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2007MY N-SERIES
ENGINE 4HK1-TC
SECTION 6
Applicable Model:
N-Series
ENGINE
Engine Mechanical (4HK1-TC)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4HK1-TC) . . . . . . . . . . 6A-3 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-61
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-63
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-63
Main Data and Specifications. . . . . . . . . . . . . . 6A-15 Torque Specifications . . . . . . . . . . . . . . . . . . . .6A-65
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Valve Stem Seal and Valve Spring . . . . . . . . . . . 6A-66
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A-17 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-67
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-68
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-71
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-71
Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 6A-26 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-75
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-89
Tightening Torque Specifications . . . . . . . . . . . 6A-28 Torque Specifications . . . . . . . . . . . . . . . . . . . .6A-96
PCV Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Piston and Connecting Rod . . . . . . . . . . . . . . . .6A-98
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-98
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-98
Inlet Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-99
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-100
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .6A-105
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-107
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-32 Torque Specifications . . . . . . . . . . . . . . . . . . .6A-109
Turbocharger and Exhaust Manifold . . . . . . . . . . 6A-33 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-109
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-33 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-110
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-33 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-110
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-110
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-36 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-113
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-39 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-113
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-116
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-116
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-44 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-45 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-118
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-53 Torque Specifications . . . . . . . . . . . . . . . . . . .6A-120
Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . . 6A-54 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . .6A-121
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-121
Dismount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-123
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Torque Specifications . . . . . . . . . . . . . . . . . . .6A-127
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-127
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-58 Crankshaft Rear Oil Seal. . . . . . . . . . . . . . . . . .6A-128
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-59 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128
Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-128
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-60 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-129
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-60 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-132
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-61
6A-2 Engine Mechanical (4HK1-TC)
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-134
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-134
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-135
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139
Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-142
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-143
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-144
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-144
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-144
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-145
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-146
Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-148
Lubrication System . . . . . . . . . . . . . . . . . . . . . . 6A-149
Service Precautions . . . . . . . . . . . . . . . . . . . . 6A-149
Functional Check . . . . . . . . . . . . . . . . . . . . . . 6A-149
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-151
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-152
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-152
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-152
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-153
Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . 6A-154
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-154
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-154
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-154
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-155
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-156
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-156
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-156
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-157
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-157
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-158
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-160
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-160
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-160
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-160
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-163
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-163
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-164
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-165
Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 6A-170
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-170
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . 6A-171
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-171
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-171
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-171
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-171
Engine Mechanical (4HK1-TC) 6A-3
N6B6112E
N6B6114E
N6B6113E
Caution:
Never rotate the crankshaft while using the
Plastigauge.
Engine Mechanical (4HK1-TC) 6A-5
How To Read The Model
2 1
N6B6001E
Legend
1. Engine Model 2. Engine Selial Number
Functional Inspection
Inspection/adjustment of valve clearance
1. Inspection of valve clearance
N6B6003E
a. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”. 2. Adjustment of valve clearance
b. Remove the fuel injector harness assembly. Caution:
c. Loosen the terminal nuts alternately to remove. Adjust valve clearance carefully so that the bridge
d. Remove the leak-off pipe. contacts the end of the 2 valve stem.
Engine Mechanical (4HK1-TC) 6A-7
a. Completely loosen all of the bridge and rocker Valve bridge clearance: ± 0.1 mm (0.0039
arm adjusting nuts and adjusting screws (8 nuts in) or less
and 8 screws). c. After making an adjustment so that the end
b. Place a 0.4 mm (0.016 in) thickness gauge of the valves on both sides may touch
between the No. 1 cylinder rocker arm end and properly, tighten up an adjusting screw nut
the bridge cap. of the bridge with a minus driver so that the
c. Tighten the rocker arm adjusting screw until the bridge adjusting screw may not rotate.
thickness gauge is snug (not tight) between the Tighten:
rocker arm end and the bridge cap. Adjusting screw nut to 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
d. Tighten the rocker arm lock nut.
e. Tighten the bridge adjusting screw until the Caution:
bridge contacts the valve head. If the adjusting screw of the bridge is poorly adjusted,
the bridge would tilt and be pushed down and seized,
f. Tighten the bridge lock nut. which may damage the bridge guide, for example.
g. Check that the thickness gauge is still held Thus, adjust it accurately.
snugly between the rocker arm end and the
bridge cap. If it is too tight, slightly loosen the
bridge adjusting screw and lock nut to restore
snugness.
h. Remove the thickness gauge.
i. Repeat Steps b through h for the remaining
cylinders.
Tighten:
Bridge lock nut to 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
N6A6005E
Tighten:
Rocker arm adjustment screw nut to 22 N⋅m (2.2 kgf⋅m/
16 lbf⋅ft)
Bridge adjustment screw nut to 22 N⋅m (2.2 kgf⋅m/16
lbf⋅ft)
Adjustment table
Cylinder No. 1 2 3 4
N6A6004E
Valve
Legend IN EX IN EX IN EX IN EX
arrangement
1. Rocker Arm
2. Bridge Cap No. 1 cylinder
3. Bridge Compression { { { {
TDC
a. With a thickness gauge kept inserted,
No. 4 cylinder
tighten an adjusting screw of the bridge
Compression × × × ×
lightly and make sure that the tip of the
TDC
adjusting screw touches the end of valve
stem and the movement of the thickness
gauge has become tight.
b. Then, check if the end of the valve stem on
the opposite side is unstable or hits
diagonally. If so, loosen the bridge adjusting
screw a little so that the end of the valves on
both sides may touch properly.
6A-8 Engine Mechanical (4HK1-TC)
• If the No. 1 cylinder is the compression • Install the cylinder head cover.
TDC, adjust a valve clearance with { mark Refer to “Cylinder Head Cover.”
given on the table and if the No. 4 cylinder is
the compression top dead center, that with × Compression pressure inspection
mark. • Warm up the engine.
• Remove a minus terminal of the battery and
remove all the glow plugs.
• Remove the harness connector for the fuel injector
built on the lower head cover (no fuel will be
injected).
Caution:
When the harness connector is removed, ECM judges
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear memory
of ECM.
(For how to clear memory of ECM, refer to Section 6E)
N6A6006E
N6A6008E
Legend
1. Fuel Injector Harness Connector
Notice:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
unified.
• Do not tighten the nuts too tightly because it leads to
damage to the terminal studs.
Engine Mechanical (4HK1-TC) 6A-9
• Install an adapter and a gauge of a compression Judgment of time to overhaul
gauge of the special tool. Rate of increase in engine oil consumption
Overhaul is needed when the consumption rate (travel
distance of kilometers per liter) drops to less than 50%
of that of new vehicle (100%).
Rate of increase in fuel consumption
Overhaul is needed when the consumption rate (km/L)
drops to less than 60% of that of new vehicle (100%).
Noise in engine
If the noise is caused by internal parts of the engine,
carry out overhaul earlier.
* Many reasons are considered to cause noise.
However, noise is caused mainly by excessive wear of
engine parts, seizure, or pinched foreign objects.
Caution:
To keep engine speed at 220 rpm or more, use fully
charged batteries.
Engine knocking
Turbocharger Troubleshooting
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2008-0
Compression Gauge Set
(J-26999-12 /
Compression Gauge,
EN-46722 /
Gauge Adapter)
5884020080
Engine Mechanical (4HK1-TC) 6A-17
Engine Assembly
Removal • Remove the connector of the boost pressure
sensor.
1. Remove a minus (-) terminal of the battery.
2. Drain the coolant.
3. Remove the starter motor.
• Disconnect the front frame harness connector
in the vicinity of the control box of the
transmission and remove each clip that fixes
the harness.
• Remove 2 bolts that fasten the starter and
remove the starter from the clutch housing.
• Fix the starter motor with wire, for instance, in a
place that does not get in the way in removing
the transmission.
4. Remove the transmission assembly.
Refer to “Transmission Assembly”.
5. Remove the charge air hose (between 2 1
turbocharger and inter cooler).
N6B6005E
Legend
1. Charge Air Hose
2 2. Boost Pressure Sensor
N6B6201E
Legend
1. Inlet Hose
2. Charge Air Hose
N6A6015E
Legend
N6B6007E 1. Screw
Legend 2. Cab Back Cover
1. Fixing Bolt 3. Nut
2. Connector
3. Bracket • Operate a hoist slowly and hoist the engine
4. A/C Compressor until it comes up to the surface of the chassis
frame.
16. Remove the AC generator harness.
Engine Mechanical (4HK1-TC) 6A-19
• Turn the engine at an angle of 90 degrees to • Operate a hoist slowly to move the engine to
move from the surface of the chassis frame and the place where it is to be installed.
remove the engine assembly.
N6A6017E
N6A6016E
• Turn the engine at an angle of 90 degrees to
lower the engine slowly to the place it is to be
installed.
N6A6017E
N6A6016E
Installation
• Make the transmission side lower and operate
Notice: a hoist slowly, pulling it backward to the engine.
Be absolutely sure that each harness is reconnected to 2. Install the engine mount.
its original position.
• Install the engine mount to fit into the holes of
1. Install the engine assembly. the engine mounting cross member and tighten
it up with the specified torque.
• Hang wire on the engine hanger and hoist to lift
up the engine. Tighten:
To cross member : 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
3. Install the feed and return sides of the fuel hose.
4. Install the front exhaust pipe.
5. Install the lower hose of the radiator.
6A-20 Engine Mechanical (4HK1-TC)
• Install the connector.
N6A6018E
N6B6007E
6. Install the power steering oil hose.
7. Install the power steering reserve tank. Legend
1. Fixing Bolt
8. Install the hydraulic booster brake hose on the
2. Connector
high-pressure side.
3. Bracket
9. Install the hydraulic booster brake tank. 4. A/C Compressor
10. Install a vacuum hose to the vacuum pump.
• Install the drive belt.
• Hang the drive belt to adjust its tension with an
adjusting bolt of the tension pulley.
• For further details for adjusting tension of the
belt, refer to “Drive Belt” in Section 6B.
• Check if a flexure is within the specified range
when the center part is pressed by the hand
with 98 N (22 lb) by using a scale, for instance.
In addition, check if it is not damaged as well.
• Flexure of the A/C compressor belt.
• 19 – 24 mm (0.748 – 0.945 in) (when the belt is
new)
• 24 – 28 mm (0.945 – 1.102 in) (when the belt is
reused)
N6B6008E
N6B6006E
N6B6284E
16. Install the fan assembly.
13. Install the cab back cover. 17. Install a bracket for the fan guide.
18. Install the coolant reserve tank hose to the radiator
side.
19. Install an upper hose of the radiator.
• Install the upper hose with a band clip.
N6A6015E
Legend
1. Screw
2. Cab Back Cover
3. Nut
N6A6012E
14. Install the engine harness. 20. Install the charge air hose (between intercooler
15. Install the heater hoses. and inlet pipe).
6A-22 Engine Mechanical (4HK1-TC)
• Install the connector of the boost pressure Refer to “Transmission Assembly”.
sensor. 25. Install the starter motor.
• Install 2 up and down bolts to fasten the starter.
• Connect the front frame harness connector and
install each clip which fixes the harness.
26. Replenish the coolant.
27. Install a minus (–) terminal of the battery.
2 1
N6B6005E
Legend
1. Charge Air Hose
2. Boost Pressure Sensor
1 3 2
N6B6116E
Legend
1. Turbocharger
2. Clip
3. White Line
4. Hose
Engine Mount
Component
N6B6009E
Legend
1. Fan Guide 3. Engine Foot
2. Engine Mount
Removal
1. Remove the fan guide bracket.
2. Remove the engine mount.
6A-24 Engine Mechanical (4HK1-TC)
• Remove the cab back cover. Installation
1. Install the engine mount and tighten up with the
specified torque.
Tighten:
The nuts on the chassis frame side to 48 N⋅m (4.9 kgf⋅m/
35 lbf⋅ft)
The bolts on the engine foot side to 82 N⋅m (8.4 kgf⋅m/
60 lbf⋅ft)
N6A6015E
Legend
1. Screw
2. Cab Back Cover
3. Nut
N6A6015E
N6A6016E
Legend
1. Screw
2. Cab Back Cover
3. Nut
Engine Mechanical (4HK1-TC) 6A-25
Torque Specifications
82 (8.4 / 60)
48 (4.9 / 35)
N6B6010E
6A-26 Engine Mechanical (4HK1-TC)
3
5
N6A6024E
Legend
1. Head Cover 4. Gasket
2. Gasket 5. Head Lower Cover
3. Sound Insulation Cover
Removal
1. Remove the 6 bolts that fasten the EGR cooler
1
(2nd) and hang the EGR cooler (2nd) with wire, for
instance, in a place that does not get in the way in
removing the cylinder head cover.
2. Remove the sound insulation cover (1).
3. Remove the head cover (2)
4. Remove the gasket.
N6A6027E
N6A6029E
N6A6028E
6. Install the sound insulation cover.
Tightening torque: 7 N⋅m (0.7 kgf⋅m/5 lbf⋅ft)
Installation
1. Install the gasket on the head lower cover (1).
2. Install the head lower cover (1). 1
Tighten:
Bolts to 18 N⋅m (1.8 kgf⋅m/13 lbf⋅ft)
3. Install the fuel injector harness connector (2).
Caution:
Push it in thoroughly until the claws of the lock raise.
N6A6027E
Legend
1. Sound Insulation Cover
2. Head Cover
N6A6028E
18 (1.8 / 13)
7 (0.7 / 5)
18 (1.8 / 13)
N6B6011E
Engine Mechanical (4HK1-TC) 6A-29
PCV Hose
Components
3
1
2
N6B6266E
Legend
1. Ventilator 3. PCV Rubber Hose
2. Bracket 4. Pipe Flange
Removal
1. Remove the PCV rubber hose (Ventilator — Pipe
flange).
2. Remove the bracket.
3. Remove the ventilator.
4. Remove the pipe flange.
Installation
1. Install the pipe flange.
Tighten:
8 N⋅m (0.8 kgf⋅m/6 lbf⋅ft)
2. Install the ventilator.
3. Install the bracket.
4. Install the PCV rubber hose (Ventilator — Pipe
flange).
6A-30 Engine Mechanical (4HK1-TC)
Inlet Cover
Component
N6B6012E
Legend
1. Throttle Assembly 3. Inlet Pipe Gasket
2. Inlet Cover
Removal
•
N6B6013E
Engine Mechanical (4HK1-TC) 6A-31
4. Remove the inlet cover. • Tighten up the stud part together with the fuel rail.
• On the place where the throttle assembly is to
be installed inside the inlet cover (arrow) is a
bolt. Be careful not to forget to remove it.
• Peel the liquid gasket off carefully.
N6B6014E
Caution:
• Be careful not to forget to fasten the bolt indicated
with an arrow.
N6B6015E
22 (2.2 / 16)
22 (2.2 / 16)
24 (2.4 / 17)
N6B6016E
Engine Mechanical (4HK1-TC) 6A-33
4
6
7
9 8
N6B6119E
Legend
1. Oil Feed Pipe 6. Exhaust Adapter
2. Water Return Pipe 7. Water Feed Pipe
3. Turbocharger Assembly 8. Oil Return Pipe
4. Heat Protector 9. Exhaust Manifold
5. Heat Protector
N6A6039E
Legend
1. Water Return Pipe
N6B6007E 2. Rubber Hose
Legend
1. Fixing Bolt 14. Remove the turbocharger.
2. A/C Compressor Harness • Remove the heat protector on the turbocharger.
3. A/C Compressor Bracket
• Remove the exhaust adapter bolts.
4. A/C Compressor
• Remove the four turbocharger clamping nuts.
10. Remove the oil feed pipe. • Remove the turbocharger from the exhaust
11. Remove the oil return pipe. manifold.
12. Remove the water feed pipe.
1
4
6
5
2 3
2 1 4
N6B6019E
3
N6B6018E Legend
1. Fixing Nut
Legend
2. Exhaust Adapter
1. Oil Feed Pipe
3. Fixing Bolt
2. Water Return Pipe
4. Fixing Nut
3. Heat Protector
4. Charge Air Hose 15. Remove the exhaust manifold.
5. Intake Duct
6. EGR Pipe
Engine Mechanical (4HK1-TC) 6A-35
• Remove the 2 nuts and 6 bolts to remove the Wheel shaft axle play
exhaust manifold. Use a dial gauge to measure the wheel axle shaft play
when a fore of 12 N (2.6 lb) is alternately applied to
both sides of the compressor wheel.
N6B6020E
Inspection
• Inspection of the exhaust manifold
Inspect the plane surface of the plane on which the
manifold and the cylinder head are to be installed.
N6A6042E
Tighten:
Nuts to 52 N⋅m (5.3 kgf⋅m/38 lbf⋅ft)
3. Tighten the adapter bolt (exhaust manifold side) to
the specified torque.
Tighten:
Bolt to 24 N⋅m (2.4 kgf⋅m/18 lbf⋅ft)
2 3
N6A6044E
Legend
1. Oil Outlet
2. Oil Inlet
Installation
4
1. Put the gasket in to install the exhaust manifold. N6B6019E
5 3
2
1
7
N6B6212E
4
6
5
N6B6021E
N6A6039E
Legend
1. Water Return Pipe
2. Rubber Hose
N6B6023E
11. Install the air intake duct and tighten the bolts to
the specified torque.
Tighten:
Bolts to 8 N⋅m (0.8 kgf⋅m/86 lbf⋅in)
12. Install the charge air pipe in the turbo charger and
the charge air cooler.
Tighten:
N6B6036E
Duct bolt to 21 N⋅m (2.1 kgf⋅m/15 lbf⋅ft)
Duct clip to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
13. Install the front exhaust pipe to the turbocharger
and tighten the nuts to the specified torque.
Tighten:
Nuts to 67 N⋅m (6.8 kgf⋅m/49 lbf⋅ft)
N6A6050E
14. Install the EGR cooler (1st) and the EGR duct
(EXH).
Refer to “EGR Valve and EGR Cooler.”
