYSTEM
TABLE OF CONTENTS
CONTENTS

PAGE

LUBRICATING OIL CIRCULATION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80


OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

80 LUBRICATING SYSTEM

LUBRICATING OIL CIRCULATION DIAGRAM


Valve opening pressure 98 kPa (1kgf/cm2)

Oil filter

Valve
opening
pressure
440 kPa
(4.5kgf/cm2)

Oil gallery

Main bearing

Idle gear bush

Cylinder head

Crankshaft

Timing gear

Rocker arm
bracket

Connecting rod

Governor

Rocker shaft

Rocker arm

Oil pump

Injection pump

Strainer

Piston
Tappet

Valve stem end

Piston
pin boss

Oil pan
Pressure feeding

Non pressure feeding

Fig. 170

LUBRICATING SYSTEM 81

OIL PUMP
With PTO

Body; Oil pump


Pin (common)

Without PTO

Front plate
(Body; integral structure)

Rotor; outer
Roter; inner
O-ring (common)

Relief valve

Pump gear

Spring
Plug
Oil pump
(common)

Common

Fig. 171

Inspection and replacement


When there is wear, damages or any other defects
found, repair or replace the rotor.
Clearance between the outer rotor or inner rotor and
the pump cover
mm (in)
Standard

Limit

0.040 0.085 (0.0016 0.0033)

0.15 (0.0059)

Clearance between the periphery of the outer rotor and


the pump body
mm (in)
Standard

Limit

0.10 0.185 (0.0039 0.0073)

0.4 (0.0157)

Clearance between the inner rotor and the outer rotor


mm (in)
Standard

Limit

0.17 (0.0067)

0.2 (0.0079)

MEMO

COOLING SYSTEM 83

SECTION 4

COOLING SYSTEM
TABLE OF CONTENTS
CONTENTS

PAGE

COOLING WATER CIRCULATION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84


WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

84 COOLING SYSTEM

COOLING WATER CIRCULATION SYSTEM DIAGRAM


Bottom bypass type
thermostat
Cyliner head

Cylinder block
Radiator

Water pump

Fig. 172

bypass circuit)

COOLING SYSTEM 85

WATER PUMP
DISASSEMBLY

Seal unit

Impeller

Bearing unit

Fan center
Cover

Body

Setscrew

Fig. 173

Fan center
Cover

Setscrew

Fan center

Cover
1.

Loosen the set screw.

2.

Remove the cover.

Note:
The cover is applied with sealant (TB1207B). When removing the cover, much care should be taken not to
deform it by applying an excessive force to it.

Fig. 174

Impeller
Seal unit
Bearing unit
Bearing unit
Impeller
Seal unit
Fig. 175

86 COOLING SYSTEM

REASSEMBLY
Bearing unit
Align holes
Body
Bearing unit

With a hole in the bearing unit set in line with one in the
body, lock the bearing unit with a setscrew.
Nm (kgfm/ft. lb)
Set screw tightening torque

Fan center

8 - 12 (0.8 1.2 / 6 9)

Setscrew
Fig. 176
Impeller

Seal unit
Impeller
1.

Apply BELCO bond No. 4 to the surface where the


seal unit comes into contact with the body, and then
assemble the seal unit.

2.

Press in the impeller with a press until the clearance


between the pump impeller and the body gets to the
specified value.

Seal unit

Fig. 177

Cover
Cover

1.

Apply sealant to the surface to which the cover is


installed, and then install the cover.

2.

Apply Screw-lock to the cover installation screws,


and then tighten them.

Fig. 178

Clearance, play and tightening allowance between parts


1.

Clearance between the pump impeller and the body


mm (in)
Standard

2.

0.53 2.17 (0.0209 0.0854)

Play in the water pump ball bearing


mm (in)
Standard

Limit

0.008 0.010 (0.0003 0.0004)

0.2 (0.0079)

3.

Tightening allowance between the fan center and


the bearing shaft
mm (in)
Standard

0.026 0.061 (0.001 0.0024)

COOLING SYSTEM 87

THERMOSTAT
Inspection and replacement
Replace the thermostat when there is wear, damages or
any other defects found.
Opening temp.

80.5 83.5C (177 182F)

Valve lift mm (in.)

8mm or more at 95C


(0.31 inch or more at 203F)

Thermometer

Agitating rod
Thermostat
Wooden piece

Fig. 179

MEMO

FUEL SYSTEM 89

SECTION 5

FUEL SYSTEM
TABLE OF CONTENTS
CONTENTS

PAGE

FUEL CIRCULATION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90


GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
NOZZLE HOLDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

90 FUEL SYSTEM

FUEL CIRCULATION SYSTEM DIAGRAM

Fuel tank

Nozzle holder

Injection pump
Nozzle

Fuel filter

Fig. 180

FUEL SYSTEM 91

GOVERNOR
1.

The adjustments of the governor-related parts require the engine performance test.

2.

Before disassembling the governor, measure the dimensions A and B given in the structural
drawing to ensure the same dimensions in reassembly.

3.

Do not disassemble the governor when the performance test cannot be conducted after reassembly.

1. STRUCTURAL DRAWING OF GOVERNOR (1)

Idle speed screw


Idle (sub) spring
Start spring
Fuel cut cover
A

Link plate

Governor shaft

Set spring

Control link

Governor cover
Injection pump
Guide lever

Main spring lever


Main spring

Timing gear case

Floating lever
B

Camshaft

Tensioner lever

Angleich
Full load stopper

Sleeve

Flyweight
Shifter

Fig. 181

92 FUEL SYSTEM

2. STRUCTURAL DRAWING OF GOVERNOR (2)


Start spring
Set spring

Control link

Snap pin

Guide lever
Floating lever

A
Guide piece

Cap nut

Link plate

Shifter
Setscrew
Shaft (floating)
Fuel cut lever

Return spring

Main
spring

Fuel cut shaft

Shifter shaft

Tensioner
lever

O-ring
Idle spring

Lever;
main spring

Bracket; start spring

Speed control screw


Angleich
Return spring

O-ring

A
Shaft

Lever bush

Sleeve

Lever bush

Full load
setscrew

Control lever

Timing gear case

Fig. 182

Cam gear
Flyweight

FUEL SYSTEM 93

3. REASSEMBLY OF CONTROL LEVER RELATED PARTS


(1) Put the lever (main spring) through the hole of the timing gear case lever.
Note:
Before hammering in the bushes, put both shafts of the lever through the holes of the timing gear case
lever respectively.
(2) Put the return spring of the control lever through the shaft of the lever (main spring).
(3) Assemble the bushes.
Assemble the bush of the lever (main spring) first, and then the control lever bush.
Note:
When assembling the bushes, apply Loctite (#601) to the periphery of the bushes.

Bush
Apply Loctite No.601
to the peniphery

Lever; Main spring

Protrusion

Pin

Return spring

Timing gear case

Bush
Apply Loctite No.601
to the peniphery

Fig. 183

(4) Hook both ends of the return spring (control lever) securely to the protrusion and the pin of the lever
(main spring) respectively.

94 FUEL SYSTEM
(6) Assemble the control lever.
Assemble the O-ring to the groove of the bushes (control lever) first, and then assemble the washers
and the control lever before tightening up the control lever with a nut.
Nm (kgfm/ft. lb)
Control lever tightening torque

12 - 18 (1.2 1.8 / 9 13)

Control lever

O-ring
Bush

Spring washer
Washer

Groove

Fig. 184

Notes:
1.

Tighten the control lever after locking the control lever firmly.
(Do not tighten the control lever after locking the main spring lever.)

2.

After assembly, confirm that the control lever moves smoothly.

Nut

FUEL SYSTEM 95

4. Reassembly of shifter
(1) Assemble the shifter to the guide lever, put the shaft through it, and then assemble the snap ring.
(2) After assembly, confirm that the shaft moves smoothly.
(3) Also, confirm that the shifter shakes smoothly.