Engine Mechanical (4HK1-TC) 6A-39
Torque Specifications
17 (1.7 / 13)
8 (0.8 / 86 lbf in)
24 (2.4 / 17) 24 (2.4 / 17)
27 (2.7 / 20)
32 (3.3 / 24)
24 (2.4 / 17)
27 (2.8 / 19.9)
41 (4.2 / 30)
24 (2.4 / 17)
9 (0.9 / 78 lbf in)
N6B6024E
Engine Mechanical (4HK1-TC) 6A-41
2
1
4
12
13
6
11
14
10
18 8
9
19
7
20 15
16
17
N6B6117E
Legend
1. Power Steering Pump 11. Rear Oil Seal
2. Idle Gear B Shaft 12. Flywheel Housing
3. Idle Gear A 13. Slinger
4. Idle Gear B 14. Plug
5. Power Steering Pump Idle Gear 15. Crankshaft Position Sensor
6. Power Steering Pump Idle Gear Cover 16. Crankshaft End Spacer (Smoother)
7. Clutch Pressure Plate 17. Oil Pan
8. Driven Plate 18. Fuel Supply Pump
9. Flexible Plate (Smoother) 19. Fuel Supply Pump Bracket
10. Flywheel (M/T) 20. Vacuum Pump
7
3 4
2
1
N6B6027E
Legend
1. Supply Pump
2. Key
3. O-ring
4. Supply Pump Bracket
5. Nut
6. Coupling
7. Flange Bolt
N6B6026E
N6B6028E
Legend
1. Vacuum Pump
2. Key
3. Gear
4. Nut
5. O-ring
N6B6025E
N6A6057E
N6A6059E N6A6061E
18. Remove the idle gear A. 2. Measurement of end clearance of the idle gear.
19. Remove the idle gear B. • Insert a thickness gauge between the idle gear
20. Remove the idle gear B shaft. and the thrust collar to measure a clearance.
• If the measurement exceeds the limit, replace
either the idle gear or the thrust collar.
N6A6060E
Inspection
1. Measurement of idle gear backlash.
• Apply a dial gauge on the teeth of the idle gear
to be measured and move the gear to right and
left lightly to read how much the dial gauge
shook (never fail to fix the gear).
• If the measurement exceeds the limit, replace
the idle gear. N6A6062E
N6A6063E
N6A6066E
Legend
1. Idle Gear
2. Thrust Collar
3. Bolt
N6A6064E
3. Install the idle gear A.
6A-46 Engine Mechanical (4HK1-TC)
• Turn the crankshaft in the normal direction of
engine rotation until the No. 1 or No. 4 cylinder
is at TDC on the compression stroke.
N6B6003E
N6A6067E
Engine Mechanical (4HK1-TC) 6A-47
2
1
3
9
0 L 0
5
7 6
N6A6653E
Legend
1. Idle Gear C 6. Crankshaft Gear
2. Camshaft Gear 7. Oil Pump Drive Gear
3. Idle Gear B 8. Fuel Supply Pump Gear
4. Power Steering Pump Gear 9. Idle Gear A
5. Power Steering Pump Idle Gear
4. Install the flywheel housing. • As the figure shows, apply the liquid gasket
• Clean the rear side of the cylinder block. In (ThreeBond 1207C or equivalent) inside a hole
particular, remove overflow liquid gasket of the bolt (except the bolt holes indicated with
thoroughly when the crankcase is installed. arrows) evenly.
N6A6069E
N6A6070E
N6A6071E
Engine Mechanical (4HK1-TC) 6A-49
Without HBB
N6A6072E
N6A6074E
Legend
1. Flywheel Housing Fixing Bolt
2. Cylinder Block Fixing Bolt
N6A6075E
N6A6076E
N6A6078E
Legend
1. Rubber Assembly 11. Install the crankshaft position sensor.
2. Oil Pan • Tighten up the fastening bolts with the prescribed
3. Gasket torque.
Engine Mechanical (4HK1-TC) 6A-51
• Align the mark line (1) in the vacuum pump side
Tighten:
with the gear slit (2).
Bolts to 8 N⋅m (0.8 kgf⋅m/69 lbf⋅in)
• Assemble the vacuum pump by referring the stud
12. Install the gear (3) to the vacuum pump (1). bolt of the cylinder block for guidance.
• Install the key (2) to the shaft of vacuum pump (1). • Check that the gear slit (2) is located near the
• Insert the gear (3) into the shaft, and tighten the center of the hole by looking through the plug hole
nut (4) to the specified torque. of the cylinder block.
Caution:
If the slit is out of the center, try again.
1
2
2
3 3
1
4
N6B6028E 6
4
Legend 5
1. Vacuum Pump
N6B6029E
2. Key
3. Gear Legend
4. Nut 1. Mark Line
5. O-ring 2. Slit
3. Slit position before insertion
13. Turn the crankshaft in the normal direction of 4. Slit position after insertion
engine rotation until the No. 1 or No. 4 cylinder is 5. Plug hole
at TDC on the compression stroke. 6. Air Compressor
Refer to illustration.
• Tighten the vacuum pump to the specified torque.
Caution:
Tighten in a diagonal order.
• M10 nut to 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
• M12 nut and bolt to 76 N⋅m (7.7 kgf⋅m/56 lbf⋅ft)
16. Apply a light coat of engine oil to the O-ring.
17. Install the oil drain adapter to the plug hole.
Tighten the bolt to the specified torque.
Tighten:
Bolt to 8 N⋅m (0.8 kgf⋅m/69 lbf⋅in)
N6B6003E
1
2
N6B6030E
Legend
1. Oil Drain Adapter
2. O-ring
4
1
3
2
N6B6027E
19 (1.9 / 14)
40 (4.1 / 29.5)
N6B6202E
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2230-0
(EN-47680)
Crankshaft Stopper
6A-54 Engine Mechanical (4HK1-TC)
N6A6083E
Legend
1. Camshaft Bracket 5. Rocker Arm Bracket
2. Rocker Arm 6. Camshaft Bracket
3. Wave Washer 7. Rocker Arm Shaft
4. Rocker Arm
Removal
1. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft assembly.
• Along with the camshaft bracket, remove the
rocker arm shaft assembly.
Engine Mechanical (4HK1-TC) 6A-55
• Keep the 2-bolts (arrowed in the figure) fixing 6. Remove the camshaft bracket to take the shaft out.
the rocker arm shaft to the camshaft bracket,
before removal of all the rocker arm brackets
N6A6085E
Legend
N6A6084E 1. Camshaft Bracket
2. Rocker Arm
Caution: 3. Wave Washer
Pay full attention so as not to drop the bridge cap in the 4. Rocker Arm
gear case of the rear part of the cylinder head or the 5. Rocker Arm Bracket
hole into which oil pours back in the front. 6. Camshaft Bracket
7. Rocker Arm Shaft
Dismount
Inspection
1. Remove the camshaft bracket.
1. Check if the oil hole of the camshaft bracket (on
2. Remove the rocker arm.
the rear side) is clogged.
3. Remove the wave washer.
4. Remove the rocker arm.
5. Remove the rocker arm bracket.
• Repeat the procedure of (2) to (5).
N6A6086E
N6A6087E
N6A6090E
N6A6092E
Reassembly 3. Install the wave washer between the rocker arm.
1. Install the camshaft bracket to one side of the 4. Install the rocker arm bracket.
rocker arm shaft tentatively first. (Tighten them up,
• Paying attention to the direction of the rocker
after the rocker arm shaft assembly is installed on
arm bracket, repeat the step 2 to 4.
the cylinder head.)
5. Install the camshaft bracket.
• Assemble in the reverse order to dismounting.
• Install the camshaft bracket on the rocker arm
shaft with the bolts indicated with an arrow
tightened tentatively. (Tighten them up, after the
rocker arm shaft assembly is installed on the
cylinder head.)
N6A6091E
N6A6085E
Legend
1. Camshaft Bracket
2. Rocker Arm
3. Wave Washer
4. Rocker Arm
5. Rocker Arm Bracket
6. Camshaft Bracket
7. Rocker Arm Shaft
6A-58 Engine Mechanical (4HK1-TC)
Installation • Apply engine oil on threads of the bolts and
nuts, and fix them tentatively (about tighten up).
1. Install the rocker arm shaft assembly.
• Tighten them up according to the order
• If the bridge cap comes off, apply engine oil
specified below gradually, taking care not to
over the inside of the bridge cap and put it
incline the entire rocker arm assembly.
together with the bridge.
Tightening order:
Caution: 1. Nuts (1) from near side of the rocker arm
Pay full attention so as not to drop the bridge cap in the shaft
gear case of the rear part of the cylinder head or the 2. Bolts (2)
hole into which oil pours back in the front. 3. Bolts (3) from out side
4. Bolts (4)
Tighten:
Bolt (3) to 56 N⋅m (5.7 kgf⋅m/41 lbf⋅ft)
Nut (1), Bolt (2), (4) to 27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft)
N6A6093E
Legend
1. Bridge Cap
2. Bridge
N6A6094E
N6A6084E
Engine Mechanical (4HK1-TC) 6A-59
Torque Specifications
N6B6213E
6A-60 Engine Mechanical (4HK1-TC)
Camshaft Assembly
Component
N6B6262E
Legend
1. Bearing Cap 3. Knock Pin
2. Bearing 4. Camshaft Gear
Removal Caution:
Put the removed bearings in order with a tag, for
1. Rotate the crank shaft to make the No. 1 cylinder
example, by cylinder.
meet the compression TDC.
2. Remove the cylinder head cover.
Refer to the “cylinder head cover.”
3. Remove the rocker arm shaft assembly.
Refer to the “rocker arm shaft assembly.”
4. Remove the camshaft bearing cap.
5. Remove the bearing upper.
6. Remove the camshaft assembly.
7. Remove the bearing lower.
Engine Mechanical (4HK1-TC) 6A-61
• Check if the journal and cam parts of the
camshaft are worn or damaged, if so, replace it.
N6A6097E
N6A6101E
Disassembly 2. Inspect an end clearance of the camshaft.
1. Remove the camshaft gear. • Use a thickness gauge to measure an end
• Remove the fastening bolts of the camshaft clearance of the camshaft gear and the
gear and put the block of wood in a puller to camshaft bracket.
remove the camshaft gear. • If the measurement exceeds the limit, replace
the camshaft gear or the camshaft.
Caution:
Measure an end clearance of the camshaft before
disassembling.
N6A6100E
Legend
1. Wood
N6A6102E
H
N6A6104E
N6A6105E
N6B6003E
Caution:
Be careful not to damage the cam and journal parts
when tightening up the gear.
N6A6651E
N6A6102E
6A-64 Engine Mechanical (4HK1-TC)
• Direct the front mark of the bearing cap toward
the front of the engine and put it together with
the cylinder head in numerical order.
N6A6109E
N6A6110E
27 (2.8 / 20)
N6B6204E
6A-66 Engine Mechanical (4HK1-TC)
N6A6112E
Legend
1. Camshaft Bearing Cap 6. Valve Spring
2. Camshaft Bearing 7. Spring Upper Seat
3. Camshaft Assembly 8. Split Collar
4. Rocker Arm Shaft Assembly 9. Bridge
5. Valve Stem Oil Seal
N6A6093E
Legend
1. Bridge Cap
2. Bridge
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or a hole N6A6114E
into which oil pours back in the front.
Caution:
7. Remove the split collar. Do not use the removed oil seal again.
• Apply compressed air over the cylinder from a
glow plug hole to keep the valve at the home
position (the piston top dead center is also
Inspection
acceptable). Inspect the valve spring
• Use a replacer to compress the valve spring to Caution:
remove the split collar. Check the valve spring visually and if there is clear
damage or wear-out, replace it.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263) 1. Free length
Pivot: 5-8840-2808-0 (EN-46721) • Measure free length of the spring and if it is
shorter than the prescribed limit, replace the
spring.
N6A6113E
N6A6115E
Installation
1. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a
valve stem seal installer.
Caution:
After installing the valve stem oil seal, check if it is
inserted deeply enough and the oil seal is not tilted or
the garter spring has not come off.
N6A6116E
3. Tension
• Use a spring tester to compress the spring to
the installation height. Measure tension of the
compressed spring. If the measurement is
lower than the limit, replace the spring.
Engine Mechanical (4HK1-TC) 6A-69
Special tool • Apply compressed air over the cylinder from the
Valve stem seal installer: 5-8840-2833-0 glow plug holes to keep the valve at the home
(EN-47685) position.
• Use a replacer to compress the valve spring
and install the split collar.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 5-8840-2808-0 (EN-46721)
N6A6118E
6. Apply engine oil over the bridge cap and install it.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
N6A6119E
Legend
1. Spring Pitch
2. Paint Mark
Tool Number /
Illustration
Description / Remarks
5-8840-2833-0
(EN-47685)
Valve Stem Seal Installer
EN47685
N6A6093E
Legend
1. Bridge Cap
2. Bridge
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2621-0 (J-43263)
Valve Spring Replacer
5-8840-2808-0
(EN-46721)
Pivot Assembly
Engine Mechanical (4HK1-TC) 6A-71
Cylinder Head
Component
1
4 2
16
5
6
3
7
8
9
10
15
11
14
12
13
N6B6031E
Legend
1. Bridge Cap 9. Idle Gear C Cover
2. Bridge 10. Idle Gear C
3. Bridge Guide 11. Glow Plug
4. Split Collar 12. Intake and Exhaust Valves
5. Spring Upper Sheet 13. Cylinder Head
6. Valve Spring 14. A/C Compressor Bracket
7. Valve Stem Oil Seal 15. Thermostat
8. Valve Guide 16. Water Outlet Pipe
Caution: Removal
To avoid electric shock;
1. Drain the coolant.
Set the switch to the ‘OFF’ position and disconnect
battery negative cable before checking or repairing the 2. Remove the engine harness.
fuel injector, wiring or/and connectors. 3. Remove the front exhaust pipe.
4. Remove the turbocharger.
Refer to “Turbocharger and Exhaust Manifold”.
6A-72 Engine Mechanical (4HK1-TC)
5. Remove the charge air hose on the right and left • Loosen the tension pulley nut and the adjust
sides of the engine. bolt and remove the drive belt.
1
1
2
N6B6004E N6B6285E
Legend Legend
1. Inlet Hose 1. Tension Pulley Nut
2. Charge Air Hose 2. Adjust Bolt
1 2
4 3
5
N6B6033E
N6A6123E
Legend
1. EGR Cooler 10. Remove the A/C compressor bracket.
2. Water Rubber Hose 11. Remove the cylinder head cover.
3. EGR Duct (EGR cooler (2nd) – EGR valve) Refer to “Cylinder Head Cover.”
4. EGR Valve 12. Loosen the fuel injector terminal nuts alternately to
5. EGR Duct (EXH) the same level, and remove the terminal.
8. Remove the A/C compressor drive belt. 13. Loosen the fuel injector harness bracket bolt,
remove the inside connector, and remove the
harness bracket.
Engine Mechanical (4HK1-TC) 6A-73
Caution:
Injector ID code is used to identify each injector.
Do not remove the injector ID code.
14. Remove the nozzle leak-off pipe (4).
N6B6035E
N6B6034E
Legend
1. High Pressure Pipe
2. Leak-off Pipe N6A6127E
Caution:
• Do not tamper with the electromagnetic portion of
the fuel injector. Reduced electromagnetic function
will result in injector failure.
N6B6082E
Legend
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
Caution: Caution:
• Injector ID code is used to identify each injector. Attach a cylinder number to the removed fuel injectors
Do not mix with other injector ID code plates. til re-install them.
• If the injector assembly has been replaced, write Be sure not to make the nozzle touch something.
the ID code in the ECM using a scan tool. Refer to
“Engine Control” chapter for how to write an
injector ID.
• When pulling out the injector using a special tool,
make sure that the injector sleeve will not come off
during the work.
Engine Mechanical (4HK1-TC) 6A-75
• Remove liquid gasket adherent to the removed
inlet cover.
N6A6130E
Caution:
Replace the head gasket with a new one once it was
removed.
N6A6132E
N6A6131E
Disassembly
1. Remove the throttle assembly.
• Remove the intake throttle valve connector.
2. Remove the inlet cover.
6A-76 Engine Mechanical (4HK1-TC)
• Put the edge of a driver on the outer circle of • Remove the special tool, then remove the
the sealing cup as shown in the drawing, tap it upper sheet and springs.
lightly, reverse it, then pull it out with pliers or
other equipment. Sort the removed valve springs by cylinder
number.
N6A6133E
N6A6113E
10. Remove the idle gear C.
14. Remove the intake and exhaust valves.
• Sort the removed valves according to cylinders
by using tags and others.
N6A6134E
Legend
1. Idle Gear C
2. Idle Gear Shaft N6A6135E
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 5-8840-2808-0 (EN-46721)
Engine Mechanical (4HK1-TC) 6A-77
• Use pliers to remove the oil seals.
N6A6137E
N6A6114E Legend
16. Remove the valve guides. 1. Nozzle Sleeve
• Use the valve guide replacer to press out the
valve guides from the bottom side of the 18. Remove the bridge guide.
cylinder head. • Electrically weld the nut on the head of the
bridge guide, attach the sliding hammer and
Special tool pull it out.
Valve guide replacer: 5-8840-2628-0 (J-43272)
N6A6138E
N6A6136E Legend
17. Put the nozzle sleeve remover on the nozzle 1. Nut
sleeve from the bottom side of the cylinder head,
then pull out the nozzle sleeve. 19. Remove the oil seal.
Special tool
Nozzle sleeve remover: 5-8840-2623-0 (J-43265)
Caution:
• Be sure not to scratch the bottom side of the
cylinder head.
• Do not reuse the removed nozzle sleeve.
• Carefully remove sawdust in the screw groove.
6A-78 Engine Mechanical (4HK1-TC)
• Press the tool against the oil seal. Strike the • Check whether there is a crack between the
tool to remove the seal from the inside of the valve sheets and in the cylinder head of the
cylinder head. exhaust port part, and replace the cylinder
head if there is serious damage or crack.
Check the collar if necessary.
N6A6139E
N6A6140E
Inspection c. Flatness of the under surface of the cylinder
1. Inspect the cylinder head assembly. head
• Remove varnish, soot and others adhered on • Use a straight edge ruler and thickness
the metal surface completely. Use metal brush gauge to measure the four sides and
and others so that the seal surface of the diagonal lines as shown in the drawing, and
surface where the gasket is installed is not replace if they exceed the limit.
damage.
• Check the following causes in the case of leak Distortion of the under surface of the
of the seal surface of the cylinder head, cylinder head mm (in)
corrosion, air leak and defective gasket.
- Defective installation. Standard 0.05 (0.002) or less
- Defective tightening of the cylinder head. Limit 0.20 (0.0079)
- Winding seal surface of the cylinder block.
a. Damage on the screw surface or extracted
cylinder head bolt due to extra tightening
torque.
Caution:
Replace suspicious bolt.
N6A6141E
N6A6142E
N6A6146E
N6A6148E
Gap between the valve guide and
valve stem mm (in) 5. Inspect the valve.
Thickness of the valve
Standard Limit • Measure the thickness of the valve.
0.039 (0.00153) – • If the measured value exceeds the limit, replace
Intake valve 0.20 (0.00787)
0.054 (0.00213) the valve and valve guide altogether.
0.064 (0.00252) –
Exhaust valve 0.25 (0.00984)
0.079 (0.00311) Thickness of the valve mm (in)
Standard Limit
Intake valve 1.71 (0.0673) 1.3 (0.0512)
Exhaust valve 1.75 (0.0689) 1.3 (0.0512)
N6A6147E
N6B6253E
N6B6251E
N6B6252E
Contact width of the valve seat mm (in)
Repair of the seat surface
Standard Limit
• Remove carbon from the surface of the valve
Intake valve 1.5 (0.0591) 3.0 (0.1181) insert seat.
Exhaust valve 2.1 (0.0827) 2.5 (0.0984)
6A-82 Engine Mechanical (4HK1-TC)
• Use a seat cutter to minimize the scratch and
other roughness (15/45/75 degree-blade),
thereby returning the contact width to the
standard value.
N6A6155E
N6A6156E
N6A6154E
Legend
• Attach abrasives in the valve insert seat. 1. Arc-weld
• Insert the valve into the valve guide. 2. Valve Seat Insert
• Attach abrasives on the valve seat surface, 3. Screw Driver
rotate the valve and hit it lightly to grind them, Install the valve seat insert
and confirm that it has even contact all round.
• Carefully place an attachment (the outer
Caution: diameter is smaller than the valve seat insert)
Remove abrasives completely after grinding. on the valve seat insert.
• Use the press to apply pressure gradually on
the washer, thereby pushing the valve seat
insert.
Engine Mechanical (4HK1-TC) 6A-83
Caution:
Do not apply too much pressure with the press.
Attach compound on the valve seat surface, rotate the
valve and hit it lightly to grind them, and confirm that it
has even contact all round.
N6A6158E
Legend
1. Cylinder Head
2. Oil Seal Installer
Caution:
Be sure not to damage the rip.
Special tool
Oil seal installer: 5-8840-2627-0 (J-43269)
N6A6159E
Legend
1. 122.5 ± 0.5 mm (4.82 ± 0.02 in)
2. 37.5 mm (1.48 in)
N6A6650E
Legend N6A6161E
Caution:
• Leave the cylinder head floating so that the ball
comes off from the under surface.
Engine Mechanical (4HK1-TC) 6A-85
• Hammer in the valve guide from the upper Special tool
surface of the cylinder head, using the valve Valve stem seal installer: 5-8840-2833-0
guide replacer. (EN-47685)
Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272)
N6A6118E
Caution:
When replacing the valve guide, it must be replaced
together with the valve.
N6A6164E
N6A6119E
Legend
1. Spring Pitch
2. Paint Mark
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 5-8840-2808-0 (EN-46721)
N6A6113E
Caution:
Make sure that the split collar is securely inserted into
the valve stem groove.
Special tool
Sealing cup installer: 5-8840-2222-0
(EN-47690)
N6A6167E
N6B6036E
N6A6166E
Legend
1. Thermostat
N6B6015E
N6A6168E
Legend
1. Distance Tube
2. Conical Spring
N6A6170E
3. Nut
17. Install the throttle assembly.
• Coat the liquid gasket and mount within 7 • Tighten the exhaust manifold in the order
minutes. described in the drawing.
Tighten: Tighten:
Bolt and nut to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft) Bolt (1),(2),(3),(4),(5),(6) and Nut (7), (8) to 34 N⋅m (3.5
kgf⋅m/25 lbf⋅ft)
Caution:
Do not tighten it too much so that it hinders extraction
and contraction of the manifold due to heat.
Engine Mechanical (4HK1-TC) 6A-89
Measurement
Head of the piston (2) and (3)
points:
6
Standard point: Upper surface of the
8 (1)
4 cylinder block
3
Caution:
5
2 Note that there are three options for the head gasket
1 according to the amount of extrusion of piston shown in
7 the following table.
Installation
1. Install the cylinder head gasket.
• Select the cylinder head gasket.
• Clean the head of the piston and the upper
surface of the cylinder block.
• Use a dial gauge to measure the extrusion of
the piston. Measure at two points of each
cylinder.
• The following drawing shows the measurement
points and the standard point of the cylinder
block.
N6A6172E
N6A6171E
6A-90 Engine Mechanical (4HK1-TC)
• Install the cylinder head gasket with the parts
number upside, along with the cylinder head
rear gear case and dowel.
N6A6173E
Legend
1. Grade Recognition Hole
N6A6175E
N6A6174E
N6A6176E
• Install the cylinder head gasket.
• Apply molybdenum disulfide on the thread and
setting face of the head bolt of M14, and apply
engine oil on the thread and setting face of the
head bolt of M10.
• Use a torque wrench and angle gauge to
tighten the head bolts in the order described in
the drawing.
Engine Mechanical (4HK1-TC) 6A-91
Tighten:
M14 bolts (1 – 18) to
1st step: 98 N⋅m (10.0 kgf⋅m/72 lbf⋅ft)
2nd step: 147 N⋅m (15.0 kgf⋅m/108 lbf⋅ft)
3rd step: 30° – 60° (degrees)
M10 bolts (19, 20) to
4th step: 38 N⋅m (3.9 kgf⋅m/28 lbf⋅ft)
• Tighten bolts from 1-18 (M14) and confirm that
they are tightened to a torque of 167 N⋅m (17.0
kgf⋅m/123 lbf⋅ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
N6A6178E
Legend
1. Fuel Injector Assembly
2. Fuel Injector Tighten Bolt
Important: Tighten:
Reinstall each fuel injector to the original cylinder from Clip to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
which it was removed during the disassembly
procedure.
6A-92 Engine Mechanical (4HK1-TC)
1
1
2
2
N6B6121E
Legend
1. Injection Clamp Bolt
2. Injection Pipe Sleeve Nut
N6A6093E
Legend
1. Bridge Cap
2. Bridge
Engine Mechanical (4HK1-TC) 6A-93
13. Install the camshaft assembly.
Refer to “Camshaft Assembly”.
14. Install the rocker arm shaft assembly.
Refer to “Rocker Arm Shaft Assembly”.
15. Install and tighten the camshaft position sensor
with the designated torque.
Tighten:
Bolt to 8 N⋅m (0.8 kgf⋅m/69 lbf⋅in)
N6A6181E
N6B6101E
N6A6627E
Legend
1. Fuel Injector 1
2. Fuel Injector Harness
3. Fuel Injector Terminal Nut
2
Legend
1. Tension Pulley Lock Nut
2. Tension Pulley Adjusting Bolt
N6B6007E
Tighten:
Nuts to
Exhaust manifold side: 67 N⋅m (6.8 kgf⋅m/49 lbf⋅ft)
Exhaust brake side: 17 N⋅m (1.7 kgf⋅m/13 lbf⋅ft)
36. Install the engine harness.
2
37. Replenish the coolant.
1
4 3
5
N6B6033E
Legend
1. EGR Cooler
2. Water Rubber Hose
3. EGR Duct (EGR cooler (2nd) – EGR valve)
4. EGR Valve
5. EGR Duct (EXH)
30. Install the oil level gauge and the guide tube.
31. Connect the radiator upper hose.
32. Install the charge air hoses on the right and left
sides of the engine to the intercooler.
33. Install the Inlet hose.
• Install the bolt and the clip band, and tighten the
bolt to the specified torque.
2 1
N6B6005E
Legend
1. Inlet Hose
2. Charge Air Hose
3.
N6B6037E
Special Tool
Tool Number / Tool Number /
Illustration Illustration
Description / Remarks Description / Remarks
5-8840-2833-0
5-8840-0019-0 (J-23907)
(EN-47685)
Sliding Hammer
Valve Stem Seal Installer
584000190 EN47685
5-8840-2808-0
5-8840-2624-0 (J-43266)
(EN-46721)
Nozzle Sleeve Installer
Pivot Assembly
5-8840-2222-0
5-8840-2626-0 (J-43268)
(EN-47690)
Bridge Guide Installer
Sealing Cup Installer
5-8840-2627-0 (J-43269)
Oil Seal Installer
5-8840-2623-0 (J-43265)
Nozzle Sleeve Remover
5-8840-2826-0
(EN-46720)
Fuel Injector Remover
EN46720
5-8840-2621-0 (J-43263)
Valve Spring Replacer
6A-98 Engine Mechanical (4HK1-TC)
7
1
1 2
N6B6038E
Legend
1. Snap Ring 5. Connecting Rod
2. Piston 6. Piston Pin
3. Bearing 7. Piston Ring
4. Connecting Rod Cap
Removal
1. Remove the oil pan.
Refer to “Oil Pan”.
2. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
3. Remove the rocker arm shaft assembly.
Refer to “Rocker Arm Shaft Assembly”.
4. Remove the camshaft assembly.
Refer to “Camshaft Assembly”.
5. Remove the cylinder head.
Refer to “Cylinder Head”.
6. Remove the connecting rod cap.
Engine Mechanical (4HK1-TC) 6A-99
Caution: Caution:
Sort the removed bearings according to cylinders by Sort the piston rings in the order of cylinders when
using tags. reusing them so that they will not be confused with the
pistons and piston rings of other cylinders.
N6A6186E
N6A6189E
N6A6187E
4. Remove the connecting rods from the piston.
8. Remove the connecting rod bearing.
5. Piston
Caution: • Clean carbon carefully that is adhered to the
Arrange the bearings in the order of cylinders. Be sure head of the piston and the groove of the piston
to put them back to the original cylinders. ring.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
6A-100 Engine Mechanical (4HK1-TC)
Caution: • Use the bench press to replace the bush.
Do not use wire brush to clean the piston because it
scratches the piston. Special tool
Inspect the piston with eyes for cracks, burns and other Connecting rod bush replacer: 5-8840-2340-0
excessive wear, and replace it if there is any (EN-47682)
abnormality.
N6A6200E
Legend
1. Bolt
2. Connecting Rod Bush Replacer
Inspection
N6A6199E
1. Measure the gap between the piston and the inner
Legend diameter of the cylinder liner.
1. Setting Bar Inner diameter of the cylinder liner.
2. Connecting Rod
• Use a cylinder bore dial indicator to measure
3. Nut
the liner inner diameter both in the thrust and
4. Collar
radial directions in the designated position.
5. Bush
6. Collar • Measurement position (from the upper surface
of the cylinder block)
• Place the connecting rod bush replacer base on 1. 20 mm (0.79 in)
press, tighten the fixation bolt. 2. 110 mm (4.33 in)
3. 190 mm (7.48 in)
• Measure the liner inner diameter based on the
average value of the actual measurement
values on 6 positions.
N6A6190E N6A6191E
Caution:
If it is found that the gap between the cylinder liner
inner diameter and the piston exceeds the standard
value, replace the piston or cylinder liner.
N6A6192E
Legend
1. Front Mark Cut
N6A6195E
N6A6196E N6A6198E
• Inspect to make sure that there is a resistance 5. Measure the clearance between the piston and the
to the extent which the piston can push the piston pin.
piston pin lightly in normal temperatures. • Apply engine oil on the piston pin. Use your
• If it feels a large looseness or instability in finger to push it in hole of the piston and rotate
normal temperatures, replace the piston or it. If the pin smoothly rotates without instability,
piston pin. the clearance is normal. If there is instability,
measure the clearance. If the clearance
exceeds the limit, replace the piston and the
piston pin.
N6A6201E N6A6202E
Caution:
Do not rotate the crankshaft.
N6A6203E
Special tool
Connecting rod bush replacer: 5-8840-2340-0
(EN-47682)
2 3
N6A6648E
Legend
1. Top and Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
N6A6205E
Legend
1. Grade Recognition Color
Reassembly
1. Install the bush
6A-106 Engine Mechanical (4HK1-TC)
• Adjust the oil hole of the connecting rod and the • Use snap ring pliers to install the snap ring of
oil hole of the bush, and use the bench press to one side.
install the bush.
N6A6645E
N6A6199E Legend
Legend 1. Front Mark
1. Setting Bar 2. Forging Mark (Projecting)
2. Connecting Rod
3. Nut 4. Apply enough engine oil on the piston pin, push it
4. Collar in the piston and the connecting rod small edge.
5. Bush 5. Use snap ring pliers to install the snap ring.
6. Collar
Caution:
• After installing the new bush, use a grinder to Make sure that the snap ring is installed in the ring
machine the pin hole so that the pin clearance groove properly. Make sure that the connecting rod
equals the standard value. moves smoothly.
N6A6206E
N6B6239E
2. Install the piston.
3. Install the connecting rod. 6. Use ring pliers to install the piston ring.
• Install it so that the front mark of the head of the • Install the oil ring so that the joint angle of the
piston and the connecting rod forging mark ring and coil expander is in the opposite 180°
(projecting) on the connecting rod face the direction.
same direction.
Engine Mechanical (4HK1-TC) 6A-107
• Install 2nd and 1st compression rings in this • Apply enough engine oil on the piston ring, ring
order so that the marks “2T” and “1T” face groove and piston side surface.
upward. • Dislocate the piston ring joint so that (1) is 1st
ring, (3) is 2nd ring and (2) is oil ring, as shown
in the drawing.
• Face the piston front mark cut to forward, use
the piston ring compressor to insert the piston
in the cylinder liner.
Caution:
• When pushing in the piston, attach the setting tool
tight to the cylinder liner. Insufficient tightness can
cause damage to the ring while pushing in.
• Be sure not to make the connecting rod touch the oil
jet when pushing in the piston.
• Be sure not to damage the inside of the liner when
pushing in the piston.
Special tool
Piston ring compressor: 5-8840-9018-0
N6A6209E
(J-8037)
Legend
1. Oil Ring
2. Compression Ring 2nd
3. Compression Ring 1st
Caution:
Note that the shapes of compression rings 1st and 2nd
are different.
Make sure that there is no gap in the position indicated
in the drawing when the oil ring coil expander was
installed.
N6B6250E
N6A6210E
Installation
1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, apply
engine oil on the bearing.
2. Install the piston and connecting rod assembly.
6A-108 Engine Mechanical (4HK1-TC)
• Install the cap, matching the numbers (1, 2, 3,
4) of the caps and connecting rods.
2 3
N6A6212E
Tighten:
Tightening bolt to
1st step: 39 N⋅m (4.0 kgf⋅m/29 lbf⋅ft)
2nd step: 60° (degrees)
3rd step: 30° (degrees)
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
Caution:
Make sure that the crankshaft smoothly rotates.
Engine Mechanical (4HK1-TC) 6A-109
Torque Specifications
N6B6039E
Special Tool
Tool Number / Tool Number /
Illustration Illustration
Description / Remarks Description / Remarks
5-8840-2340-0
(EN-47682) 5-8840-0266-0 (J-45059)
Connecting Rod Bush Angle Gauge
Replacer
5-8840-9018-0 (J-8037)
Piston Ring compressor
6A-110 Engine Mechanical (4HK1-TC)
Flywheel
Component
N6B6040E
Legend
1. Flywheel Housing 6. Pilot Bearing (MT)
2. Flywheel Assembly (MT) 7. Crankshaft Position Sensor
3. Washer 8. Flexible Plate (Smoother)
4. Clutch Assembly (MT) 9. Crankshaft End Spacer (Smoother)
5. Clutch Pressure Plate Assembly (MT)
Removal
1. Remove the starter motor.
• Remove the earth cable of the starter motor.
Engine Mechanical (4HK1-TC) 6A-111
• Disconnect the front frame harness connector • Remove the clutch pressure plate assembly
near the control box of the transmission, from the flywheel.
remove the clips that fix the harness.
N6A6217E
N6B6041E
4. Remove the clutch plate assembly.
• Remove the two bolts on the upper side and • Remove the clutch plate assembly from the
lower side that fix the starter, remove the starter flywheel along with the clutch aligner (1).
from the clutch housing.
• Use wire to secure the starter to the
transmission. Position the wire and starter so
that it does not interfere with the transmission
removal procedure.
N6A6218E
Legend
1. Clutch Aligner
N6A6057E
N6A6078E
5. Remove the crankshaft position sensor.
• Remove to prevent contact damage when the 8. Remove the pilot bearing.
flywheel is removed. • Remove the pilot bearing from the flywheel.
• Do not throw or drop because it is vulnerable to
shock.
N6A6219E
Legend
N6B6025E 1. Washer
6. Remove the washer. 2. Pilot Bearing
3. Flywheel
7. Remove the flywheel.
• Gradually loosen the flywheel installation bolts 9. Remove the ring gear.
in the order shown in the drawing so that the
flywheel does not rotate.
• After loosening the bolts, remove the stopper
and remove the flywheel.
Engine Mechanical (4HK1-TC) 6A-113
• Put a bar on the ring gear and hit it with a Depth = From the pressure installation surface
hammer to remove it. to the friction surface.
N6A6220E N6A6221E
Inspection Installation
1. Inspection with eyes 1. Install the ring gear.
• Inspect the flywheel friction surface for cracks • After heating the ring gear with a gas burner
and damages, and replace it if it has equally, install it in the flywheel. Do not allow
abnormality. the temperature of the gas burner to exceed
• Inspect the tooth part of the ring gear, replace 200°C (390°F).
the ring gear if it has damage or serious wear. • During shrinkage cooling of the ring gear,
2. Measurement of the friction surface maintain the flatness by applying force of
68.6 kN (15,400 lbf).
• Measure the depth of the friction surface of the
flywheel. Caution:
• Adjust it if the measured value is between the • Install the ring gear in the direction within the
standard value and the limit. chamfered face comes to the side of pressure
• If the measured value exceeds the limit, replace installation surface.
the flywheel. • Shrink fit the ring gear to the flywheel.
Make sure that flywheel and ring gear adhesion is
Depth of the friction surface of the complete.
flywheel mm (in)
Standard 19 (0.75 )
Limit 20 (0.79)
N6A6222E
6A-114 Engine Mechanical (4HK1-TC)
2. Install the flywheel. Smoother specification
3. Install the washer. 1) Align the knock pin on the crankshaft to install
M/T specification the spacer.
1) Align the flywheel with the crankshaft knock pin 2) Install the flexible plate and washer, also
and temporarily tighten the flywheel bolts. aligning to the knock pin on the crankshaft.
2) Use the crankshaft stopper to prevent the 1st step; 78.4 ± 5.0 N⋅m (8.0 ± 0.5 kgf⋅m/58 ±
crankshaft from turning. 3.6 lbf⋅ft)
Crankshaft stopper: 5-8840-2230-0 (EN-47680) 2nd step; 120° – 150° (degrees)
3) Install the washer and the flywheel bolts and
tighten to the specified torque in numerical order
show in the illustration.