Guide lever

Shifter
Snap ring

Shaft
Fig. 185

96 FUEL SYSTEM

5. Reassembly of governor cover


Assemble the related parts such as the fuel cut lever and the idle spring to the governor cover.

[Stop]

Governor cover

22

Return spring

(Bent-up part)

Thrust
washer

O-ring
Shaft

[Operate]

22
Governor

Nut

Idle spring

Spring washer
(Notched groove)

Fuel cut lever

Fig. 186

Cap
Cap nut
Packing
Lock nut
()
Gasket

Idle screw

Governor
lever
Tensioner lever

Washer

Idle spring
Washer

Snap ring

(Z view of the drawing above)


Fig. 187

(1) When assembling the shaft, apply engine oil to the


sliding portion with the governor cover.
(2) Set both ends of the return spring securely to the
notched groove at the bottom of the cover and the
bent-up arm of the lever respectively.
(3) After reassembling the governor cover, confirm that
the governor moves smoothly.
(4) When assembling the timing gear case to the governor cover, tighten the A dimension shown in the
illustration to 2 3 mm temporarily.
The parts given in the square indicated by (*) are assembled after performance test.
mm (in)
A dimension

(When assembling temporarily)


2 3 (0.0787 0.0118)

FUEL SYSTEM 97

6. Reassembly of full-load stopper


Install the full-load stopper to the timing gear case, and then tighten it with a nut temporarily.

Timing gear case

Full load stopper

Nut; setscrew

Fig. 188

98 FUEL SYSTEM

7. Reassembly of governor lever related components


Assemble each lever and spring to the timing gear case.

Main spring lever


Lever shaft
Tensioner lever
Link plate
Main spring

Eye; start spring

Set spring

Guide piece
Start spring
Guide lever

Snap pin
Plug

Floating lever
Shaft;
floatong lever

Fig. 189

8. Notes when assembling governor related components


(1) When assembling components, apply engine oil to each slide (such as the end face of the lever, the
hole in the shaft, and the periphery of the shaft).
(2) Install the set spring securely to the groove of the pin connecting the floating lever, with much care to
its assembling direction.
(3) Confirm that each lever moves by its dead weight before installing the start spring.
(4) After assembly, confirm that each lever moves smoothly.
And also confirm that each spring operates properly.

FUEL SYSTEM 99

NOZZLE HOLDER ASSEMBLY


DISASSEMBLY

Push rod
Bolt
Spacer
Gasket
Gasket

Nozzle

Nozzle holder

Retainer nut
Adjusting shim

Spring

Fig. 190

NOZZLE ASSEMBLY
Inspection and replacement
Place the removed nozzle in the clean light oil, disassemble it into the nozzle body and the needle valve and
clean them thoroughly. Then check to see if the valve
moves smoothly in the body.
When it does not move smoothly, repair or replace the
nozzle.
Light oil
Fig. 191

Adjustment
For the adjustment of the injection pressure and the
spray condition of fuel, refer to Section 1 INSPECTION
AND SERVICE.

MEMO

TROUBLESHOOTING 101

SECTION 6

TROUBLESHOOTING
Engine does not start

Starter does not run

Engine starts but


does not run
continuously.

Starter runs but does


not start

Check battery
Engine
Battery in
discharging
(Charge)

Fuel system

Fuel injected

No fuel
injected

Fuel injected

Air mixed in
fuel pump

OK
Check
compression
ratio

( )

Check wiring

Loosened
connector or
broken wire
(Retighten or
replace with
new wiring)

OK

Low
compression
ratio

OK

Check for air


mixing

Defective
valve, spring,
gasket, etc.
(Overhaul)

Air mixed
(Retighten it,
replace
packing, bleed
air)

Check starter switch

Defective
(Replace)

Check
preheating
circuit

Check if fuel
comes
to fuel pump

OK

OK

Check magnetic
switch

Defective
(Replace)

OK

Clogged
(Clean)

OK

Normal
operation
of glow
plug
control
resistance
OK

Abnormal
(Adjust)

OK

Disordered
idling

Adjust
idling

Check
injection
timing

Check fuel
filter

( )

Poor
operation
of glow
plug
control
resistance
(Replace)

OK

Retighten,
replace
packing,
bleed air

OK

OK

Check nozzle
Check engine stop
solenoid return

Defective
(Repair or
replace)

Check starter bush

OK

Check solenoid

Poor contact
(Repair or
replace)

OK

Defective starter
(Bring it to a specialty
shop for repair)

Stuck solenoid or
poor operation
(Repair or replace)

OK

Defective injection
pump (Bring
it to a specialty
shop for repair)

Note: Bring it to a specialty shop means that defective parts of the injection pump
and electricals must be brought to a specialty shop for repair. (This note is
applicable to all the following procedures.)

102 TROUBLESHOOTING
Unstable engine rotation

Unstable engine
idling

Idling speed
too high

Unstable rotation at
medium speed
(Hunting)

Unstable rotation at
high speed

Engine does not


change from high to
low rotation

Defective idling
adjustment

Defective control
lever adjustment

Governor spring
deteriorated

Check fuel for air


mixing

Check accelerator
pedal

Defective
valve return
(Adjust)

OK

Check high pressure


pipe for cracking,
clogging or bending

Cracked,
clogged or
bent
(Replace)

OK

OK

Check cylinder for


uneven compression
pressure

Uneven
compression
pressure
(Adjust)

OK

Defective injection
pump (Bring it to a
specialty shop for
repair)

Air mixed
(Bleed
air)mixing

Check fuel pipe for


crash

Crash
(Replace)

OK

OK

OK

Defective injection
pump (Bring it to a
specialty shop for
repair)

Pedal
sticking or
hitching
(Clean or
replace)

OK

Check fuel filter for


clogging

Clogged
(Clean or
replace)

OK

Check uneven fuel


injection

Check nozzle

Defective
(Repair or
replace)

Defective
(Repair or
replace)

Uneven
(Adjust)

OK

Check valve clearance


adjustment

Poor
adjustment
(Adjust)

OK

Defective injection
pump (Bring it to a
specialty shop for
repair)

Defective injection
pump (Bring it to a
specialty shop for
repair)

TROUBLESHOOTING 103

Insufficient output

Fuel system

Check fuel for air


mixing

Air mixed
(Bleed air)

Overheat

Mechanical
system

Check engine
control

Cooling system

Check cooling
water level

Insufficient

OK
Poor
adjustment

OK

OK

Handling

Check fan belt


for slip

Slipping
(Adjust)

OK

(Adjust)
Check fuel filter
or fuel hose for
clogging

Clogged
(Clean or
Replace)

Check inlet air


temperature

Temperatu
re too high
(Improve
ventilation)

OK

OK

Check injection
timing

Abnormal
(Adjust)

Check thermostat

Malfunction
(Replace)

OK

Leak to Leak to
external internal

Repair
Insufficient inlet
air

Air cleaner
stained
(Clean or
replace)

OK

Check nozzle

Defective
(Repair or
replace)

Check
for
leakage

OK

Check valve
clearance and
cam lift

Abnormal
(Adjust or
replace)

OK

Check compression
pressure

Low
Defective
injection pump
(Bring it to a
specialized shop
for repair)

Low
Excessive
blow-by
gas
(Overhaul)

Gas leak from


valve and gasket
(Repair or replace)

Repair or
replace

Care must
be taken
when
replenishing
(Replace)

OK

OK
Engine
rotation
too high

OK

Check high
pressure pipe for
clogging or
bending

Clogged
or bent
(Replace)

Replenish

Check if oil used


is inferior quality,
or engine oil is
too much

Overloaded

Check cooling
system for stain,
and radiator for
clogging
Temperature
abnormally high
Stained or
clogged
(Clean)

OK

Improve
ventilation

104 TROUBLESHOOTING
Abnormal exhaust gas

Check if fuel used is of


inferior quality

OK

Change fuel

Check if engine oil is too


much

White smoke too much

Black smoke too much

Check fuel for water


mixing

Check nozzle

Water mixed
(Change fuel)

OK

Defective
(Repair or replace)

Air cleaner clogged

OK

Replace air
cleaner element

OK

Check air hose for crash

Check injection timing


Check injection timing
Advanced too much

Delayed
(Adjust)

OK

(Adjust)

OK

Check injection pump


Check compression ratio

Low

Excessive
blow-by gas
(Overhaul)

Gas leak from


valve and
gasket (Repair
or replace)

OK

OK

Defective injection pump


(Bring it to a specialty
shop for repair)

Check up and
down
movement of oil

1. Disordered valve timing


2. Broken piston ring or
misassembly
3. Worn camshaft
4. Worn valve or insert
(Overhaul)

Stuck (Overhaul)

Over-discharge of battery
Battery

Wiring

Regulator and generator

Check electrolyte level

Check terminals for warp,


deformation or corrosion

Check belt for slip or damage

Low

OK
Poor contact
(Repair or replace)

Battery
Natural
case
consumpt
cracked
ion
(Replace) (Replenish)

Over
charge

Note: Improper maintenance

Check for broken wire


(Repair or replace)

OK

Slipping or
damaged (Repair
or replace)

Test charging condition

Abnormal

Bring it to a battery shop


Check specific gravity
Low

Recharge

Recharging
impossible

Bring it to a battery specialty shop

OK

OK

TROUBLESHOOTING 105

Oil pressure too low

Oil consumption too much

Oil consumption too much

Check oil level

Check for oil leakage

Check for oil leakage

Low (Replenish)

OK

OK

Leaking (Retighten,
replace packing seal)

Leaking (Retighten,
replace packing seal)

OK

Check cooling water temperature


Check nozzle

Check oil quality

OK

High
(See Overheat)

OK

Defective
(Repair or replace)

Poor quality
(Change to specified oil)

OK

Check oil in crankcase


Check injection timing
Improper
viscosity

Abnormal (Adjust)

Water or fuel mixed. Check fuel


system and cooling system

Low
OK

Defective
(Repair or replace)

Oil pump malfunction


Loosened or cracked pipe
Wear of sliding part
Oil pump clogged
(Overhaul)

OK

Gas leak from


valve and gasket
(Repair or
replace)

1.
2.
3.
4.
5.

Oil pump malfunction


Loosened or cracked pipe
Wear of sliding part
Oil pump clogged
Defective valve stem seal
(Overhaul)

(*) Worn bore,and worn or broken


ring (Measure compression
pressure, and check entrance of
dust)

Engine knocking
Mechanical system

Fuel system

Check up movement of oil

Check injection timing

Oil stained (Overhaul)

OK

Check compression pressure

Low

OK

Abnormal (Adjust)

OK

Check nozzle

Defective
(Repair or replace)

OK

To fuel system
Note: Fuel used is of poor quality.
Excessive
blow-by gas
(Overhaul)

Gas leak from


valve and gasket
(Repair or
replace)

OK

Check up and down movement of oil

Defective injection pump


(Bring it to a specialty
shop for repair)

Excessive
blow-by gas

Clogged (Clean)

OK

Check compression ratio

Check relief valve

1.
2.
3.
4.

Check bleeder for clogging

OK

MEMO

SPECIAL TOOLS 107

SECTION 7

SPECIAL TOOLS
The alphanumeric codes in parentheses (
No.

Illustration

) are part numbers assigned by special tool manufacturers.

Part Number

Part Name

Page

1.

5-8840-2675-0

Compression gauge

23

2.

5-8840-9029-0

Compression gauge adapter

23

3.

5-8840-9016-0
(J-28829)

Nozzle tester

24

4.

5-8840-9015-0
(JKM-9004)

Oil filter wrench

5.

5-8840-9030-0

Valve spring compressor

57

6.

1-85221-029-0

Piston ring pliers

41

7.

5-8840-9018-0
(J-8037)

Piston ring compressor

8.

5-8840-9031-0

Front oil seal installer

9.

5-8840-9032-0

Rear oil seal installer

10.

5-8840-9034-0

Camshaft bearing installer

11.

5-8840-9035-0

Valve guide installer

12.

5-8840-9033-0

Valve stem seal installer

MEMO

CONVERSION TABLE 109

SECTION 8

CONVERSION TABLE
TABLE OF CONTENTS
ITEM

PAGE

LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
MASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
LENGTH
MILLIMETERS TO INCHES

INCHES TO MILLIMETERS

mm

in.

mm

in.

mm

in.

mm

in.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

0.0394
0.0787
0.1181
0.1575
0.1969
0.2362
0.2756
0.3150
0.3543
0.3937
0.4331
0.4724
0.5118
0.5512
0.5906
0.6299
0.6693
0.7087
0.7480
0.7874
0.8268
0.8661
0.9055
0.9449
0.9843

26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50

1.0236
1.0630
1.1024
1.1417
1.1811
1.2205
1.2598
1.2992
1.3386
1.3780
1.4173
1.4567
1.4961
1.5354
1.5748
1.6142
1.6535
1.6929
1.7323
1.7717
1.8110
1.8504
1.8898
1.9291
1.9685

51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75

2.0079
2.0472
2.0866
2.1260
2.1654
2.2047
2.2441
2.2835
2.3228
2.3622
2.4016
2.4409
2.4803
2.5197
2.5591
2.5984
2.6378
2.6772
2.7165
2.7559
2.7953
2.8346
2.8740
2.9134
2.9528

76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

2.9921
3.0315
3.0709
3.1102
3.1496
3.1890
3.2283
3.2677
3.3071
3.3465
3.3858
3.4252
3.4646
3.5039
3.5433
3.5827
3.6220
3.6614
3.7008
3.7402
3.7795
3.8189
3.8583
3.8976
3.9370

in.

mm
1/64

1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32

101
102
103
104
105
106
107
108
109

3.9764
4.0157
4.0551
4.0945
4.1339
4.1732
4.2126
4.2520
4.2913

111
112
113
114
115
116
117
118
119

4.3701
4.4094
4.4488
4.4882
4.5276
4.5669
4.6063
4.6457
4.6850

121
122
123
124
125
126
127
128
129

4.7638
4.8031
4.8425
4.8819
4.9213
4.9606
5.0000
5.0394
5.0787

131
132
133
134
135
136
137
138
139

5.1575
5.1969
5.2362
5.2756
5.3150
5.3543
5.3937
5.4331
5.4724

27/64
7/16
29/64
15/32
31/64
1/2

0.3969
0.7938
1.1906
1.5875
1.9844
2.3813
2.7781
3.1750
3.5719
3.9688
4.3656
4.7625
5.1594
5.5563
5.9531
6.3500
6.7469
7.1438
7.5406
7.9375
8.3344
8.7313
9.1281
9.5250
9.9219
10.3188
10.7156
11.1125
11.5094
11.9063
12.3031
12.7000

in.

mm
33/64

17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1

13.0969
13.4938
13.8906
14.2875
14.6844
15.0813
15.4781
15.8750
16.2719
16.6688
17.0656
17.4625
17.8594
18.2563
18.6531
19.0500
19.4469
19.8438
20.2406
20.6375
21.0344
21.4313
21.8281
22.2250
22.6219
23.0188
23.4156
23.8125
24.2094
24.6063
25.0031
25.4000

110 CONVERSION TABLE


LENGTH
FEET TO METERS
ft.

10
20
30
40
50
60
70
80
90
100

0
3.048
6.096
9.144
12.192
15.240
18.288
21.336
24.384
27.432
30.480

0.305
3.353
6.401
9.449
12.497
15.545
18.593
21.641
24.689
27.737
30.785

0.610
3.658
6.706
9.754
12.802
15.850
18.898
21.946
24.994
28.042
31.090

0.914
3.962
7.010
10.058
13.106
16.154
19.202
22.250
25.298
28.346
31.394

1.219
4.267
7.315
10.363
13.411
16.459
19.507
22.555
25.603
28.651
31.699

1.524
4.572
7.620
10.668
13.716
16.764
19.812
22.860
25.908
28.956
32.004

1.829
4.877
7.925
10.973
14.021
17.069
20.117
23.165
26.213
29.261
32.309

2.134
5.182
8.230
11.278
14.326
17.374
20.422
23.470
26.518
29.566
32.614

2.438
5.486
8.534
11.582
14.630
17.678
20.726
23.774
26.822
29.870
32.918

2.743
5.791
8.839
11.887
14.935
17.983
21.031
24.079
27.127
30.175
33.223

ft.