Tighten:
Bolts to
1st step: 78.4 ± 5.0 N⋅m (8.0 ± 0.5 kgf⋅m/58 ± 3.6 lbf⋅ft)
2nd step: 120° – 150° (degrees)
Special tool
Crankshaft stopper: 5-8840-2230 (EN-47680)
Angle gauge: 5-8840-0266-0 (J-45059)
N6A6078E
N6A6218E
Legend
N6A6057E
1. Clutch Aligner
N6B6041E
N6A6217E
N6B6042E
N6B6044E
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2230-0
(EN-47680)
Crankshaft Stopper
5-8840-0266-0 (J-45059)
Angle Gauge
Engine Mechanical (4HK1-TC) 6A-117
Front Cover
Component
N6B6045E
Legend
1. Adjust Plate 8. Front Oil Seal
2. Generator 9. Crankshaft Pulley
3. Front Cover 10. Water Pump Assembly
4. Oil Pan Gasket 11. Fan Belt
5. Oil Pan 12. Water Pump Pulley
6. Rubber Assembly 13. Fan Assembly
7. Front Slinger
N6B6264E
N6A6227E
• Remove the oil relief valve (arrowed), loosen
the front cover installation bolts and remove the
front cover.
Installation
1. Install the oil cooler bypass valve.
• Insert the oil cooler bypass valve into the
cylinder block. Be sure not to insert in a wrong
direction.
N6B6265E
N6A6228E
Caution:
Apply liquid gasket so that it does not adhere to the O-
ring.
N6A6230E
Legend
1. BOLT : L = 35 mm (1.38 in)
2. BOLT : L = 25 mm (0.98 in)
3. BOLT : L = 65 mm (2.56 in)
4. BOLT : L = 30 mm (1.18 in)
N6A6229E
5. Oil Relief Valve
N6B6046E
Engine Mechanical (4HK1-TC) 6A-121
3
2
1
N6B6137E
Legend
1. Crankshaft Pulley 3. Crankshaft Front Slinger
2. Crankshaft Front Oil Seal
N6B6042E
N6B6047E N6A6235E
N6A6234E N6B6048E
N6A6238E
N6A6237E
• After you have pressed the front slinger, confirm
Legend the measurement shown (depth from the end
1. Front Slinger surface of the crankshaft to the flange of the
2. Adapter (Front) slinger) and check for deflection of the slinger.
3. Fixing Bolt
4. Sleeve (Front) Caution:
5. Washer (Front) Be careful not to put the slinger inside out or mistake
6. Center Bolt front side slinger for rear one, and vice versa. Rear side
slinger has four right-hand threads on it while front one
Special tool has four left-hand threads. Slinger and oil seal should
Oil seal installer kit: 5-8840-2703-0 (J-43282) always be replaced in pairs.
(Use the parts listed below for the front oil seal.)
Caution:
Oil seal installer kit includes the sleeve (5-8840-2712-
0) for engine of May in 1993 model before, but it is not
used for this engine.
N6A6239E
• Insert the front slinger into the end of the Legend
adapter and fit them on the crankshaft. 1. Adapter
2. Sleeve
3. Slinger
4. 40.5 ± 0.3 mm (1.594 ± 0.012 in)
5. 34 ± 0.1 mm (1.339 ± 0.004 in)
6A-124 Engine Mechanical (4HK1-TC)
2. Install the crankshaft front oil seal. • Put the front side adapter ring in the sleeve and
• Press fit the oil seal using an oil seal installer fix the sleeve on the adapter with the center bolt
kit. and a washer.
• Tighten the bolt until the sleeve touches the
adapter to press fit the front oil seal.
N6A6240E
Legend
1. Oil Seal N6A6242E
N6A6238E
N6A6241E
Legend
1. Adapter (Front)
Caution:
Be sure to apply oil to the oil seal lip.
Engine Mechanical (4HK1-TC) 6A-125
• After you have press-fitted the front oil seal, 4. Install the fan belt.
confirm the measurement shown (depth from • When adjusting the fan belt, you should also
the end surface of the crankshaft to the oil seal) adjust ACG belt and air conditioner belt at the
and check for deflection of the oil seal. same time.
• Fit the fan belt and adjust the tension following
the below procedures.
• Refer to “Drive Belt” in Section 6B for details of
the belt tension adjustment.
a. Inspection of fan belt deflection
Refer to “Drive Belt.” in Section 6B.
5. Tighten the fan assembly to the specified
tightening torque.
Tighten:
Nuts to 24 N⋅m (2.4 kgf⋅m/18 lbf⋅ft)
N6A6243E
Legend
1. Adapter Ring
2. Sleeve
3. Adapter
4. Oil Seal
5. 31 ± 0.3 mm (1.220 ± 0.012 in)
3 4
N6B6049E
6A-126 Engine Mechanical (4HK1-TC)
Rigid suspension model
N6A6247E
Legend
1. Flange Nut
2. Rubber
3. Stud Bolt
4. Frame Side Bracket
5. Radiator Side Bracket
6. Washer
N6B6042E
N6B6205E
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2230-0
(EN-47680)
Crankshaft Stopper
8-8840-2360-0 (J-43285)
Slinger Puller
5-8840-2703-0 (J-43282)
Oil Seal Installer Kit
6A-128 Engine Mechanical (4HK1-TC)
N6B6286E
Legend
1. Starter 6. Crankshaft Rear Oil Seal
2. Transmission Assembly 7. Crankshaft Rear Slinger
3. Clutch Pressure Plate Assembly (MT) 8. Flexible Plate (Smoother)
4. Clutch Plate Assembly (MT) 9. Crankshaft End Spacer (Smoother)
5. Flywheel (MT)
Removal
1. Remove the transmission assembly.
Refer to "Transmission Assembly".
2. Remove the pressure plate and the clutch disc.
3. Remove the crankshaft position sensor.
4. Remove the flywheel.
Refer to “Flywheel”.
5. Remove the crankshaft rear oil seal.
Engine Mechanical (4HK1-TC) 6A-129
• Remove only the oil seal off with a screwdriver Installation
or the like avoiding damage to the oil seal
1. Install the crankshaft rear slinger.
contact surface on the flywheel housing and the
shaft. • Press fit the rear sling using the oil seal installer
kit.
N6A6235E
N6A6251E
Legend
1. Felt Legend
2. Slinger 1. Rear Slinger
3. Oil Seal 2. Fixing Bolt
3. Center Bolt
6. Remove the crankshaft slinger. 4. Sleeve (Rear)
5. Collar (Rear)
• Pull out the slinger using a slinger puller.
6. Adapter (Rear)
(Fixing the circumference of the puller with a
clip band will make the procedure easier.)
Special tool
Special tool Oil seal installer kit: 5-8840-2703-0 (J-43282)
Slinger puller: 5-8840-2360-0 (J-43285)
No. Part Name Slinger Oil seal
1 Sleeve (rear) { {
2 Adapter (rear) { {
3 Collar (rear) { {
4 Adapter ring (rear) — {
5 Center bolt { {
6 Fixing bolt { {
Caution:
Oil seal installer kit includes the sleeve (5-8840-2712-
0) for engine of May in 1993 model before, but it is not
used for this engine.
N6A6250E
6A-130 Engine Mechanical (4HK1-TC)
• Insert the rear slinger into the end of the rear
side adapter and mount the adapter on the
crankshaft with the fixing bolt with a collar
placed on it.
3 N6A6254E
Legend
1. Rear Part of The Crankshaft
2. Adapter
N6A6252E 3. 17.3 ± 0.3 mm (0.681 ± 0.012 in)
Legend 4. 10.8 ± 0.1 mm (0.425 ± 0.004 in)
1. Collar 5. Slinger
2. Fixing Bolt 6. Sleeve
3. Adapter 7. Collar
• Put a sleeve over the adapter and tighten the 2. Install the crankshaft rear oil seal.
center bolt until the sleeve touches the adapter • Press-fit the rear oil seal using an oil seal
to press fit the rear slinger. installer kit.
N6A6253E N6A6255E
• After you have press-fitted the rear slinger, Legend
confirm the measurement shown (depth from 1. Adapter (Rear)
the end surface of the crankshaft to the slinger) 2. Fixing Bolt
and check for deflection of the slinger. 3. Center Bolt
4. Sleeve (Rear)
Caution: 5. Collar (Rear)
Be careful not to put the slinger inside out or mistake 6. Adapter Ring (Rear)
the front slinger for the rear one, and vice versa. Rear 7. Rear Oil Seal
side slinger has four right-hand threads on it while front
one has four left-hand threads. Slinger and oil seal
should always be replaced in pairs.
Engine Mechanical (4HK1-TC) 6A-131
• Put a collar on the fixing bolt and mount the • Tightening the center bolt until the sleeve
adapter onto the crankshaft. touches the adapter to press fit the oil seal.
N6A6252E N6A6253E
N6A6257E
Legend
1. Rear Part of The Crankshaft
2. Oil Seal
N6A6256E
3. 7.8 ± 0.3 mm (0.31 ± 0.012 in)
Legend 4. Collar
1. Sleeve 5. Adapter Ring
2. Adapter Ring 6. Sleeve
7. Adapter
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2703-0 (J-43282)
Oil Seal Installer Kit
5-8840-2360-0 (J-43285)
Slinger Puller
Engine Mechanical (4HK1-TC) 6A-133
Crankshaft
Component
N6A6258E
Legend
1. Upper Bearing 5. Lower Bearing
2. Upper Thrust Bearing 6. Lower Thrust Bearing
3. Gear 7. Crankcase
4. Crankshaft
N6A6261E
Disassembly
1. Remove the gear.
• Remove the gear using a gear puller.
Special tool
Crankshaft gear puller: 8-9439-1097-0
(EN-47684)
N6A6259E
N6A6262E
Reassembly
1. Install the gear.
• Heat the gear to 170 – 250°C (338 – 482°F)
and install it aligning the groove on the gear
with the pin on the crankshaft.
N6A6260E
Special tool
Crankshaft gear installer: 5-8840-2667-0
(J-41222)
N6A6264E
Caution:
Measure the thrust clearance before dismounting.
N6A6265E
N6A6268E
N6A6266E Tighten:
M14 bolts (1 – 10) to
• Install the crankcase and tighten bolts to the
specified tightening torque. 1st step: 98 N⋅m (10.0 kgf⋅m/72 lbf⋅ft)
2nd step: 132 N⋅m (13.5 kgf⋅m/97 lbf⋅ft)
• Tighten the crankcase in the sequence shown
using a torque wrench and an angle gauge. 3rd step: 30° – 60° (degrees)
M10 bolts (11 – 27) to
4th step: 38 N⋅m (3.9 kgf⋅m/28 lbf⋅ft)
• Tighten the bolts (M14) from 1-10 and confirm
that they are tightened to a torque of 167 N⋅m
(17.0 kgf⋅m/123 lbf⋅ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
Caution:
Do not turn the crankshaft after you have tightened the
crankcase.
N6A6269E
N6A6270E
6A-138 Engine Mechanical (4HK1-TC)
• Journals are numbered from 1 to 5 from left to right
when viewed so that the numbers are in normal
reading orientation.
N6B6206E
Legend
1. Do not drop solution in this area.
2. Test area N6A6272E
Caution:
Do not let the solution contact the area around the oil
port.
Judgment
• Wait for 30 to 40 seconds.
• The crankshaft is usable if the color does not
change after 30 to 40 seconds. (This means the
tuftride layer still stays on.)
Replace the crankshaft if the color is changed (test
surface turns a copper color).
Caution:
• The test solution is strong corrosive. Wipe it off
immediately after the test, and thoroughly clean N6A6273E
with water, steam, etc.
• Do not allow the solution to contact eyes, hands, Caution:
cloth, etc. If it goes into an eye, immediately flush Be careful about difference in the shape of the bearings
with large amount of water and seek for medical when installing them.
attention.
N6A6274E
Legend
1. Upper Bearing
2. Oil Gallery
3. Grade Identification Color
4. Oil Groove
5. Lower Bearing
6. Grade Identification Color
Installation
1. Install the crankshaft upper bearing.
• Install the upper bearing in the cylinder block
and apply oil.
6A-140 Engine Mechanical (4HK1-TC)
Caution: • Press the crankshaft to the rear and insert the
When replacing the crankshaft bearings, select grades upper thrust bearing in the rear side of the
referring to the Bearing Selection table. Do not apply oil cylinder block journal No.5.
to the bearing installation surface on the cylinder block
and external surface of the bearing. Caution:
Install the thrust bearing so that the oil groove contacts
the crankshaft.
N6A6275E
N6A6278E
N6A6279E
Torque Specifications
N6B6287E
Engine Mechanical (4HK1-TC) 6A-143
Special Tool
Tool Number /
Illustration
Description / Remarks
8-9439-1097-0
(EN-47684)
Crankshaft Gear Puller
5-8840-2667-0 (J-41222)
Crankshaft Gear Installer
5-8840-0266-0 (J-45059)
Angle Gauge
6A-144 Engine Mechanical (4HK1-TC)
Cylinder Block
Component
N6B6052E
Legend
1. Cylinder Liner 3. Cover
2. Cylinder Block
N6A6283E
Inspection
1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
• Be careful not to damage the cylinder block.
2. Carefully remove the liquid gasket on the
crankcase mounting surface.
3. Clean up the cylinder block.
4. Visually inspect the cylinder block.
N6A6284E
(Reference)
When replacing liners, a “liner set” let you
obtain a piston of proper grade for a given liner
bore diameter only by specifying a liner outside
diameter grade.
N6A6285E
2. Install the cylinder liners.
• Install the cylinder liners perpendicular to the
Installation cylinder block.
1. Cylinder liner grade selection • Do not hammer the liner or apply excessive
force to insert it.
• Select liner outer diameter grades according to
the cylinder block bore grades stamped on the Caution:
cylinder block at arrowed positions in the figure. Clean up and blow with compressed air the cylinder
block and the cylinder liners before installing them.
Grade matching of cylinder block and liner
Grade of Cylinder block (stamp) 1, 2 3
Grade of Liner outside diameter 1X 3X
Engine Mechanical (4HK1-TC) 6A-147
Caution:
Be careful not to deform or damage the oil jet nozzle.
N6A6287E
21 (2.1 / 15)
N6B6124E
Engine Mechanical (4HK1-TC) 6A-149
Lubrication System
Service Precautions • Avoid excessive or insufficient coating amount.
Note that seizure may occur in case of excessive
• During each disassembly, remove the old gasket
coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely
and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid
is insufficient.
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton • Always, the starting and ending piston of
and apply the specified new fluid gasket at each application should be overlapped.
location.
Explanations on Functions and Operation
The lubrication system uses the filter element
combined with a full flow bypass, water-cooled oil
cooler, and oil jet for piston cooling.
N6B6053E
N6B6207E
Legend
1. Oil dipstick
Engine Mechanical (4HK1-TC) 6A-151
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2843-0
Oil Pressure Gauge Set
(J-43630-20 /
Oil Pressure Gauge,
J-43630 / Hose,
J-43630-14 / Connector,
EN-46333 / Oil Pressure
5884028430 Testing Adapter)
6A-152 Engine Mechanical (4HK1-TC)
N6A6294E
Legend
1. Oil Pressure Switch 3. O-ring
2. Oil Filter Body
Removal
1. Place a tray under the oil filter cartridge.
2. Remove the oil pressure switch.
3. Remove the oil filter body.
4. Remove the O-ring.
Engine Mechanical (4HK1-TC) 6A-153
Installation
1. Install the O-rings and on the oil filter body.
N6A6297E
N6B6055E
Legend
1. O-ring
2. O-ring
N6A6296E
N6A6298E
Legend
1. Oil Filter Cartridge
Caution:
Be careful not to pinch the rotary sensor harness while
installing / removing the cartridge.
N6A6299E
Installation
1. Install the oil filter cartridge.
• Apply grease or engine oil to the seal in the
cartridge and install it using the oil filter wrench.
Engine Mechanical (4HK1-TC) 6A-155
Special Tool
Tool Number /
Illustration
Description / Remarks
1-8522-1097-0
(EN-47683)
Oil Filter Wrench
6A-156 Engine Mechanical (4HK1-TC)
Oil Cooler
Components
N6B6056E
Legend
1. Bypass Hose 5. Fuel Supply Pump
2. EGR Cooler Water Return Pipe 6. EGR Cooler Water Feed Pipe
3. Oil Cooler 7. Suction Pipe
4. Fuel Rail
Removal
1. Remove the fuel rail.
Refer to “Fuel Rail” in Section 6C.
2. Remove the fuel supply pump.
3. Remove the vacuum pump.
4. Remove the A/C drive belt.
5. Remove the idling pulley bracket.
• Remove the drive belt for A/C and the bracket
fixing bolts, and then remove the bracket along
with tensioner and idling pulley.
N6A6301E
N6A6304E
N6B6057E Legend
1. Element
Legend
2. O-ring
1. Bypass Hose
2. EGR Cooler Water Return Pipe
3. EGR Cooler Water Feed Pipe
4. Suction Pipe Reassembly
1. Install the O-ring on the oil cooler case.
9. Remove the oil cooler assembly.
2. Install the element.
• Screw the removed fixing bolt of the oil cooler
into the replacer hole at the location 1 of the 3. Tighten the element fixing bolts using the specified
figure and remove the oil cooler. torque.
Tighten:
Bolts to 20 N⋅m (2.0 kgf⋅m/15 lbf⋅ft)
N6A6303E
Legend
1. Oil Cooler Assembly N6A6304E
N6A6306E
Legend
1. Oil Cooler Assembly
N6A6307E
Legend
1. Liquid Gasket
Engine Mechanical (4HK1-TC) 6A-159
Caution: 6. Install the idling pulley bracket and tighten it using
The water suction pipe must be installed immediately the specified torque.
after the oil cooler (the pipe and cooler use the same
Tighten:
liquid gasket).
Idling pulley bracket to 24 N⋅m (2.4 kgf⋅m/18 lbf⋅ft)
7. Install the A/C drive belt.
Refer to “Drive Belt” in Section 6B.
N6A6308E
N6A6308E
Oil Pan
Components
N6B6058E
Legend
1. Oil Pan Gasket 3. Oil Pan Rubber
2. Oil Pan
Removal Installation
1. Drain out the engine oil. 1. Install the oil pan.
• After draining oil, tighten the drain plug to the • At the seam between the cylinder block and the
specified torque. front cover with the flywheel housing, apply the
liquid gasket (ThreeBond 1207C or equivalent)
Tighten:
to a bead diameter of 3 mm (0.12 in).
Drain plug to 83 N⋅m (8.5 kgf⋅m/61 lbf⋅ft)
Caution:
Do not forget tighten the drain plug.
N6A6075E
N6A6077E
• Install the gasket using the studs of the
crankcase, flywheel housing, and front cover as
Tighten:
guide and mount the oil pan.
Nuts and bolts to 11 N⋅m (1.1 kgf⋅m/95 lbf⋅in)
Install the rubber assembly on the oil pan and
secure it using nuts and bolts. 2. Replenish the engine oil.