10
20
30
40
50
60
70
80
90
100

METERS TO FEET
m

10
20
30
40
50
60
70
80
90
100

ft.

ft.

ft.

ft.

ft.

ft.

ft.

ft.

ft.

ft.

00
32.8084
65.6168
98.4252
131.2336
164.0420
196.8504
229.6588
262.4672
295.2756
328.0840

3.2808
36.0892
68.8976
101.7060
134.5144
167.3228
200.1312
232.9396
265.7480
298.5564
331.3648

6.5617
39.3701
72.1785
104.9869
137.7953
170.6037
203.4121
236.2205
269.0289
301.8373
334.6457

9.8425
42.6509
75.4593
108.2677
141.0761
173.8845
206.6929
239.5013
272.3097
305.1181
337.9265

13.1234
45.9318
78.7402
111.5486
144.3570
177.1654
209.9738
242.7822
275.5906
308.3990
341.2074

16.4042
49.2126
82.0210
114.8294
147.6378
180.4462
213.2546
246.0630
278.8714
311.6798
344.4882

19.6850
52.4934
85.3018
118.1102
150.9186
183.7270
216.5354
249.3438
282.1522
314.9606
347.7690

22.9659
55.7743
88.5827
121.3911
154.1995
187.0079
219.8163
252.6247
285.4331
318.2415
351.0499

26.2467
59.0551
91.8635
124.6719
157.4803
190.2887
223.0971
255.9055
288.7139
321.5223
354.3307

29.5276
62.3360
95.1444
127.9528
160.7612
193.5696
226.3780
259.1864
291.9948
324.8032
357.6116

10
20
30
40
50
60
70
80
90
100

MILES TO KILOMETERS
miles

10
20
30
40
50
60
70
80
90
100

km

km

km

km

km

km

km

km

km

km

00
16.093
32.187
48.280
64.374
80.467
96.560
112.654
128.747
144.841
160.934

1.609
17.703
33.796
49.890
65.983
82.076
98.170
114.263
130.357
146.450
162.543

3.219
19.312
35.405
51.499
67.592
83.686
99.779
115.872
131.966
148.059
164.153

4.828
20.921
37.015
53.108
69.202
85.295
101.388
117.482
133.575
149.669
165.762

6.437
22.531
38.624
54.718
70.811
86.904
102.998
119.091
135.185
151.278
167.371

8.047
24.140
40.234
56.327
72.420
88.514
104.607
120.701
136.794
152.887
168.981

9.656
25.749
41.843
57.936
74.030
90.123
106.216
122.310
138.403
154.497
170.590

11.265
27.359
43.452
59.546
75.639
91.732
107.826
123.919
140.013
156.106
172.199

12.875
28.968
45.062
61.155
77.248
93.342
109.435
125.529
141.622
157.715
173.809

14.484
30.577
46.671
62.764
78.858
94.951
111.044
127.138
143.231
159.325
175.418

10
20
30
40
50
60
70
80
90
100

KILOMETERS TO MILES
km

10
20
30
40
50
60
70
80
90
100

miles

miles

miles

miles

miles

miles

miles

miles

miles

miles

0
6.214
12.427
18.641
24.855
31.069
37.282
43.496
49.710
55.923
62.137

0.621
6.835
13.049
19.262
25.476
31.690
37.904
44.117
50.331
56.545
62.758

1.243
7.456
13.670
19.884
26.098
32.311
38.525
44.739
50.952
57.166
63.380

1.864
8.078
14.292
20.505
26.719
32.933
39.146
45.360
51.574
57.787
64.001

2.485
8.699
14.913
21.127
27.340
33.554
39.768
45.981
52.195
58.409
64.622

3.107
9.321
15.534
21.748
27.962
34.175
40.389
46.603
52.816
59.030
65.244

3.728
9.942
16.156
22.369
28.583
34.797
41.010
47.224
53.438
59.652
65.865

4.350
10.563
16.777
22.991
29.204
35.418
41.632
47.845
54.059
60.273
66.487

4.971
11.185
17.398
23.612
29.826
36.039
42.253
48.467
54.681
60.894
67.108

5.592
11.806
18.020
24.233
30.447
36.661
42.875
49.088
55.302
61.516
67.729

10
20
30
40
50
60
70
80
90
100

CONVERSION TABLE 111


AREA
SQUARE INCHES TO SQUARE CENTIMETERS
in2

10
20
30
40
50
60
70
80
90
100

in2

cm2

cm2

cm2

cm2

cm2

cm2

cm2

cm2

cm2

cm2

00
64.516
129.032
193.548
258.064
322.580
387.096
451.612
516.128
580.644
645.160

6.452
70.968
135.484
200.000
264.516
329.032
393.548
458.064
522.580
587.096
651.612

12.903
77.419
141.935
206.451
270.967
335.483
399.999
464.515
529.031
593.547
658.063

19.355
83.871
148.387
212.903
277.419
341.935
406.451
470.967
535.483
599.999
664.515

25.806
90.322
154.838
219.354
283.870
348.386
412.902
477.418
541.934
606.450
670.966

32.258
96.774
161.290
225.806
290.322
354.838
419.354
483.870
548.386
612.902
677.418

38.710
103.226
167.742
232.258
296.774
361.290
425.806
490.322
554.838
619.354
683.870

45.161
109.677
174.193
238.709
303.225
367.741
432.257
496.773
561.289
625.805
690.321

51.613
116.129
180.645
245.161
309.677
374.193
438.709
503.225
567.741
632.257
696.773

58.064
122.580
187.096
251.612
316.128
380.644
445.160
509.676
574.192
638.708
703.224

10
20
30
40
50
60
70
80
90
100

cm2

SQUARE CENTIMETERS TO SQUARE INCHES


cm2

10
20
30
40
50
60
70
80
90
100

in2

in2

in2

in2

in2

in2

in2

in2

in2

in2

0
1.550
3.100
4.650
6.200
7.750
9.300
10.850
12.400
13.950
15.500

0.155
1.705
3.255
4.805
6.355
7.905
9.455
11.005
12.555
14.105
15.655

0.310
1.860
3.410
4.960
6.510
8.060
9.610
11.160
12.710
14.260
15.810

0.465
2.015
3.565
5.115
6.665
8.215
9.765
11.315
12.865
14.415
15.965

0.620
2.170
3.720
5.270
6.820
8.370
9.920
11.470
13.020
14.570
16.120

0.775
2.325
3.875
5.425
6.975
8.525
10.075
11.625
13.175
14.725
16.275

0.930
2.480
4.030
5.580
7.130
8.680
10.230
11.780
13.330
14.880
16.430

1.085
2.635
4.185
5.735
7.285
8.835
10.385
11.935
13.485
15.035
16.585

1.240
2.790
4.340
5.890
7.440
8.990
10.540
12.090
13.640
15.190
16.740

1.395
2.945
4.495
6.045
7.595
9.145
10.695
12.245
13.795
15.345
16.895

10
20
30
40
50
60
70
80
90
100

in3

VOLUME
CUBIC INCHES TO CUBIC CENTIMETERS
in3

10
20
30
40
50
60
70
80
90
100

cm3(cc)

cm3(cc)

cm3(cc)

cm3(cc)

cm3(cc)

cm3(cc)

cm3(cc)

cm3(cc)

cm3(cc)

cm3(cc)

00
163.871
327.741
491.612
655.483
819.353
983.224
1147.094
1310.965
1474.836
1638.706

16.387
180.258
344.128
507.999
671.870
835.740
999.611
1163.482
1327.352
1491.223
1655.093

32.774
196.645
360.515
524.386
688.257
852.127
1015.998
1179.869
1343.739
1507.610
1671.481

49.161
213.032
376.902
540.773
704.644
868.514
1032.385
1196.256
1360.126
1523.997
1687.868

65.548
229.419
393.290
557.160
721.031
884.901
1048.772
1212.643
1376.513
1540.384
1704.255

81.935
245.806
409.677
573.547
737.418
901.289
1065.159
1229.030
1392.900
1556.771
1720.642

98.322
262.193
426.064
589.934
753.805
917.676
1081.546
1245.417
1409.288
1573.158
1737.029

114.709
278.580
442.451
606.321
770.192
934.063
1097.933
1261.804
1425.675
1589.545
1753.416

131.097
294.967
458.838
622.708
786.579
950.450
1114.320
1278.191
1442.062
1605.932
1769.803

147.484
311.354
475.225
639.095
802.966
966.837
1130.707
1294.578
1458.449
1622.319
1786.190

10
20
30
40
50
60
70
80
90
100

cm3(cc)

CUBIC CENTIMETERS TO CUBIC INCHES


cm3(cc)

10
20
30
40
50
60
70
80
90
100

in3

in3

in3

in3

in3

in3

in3

in3

in3

in3

0
0.6102
1.2205
1.8307
2.4409
3.0512
3.6614
4.2716
4.8818
5.4921
6.1023

0.0610
0.6713
1.2815
1.8917
2.5019
3.1122
3.7224
4.3326
4.9429
5.5531
6.1633

0.1220
0.7323
1.3425
1.9527
2.5630
3.1732
3.7834
4.3937
5.0039
5.6141
6.2243

0.1831
0.7933
1.4035
2.0138
2.6240
3.2342
3.8444
4.4547
5.0649
5.6751
6.2854

0.2441
0.8543
1.4646
2.0748
2.6850
3.2952
3.9055
4.5157
5.1259
5.7362
6.3464

0.3051
0.9153
1.5256
2.1358
2.7460
3.3563
3.9665
4.5767
5.1870
5.7972
6.4074

0.3661
0.9764
1.5866
2.1968
2.8071
3.4173
4.0275
4.6377
5.2480
5.8582
6.4684

0.4272
1.0374
1.6476
2.2579
2.8681
3.4783
4.0885
4.6988
5.3090
5.9192
6.5295

0.4882
1.0984
1.7086
2.3189
2.9291
3.5393
4.1496
4.7598
5.3700
5.9803
6.5905

0.5492
1.1594
1.7697
2.3799
2.9901
3.6004
4.2106
4.8208
5.4310
6.0413
6.6515

10
20
30
40
50
60
70
80
90
100

112 CONVERSION TABLE


VOLUME
GALLONS (U.S.) TO LITERS
U.S. gal.

10
20
30
40
50
60
70
80
90
100

liters

liters

liters

liters

liters

liters

liters

liters

liters

liters

U.S.gal.

00
37.8543
75.7085
113.5628
151.4171
189.2714
227.1256
264.9799
302.8342
340.6884
378.5427

3.7854
41.6397
79.4940
117.3482
155.2025
193.0568
230.9110
268.7653
306.6196
344.4739
382.3281

7.5709
45.4251
83.2794
121.1337
158.9879
196.8422
234.6965
272.5507
310.4050
348.2593
386.1136

11.3563
49.2106
87.0648
124.9191
162.7734
200.6276
238.4819
276.3362
314.1904
352.0447
389.8990

15.1417
52.9960
90.8502
128.7045
166.5588
204.4131
242.2673
280.1216
317.9759
355.8301
393.6844

18.9271
56.7814
94.6357
132.4899
170.3442
208.1985
246.0528
283.9070
321.7613
359.6156
397.4698

22.7126
60.5668
98.4211
136.2754
174.1296
211.9839
249.8382
287.6925
325.5467
363.4010
401.2553

26.4980
64.3523
102.2065
140.0608
177.9151
215.7693
253.6236
291.4779
329.3321
367.1864
405.0407

30.2834
68.1377
105.9920
143.8462
181.7005
219.5548
257.4090
295.2633
333.1176
370.9718
408.8261

34.0688
71.9231
109.7774
147.6317
185.4859
223.3402
261.1945
299.0487
336.9030
374.7573
412.6115

10
20
30
40
50
60
70
80
90
100

liters

LITERS TO GALLONS (U.S.)


liters

10
20
30
40
50
60
70
80
90
100

gal.

gal.

gal.

gal.

gal.

gal.

gal.

gal.

gal.

gal.

00
2.6417
5.2834
7.9252
10.5669
13.2086
15.8503
18.4920
21.1338
23.7755
26.4172

0.2642
2.9059
5.5476
8.1893
10.8311
13.4728
16.1145
18.7562
21.3979
24.0397
26.6814

0.5283
3.1701
5.8118
8.4535
11.0952
13.7369
16.3787
19.0204
21.6621
24.3038
26.9455

0.7925
3.4342
6.0760
8.7177
11.3594
14.0011
16.6428
19.2846
21.9263
24.5680
27.2097

1.0567
3.6984
6.3401
8.9818
11.6236
14.2653
16.9070
19.5487
22.1904
24.8322
27.4739

1.3209
3.9626
6.6043
9.2460
11.8877
14.5295
17.1712
19.8129
22.4546
25.0963
27.7381

1.5850
4.2268
6.8685
9.5102
12.1519
14.7936
17.4354
20.0771
22.7188
25.3605
28.0022

1.8492
4.4909
7.1326
9.7744
12.4161
15.0578
17.6995
20.3412
22.9830
25.6247
28.2664

2.1134
4.7551
7.3968
10.0385
12.6803
15.3220
17.9637
20.6054
23.2471
25.8889
28.5306

2.3775
5.0193
7.6610
10.3027
12.9444
15.5861
18.2279
20.8696
23.5113
26.1530
28.7947

10
20
30
40
50
60
70
80
90
100

Imp gal.

GALLONS (IMP.) TO LITERS


Imp gal.

10
20
30
40
50
60
70
80
90
100

liters

liters

liters

liters

liters

liters

liters

liters

liters

liters

00
45.4590
90.9180
136.3770
181.8360
227.2950
272.7540
318.2130
363.6720
409.1310
454.5900

4.5459
50.0049
95.4639
140.9229
186.3819
231.8409
277.2999
322.7589
368.2179
413.6769
459.1359

9.0918
54.5508
100.0098
145.4688
190.9278
236.3868
281.8458
327.3048
372.7638
418.2228
463.6818

13.6377
59.0967
104.5557
150.0147
195.4737
240.9327
286.3917
331.8507
377.3097
422.7687
468.2277

18.1836
63.6426
109.1016
154.5606
200.0196
245.4786
290.9376
336.3966
381.8556
427.3146
472.7736

22.7295
68.1885
113.6475
159.1065
204.5655
250.0245
295.4835
340.9425
386.4015
431.8605
477.3195

27.2754
72.7344
118.1934
163.6524
209.1114
254.5704
300.0294
345.4884
390.9474
436.4064
481.8654

31.8213
77.2803
122.7393
168.1983
213.6573
259.1163
304.5753
350.0343
395.4933
440.9523
486.4113

36.3672
81.8262
127.2852
172.7442
218.2032
263.6622
309.1212
354.5802
400.0392
445.4982
490.9572

40.9131
86.3721
131.8311
177.2901
222.7491
268.2081
313.6671
359.1261
404.5851
450.0441
495.5031

10
20
30
40
50
60
70
80
90
100

liters

LITERS TO GALLONS (IMP.)


liters

10
20
30
40
50
60
70
80
90
100

gal.

gal.

gal.

gal.

gal.

gal.

gal.

gal.

gal.

gal.