N6A6076E
Legend
1. Rubber Assembly
2. Oil Pan
3. Gasket
6A-162 Engine Mechanical (4HK1-TC)
Oil Pump
Components
N6A6312E
Legend
1. Oil Pump Assembly 5. Driven Gear and Shaft
2. Spring 6. Oil Pump Body
3. Ball 7. Slinger
4. Split Pin
N6A6058E N6A6313E
17. Remove the flywheel housing. 19. Remove the oil pump assembly.
• Make sure you remove the bolts shown in the
figure.
N6A6314E
N6A6059E
Disassembly
1. Remove the driven gear and shaft.
2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Reassembly
1. Install the ball.
2. Install the spring.
6A-164 Engine Mechanical (4HK1-TC)
3. Install the split pin and fold it according to (1).
N6B6059E
N6A6315E
2. Measure the clearance between the gear side
4. Apply engine oil on the driven gear and shaft and surface and the upper surface of the oil pump
mount them on the oil pump body. body.
• Measure the clearance between the gear
surface and the upper surface of the oil pump
body using the thickness gauge and square.
• If the clearance between the gear and inner
wall of the body exceeds the limit, replace the
gear assembly or the driven gear assembly.
N6A6316E
Inspection
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
• Measure the clearance between the gear and
oil pump body using a thickness gauge.
• If the clearance between the gear and inner
wall of the body exceeds the limit, replace the
gear assembly or the driven gear assembly.
Caution:
Apply the fluid gasket such that it does not enter the
holes shown by arrows in the figure, gear, and the oil
pump body.
N6A6319E
N6A6320E
N6A6067E
6A-166 Engine Mechanical (4HK1-TC)
• Match the coincidence marks of the crankshaft
Tighten:
gear and the idle gear A, and install them on
Bolts (1) to 96 N⋅m (9.8 kgf⋅m/71 lbf⋅ft)
the cylinder block.
Bolts (2) to 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
Bolts (3) to 38 N⋅m (3.9 kgf⋅m/28 lbf⋅ft)
• The seal is tightened from the cylinder block
side.
N6A6322E
N6A6069E
N6A6070E
N6A6071E
N6A6072E
6A-168 Engine Mechanical (4HK1-TC)
With HBB
N6A6073E
N6A6218E
Legend
1. Clutch Aligner
N6A6217E
N6A6323E
Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and
confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the
circuit between the meter and the oil pressure
switch, and repair the disconnected locations.
N6A6324E
Engine Mechanical (4HK1-TC) 6A-171
Inspection
• Check for damage to the element or clogging due
to dirt. If the element is damaged, then replace it. If
clogged, then clean it.
• The viscous-type (wet type) element cannot be
cleaned; therefore, it has to be replaced if it is very
dirty.
Installation
1. Install the air cleaner element assembly.
2. Tighten the air cleaner cover fixing bolt.
Cleaning
Dry type element
• While rotating the element, blow air under 690 kPa
(7.0 kg/cm2 / 100 psi) and remove the dust.
N6A6325E
Notice:
It advises on not using wet type element by any means
in order to give a damage to a sensor strongly.
Cooling System 6B-1
ENGINE
Cooling System
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6B-2
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
A List of Defective Phenomena . . . . . . . . . . . . . 6B-7
Main Data and Specifications. . . . . . . . . . . . . . . 6B-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6B-12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6B-15
Engine Coolant Temperature Sensor . . . . . . . . . 6B-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-17
Radiator and Intercooler . . . . . . . . . . . . . . . . . . . 6B-18
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-20
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6B-21
Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-22
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-22
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-22
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-23
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6B-25
6B-2 Cooling System
Cooling System
10
11
12
9 15
8
13
16
14
7
1
3
2
5
N6B6060E
Legend
1. Water Jacket 9. Reserve Tank
2. Oil Cooler 10. Air Bleeding Plug
3. Water Pump 11. Water Outlet Pipe
4. Heater Core 12. Thermostat (2 nos.)
5. Drain Cock 13. Thermometer Unit
6. Radiator 14. Bypass Route
7. Cooling Fan 15. Turbo Charger
8. Radiator Cap 16. EGR Cooler
Cooling System 6B-3
Water Pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.
N6B6126E
Legend
1. Fan Center 4. Seal Unit
2. Fan Pulley 5. Impeller
3. Bearing 6. Groove
6B-4 Cooling System
Thermostat
The thermostat is a wax pellet type and consists of two
units, in which one unit (bottom bypass type) has an
valve initial opening temperature of 82 °C (180 °F) and
the second (inline type) has an valve initial opening
temperature of 85 °C (185 °F). It is designed such that
the water temperature can be adjusted finely and it is
mounted within the thermostat-housing unit.
N6A6328E
Legend
1. Jiggle Valve 4. Gasket
2. Stamp Mark (Valve Initial Opening Temperature) 5. Piston
3. Valve
Cooling System 6B-5
Radiator
The radiator is a tube with corrugated fins. To increase
the boiling point of the cooling water, a radiator cap of
injection valve opening pressure of 108 ± 14.7 kPa (1.1
± 0.15 kg/cm2 / 15.7 ± 2.1 psi) is attached.
N6A6330E
Legend
1. Reserve Tank
2. MAX Line (Upper Limit)
3. MIN Line (Lower Limit)
N6A6329E
Inspection
Functional Check Cooling water leak check
1. Cooling water level check • Use the radiator cap tester and apply a pressure of
• Check the cooling water level within the reserve 196 kPa (2.0 kg/cm2 / 28.4 psi) and check for leaks
tank and the level is appropriate when the in the locations given below. Check that the
cooling water level is within the MAX (upper radiator hose and heater hose are not damaged or
limit) and MIN (lower limit) range. In case the degraded and the hose clamp is not loose.
volume of the cooling water is deficient, remove
the reserve tank cap and replenish with a Inspection locations
mixture of tap water and engine coolant in the • Radiator assembly, water pump assembly, radiator
ratio of 1:1 until the level comes close to the hose, and heater hose.
MAX line.
Standard value
Cooling water level 18 liters (4.76 US gal. / 3.96
Imp gal.)
(between MIN and MAX level)
Replacement period Every two years or 40,000
kilometers (24,000 miles)
N6A6331E
Coolant
1. About the engine coolant concentration
6B-6 Cooling System
• Take the concentration corresponding to the • Use a deep container to suit the height of the
minimum temperature because the freezing specific gravity meter.
temperature varies according to the
concentration of the engine coolant.
• Use only genuine Isuzu engine coolant.
• Use engine coolant with a mix ratio in the range
of 30 to 60% because over heating is likely to
occur if the ratio is greater than 60% and
corrosion prevention is inadequate if the ratio is
less than 30%.
N6A6333E
Legend
1. Anti-Freeze Specific Gravity Meter
2. Radiator
N6A6334E
Cooling System 6B-7
Coolant scooping method
• Measure the concentration using the coolant
scoop.
A List of Defective Phenomena
• Engine overheats
• Engine overcools
Engine overheats
Engine overcools
Water Pump
Components
N6B6061E
Legend
1. Radiator Lower Hose 5. Setting Plate
2. Fan Guide 6. Water Pump Pulley
3. Fan 7. Fan Belt
4. Cooling Fan Clutch 8. Water Pump Assembly
Cooling System 6B-9
Removal 4. Remove the four mounting nuts and then the fan
assembly. Also, loosen the four bolts for tightening
1. Drain the coolant water.
the setting plate and water pump pulley together.
1 4
5
1
3
N6B6062E
N6B6128E
Legend
Legend
1. Radiator Drain Cock
1. Fan
2. Nut
3. Setting Plate
4. Water Pump Pulley
5. Bolt
5. (2) and (3) that tighten the setting plate and water
pump together. Loosen the adjusting bolts (1) in
the generator and remove the fan belt.
N6A6337E
Legend
1. Power Steering Pump
2. Drain Plug
Legend
1. Adjusting Bolt (With A/C)
2. Lock Nut
3. Bolt
3
N6A6342E
N6B6127E
Legend
1. Water Pump Installation
2. Water Pump Pulley 1. Mount the water pump assembly.
3. Setting Plate • Coat the fluid gasket (ThreeBond 1207C or
equivalent) to a bead diameter 3 to 5 mm (0.12
to 0.20 in) in the groove of the mounting surface
Inspection of the water pump.
1. External check • Mount the water pump to match with the studs
of the front cover within 7 minutes after coating
• Check for cracks or damage in the pump body. the fluid gasket.
• Check for cracks and corrosion in the impeller. • Refer to the figure for the offset in position of
• Check for water leakage from the seal unit. the fluid gasket.
• If you find abnormalities, replace with the water
Tighten:
pump assembly.
Bolts and nuts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
N6A6341E
N6A6343E
2. Bearing unit check
• Rotate the fan center while pushing it along the
radial direction. Confirm that there is no
abnormal noise and no excessive play.
Cooling System 6B-11
2. Temporarily fit the bolts until the water pump pulley 5. After the fan belt adjustments, tighten the
and the setting plate are properly seated in the temporarily fitted fan pulley and setting plate using
water pump assembly. the specified torque.
Tighten:
Bolt to 24 N⋅m (2.4 kgf⋅m / 17 lbf⋅ft)
6. Tighten the fan assembly using the specified
torque for mounting.
Tighten:
Nut to 24 N⋅m (2.4 kgf⋅m / 17 lbf⋅ft)
1 4
N6B6066E
Legend
1. Fan Pulley
2. Setting Plate
5
N6B6050E
Legend
1. Adjusting Bolt (With A/C)
2. Lock Nut
3. Bolt
6B-12 Cooling System
Torque Specifications
N6B6065E
Cooling System 6B-13
Thermostat
Components
N6B6067E
Legend
1. Radiator Upper Hose 3. Thermostat
2. Water Outlet Pipe 4. Gasket
Inspection
• Place the thermostat in water and increase the
temperature while stirring it sufficiently.
N6A6347E
6B-14 Cooling System
Installation 4. Replenish the cooling water stored during the
discharge, and check the volume of the cooling
1. Mount the gasket on the thermostat and mount it at
water.
the position shown in the figure.
• Mount the thermostat at the position shown in
the figure, as there are two types of thermostats
with different shapes.
• Fit the thermostat gasket ensuring that it does
not come out of and on top of the external
housing on the cylinder head side.
N6A6330E
Legend
1. Reserve Tank
2. MAX Line (Upper Limit)
3. MIN Line (Lower Limit)
N6A6348E
Legend
1. Thermostat
2. Cylinder Head
Tighten:
Bolt to 24 N⋅m (2.4 kgf⋅m / 17 lbf⋅ft)
3. Mount the radiator upper hose.
N6A6349E
Cooling System 6B-15
Torque Specifications
N6B6288E
6B-16 Cooling System
Removal
1. Disconnect the wire connector.
2. Remove the engine coolant temperature sensor.
Inspection
This thermo-sensor works for the ECM and the
thermometer unit. It is thermistor type which has
characteristic that electrical resistance decreases
according to increase in temperature.
1 3
Caution:
4 2 Take care not to allow water to get into the terminal.
1 3 2
Also wipe off the water splash on the sensor after
inspection.
Resistance value relative to temperature (approximate
value):
Terminal No. Resistance Remarks
5
Approx. 2.55(kΩ) 20°C
1←→3 (For ECM)
N6B6129E
Approx. 0.33(kΩ) 80°C
Legend 2←→Body (for meter) 142.6 to173.1(Ω) 60°C
1. This indicates wire connection.
2. This indicates wire connection.
3. This indicates wire connection. Thermistor characteristic
30
4. Thermistor for ECM
5. Thermistor for thermometer 20
10
1. Immerse the thermo-sensor into water, and check
Resistance value
7.0
if the resistance value matches with a value in the 5.0
graph of thermistor characteristic while changing 3.0
the water temperature. 2.0
1.0
0.7
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100 120
Engine coolant temperature
N6B6130E
Tighten:
25 N⋅m (2.5 kgf⋅m/18 lbf⋅ft)
N6B6131E
Legend
1. Engine coolant temperature sensor
2. Loctite applied area
N6B6068E
Legend
1. Coolant Reserve Tank Hose 4. Fan Guide
2. Radiator Upper Hose 5. Radiator Lower Hose
3. Radiator and Intercooler
Removal
1. Loosen the water drain plug (on the rear of right
side) and radiator drain plug, and discharge the
cooling water completely.
Cooling System 6B-19
• After discharging the water, tighten the drain 9. Take care to avoid damage to the radiator core
cock. from the fan blade, and remove the brackets on
the right and left sides of the radiator.
Simultaneously remove the radiator and inter-
cooler.
N6B6062E
Legend
1. Radiator Drain Cock
N6A6351E
Inspection
Radiator cap
1. Check the valve opening pressure using the
radiator cap tester. If the valve opening pressure
deviates from the standard value, replace the
radiator cap.
Valve opening pressure =
108 ± 14.7 kPa (1.1 ± 0.15 kg/cm2 / 15.7 ± 2.1 psi)
N6A6337E
Legend
1. Power Steering Pump
2. Drain Plug
5. Remove the upper hose on the radiator side. 2. Check the state of the negative pressure valve
6. Remove the lower hose on the radiator side. situated at the center on the valve seat side of the
cap. If the valve seat does not function smoothly
7. Remove the coolant reserve tank hose from the
due to rust or dirt, clean or replace the radiator
radiator side.
cap.
8. Remove the fan guide from the lower side.
6B-20 Cooling System
Radiator core 8. Install the intake pipe from the intake manifold and
1. If the radiator fin is deformed, the radiation effect inter-cooler (right side).
deteriorates causing overheating. Therefore, 9. Fill the cooling water.
modify the fin. Make sure that the root base of the Cooling water injection procedure (in case of changing
fin is not damaged during modification. the cooling water completely)
• Eliminate dust or other foreign matter. • Confirm that the engine has cooled.
• Open the radiator cap and the reserve tank cap.
Washing the radiator • Loosen the air bleeding bolt on the engine outlet.
1. Wash the internal parts of the radiator and cooling • Pour the cooling water up to the filler neck.
water passage using water. Eliminate scale and
• After filling the system to the full, push the radiator
rust completely.
upper hose two or three times. In doing so, if air in
the hose comes out and the coolant level goes
Installation down, add the coolant to the original level.
1. Ensure that no damage occurs to the radiator core • Pour the cooling water up to the “MAX” line in the
reserve tank.
because of the fan blade. Mount the brackets on
the left and right sides of the radiator on the frame • Bleeding air from the EGR cooler.
according to the figure. - Disconnect the out side hose (located at the top
of the EGR on the head cover) of the EGR
Tighten: cooler (2nd) to let air come out. Then,
Bolts to 26 N⋅m (2.6 kgf⋅m / 19 lbf⋅ft)
reconnect the hose back to the original position.
- In doing so, if air in the EGR comes out and the
coolant level goes down, add the coolant to the
original level.
N6A6247E
Legend
1. Flange Nut
2. Rubber N6B6294E
3. Stud Bolt • Tighten the air bleeding bolt on the engine outlet
4. Frame securely.
5. Bracket on The Radiator Side
6. Washer • Close the radiator cap and the reserve tank cap
and start the engine. Stop the engine after running
2. Install the fan guide. for about 2 to 3 minutes at the idling rpm. Open the
radiator cap again and replenish if the water level
3. Mount the reserve tank hose of the coolant on the
is low.
radiator.
4. Mount the radiator lower hose.
5. Mount the radiator upper hose.
6. Install the 2 transmission oil pipes on the
underside of the radiator.
7. Install the intake pipe from the turbocharger and
inter-cooler (left side).
Cooling System 6B-21
WARNING: • Pour the cooling water up to the “MAX” line in the
DO NOT LOOSEN OR REMOVE THE RADIATOR reserve tank again.
CAP WHEN THE TEMPERATURE OF THE COOLING
WATER IS HIGH. STEAM OR BOILING WATER WILL
GUSH OUT AND YOU MAY BE BURNT. TO OPEN
THE RADIATOR CAP, COVER THE CAP WITH A
THICK CLOTH WHEN THE COOLING WATER IS
COOL, RELEASE THE PRESSURE BY SLOWLY
TURNING THE CAP, AND THEN REMOVE THE CAP.
Torque Specifications
N6B6132E
6B-22 Cooling System
Drive Belt
Components
6 9
10
11
8
12
13
5
2 9 3
2 9
N6B6241E
Legend
1. Crank Pulley 8. Adjusting Plate
2. Generator Drive Belt 9. A/C Compressor Drive Belt
3. Bolt 10. Water Pump Pulley
4. Generator 11. Lock Nut
5. Adjusting Bolt 12. Tension Pulley
6. A/C Compressor 13. Adjusting Bolt
7. Lock Nut
Caution:
You must adjust the tension of A/C compressor drive
belt after adjusting generator belt.
Tighten:
Lock nut to 27 N⋅m (2.8 kgf⋅m / 20 lbf⋅ft)
Caution:
When replacing the belt, be sure to replace two belts
together.
N6B6260E
Legend
1. A/C Compressor Drive Belt 5 12
2. Generator Drive Belt 7
8
9
10
Adjustment 4
Caution:
When replacing the belt, be sure to replace two belts
together.
5 12
7
8
9
11 10
6 4
2
14
13
N6B6295E
Legend
1. Crank Pulley
2. Bolt
3. Generator
4. Adjusting Bolt
5. A/C Compressor
6. Lock Nut
7. Water Pump Pulley
8. Lock Nut
9. Tension Pulley
10. Adjusting Bolt
11. Generator Drive Belt
12. A/C Compressor Drive Belt
13. Lock Nut
14. Tension Pulley
Cooling System 6B-25
Torque Specifications
For 50 A
24 (2.4 / 17)
24 (2.4 / 17)
27 (2.8 / 20)
40 (4.1 / 30)
N6B6259E
For 80 A
24 (2.4 / 17)
24 (2.4 / 17)
40 (4.1 / 30)
41 (4.2 / 30)
N6B6261E
Fuel System 6C-1
ENGINE
Fuel System
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . .6C-2
A List of Defective Phenomena . . . . . . . . . . . . .6C-7
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-7
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . .6C-8
Fuel System Check . . . . . . . . . . . . . . . . . . . . . .6C-9
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-14
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .6C-15
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . .6C-16
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . .6C-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-25
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-25
Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .6C-26
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-27
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-31
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-32
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-32
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-34
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-37
Fuel Sedimenter Switch . . . . . . . . . . . . . . . . . . .6C-38
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-40
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . .6C-41
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-41
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-42
Tightening Torque Specifications . . . . . . . . . . .6C-42
6C-2 Fuel System
Fuel System
Service Precautions Do not use water removal agent in the fuel tank. It
helps light oil to absorbs moisture that may cause rust.