00
2.1998
4.3996
6.5994
8.7992
10.9990
13.1988
15.3986
17.5984
19.7982
21.9980

0.2200
2.4198
4.6196
6.8194
9.0192
11.2190
13.4188
15.6186
17.8184
20.0182
22.2180

0.4400
2.6398
4.8396
7.0394
9.2392
11.4390
13.6388
15.8386
18.0384
20.2382
22.4380

0.6599
2.8597
5.0595
7.2593
9.4591
11.6589
13.8587
16.0585
18.2583
20.4581
22.6579

0.8799
3.0797
5.2795
7.4793
9.6791
11.8789
14.0787
16.2785
18.4783
20.6781
22.8779

1.0999
3.2997
5.4995
7.6993
9.8991
12.0989
14.2987
16.4985
18.6983
20.8981
23.0979

1.3199
3.5197
5.7195
7.9193
10.1191
12.3189
14.5187
16.7185
18.9183
21.1181
23.3179

1.5399
3.7397
5.9395
8.1393
10.3391
12.5389
14.7387
16.9385
19.1383
21.3381
23.5379

1.7598
3.9596
6.1594
8.3592
10.5590
12.7588
14.9586
17.1584
19.3582
21.5580
23.7578

1.9798
4.1796
6.3794
8.5792
10.7790
12.9788
15.1786
17.3784
19.5782
21.7780
23.9778

10
20
30
40
50
60
70
80
90
100

CONVERSION TABLE 113


MASS
POUNDS TO KILOGRAMS
lbs.

10
20
30
40
50
60
70
80
90
100

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

lbs.

0
4.536
9.072
13.608
18.144
22.680
27.215
31.751
36.287
40.823
45.359

0.454
4.989
9.525
14.061
18.597
23.133
27.669
32.205
36.741
41.277
45.813

0.907
5.443
9.979
14.515
19.051
23.587
28.123
32.658
37.194
41.730
46.266

1.361
5.897
10.433
14.968
19.504
24.040
28.576
33.112
37.648
42.184
46.720

1.814
6.350
10.886
15.422
19.958
24.494
29.030
33.566
38.102
42.637
47.173

2.268
6.804
11.340
15.876
20.412
24.947
29.483
34.019
38.555
43.091
47.627

2.722
7.257
11.793
16.329
20.865
25.401
29.937
34.473
39.009
43.545
48.081

3.175
7.711
12.247
16.783
21.319
25.855
30.391
34.926
39.462
43.998
48.534

3.629
8.165
12.701
17.236
21.772
26.308
30.844
35.380
39.916
44.452
48.988

4.082
8.618
13.154
17.690
22.226
26.762
31.298
35.834
40.370
44.905
49.441

10
20
30
40
50
60
70
80
90
100

kg

KILOGRAMS TO POUNDS
kg

10
20
30
40
50
60
70
80
90
100

lbs.

lbs.

lbs.

lbs.

lbs.

lbs.

lbs.

lbs.

lbs.

lbs.

00
22.046
44.092
66.139
88.185
110.231
132.277
154.323
176.370
198.416
220.462

2.205
24.251
46.297
68.343
90.389
112.436
134.482
156.528
178.574
200.620
222.667

4.409
26.455
48.502
70.548
92.594
114.640
136.686
158.733
180.779
202.825
224.871

6.614
28.660
50.706
72.752
94.799
116.845
138.891
160.937
182.983
205.030
227.076

8.818
30.865
52.911
74.957
97.003
119.049
141.096
163.142
185.188
207.234
229.280

11.023
33.069
55.116
77.162
99.208
121.254
143.300
165.347
187.393
209.439
231.485

13.228
35.274
57.320
79.366
101.413
123.459
145.505
167.551
189.597
211.644
233.690

15.432
37.479
59.525
81.571
103.617
125.663
147.710
169.756
191.802
213.848
235.894

17.637
39.683
61.729
83.776
105.822
127.868
149.914
171.960
194.007
216.053
238.099

19.842
41.888
63.934
85.980
108.026
130.073
152.119
174.165
196.211
218.257
240.304

10
20
30
40
50
60
70
80
90
100

kg

KILOGRAMS TO NEWTON
kg

10
20
30
40
50
60
70
80
90
100

0
98.07
196.13
294.20
392.27
490.34
588.40
686.47
784.54
882.60
980.67

9.81
107.87
205.94
304.01
402.07
500.14
598.21
696.28
794.34
892.41
990.48

19.61
117.68
215.75
313.81
411.88
509.95
608.02
706.08
804.15
902.22
1000.28

29.42
127.49
225.55
323.62
421.69
519.76
617.82
715.89
813.96
912.02
1010.09

39.23
137.29
235.36
333.43
431.49
529.56
627.63
725.70
823.76
921.83
1019.90

49.03
147.10
245.17
343.23
441.30
539.37
637.44
735.50
833.57
931.64
1029.70

58.84
156.91
254.97
353.04
451.11
549.18
647.24
745.31
843.38
941.44
1039.51

68.65
166.71
264.78
362.85
460.91
558.98
657.05
755.12
853.18
951.25
1049.32

78.45
176.52
274.59
372.65
470.72
568.79
666.86
764.92
862.99
961.06
1059.12

88.26
186.33
284.39
382.46
480.53
578.60
676.66
774.73
872.80
970.86
1068.93

10
20
30
40
50
60
70
80
90
100

NEWTON TO KILOGRAMS
N

100
200
300
400
500
600
700
800
900
1000

10

20

30

40

50

60

70

80

90

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

00
10.197
20.394
30.592
40.789
50.986
61.183
71.380
81.578
91.775
101.972

1.020
11.217
21.414
31.611
41.809
52.006
62.203
72.400
82.597
92.795
102.992

2.039
12.237
22.434
32.631
42.828
53.025
63.223
73.420
83.617
93.814
104.011

3.059
13.256
23.454
33.651
43.848
54.045
64.242
74.440
84.637
94.834
105.031

4.079
14.276
24.473
34.670
44.868
55.065
65.262
75.459
85.656
95.854
106.051

5.099
15.296
25.493
35.690
45.887
56.085
66.282
76.479
86.676
96.873
107.071

6.118
16.316
26.513
36.710
46.907
57.104
67.302
77.499
87.696
97.893
108.090

7.138
17.335
27.532
37.730
47.927
58.124
68.321
78.518
88.716
98.913
109.110

8.158
18.355
28.552
38.749
48.947
59.144
69.341
79.538
89.735
99.933
110.130

9.177
19.375
29.572
39.769
49.966
60.163
70.361
80.558
90.755
100.952
111.149

100
200
300
400
500
600
700
800
900
1000

114 CONVERSION TABLE


PRESSURE
POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS
lb/in2

lb/in2

(psi)

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

(psi)

10
20
30
40
50
60
70
80
90
100

0
0.7031
1.4061
2.1092
2.8123
3.5154
4.2184
4.9215
5.6246
6.3276
7.0307

0.0703
0.7734
1.4764
2.1795
2.8826
3.5857
4.2887
4.9918
5.6949
6.3979
7.1010

0.1406
0.8437
1.5468
2.2498
2.9529
3.6560
4.3590
5.0621
5.7652
6.4682
7.1713

0.2109
0.9140
1.6171
2.3201
3.0232
3.7263
4.4293
5.1324
5.8355
6.5386
7.2416

0.2812
0.9843
1.6874
2.3904
3.0935
3.7966
4.4996
5.2027
5.9058
6.6089
7.3119

0.3515
1.0546
1.7577
2.4607
3.1638
3.8669
4.5700
5.2730
5.9761
6.6792
7.3822

0.4218
1.1249
1.8280
2.5311
3.2341
3.9372
4.6403
5.3433
6.0464
6.7495
7.4525

0.4921
1.1952
1.8983
2.6014
3.3044
4.0075
4.7106
5.4136
6.1167
6.8198
7.5228

0.5625
1.2655
1.9686
2.6717
3.3747
4.0778
4.7809
5.4839
6.1870
6.8901
7.5932

0.6328
1.3358
2.0389
2.7420
3.4450
4.1481
4.8512
5.5543
6.2573
6.9604
7.6635

10
20
30
40
50
60
70
80
90
100

kg/cm2

KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES


kg/cm2

10
20
30
40
50
60
70
80
90
100

lb/in2(psi)

lb/in2(psi)

lb/in2(psi)

lb/in2(psi)

lb/in2(psi)

lb/in2(psi)

lb/in2(psi)

lb/in2(psi)

lb/in2(psi)

lb/in2(psi)

00
142.23
284.46
426.69
568.92
711.15
853.38
995.61
1137.84
1280.07
1422.30

14.22
156.45
298.68
440.91
583.14
725.37
867.60
1009.83
1152.06
1294.29
1436.52

28.45
170.68
312.91
455.14
597.37
739.60
881.83
1024.06
1166.29
1308.52
1450.75

42.67
184.90
327.13
469.36
611.59
753.82
896.05
1038.28
1180.51
1322.74
1464.97

56.89
199.12
341.35
483.58
625.81
768.04
910.27
1052.50
1194.73
1336.96
1479.19

71.12
213.35
355.58
497.81
640.04
782.27
924.50
1066.73
1208.96
1351.19
1493.42

85.34
227.57
369.80
512.03
654.26
796.49
938.72
1080.95
1223.18
1365.41
1507.64

99.56
241.79
384.02
526.25
668.48
810.71
952.94
1095.17
1237.40
1379.63
1521.86

113.78
256.01
398.24
540.47
682.70
824.93
967.16
1109.39
1251.62
1393.85
1536.08

128.01
270.24
412.47
554.70
696.93
839.16
981.39
1123.62
1265.85
1408.08
1550.31

10
20
30
40
50
60
70
80
90
100

kg/cm2

KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL


kg/cm2

10
20
30
40
50
60
70
80
90
100

KPa

KPa

KPa

KPa

KPa

KPa

KPa

KPa

KPa

KPa

00
980.7
1961.3
2942.0
3922.7
4903.4
5884.0
6864.7
7845.4
8826.0
9806.7

98.1
1078.7
2059.4
3040.1
4020.7
5001.4
5982.1
6962.8
7943.4
8924.1
9904.8

196.1
1176.8
2157.5
3138.1
4118.8
5099.5
6080.2
7060.8
8041.5
9022.2
10002.8

294.2
1274.9
2255.5
3236.2
4216.9
5197.6
6178.2
7158.9
8139.6
9120.2
10100.9

392.3
1372.9
2353.6
3334.3
4314.9
5295.6
6276.3
7257.0
8237.6
9218.3
10199.0

490.3
1471.0
2451.7
3432.3
4413.0
5393.7
6374.4
7355.0
8335.7
9316.4
10297.0

588.4
1569.1
2549.7
3530.4
4511.1
5491.8
6472.4
7453.1
8433.8
9414.4
10395.1

686.5
1667.1
2647.8
3628.5
4609.1
5589.8
6570.5
7551.2
8531.8
9512.5
10493.2

784.5
1765.2
2745.9
3726.5
4707.2
5687.9
6668.6
7649.2
8629.9
9610.6
10591.2

882.6
1863.3
2843.9
3824.6
4805.3
5786.0
6766.6
7747.3
8728.0
9708.6
10689.3

10
20
30
40
50
60
70
80
90
100

KPa

KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS


KPa
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000

100

200

300

400

500

600

700

800

900

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

kg/cm2

00
10.197
20.394
30.592
40.789
50.986
61.183
71.380
81.578
91.775
101.972

1.020
11.217
21.414
31.611
41.809
52.006
62.203
72.400
82.597
92.795
102.992

2.039
12.237
22.434
32.631
42.828
53.025
63.223
73.420
83.617
93.814
104.011

3.059
13.256
23.454
33.651
43.848
54.045
64.242
74.440
84.637
94.834
105.031

4.079
14.276
24.473
34.670
44.868
55.065
65.262
75.459
85.656
95.854
106.051

5.099
15.296
25.493
35.690
45.887
56.085
66.282
76.479
86.676
96.873
107.071

6.118
16.316
26.513
36.710
46.907
57.104
67.302
77.499
87.696
97.893
108.090

7.138
17.335
27.532
37.730
47.927
58.124
68.321
78.518
88.716
98.913
109.110

8.158
18.355
28.552
38.749
48.947
59.144
69.341
79.538
89.735
99.933
110.130

9.177
19.375
29.572
39.769
49.966
60.163
70.361
80.558
90.755
100.952
111.149

0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000

CONVERSION TABLE 115


TORQUE
FOOT POUNDS TO KILOGRAMMETERS
ft. lbs.

10
20
30
40
50
60
70
80
90
100

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

ft lbs.

0
1.383
2.765
4.148
5.530
6.913
8.296
9.678
11.061
12.443
13.826

0.138
1.521
2.903
4.286
5.669
7.051
8.434
9.816
11.199
12.582
13.964

0.277
1.659
3.042
4.424
5.807
7.190
8.572
9.955
11.337
12.720
14.103

0.415
1.797
3.180
4.563
5.945
7.328
8.710
10.093
11.476
12.858
14.241

0.553
1.936
3.318
4.701
6.083
7.466
8.849
10.231
11.614
12.996
14.379

0.691
2.074
3.457
4.839
6.222
7.604
8.987
10.370
11.752
13.135
14.517

0.830
2.212
3.595
4.977
6.360
7.743
9.125
10.508
11.890
13.273
14.656

0.968
2.350
3.733
5.116
6.498
7.881
9.263
10.646
12.029
13.411
14.794

1.106
2.489
3.871
5.254
6.636
8.019
9.402
10.784
12.167
13.549
14.932

1.244
2.627
4.010
5.392
6.775
8.157
9.540
10.923
12.305
13.688
15.070

10
20
30
40
50
60
70
80
90
100

kg-m

KILOGRAMMETERS TO FOOT POUNDS


kg-m

10
20
30
40
50
60
70
80
90
100

ft. lbs.

ft. lbs.

ft. lbs.

ft. lbs.

ft. lbs.

ft. lbs.

ft. lbs.

ft. lbs.

ft. lbs.

ft. lbs.