Parts of the fuel system such as the internal part of the
If water removal agent is used in the fuel then it will
fuel injector, holes and clearances that form passages
absorb moisture in the light oil and may cause rust.
for fuel are finished to a very high degree of accuracy.
Therefore, do not use water removal agent in the fuel
They are therefore highly sensitive to foreign matter
tank.
and the entry of foreign matter could cause damage to
the fuel passage. Therefore, effective measures should
Work Procedure
be taken to prevent the entry of foreign matter.
Holes and clearances in the fuel system which serve as • The fuel opening must be quickly sealed when
a passage of fuel, including the inside of injector, are removing the fuel pipe, injection pipe, fuel injector,
finished extremely precisely. For this reason, they are fuel supply pump, and fuel rail.
highly sensitive to foreign matter. If it gets inside, it can • The eyebolts and gasket must be stored in a clean
lead to breakdown on the road. Be sure to prevent it parts box with a lid to prevent adhesion of foreign
from getting inside. matter.
Injector ID code plate is unique to each injector. Do not • Fuel leakage could cause fires. Therefore, after
mix with other injector ID code plates. finishing the work, wipe off the fuel that has leaked
If the injector ASM has been replaced, write the ID out and make sure there is no fuel leakage after
code in the ECU using a scan tool. Refer to “Engine starting the engine.
Control” chapter for how to write an injector ID.
Explanations on Functions and Operation
Fuel System Diagram
8
5
N6A6661E
Fuel System 6C-3
Legend
1. Fuel Rail 7. Ventilation Hose
2. Leak-off Pipe 8. Fuel Filler Cap
3. Fuel Injector 9. Fuel Level Sensor
4. Fuel Return Pipe 10. Fuel Filter With Sedimenter
5. Fuel Feed Pipe 11. Fuel Supply Pump
6. Fuel Tank
Caution:
• Do not let foreign matter such as sand or dust get
into fuel.
• Use gas oil for fuel, not others.
Fuel Rail
2
1
N6B6133E
Legend
1. Pressure Limiter 2. Pressure Sensor
6C-4 Fuel System
Fuel Supply Pump
N6A6359E
Legend
1. Fuel Temperature Sensor 4. Camshaft Key
2. Fuel Rail Pressure Regulator 5. Camshaft Nut
3. High Pressure Piping
Fuel System 6C-5
Fuel Injector Fuel Filter
2 3
N6B6070E
Legend
1. Cartridge
2. Sensor
3. Drain Plug
Functional check
Air bleeding
N6A6360E
Legend
1. Terminal Stud
2. Fuel Leak-off Port
3. O-ring
4. Fuel Inlet Port 2
5. Injector Parts Number Marking
6. Fuel Injector ID Plate
N6B6071E
Legend
1. Priming Pump
2. Air Bleed Plug
Important:
Vinyl hose
The fuel pressure/vacuum gauge assembly (gauge (1))
and the fuel pressure/vacuum gauge adapter (adapter
(5)) must be cleaned before connect to the fuel line.
Air bleed plug Otherwise, foreign material adherent to the tools may
damage the fuel supply pump.
Special tool
N6B6209E
Fuel Pressure/Vacuum Gauge Set:
5-8840-2844-0
c. Tighten the plug securely, and wipe off fuel (Fuel pressure/vacuum gauge adapter:
around the plug completely. EN-47667)
d. Operate the priming pump up and down 3. Connect the gauge (1) with hose to the adapter
another 10 times or more to feed air from the (5).
fuel system to the fuel injection pump.
e. Turn the starter to start the engine. Special tool
2. After starting engine Fuel Pressure/Vacuum Gauge Set:
5-8840-2844-0
a. Without depressing the accelerator pedal, turn
(Fuel pressure/vacuum gauge assembly:
the starter to start the engine.
J-44638)
b. After the engine start-up, keep idling for five
4. Loosen the air bleeding plug on the supply pump.
seconds.
5. Use your hand to operate the fuel filter priming
c. Slowly turn the idling control knob fully
pump. Operate the pump until all the air has been
clockwise, and hold it for three minutes.
bled from the system.
d. Fully depress the accelerator pedal to rev up to
6. Start the engine and allow it to idle.
the maximum speed. (Repeat this operation
several times.) 7. Note the gauge (1) reading. If the reading is
normal, go to Step 8. If the fuel vacuum is greater
e. Turn the idling control knob counterclockwise to
than the specified value, there is a problem in the
return to the idle speed.
fuel system. Perform the procedures outlined
Caution: below.
• Insufficient air bleeding may cause engine Standard fuel vacuum: Less than 5 inHg
malfunction. Be sure to perform this procedure after
starting the engine. • Replace the cartridge fuel filter element.
• It is strongly advisable to use an Isuzu genuine fuel • Check the fuel delivery pipe. If it is clogged, it
filter assembly for replacement. must be replaced.
• Remove the fuel pipe at the fuel filter inlet. Use
Water drain high-pressure air forced through the fuel pipe to
A warning lamp will light up if water is collected more clean the fuel system.
than fixed quantity in the sedimenter. If the warning
lights up, drain out the water by following operations:
• Fit a tray below the fuel filter.
Fuel System 6C-7
Caution: 11. Use your hand to operate the fuel filter priming
• Remove the fuel filler cap before applying high- pump. Operate the pump until all the air has been
pressure air. bled from the system.
• Do not perform this procedure if the fuel tank is 12. Start the engine and allow it to idle.
nearly full (fuel approaching or flowing into the fuel 13. Inspect the fuel system for fuel leakage.
filler neck). The forced air will spray fuel from the
fuel filler neck.
A List of Defective Phenomena
8. Remove the gauge (1) and hose from the adapter • Problems with starting
(5).
• Hunting during idling
9. Remove the adapter (5).
• Insufficient horsepower
10. Connect the fuel hose.
• Maximum engine speed is too low
• Engine does not stop
• Exhaust gas is blue or black.
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2844-0
Fuel Pressure / Vacuum
Gauge Set
(J-44638 [Fuel Pressure /
Vacuum Gauge
Assembly]
EN-47667 [Suction Side
5884028440 Fuel Pressure / Vacuum
Gauge Adapter])
6C-8 Fuel System
Trouble Shooting
Problems with starting
Unstable idling
Insufficient power
Notice:
Fuel may leak under the cylinder head cover from
the inlet high pressure line. In such case, the
engine oil level will rise. Inspect for fuel leakage
into the engine oil.
2. Repair any fuel system leaks as necessary.
Notice:
The fuel system from the fuel tank(s) to the fuel
supply pump is under a slight vacuum with the
engine running. As a result, air can enter the fuel
system if these connections are not tight. Air in the
fuel system will cause fuel rail pressure
fluctuations especially at high engine speed and
load, which may set this DTC.
2. Pump the priming pump until it becomes firm.
If there is a leak on the suction side of the fuel
4 system between the priming pump and the —
fuel supply pump, the priming pump will not
build up sufficient firmness and fuel leakage
may occur.
3. Start the engine and check for high side fuel
system leaks at the fuel supply pump and fuel
rail.
Notice:
Fuel may leak under the cylinder head cover from
the inlet high pressure line. In such case, the
engine oil level will rise. Inspect for fuel leakage
into the engine oil
4. Repair any fuel system leaks as necessary.
Did you find and correct the condition? Go to Step 20 Go to Step 5
Fuel System 6C-11
Important:
The fuel pressure/ vacuum gauge connector and
the adapter hose must be cleaned before
connecting to the fuel line. Otherwise, foreign
material internal to the tools line may damage the
fuel supply pump.
4. Connect the gauge adapter (5-8840-2844-0/
EN-47667) with fuel pressure/ vacuum gauge
assembly (5-8840-2844-0/ J-44638) in series
with the filter housing and the disconnected
6 fuel hose. Ensure the service tool and fuel line 8 inHg
connections are tight.
5. Bleed the fuel system by priming the priming
pump until it becomes firm, then crank over
the engine for a maximum of 5 seconds.
Perform procedure three times.
6. Fully clamp off a fuel hose as close to the fuel
tank as possible (this will draw vacuum on the
fuel system). You can also disconnect a fuel
line and plug it.
7. Crank over the engine (for no longer than 15
seconds) while monitoring the fuel pressure/
vacuum gauge.
Notice:
Release the clamp or open the plug when the
gauge is likely to be more than 8 inHg during the
test.
Important:
14 3ml
Replacement injector must be programmed.
3. Replace the injector(s) that return fuel more
than the specified value. Refer to Fuel Injector
Replacement/ Fuel Injector ID Code Data
Programming.
4. Retest after replacement of the fuel injector(s).
Special Tool
Tool Number / Tool Number /
Illustration Illustration
Description Description
5-8840-2844-0
Fuel Pressure / Vacuum
Gauge Set
(J-44638 [Fuel Pressure / 5-8840-0279-0
Vacuum Gauge (J-23738-A)
Assembly] Vacuum Pump
EN-47667 [Suction Side
5884028440 Fuel Pressure / Vacuum
5884002790
Gauge Adapter])
Fuel System 6C-15
Tool Number /
Illustration
Description
5-8840-2845-0
Fuel Test Adapter Set
(J-45873 / Fuel Test
Adapter Kit,
J-45873-100 / Fuel Test
Adapters)
5884028450
Specifications
Fuel pump specifications
Injector specifications
Items Specifications
Injector model DX1534
Nozzle hole (mm) × number of pieces φ 0.14 × 7
6C-16 Fuel System
N6B6072E
Legend
1. Filler Cap 3. Fuel Sedimenter Connector
2. Fuel Hose 4. Fuel Filter Assembly
Removal
1. Remove the filler cap.
2. Remove the fuel sedimenter connector.
3. Remove the feed hose and the return hose from
the fuel filter and plug it so that the fuel does not
flow out.
4. Remove the bolts for mounting the fuel filter.
5. Remove the fuel filter assembly.
6. Remove the fuel filter bracket.
Installation
1. Install the fuel filter bracket.
2. Install the fuel filter assembly.
3. Install the bolts for mounting the fuel filter.
4. Install the inlet hose and the outlet hose.
5. Install the fuel sedimenter and clip the cable to the
bracket.
6. Install the filler cap.
7. Bleed out the air.
• Refer to “Fuel System/Air bleeding”.
Fuel System 6C-17
N6B6073E
Legend
1. O-Ring
2. Filter Element
3. Case
4. Body
Installation
1. If foreign matter accumulates on the inner
circumference of the body, wipe it with a clean
cloth. N6B6134E
Caution:
To remove foreign matter, be sure to wipe it with a
cloth. Do not use an air blower etc.
If blown foreign matter gets into the clean-side
passage, the supply pump will malfunction.
6C-18 Fuel System
Fuel Injector
Components
13
10 8
12
1
2
N6B6074E
Legend
1. Fuel Injection Pipe Clip 8. EGR Valve Gasket
2. Fuel Injection Pipe 9. EGR Valve
3. Fuel Injector Leak-off Pipe 10. EGR Valve Gasket
4. Fuel Injector 11. Cylinder Head Cover
5. Fuel Injector Clamp 12. Fuel Injector Harness Bracket
6. Fuel Injector Clamp Bolt 13. Fuel Injector Terminal
7. EGR Adapter
The fuel system consists of many tiny holes and removal and installation procedure.
spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to Caution:
extremely high precision. This is especially true of the To avoid electric shock;
fuel injectors. Set the switch to the ‘OFF’ position and disconnect
The fuel injector is very sensitive to foreign material. battery negative cable before checking or repairing the
Foreign material will result in fuel system breakdown. fuel injector, wiring or/and connectors.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
Fuel System 6C-19
Important: 6. Remove the head cover.
The Fuel Injector ID Code Data Programming MUST be
done when the fuel injector is being replaced. The Fuel
Injector ID Code information MUST be recorded before 1
assembling the cylinder head cover.
Removal
1. Remove the fuel filter assembly and fuel filter
bracket. Refer to “Fuel Filter Assembly”.
2. Remove the engine harness, the throttle position
sensor, the EGR valve, the pressure sensor, and
all of the fuel injector connectors.
3. Remove the EGR valve and the EGR adapter.
4. Tape the EGR case holes shut to prevent the entry
of foreign material. 2
N6A6027E
Legend
1
1. Sound Insulation Cover
2. Head Cover
N6B6075E
Legend
1. EGR Duct (EGR cooler (2nd) – EGR valve)
2. EGR Valve
N6A6124E
Legend
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal
4. Fuel Leak-off Pipe
6C-20 Fuel System
11. Remove the fuel injection pipe clips and the Special tools
injection pipes. Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-0 (J-23907)
1
N6B6082E
N6A6129E
Legend
1. Fuel Injection Pipe Legend
2. Pipe Clip 1. Sliding Hammer
2. Remover
12. Loosen the fuel injector clamp fixing bolts and 3. Fuel Injector Assembly
remove the fuel injectors.
If the fuel injectors are difficult to remove, use the fuel 13. Mark each fuel injector with the number of the
injector remover. Install the fuel injector remover to the cylinder from which it was removed. Store the fuel
leak-off pipe attachment part on the fuel injector. Use a injectors in a safe place. Position the fuel injector
sliding hammer to force the fuel injector clamp off the so that the nozzle is protected.
fuel injector.
Caution:
Caution: • Do not tamper with the electromagnetic portion of
Do not remove the fuel injector sleeve. the fuel injector. Reduced electromagnetic function
will result in injector failure.
Fuel System 6C-21
Recording from the each fuel injector ID plate
Record 24 figures of each fuel injector ID plate. The
correct order for the fuel injector ID code for the
following illustration is as follows:
56 00 D1 CA 00 00 EC 00 23 14 21 B7
2 1
5600 D1CA
0000 EC00
2314 2100
0000 B7
3
N6A6370E
Legend
1. Gasket
2. Fuel Injector
3. Bolt
N6A6524E 4. Fuel Injector Clamp
Legend
1. Fuel Injector ID Plate 2. Apply molybdenum to the threads and seating
2. Fuel Injector ID Code surfaces of the clamp bolts.
3. Fuel Injector 3. Install the fuel injector clamps to the cylinder head.
4. Temporarily tighten the clamp bolts.
5. Apply a thin coat of engine oil to the outer surface
Installation of the fuel injector side sleeve nuts.
Important: 6. Install the fuel injection pipes to the position shown
Install each of the fuel injectors on its original position. in the illustration.
(the cylinder from which it was removed) 7. Use a spanner to carefully the sleeve nuts until the
fuel injection pipes contact the fuel injector and
1. Install a new gasket and O-ring to each of the fuel common rail.
injector clamps. Refer to the illustration. 8. Tighten the fuel injection pipe clips to the specified
torque.
Tighten:
Clips to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
6C-22 Fuel System
1
1
2
2
N6B6121E
Legend
1. Clamp Bolt
2. Sleeve Nut
Tighten:
N6B6082E Pipes to 12 N⋅m (1.2 kgf⋅m/104 lbf⋅in)
Legend
1. Fuel Injection Pipe
2. Pipe Clip
Tighten:
Bolts to 30 N⋅m (3.1 kgf⋅m/22 lbf⋅ft)
10. Tighten the injection pipes to the specified torque.
Tighten:
Injection pipes to
Injector side: 30 N⋅m (3.1 kgf⋅m/22 lbf⋅ft)
Fuel rail side: 25 N⋅m (2.5 kgf⋅m/18 lbf⋅ft)
N6A6181E
Tighten:
Bolts to 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
Fuel System 6C-23
N6A6182E N6A6029E
14. Install the fuel injector terminal nuts to the injector. 17. Install the sound insulation cover.
Tighten: Tighten:
Nut to 2 N⋅m (0.2 kgf⋅m/17 lbf⋅in) Bolts to 7 N⋅m (0.7 kgf⋅m/5 lbf⋅ft)
Caution:
• Do not overtighten the nuts. Damage to the
1
terminal studs will result.
• The terminal nut with two wires is engine front
side.
2
1
N6A6027E
Legend
1. Sound Insulation Cover
2 2. Head Cover
18. Install the gasket to the EGR valve and tighten the
N6A6627E
bolts to the specified torque.
Legend
1. Fuel Injector Tighten:
2. Harness Bolts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
3. Terminal Nut 19. Install the gasket to the EGR duct (EGR cooler
(2nd) – EGR valve) and tighten the bolts to the
15. Install the gasket to the cylinder head cover. specified torque.
16. Install the cylinder head cover and tighten up
Tighten:
according to the order. Bolts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
Tighten:
Bolts to 18 N⋅m (1.8 kgf⋅m/13 lbf⋅ft)
6C-24 Fuel System
2 1
5600 D1CA
0000 EC00
2314 2100
0000 B7
3
3
4
2
N6B6214E
Legend Legend
1. EGR Duct (EGR cooler (2nd) – EGR valve) 1. Fuel Injector ID Plate
2. EGR Valve Gasket 2. Fuel Injector ID Code
3. EGR Valve 3. Fuel Injector
4. EGR Valve Gasket
5. After complete the registration, turn OFF the
20. Attach the engine harness connectors. Each ignition for 30 second.
composite connector should make a loud click 6. Turn ON the ignition.
when it is securely attached.
7. Select Diagnostics > appropriate vehicle
21. Install the fuel filter bracket. identification > 4HK1 (Common Rail) >
Refer to “Fuel Filter Assembly”. Programming > Injector ID Code > Injector ID
22. Install the fuel filter assembly. Code. At this point, all registered fuel injector ID
Refer to “Fuel Filter Assembly”. code data can be verified. Compare the ID code
values registered into the ECM and each fuel
Fuel Injector ID Code Data Programming Procedure injector including the last 2 figures. If the registered
1. Install the Tech 2. ID code is incorrect, go back to Step 4 ID Code
Registration.
2. Turn ON the ignition, with the engine OFF.
8. Start the engine and let idle.
3. Select Diagnostics > appropriate vehicle
identification > 4HK1 (Common Rail) > 9. Inspect for a proper engine running condition and
Programming > Injector ID Code > ID Code for no DTC’s. Refer to the Diagnostic System
Registration. Check-Engine Controls if needed.
4. Select replaced cylinder and press Change. Input Notice:
22 figures. Then, input in order from the left edge After replacement of the fuel injector, perform the
of upper sequence to the right sequence. The following procedure.
correct order for the fuel injector ID code for the All fuel injectors are replaced:
following illustration is as follows: Remove the fuel injector ID code label on the cylinder
56 00 D1 CA 00 00 EC 00 23 14 21 head cover.
Any fuel injector(s) is replaced:
Important:
Blackout the replaced cylinder fuel injector ID code on
The number of places required for input is 22 figures
the cylinder head cover with a marking pen or
except last 2 figures.
equivalent.
Fuel System 6C-25
Torque Specifications
24 (2.4 / 17)
Special Tool
Tool Number / Tool Number /
Illustration Illustration
Description / Remarks Description / Remarks
5-8840-2826-0
5-8840-0019-0 (J-23907)
(EN-46720)
Sliding Hammer
Fuel Injector Remover
5884000190 EN46720
6C-26 Fuel System
10
9
8
7
4 5 6
3
N6B6076E
Legend
1. Fuel Leak-off Pipe 6. Bracket O-ring
2. Fuel Pipe 7. Coupling
3. Fuel Supply Pump 8. Vacuum Pump
4. O-ring 9. Vacuum Gear
5. Bracket 10. Oil Drain Adapter
The fuel system consists of many tiny holes and 3. Remove the intake pipe and the intake throttle
spaces that allow the movement of fuel from one place valve.
to another. These holes and spaces are milled to 4. Remove the fuel pipe and fuel leak-off pipe.
extremely high precision. This is especially true of the
5. Remove the Vacuum pipe.
fuel injectors.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
removal and installation procedure.
Important:
The Fuel supply pump must be timed to the engine.
Removal
1. Remove the fuel filter assembly.
Refer to “Fuel Filter Assembly”.
2. Remove the fuel filter bracket.
Refer to “Fuel Filter Assembly”.
Fuel System 6C-27
N6B6013E N6A6376E
6. Remove the fuel feed hose. 11. Loosen the 3 bolts holding the fuel supply pump
7. Disconnect the fuel temperature sensor and the bracket. Remove the bracket and the O-ring.
fuel rail pressure regulator harness connector from
the fuel supply pump.
8. Remove the fuel supply pump attachment bolts
and nuts, then remove the fuel supply pump and
coupling. 4
1
9. Remove the vacuum pump. 3
2
Notice:
One of the attachment bolt (5) secures the vacuum
pump to the flywheel housing as denoted in the picture 5
below. 6
4 5 N6B6027E
2 3
1
Legend
1. Fuel Supply Pump
2. Key
3. O-ring
4. Supply Pump Bracket
5. Nut
6. Coupling
7. Flange Bolt
Installation
N6B6299E
1. Install the O-ring to the fuel supply pump.
Legend
1. Supply Pump 2. Install the pump to the bracket and tighten the 3
2. O-ring bolts to the specified torque.
3. Coupling Tighten:
4. Vacuum Pump Bolts to 19 N⋅m (1.9 kgf⋅m/14 lbf⋅ft)
2
4
1 3
3
2
4
N6B6027E N6B6028E
Legend Legend
1. Fuel Supply Pump 1. Vacuum Pump
2. Key 2. Key
3. O-ring 3. Vacuum Pump Gear
4. Supply Pump Bracket 4. Nut
5. Nut 5. O-ring
6. Coupling
7. Flange Bolt 4. Turn the crankshaft in the normal direction of
engine rotation until the No. 1 or No. 4 cylinder is
3. Align the fuel supply pump shaft key and gear. at TDC on the compression stroke.
Install the gear and tighten the nut to the specified Refer to the illustration.
torque.
There is a round alignment mark on the gear
(white paint).
Tighten:
Nut to 137 N⋅m (14 kgf⋅m/101 lbf⋅ft)
N6B6003E
2
3
1
6
4
5
N6B6029E
N6B6298E
Legend
1. Mark Line 7. Apply a light coat of engine oil to the O-ring.
2. Slit 8. Install the oil drain adapter to the plug hole.
3. Slit position before insertion Tighten the bolt to the specified torque.
4. Slit position after insertion
5. Plug hole Tighten:
Bolt to 8 N⋅m (0.8 kgf⋅m/69 lbf⋅in)
6. Vacuum Pump
1
2
N6B6030E
Legend
1. Oil Drain Adapter
2. O-ring
Tighten:
Throttle assembly to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
• Install the intake throttle valve chamber hose.
N6B6015E
Legend
1. Intake Throttle Valve Chamber
Important:
In order to make the fuel supply pump characteristic
learn into the ECM, let the engine idle until warm-up. If
the fuel system DTC’s stored in the meantime, once
clear DTC and warm-up the engine again.
N6B6086E
6C-32 Fuel System
Fuel Rail
Components
5
7
9 6 4
8
N6B6081E
Legend
1. Fuel Leak-off Pipe 6. Injection Pipe Clip
2. Fuel Pipe 7. Injection Pipe (#1 to #4)
3. EGR Valve 8. Fuel Rail
4. EGR Valve Gasket 9. Fuel Rail Bracket
5. EGR Duct (EGR cooler (2nd) — EGR valve)
Parts of the fuel system such as the internal part of the Removal
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy. WARNING:
They are therefore highly sensitive to foreign matter TO PREVENT LEAKED FUEL FROM CATCHING
and the entry of foreign matter could cause damage to FIRE, DO NOT WORK WHILE THE ENGINE IS HOT.
the fuel passage. Therefore, effective measures should
be taken to prevent the entry of foreign matter. Preparation:
• Pour detergent into a steam cleaner, and throughly
wash around the sensor and the fuel rail.
• Remove water completely using air blow.
Fuel System 6C-33
Notice: 8. Remove the injection pipe clip and remove the
Make sure that foreign matter will be prevented from injection pipes.
getting in.
Important:
1. Remove the air intake pipe. Loosen the injection pipes gradually not to scatter high
• Disconnect the connector for the intake air pressure fuel.
temperature sensor.
2. Remove the fuel filter assembly. 1
Refer to “Fuel Filter Assembly”.
3. Remove the fuel filter bracket.
Refer to “Fuel Filter Assembly”.
4. Remove the fuel pipe and fuel leak-off hose from
the leak-off pipe.
• Cover the removed fuel hose, keep it facing
upward and secure it using wire, etc.
5. Disconnect the fuel rail pressure sensor harness
connectors.
6. Remove the EGR valve and the EGR duct (EGR
cooler (2nd) – EGR valve).
7. Tape the EGR case holes shut to prevent the entry 2
of foreign material.
N6B6082E
Legend
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
3 2
N6B6106E
Legend
1. Fuel Pipe
N6B6108E
2. Fuel Leak-off Pipe
Legend
11. Remove the fuel rail and the fuel rail bracket. 1. Fuel Rail
2. Fuel Rail Pressure Sensor
• Do not remove the flow damper.
3. Fuel Pressure Limiter
The dampers should always remain in the fuel
rail.
• Take care not to damage the connector unit of
the pressure sensor. Reassembly
1. Install the fuel pressure limiter.
Tighten:
Fuel pressure limiter to 172 N⋅m (17.5 kgf⋅m/127 lbf⋅ft)
2. Install the fuel rail pressure sensor.
Tighten:
Fuel rail pressure sensor to 98 N⋅m (10 kgf⋅m/72 lbf⋅ft)
N6B6107E
Legend
1. Fuel Rail Bracket
2. Fuel Rail
Fuel System 6C-35
3. Tighten the fuel leak-off pipe (1) using the
mounting eyebolt and the clips using the specified
torque.
Tighten:
(2) to 18 N⋅m (1.8 kgf⋅m/13 lbf⋅ft)
(3) to 12 N⋅m (1.2 kgf⋅m/104 lbf⋅in)
1
(4) to 8 N⋅m (0.8 kgf⋅m/69 lbf⋅in)
4. Tighten the fuel pipe (5) using the mounting sleeve
nut and the clip using the specified torque.
Tighten:
(6) to 44 N⋅m (4.5 kgf⋅m/33 lbf⋅ft)
(7) to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
3 2
(8) to 44 N⋅m (4.5 kgf⋅m/33 lbf⋅ft)
N6B6108E
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter
Installation
8
1. Tighten the fuel rail bracket using the specified
mounting torque.
2
6
Tighten: 5
7
Bolts to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft) 2
2. Tighten the fuel rail using the specified mounting
torque.
Tighten:
Nuts to 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
N6B6219E
Tighten:
Injection pipe sleeve nut to
Injector side: 30 N⋅m (3.1 kgf⋅m/22 lbf⋅ft)
1
Fuel rall side: 25 N⋅m (2.5 kgf⋅m/18 lbf⋅ft)
Tighten:
Injection pipe clip to 6 N⋅m (0.6 kgf⋅m/52 lbf⋅in)
• Apply a thin coat of engine oil on the periphery
of the sleeve nut on the fuel injector side and 3
assemble.
1
4
2
N6B6214E
Legend
1. EGR Duct (EGR cooler (2nd) – EGR valve)
2. EGR Valve Gasket
3. EGR Valve
4. EGR Valve Gasket
N6B6082E
Legend
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
Tighten:
Bolt to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
9. Install the gasket to the EGR duct and tighten the
bolts to the specified torque.
Tighten:
Bolt to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
10. Install the fuel filter bracket. Refer to “Fuel Filter
Assembly”.
11. Install the fuel filter assembly. Refer to “Fuel Filter
Assembly”.
Fuel System 6C-37
Torque Specifications
30 (3.1 / 22)
22 (2.2 / 16.2)
24 (2.4 / 17)
172 (17.5 / 127)
24 (2.4 / 17)
N6B6109E
6C-38 Fuel System
4
1
Sedimenter Sedimenter
Switch Switch
N6B6083E
Legend
1. Float
2. Connector on Engine Harness Side
3. Harness
4. Filter Element Case Assembly
5. Sedimenter Switch Connector
Fuel System 6C-39
Fuel Tank
Components
3
1
2 4
N6A6389E
Legend
1. Fuel Gauge Unit Connector 4. Fuel Return Hose
2. Evaporated Fuel Hose 5. Band
3. Fuel Feed Hose 6. Fuel Tank
2
3
N6A6390E
Legend
1. Fuel Gauge Unit Connector
2. Fuel Gauge Unit
3. Cross-member
4. Fuel Tank
Installation
1. Install the fuel tank.
Caution:
When the bracket has been removed while taking out
the fuel tank, attach the bracket to the frame and
tighten it to the specified torque.
Tighten:
55 N⋅m (5.6 kgf⋅m/41 lbf⋅ft)
Also, when placing the fuel tank on the bracket, make
sure that the rubber part attached on the fuel tank is put
onto the bracket.
2. Install the band to the fuel tank and tighten up the
nuts with the specified torque.
Tighten:
12 N⋅m (1.2 kgf⋅m/9 lbf⋅ft)
3. Install the fuel return hose.
4. Install the fuel feed hose.
• Insert the hose into the pipe for more than 25
mm (1.0 in).
5. Install the evaporated fuel hose.
• Fill the fuel tank with fuel, and tighten the fuel
filler cap.
• Connect the battery earth cable.
• Make sure there is no fuel leakage from the
connector parts of hoses after starting the
engine.
Fuel System 6C-41
N6A6391E
Legend
1. Fuel Gauge Unit Connector 2. Fuel Gauge Unit
Removal Inspection
1. Remove the wiring connector from the fuel gauge The fuel tank unit changes the internal resistance
unit. according to the float position (fluid level) to operate the
2. Remove the installed screw and remove the fuel indicator of the fuel meter.
gauge unit.
Caution:
When removing/installing the fuel gauge unit, take care
not to interfere with adjacent parts and not to let the F
arm etc. deformed. Also, after removing the fuel gauge
unit, cover the tank with a cloth to prevent the entry of
dust.
E
N6A6392E
6C-42 Fuel System
1. While moving the float from “E” to “F”, measure the Installation
resistance between the connector terminals 1J-28
Assemble in the reverse order of disassembly.
and 2J-28.
1. Install the fuel gauge unit.
2. Check that the fuel level warning lamp comes on
when the float is at “E” position. If the result of the 2. Connect the wiring connector to the fuel gauge
inspection is unsatisfactory, replace with a new unit.
part.
12 (1.2 / 9)
20 (2.0 / 15)
N6B6292E
Engine Electrical 6D-1
ENGINE
Engine Electrical
TABLE OF CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . . . . .6D-2
General Procedure. . . . . . . . . . . . . . . . . . . . . . .6D-2
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-3
General Description . . . . . . . . . . . . . . . . . . . . . .6D-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-3
On-vehicle Service . . . . . . . . . . . . . . . . . . . . . . .6D-3
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .6D-6
General Description . . . . . . . . . . . . . . . . . . . . . .6D-6
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-8
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-8
Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . .6D-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Inspection and Repair . . . . . . . . . . . . . . . . . . . 6D-11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-17
Main Data and Specifications. . . . . . . . . . . . . .6D-18
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . .6D-19
General Description . . . . . . . . . . . . . . . . . . . . .6D-19
On-vehicle Service: Starter System . . . . . . . . .6D-21
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-22
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6D-22
On-vehicle Service . . . . . . . . . . . . . . . . . . . . . . .6D-23
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-24
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-25
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-25
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6D-26
Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-28
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-31
Torque Specifications . . . . . . . . . . . . . . . . . . . .6D-34
Preheating System . . . . . . . . . . . . . . . . . . . . . . .6D-35
Glow Plug Replacement. . . . . . . . . . . . . . . . . .6D-35
Service Precautions . . . . . . . . . . . . . . . . . . . . .6D-36
A List of Defective Phenomena . . . . . . . . . . . .6D-37
Main Data and Specifications. . . . . . . . . . . . . .6D-37
6D-2 Engine Electrical
Service Precautions
General Procedure
When fasteners are removed, always reinstall them at
the same location from which they were removed. If a
fastener needs to be replaced, use the correct part
number fastener for that application. If the correct part
number fastener is not available, a fastener of equal
size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking
compound will be called out. The correct torque value
must be used when installing fasteners that require it. If
the above conditions are not followed, parts or system
damage could result.
Engine Electrical 6D-3
Battery
General Description b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE - Drop charging voltage to
There are six battery fluid caps at the top of the battery.
15V and charge for 10 — 15 hours.
Diagnosis Then go to “Load test”.
c. VOLTAGE IS BETWEEN 12V AND 16V
Visual Inspection - Continue charging at the same rate for an
Inspect the battery for obvious physical damage, such additional 3-1/2 hours. Then go to “Load test”.
as a cracked or broken case, which would permit d. VOLTAGE IS BELOW 12V - Replace battery.
electrolyte loss.
Replace the battery if obvious physical damage is Load Test
discovered during inspection. 1. Connect a voltmeter and a battery load tester
Check for any other physical damage and correct it as across the battery terminals.
necessary. 2. Apply 300 ampere load for 15 seconds to remove
surface charge from the battery.
Fluid Level Check
Remove load.
The fluid level should be between the upper level line
3. Wait 15 seconds to let battery recover. Then apply
and lower level line on side of the battery.
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
1) VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN FOLLOWING TABLE
- The battery is good and should be returned to
service.
2) VOLTAGE IS LESS THAN MINIMUM LISTED
- Replace battery.
ESTIMATED
TEMPERATURE MINIMUM VOLTAGE
°F °C
70 21 9.6
60 16 9.5
50 10 9.4
N6A0983E 40 4 9.3
30 −1 9.1
Legend
1. Battery 20 −7 8.9
2. Upper Level 10 − 12 8.7
3. Lower Level
0 − 18 8.5
N6A0984E
Installation
To install the battery, follow the removal procedure in
the reverse order, noting the following points:
1. Make sure that the rod is hooked on the body side.
6D-6 Engine Electrical
Charging System
General Description
The main charging system components are the
batteries, the generator and the battery discharge
indicator light circuit. The generator is a 110-amp,
selfrectifying type with a built-in regulator. The battery
discharge indicator light is mounted in the instrument
panel. For more details on this circuit, refer to “Meter
and Warning/Indicator Lights” in Section 8.
Circuit Diagram
N6B6296E
Legend
1. Engine Control Switch 8. Glow Plug Indicator Light
2. Generator (Integral Regulator) 9. ECM
3. Charge Relay 10. Starter Cut Relay
4. To Heater and A/C Relay 11. To Exhaust Brake Solenoid Valve
5. Low Charge Indicator Light 12. Starter Relay
6. Glow Plug Relay 13. Starter
7. Glow Plugs 14. ECM Main Relay
Engine Electrical 6D-7
Maintenance Electrical Tests
The most common indication of charging system Before performing the following generator electrical
troubles is an undercharged or overcharged battery. tests on the vehicle, be certain that the system wiring is
Since the battery itself may be defective, the first step not defective and generator belts are not slipping. Also,
should be to check its condition as described under the battery must be fully charged for a valid test of the
“Diagnosis of Battery.” In the case of an undercharged charging system.
battery, check for battery drain caused by grounds or
by accessories left turned on. Notice:
Keep the generator and all other electrical system To avoid damage to the vehicle electrical system,
terminals clean and tight. A loose or badly corroded always observe the following precautions:
terminal connection will create excessive resistance in • Do not polarize the generator.
the system and result in hard starting, dim lights etc. • Do not short across or ground any of the terminals
Inspect the generator system at regular intervals and in the charging circuit except as specifically
correct any potential causes of trouble before vehicle instructed herein.
performance is affected.
• NEVER operate the generator with the output
terminal open-circuited.
Diagnosis of Charging System
• Be sure the generator and battery have the same
Trouble in the charging system will be evidenced as
ground polarity.
one or more of the following three conditions:
• When connecting a charger or booster battery to
1. The battery discharge warning light will stay on.
the vehicle battery, connect negative to negative
2. An undercharged battery as evidenced by slow and positive to positive.
cranking.
3. An overcharge, or overvoltage, condition. 1. With the engine control switch “ON” and engine not
running, connect a voltmeter from terminal “E” to
Undercharged Battery ground. The voltmeter should read zero volts.
Inspection 2. With the engine control switch “ON” and engine not
1. Accessories to be sure none were left on for running, connect a voltmeter from terminal “B” to
extended periods. ground. The voltmeter should read at least 24
2. Drive belt for proper tension. Refer to “Drive Belt” volts.
in Section 6B. 3. With the engine control switch “ON” and the engine
3. The ECM main relay has been ON stuck at the not running, connect a voltmeter from white wire
ignition switch OFF position. (Battery voltage is side of the connector to ground. The voltmeter
consumed.) should show 24 volts.
4. Battery. Refer to “Diagnosis of Battery” earlier in 4. With the engine control switch “ON” and the engine
this section. not running, the “charge” light should be on. This
5. Wiring and connections for corrosion or looseness. shows that the other circuit in the connection is
Overcharge (or Overvoltage) condition working.
A charging rate in excess of 29.5-volts for a prolonged 5. With the engine running and the headlight high
period may cause early electrical system failure. beams turned on, read the voltage at the “B” post
Blown fuses, light bulbs burned out, and even battery on the generator. The voltage should be at least 24
failure may result. If this condition exists, test the volts.
generator as described under “Generator Output Tests” 6. If steps 1 through 4 are not OK, check connectors
later in this section. in the harness for looseness or corrosion and
retest.