0
72.33
144.66
216.99
289.32
361.65
433.98
506.31
578.64
650.97
723.30

7.23
79.56
151.89
224.22
296.55
368.88
441.21
513.54
585.87
658.20
730.53

14.47
86.80
159.13
231.46
303.79
376.12
448.45
520.78
593.11
665.44
737.77

21.70
94.03
166.36
238.69
311.02
383.35
455.68
528.01
600.34
672.67
745.00

28.93
101.26
173.59
245.92
318.25
390.58
462.91
535.24
607.57
679.90
752.23

36.17
108.50
180.83
253.16
325.49
397.82
470.15
542.48
614.81
687.14
759.47

43.40
115.73
188.06
260.39
332.72
405.05
477.38
549.71
622.04
694.37
766.70

50.63
122.96
195.29
267.62
339.95
412.28
484.61
556.94
629.27
701.60
773.93

57.86
130.19
202.52
274.85
347.18
419.51
491.84
564.17
636.50
708.83
781.16

65.10
137.43
209.76
282.09
354.42
426.75
499.08
571.41
643.74
716.07
788.40

10
20
30
40
50
60
70
80
90
100

kg-m

KILOGRAMMETERS TO NEWTONMETERS
kg-m

10
20
30
40
50
60
70
80
90
100

N-m

N-m

N-m

N-m

N-m

N-m

N-m

N-m

N-m

N-m

00
98.07
196.13
294.20
392.27
490.34
588.40
686.47
784.54
882.60
980.67

9.81
107.87
205.94
304.01
402.07
500.14
598.21
696.28
794.34
892.41
990.48

19.61
117.68
215.75
313.81
411.88
509.95
608.02
706.08
804.15
902.22
1000.28

29.42
127.49
225.55
323.62
421.69
519.76
617.82
715.89
813.96
912.02
1010.09

39.23
137.29
235.36
333.43
431.49
529.56
627.63
725.70
823.76
921.83
1019.90

49.03
147.10
245.17
343.23
441.30
539.37
637.44
735.50
833.57
931.64
1029.70

58.84
156.91
254.97
353.04
451.11
549.18
647.24
745.31
843.38
941.44
1039.51

68.65
166.71
264.78
362.85
460.91
558.98
657.05
755.12
853.18
951.25
1049.32

78.45
176.52
274.59
372.65
470.72
568.79
666.86
764.92
862.99
961.06
1059.12

88.26
186.33
284.39
382.46
480.53
578.60
676.66
774.73
872.80
970.86
1068.93

10
20
30
40
50
60
70
80
90
100

N-m

NEWTONMETERS TO KILOGRAMMETERS
N-m

100
200
300
400
500
600
700
800
900
1000

10

20

30

40

50

60

70

80

90

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

kg-m

00
10.197
20.394
30.591
40.788
50.985
61.182
71.379
81.576
91.773
101.970

1.020
11.217
21.414
31.611
41.808
52.005
62.202
72.399
82.596
92.793
102.990

2.039
12.236
22.433
32.630
42.827
53.024
63.221
73.418
83.615
93.812
104.009

3.059
13.256
23.453
33.650
43.847
54.044
64.241
74.438
84.635
94.832
105.029

4.079
14.276
24.473
34.670
44.867
55.064
65.261
75.458
85.655
95.852
106.049

5.099
15.296
25.493
35.690
45.887
56.084
66.281
76.478
86.675
96.872
107.069

6.118
16.315
26.512
36.709
46.906
57.103
67.300
77.497
87.694
97.891
108.088

7.138
17.335
27.532
37.729
47.926
58.123
68.320
78.517
88.714
98.911
109.108

8.158
18.355
28.552
38.749
48.946
59.143
69.340
79.537
89.734
99.931
110.128

9.177
19.374
29.571
39.768
49.965
60.162
70.359
80.556
90.753
100.950
111.147

100
200
300
400
500
600
700
800
900
1000

116 CONVERSION TABLE


TEMPERATURE
FAHRENHEIT TO CENTIGRADE
F

-60
-58
-56
-54
-52
-50
-48
-46
-44
-42
-40
-38
-36
-34
-32
-30
-28
-26
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4

-51.1
-50.0
-48.9
-47.8
-46.7
-45.6
-44.4
-43.3
-42.2
-41.1
-40.0
-38.9
-37.8
-36.7
-35.6
-34.4
-33.3
-32.2
-31.1
-30.0
-28.9
-27.8
-26.7
-25.6
-24.4
-23.3
-22.2
-21.1
-20.0

-2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54

-18.9
-17.8
-16.7
-15.6
-14.4
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-6.7
-5.6
-4.4
-3.3
-2.2
-1.1
0.0
1.1
2.2
3.3
4.4
5.6
6.7
7.8
8.9
10.0
11.1
12.2

56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112

13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4

114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
152
154
156
158
160
162
164
166
168
170

45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
61.1
62.2
63.3
64.4
65.6
66.7
67.8
68.9
70.0
71.1
72.2
73.3
74.4
75.6
76.7

172
174
176
178
180
182
184
186
188
190
192
194
196
198
200
202
204
206
208
210
212
214
216
218
220
222
224
226
228

77.8
78.9
80.0
81.1
82.2
83.3
84.4
85.6
86.7
87.8
88.9
90.0
91.1
92.2
93.3
94.4
95.6
96.7
97.8
98.9
100.0
101.1
102.2
103.3
104.4
105.6
106.7
107.8
108.9

230
232
234
236
238
240
242
244
246
248
250
252
254
256
258
260
262
264
266
268
270
272
274
276
278
280
282
284
286

110.0
111.1
112.2
113.3
114.4
115.6
116.7
117.8
118.9
120.0
121.1
122.2
123.3
124.4
125.6
126.7
127.8
128.9
130.0
131.1
132.2
133.3
134.4
135.6
136.7
137.8
138.9
140.0
141.1

288
290
292
294
296
298
300
302
304
306
308
310
312
314
316
318
320
322
324
326
328
330
332
334
336
338
340
342
344

142.2
143.3
144.4
145.6
146.7
147.8
148.9
150.0
151.1
152.2
153.3
154.4
155.6
156.7
157.8
158.9
160.0
161.1
162.2
163.3
164.4
165.6
166.7
167.8
168.9
170.0
171.1
172.2
173.3

346
348
350
352
354
356
358
360
362
364
366
368
370
372
374
376
378
380
382
384
386
388
390
392
400
410
420
430
440

174.4
175.6
176.7
177.8
178.9
180.0
181.1
182.2
183.3
184.4
185.6
186.7
187.8
188.9
190.0
191.1
192.2
193.3
194.4
195.6
196.7
197.8
198.9
200.0
204.4
210.0
215.6
221.1
226.7

CENTIGRADE TO FAHRENHEIT
C

-50
-49
-48
-47
-46
-45
-44
-43
-42
-41
-40
-39
-38
-37
-36
-35
-34
-33
-32
-31
-30
-29
-28
-27
-26
-25
-24
-23
-22
-21
-20
-19

-58.0
-56.2
-54.4
-52.6
-50.8
-49.0
-47.2
-45.4
-43.6
-41.8
-40.0
-38.2
-36.4
-34.6
-32.8
-31.0
-29.2
-27.4
-25.6
-23.8
-22.0
-20.2
-18.4
-16.6
-14.8
-13.0
-11.2
-9.4
-7.6
-5.8
-4.0
-2.2

-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13

-0.4
1.4
3.2
5.0
6.8
8.6
10.4
12.2
14.0
15.8
17.6
19.4
21.2
23.0
24.8
26.6
28.4
30.2
32.0
33.8
35.6
37.4
39.2
41.0
42.8
44.6
46.4
48.2
50.0
51.8
53.6
55.4

14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

57.2
59.0
60.8
62.6
64.4
66.2
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
82.4
84.2
86.0
87.8
89.6
91.4
93.2
95.0
96.8
98.6
100.4
102.2
104.0
105.8
107.6
109.4
111.2
113.0

46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77

114.8
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6

78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109

172.4
174.2
176.0
177.8
179.6
181.4
183.2
185.0
186.8
188.6
190.4
192.2
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
212.0
213.8
215.6
217.4
219.2
221.0
222.8
224.6
226.4
228.2

110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141

230.0
231.8
233.6
235.4
237.2
239.0
240.8
242.6
244.4
246.2
248.0
249.8
251.6
253.4
255.2
257.0
258.8
260.6
262.4
264.2
266.0
267.8
269.6
271.4
273.2
275.0
276.8
278.6
280.4
282.2
284.0
285.8

142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173

287.6
289.4
291.2
293.0
294.8
296.6
298.4
300.2
302.0
303.8
305.6
307.4
309.2
311.0
312.8
314.6
316.4
318.2
320.0
321.8
323.6
325.4
327.2
329.0
330.8
332.6
334.4
336.2
338.0
339.8
341.6
343.4

174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
210
220
230
240
250

345.2
347.0
348.8
350.6
352.4
354.2
356.0
357.8
359.6
361.4
363.2
365.0
366.8
368.6
370.4
372.2
374.0
375.8
377.6
379.4
381.2
383.0
384.8
386.6
388.4
390.2
392.0
410.0
428.0
446.0
464.0
482.0

Copyright reserved for this manual may not be


reproduced or copied, in whole or in part, without the
written consent of ISUZU MOTORS LIMITED.

WORKSHOP MANUAL (INDUSTRIAL)


4LE2
(IDE-2330)
Issued by

ISUZU MOTORS LIMITED


Powertrain Service & Parts
Powertrain Operations
6-26-1, Minami-oi, Shinagawa-ku,Tokyo, 140-8722, Japan
TEL 03-5471-1111
First edition Sep., 1999

107-02K

IDE-2330

PRINTED IN JAPAN