Noisy Generator 7. If step 5 voltage is low, substitute a known good
Inspection regulator and test again. If the voltage is still low,
1. Drive pulley for looseness. bench test the generator.
2. Mounting bolts for looseness.
3. Bearings for dirt, damage, or wear.
Generator noise may also be caused by worn or
damaged diodes and/or starter.
6D-8 Engine Electrical
Generator
Component 1. Connect an ammeter from the positive (+) battery
side to the generator output wire. This is 8 mm
(0.032 in) (black) wire. Leave the carbon pile
disconnected.
2. Slowly increase the generator speed and observe
the voltage meter. If voltage is uncontrolled with
speed and increases above 30 volts on a 24-volt
system, replace the regulator and check the rotor
winding. If the voltage is below 30 volts, connect
the carbon pile across the battery.
3. Run the generator at 5,000 RPM and adjust the
carbon pile to obtain maximum current output,
which should be more than 42A (50A) or 75A (80A)
at 28 to 29 volts.
4. If the output is not within 10 amperes of the rated
output, check the rotor winding, rectifier bridge,
and stator as described later under “Inspection”
and “Electrical Bench Tests.”
N6B6211E
50A Model
Legend
1. Generator Adjusting Bracket
2. Bracket Mounting Bolt
3. Generator Adjusting Nut
4. Generator Bracket
5. Generator Bracket Mounting Bolt
6. Generator
7. Generator Adjusting Bolt (Model equipped with
A/C only)
Repair Instruction
Description of Generator
The generator is a 24 volt, 50A or 80A, model with a
solid state regulator mounted to the brush holder. The
generator must be disassembled to remove the
regulator or brush holder assembly. The generator rotor N6A6402E
Important:
• Use a fully charged battery when performing these
tests.
N6A6587E
Engine Electrical 6D-9
Disassembly
1 1. Remove the through bolts.
2. Insert a flat-blade screwdriver between the front
2
3 cover and the stator. Pry the parts apart.
3. Separate the front cover/rotor assembly from the
rear cover/stator assembly.
N6B6110E
Legend
1. Ball Bearings
2. Brush Holder
3. Voltage Regulator
4. Generator
N6B6272E
Notice: 4. Place the front cover and rotor in a vise.
• Before performing the generator output test,
5. Remove the pulley nut and the pulley.
inspect all charging system components, wires
and terminals for wear or damage. Repair or 6. Remove the rotor from the front cover.
replace any parts found defective.
Removal
• Disconnect the battery negative cable.
• Remove the A/C compressor. (Refer to “Engine
Assembly” in Section 6A)
1. Electrical wiring at the generator.
2. Loosen the lower mounting bolts.
3. Loosen the adjusting nut.
4. Drive belts.
5. Adjusting bolts.
6. Generator.
Inspection
N6B6273E
• Mount brackets for damage.
• Drive belts for wear or damage. 7. Remove the screw from the front cover.
8. Remove the bearing retainer and the bearing.
6D-10 Engine Electrical
12. Remove the rectifier assembly from the stator
assembly.
N6B6274E
N6B6275E
N6A6605E
Engine Electrical 6D-11
5
4
3
10
9
1
8
7
N6B6271E
Legend
1. Pulley Nut 6. Through Bolt
2. Pulley 7. Rear Cover Assembly
3. Front Cover Assembly 8. Rectifier Assembly
4. Rotor Assembly 9. Ball Bearing
5. Stator Assembly 10. Ball Bearing
slip rings
N6A6596E N6B6279E
stator coil
neutral point
N6B6278E
stator core
2
6.5 (0.253)
N6A6602E
Brushes
Measure the brush height. If the height is less than the
25 (0.984)
specified limit, the brushes must be replaced.
Legend
1. Brush
2. Limit Line
Rectifier Assembly
Measure each of the diode resistances in both
directions (anodeacathode and cathodeaanode). If any
of the diodes have the same resistance in both
directions, the rectifier must be replaced.
N6A6603E
6D-14 Engine Electrical
Tester wire
E BAT
+ − + −
U, V, and WN U, V, and WN
+ ----- Conductivity + ----- No conductivity
− No conductivity ----- − Conductivity -----
Negative side diode check Positive side diode check
Engine Electrical 6D-15
Rectifier Assembly
50 A
L
E
8
B +
6
5~30V
3
4
5 -
1kHz
1
V 2
N6B6281E
Legend
1. Voltmeter 5. Switch 3
2. DC Regulated Power Supply 6. Switch 2
3. Lamp 2 7. Pulse Generator
4. Lamp 1 8. Output Signal
80 A
L
E
S
9
B +
7
5~30V
4
5
2 6 -
1kHz
1
V 3
N6A6604E
Legend
1. Voltmeter 6. Switch 3
2. Switch 1 7. Switch 2
3. DC Regulated Power Supply 8. Pulse Generator
4. Lamp 2 9. Output Signal
5. Lamp 1
6D-16 Engine Electrical
Test circuit
Refer to the judgment criteria shown in the Table below.
Carefully check Items 1 − 5. If all the items are OK, the
IC regulator is normal.
Circuit components
1 DC regulated power supply 0 − 30 volts variable with output of 1 ampere or more
2 Lamps (2) 24 volts, 1.8 watts
3 Switches (3) -----
4 DC voltmeter 0 − 60 volts, 0.5 grade
5 Pulse generator (Oscillator) 5 − 30 volts output at a frequency of 1kHz
Judgment criteria
Switch Switch Switch Voltmeter Lamp condition
No. Remarks
1 2 3 reading Lamp 1 Lamp 2
1 ON OFF OFF On (dim) ON Initial excitation check
24V On or
2 ON ON OFF Full excitation check
flashing
OFF
Off or Lamp 1 off or dimly lit when the voltmeter
3 ON ON OFF 32V
on (dim) shows less than 24 volts or 32 volts
On or
4 OFF ON OFF 24V Stator and brush separation check
flashing ON
5 ON ON ON 36V On Excess voltage check
Tighten:
Pulley nut to 110 N⋅m(11.2 kgf⋅m/81 lbf⋅ft)
Engine Electrical 6D-17
N6A6605E N6B6283E
Insert the pin from the outside of the rear cover. 4. Through bolts.
Press the brushes into the brush holder. Complete • Place a guide bar through the holes in the front
the assembly procedure. cover and rear cover flange for proper
alignment. Install the through bolts.
Tighten:
Pin
Through bolts to 4 N⋅m (0.4 kgf⋅m/35 lbf⋅in)
Installation
1. Generator.
Tighten:
Bracket Mount Bolt to 48 N⋅m (4.9 kgf⋅m/35.4 lbf⋅ft)
2. Adjusting bolts.
Tighten:
Adjusting Nut to 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
3. Drive belts.
Tighten:
Lower mount bolt to 40 N⋅m (4.1 kgf⋅m/30 lbf⋅ft)
N6B6282E 4. Vacuum and oil hoses at the vacuum pump.
3. Use a bench press to install the rear cover 5. Electrical wiring at the generator.
assembly to the cover assembly. • Battery negative cable.
6. Install the A/C compressor. (Refer to “Engine
Assembly” in Section 6A.)
6D-18 Engine Electrical
Main Data and Specifications
Rated Voltage 24 V
Rated Output 50/80 amp
Rated Output at 5000 RPM More than 42/75 amp
Regulated Voltage 28.0 – 29.0 V
Brush Length
Standard 25 mm (0.984 in)
Limit 6.5 mm (0.256 in)
Slip Ring Diameter
Standard 31.7 mm (1.248 in)
Limit 30.6 mm (1.205 in)
Generator Pulley Direction (Viewed From Pulley Side) Clockwise Pulley
Pulley Diameter 82 mm (3.23 in)
Generator Weight (With Vacuum Pump) 50A: 7.4 kg (16.3 lb)
80A: 9.6 kg (21.2 lb)
Maximum Vacuum Pump Output 90.7 kPa (0.29 kg/cm2 / 13.2 psi)
Vacuum Pump Vane
Standard Length 17.0 – 18.0 mm (0.669 – 0.709 in)
Vacuum Pump Housing Inside Diameter
Standard 69.5 – 69.6 mm (2.736 – 2.740 in)
Engine Electrical 6D-19
Starting System
General Description
Circuit Diagram
N6B6296E
Legend
1. Engine Control Switch 8. Glow Plug Indicator Light
2. Generator (Integral Regulator) 9. ECM
3. Charge Relay 10. Starter Cut Relay
4. To Heater and A/C Relay 11. To Exhaust Brake Solenoid Valve
5. Low Charge Indicator Light 12. Starter Relay
6. Glow Plug Relay 13. Starter
7. Glow Plugs 14. ECM Main Relay
6D-20 Engine Electrical
Starter and Glow Plug Relays Diagnosis of Starting System
The starter is a 4.5 kilowatt, reduction drive model. 1. No Cranking, No Sound
The gear housing and armature end bearing housings • Discharged batteries. Turn on the headlights and
are aluminum. The brush assembly has replaceable check the brightness. If the headlights are dim,
brushes. The commutator bars are mica insulated and charge the batteries. Check for the cause of the
are undercut. discharged batteries.
The starter circuit starts at the batteries. The battery
• Sulfated battery terminals. Turn on the headlights.
cable goes to the large terminal on the starter.
The headlights will be bright. Attempt to start the
From that terminal wires lead to the engine control
engine. The headlights will be very dim or go out.
switch and the starter relay.
Clean all the battery terminals and cable ends.
From the engine control switch the starter circuit goes
through Fuse #3 and the transmission neutral switch to • A starter that draws too much current.
the starter relay. When the engine control switch is • Starter relay won’t work. Attempt to start and listen
turned to start and the transmission neutral switch is for a “click” at the starter relay. If there is no “click,”
closed, the starter relay closes to complete the circuit check the starter relay control terminals with a test
from the batteries to the starter solenoid. The starter light. If the test light shows that power is getting to
circuit is also connected to the Engine Control Module the starter relay, check the ground circuit with the
(ECM). The Engine Control Module (ECM) operates test light. If the ground circuit is OK, replace the
when the engine control switch is turned to the “ON” starter relay.
position. • Engine control switch start circuit won’t close.
The starter and glow plug relays are located on the
With the engine control switch turned to start,
frame at the left rear side of the cab.
check the starter relay with a test light. If the test
light doesn’t come on, check the starter circuit at
the engine control switch with the test light. If the
test light comes on, check the harness for an open
and repair. If the test light does not come on,
replace the engine control switch.
• Starter relay power circuit isn’t closing. Attempt to
start. The starter relay “clicks.” Check the
secondary terminals with a test light. If the test light
lights on the battery side only, replace the starter
relay. If the test light lights on both terminals, check
for an open at the starter.
• Starter clicks when start is attempted. Check all
power connections for corrosion. Clean
2 connections if corrosion is present. Terminal on
starter should have at least 18 volts on it when
1
cranking the engine. If voltage is OK, replace the
starter.
• Starter cut relay
If the problem found, repair the following circuit as
necessary.
- Starter cut relay ground circuit. (Between starter
cut relay and ECM.)
- ECM power supply circuit. (Between fuse 10 A
and starter cut relay circuit.)
• Neutral switch or inhibitor switch
N6A6412E
If the problem found, repair the following circuit as
Legend necessary.
1. Starter Relay
- Neutral switch or inhibitor switch ground circuit.
2. Glow Plug Relay
(Between Frame-LH and neutral switch.)
- Starter relay power supply circuit. (Between
Maintenance fuse 10 A and starter relay.)
Keep the starter’s exterior clean. Remove corrosion - Starter relay ground circuit. (Between starter cut
from the terminals, leads, and connectors. relay and diode.)
Tighten the starter to engine mounting bolts and the 2. Slow Cranking, Solenoid Clicks or Chatters
electrical cable retaining nuts.
Engine Electrical 6D-21
• Discharged batteries. Turn on the headlights and
check the brightness. If the headlights are dim,
charge the batteries. Check for cause of
discharged batteries.
• Corrosion on the battery terminals. Check for
corrosion. Hint: Test for warm terminals. Clean all
the battery terminals and connectors.
• Loose or dirty connections. Measure the cranking
voltage at the battery terminals. If the voltage is
less than 18 volts, load test the battery. If the
battery is bad, replace the battery. If the battery is
good, repair the starter.
If the voltage is 18 volts or more, measure the voltage
from the battery NEGATIVE terminal to the engine
block. If the voltage is 0.5 volt or more, repair the
ground cable and connections.
If the voltage is less than 0.5 volt, measure the voltage
at the battery cable terminal on the starter. If the
voltage is 18 volts or more, repair the starter. If the
voltage is less than 18 volts, clean and tighten the
positive cable connections. If the voltage is still less
than 18 volts, replace the positive cable.
Starter
Components
Starting Motor
N6B6293E
Legend
1. Magnetic Switch 7. Rear Cover
2. Gear Case 8. Armature
3. Torsion Spring 9. Yoke
4. Clutch 10. Brush
5. Pinion 11. Through Bolt
6. Dust Cover
Engine Electrical 6D-23
On-vehicle Service
Component
Starter
N6A0988E
Legend
1. Starter Earth Cable 3. Starter Wiring Connector
2. Starter Assembly
Removal
Preparation
• Disconnect the battery ground cable (both
batteries).
1. Starter Earth Cable
N6A0989E
N6A0990E
Tighten:
Starter bolt to 76 N⋅m (7.7 kgf⋅m / 56.1 lbf⋅ft)
3. Starter Earth Cable
N6A0990E
• Connect the earth cable to the starter motor.
• Remove the starter assembly from flywheel • Connect the battery ground cable.
housing.
Installation
1. Starter Assembly
2. Starter Wiring Connector
N6A0991E
Legend
1. Terminal B
2. Terminal S
Engine Electrical 6D-25
Unit Repair
Component
S25-501B
24
25 22 23
20 28 26 27
14 15
16 13 17 18 19
21 12
3 2 5 6 10 11
1 4 9 8
N6B6237E
Legend
1. Armature 15. Ball Bearing
2. Ball Bearing 16. Pinion Shaft
3. Ball Bearing 17. Pinion Stopper Set
4. Field Coil Assembly 18. Ball Bearing
5. Pole Core Set Screw 19. Bearing Holder
6. Brush (+) 20. Magnetic Switch Assembly
7. O-ring 21. Bearing Retainer
8. Rear Cover 22. Gear Case
9. Brush Holder 23. Shift Lever
10. Brush Spring 24. Dust Cover Set
11. Brush (-) 25. Bolt
12. Pinion Assembly 26. Through Bolt
13. Clutch 27. Screw
14. Ball Bearing 28. M Terminal Cover
6D-26 Engine Electrical
Disassembly
1. Lead Wire
Disconnect the lead wire at the magnetic switch.
N6B6242E
3. Through Bolt
4. Screw
N6B6221E
5. Rear Cover
2. Magnetic Switch Assembly Remove the through bolts, then remove the rear
Remove the magnetic switch bolts, then remove cover.
the switch from the shift lever.
N6B6223E
N6B6222E
N6B6226E
N6B6224E
10. Bearing Retainer
11. Pinion Assembly
Remove the yoke along with the armature and the 12. Dust Cover
brush holder from the gear case. 13. Shift Lever
Remove the brushes and commutator carefully so 14. Gear Case
as not to allow them in contact with the adjacent
1) Remove the bearing retainer.
parts.
2) Remove the pinion from the gear case.
N6B6225E
N6B6227E
7. Brush Holder
8. Yoke 3) Use a screwdriver to remove the stopper clip.
9. Armature Then disassemble the pinion assembly.
Remove the brush holder and pull out the armature
assembly free from the yoke.
6D-28 Engine Electrical
N6B6263E
Armature
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
N6B6229E
Commutator Run-Out mm (in)
Standard Limit Legend
0.05 (0.002) or less 0.20 (0.008) 1. Insulator
2. 0.5 — 0.8 mm (0.020 — 0.03 in)
3. Commutator Segments
4. Correct
5. Incorrect
N6B6228E
N6A1006E N6B6231E
N6B6230E
continuity.
2. Use the circuit tester to check the field winding
1) Hold the circuit tester probes against two continuity.
commutator segments.
1) Hold one circuit tester probe against the “M”
2) Repeat Step 1 at different segments of the terminal lead wire.
armature core.
2) Hold the other circuit tester probe against the
There should be continuity between all segments
field winding brush.
of the commutator.
There should be continuity.
If there is not, the armature must be replaced.
If there is no continuity, the yoke must be replaced.
6D-30 Engine Electrical
N6B6244E N6A1013E
Brush and Brush Holder 3. Inspect the brushes for excessive wear.
1. Use a vernier caliper to measure the brush length If the negative brushes have excessive wear, the
(four brushes). entire brush holder assembly must be replaced.
Replace the brushes as a set if one or more of the If the positive brushes have excessive wear, the
brush length is less than the specified limit. entire yoke must be replaced.
1) Use a pair of side cutters to cut the lead wire
Brush Length mm (in) from the brush.
N6B6245E
N6A6508E
4. Pinion Assembly
Apply a coat of grease to the reduction gear and
N6B6232E install the pinion assembly to the armature shaft.
Reassembly
1. Magnetic Switch Assembly
1) Attach the torsion spring to the hole in the
magnetic switch as illustrated.
2) Insert the shift lever into the plunger hole of the
magnetic switch.
N6A1025E
5. Brush Holders
1) Install the brushes into the brush holder with
raising the spring end of the brush spring.
Take care not to damage the commutator face.
2) Install the brush holder with aligning the
N6A1023E peripheries of the yoke and the brush holder.
2. Gear Case
3. Dust Cover
1) Install the magnetic switch assembly in the
gear case.
2) Install the dust cover.
Tighten:
Dust cover bolt to 10.6 N⋅m (1.08 kgf⋅m / 93.8 lbf⋅in)
6D-32 Engine Electrical
N6B6247E N6B6221E
0.3~1.0
N6A1028E
Tighten:
Lead wire terminal nut to 10 N⋅m (1.0 kgf⋅m / 87 lbf⋅in)
Engine Electrical 6D-33
Magnetic Switch The pinion should return to its home position.
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M”
terminal.
To prevent coil burning, complete each test as quickly
as possible (within three to five seconds).
N6B6236E
N6B6234E
N6B6235E
3. Return Test
Disconnect the battery positive lead at the S
terminal.
6D-34 Engine Electrical
Torque Specifications
N6B6248E
Engine Electrical 6D-35
Preheating System
Glow Plug Replacement
Circuit Diagram
N6B6296E
Legend
1. Engine Control Switch 8. Glow Plug Indicator Light
2. Generator (Integral Regulator) 9. ECM
3. Charge Relay 10. Starter Cut Relay
4. To Heater and A/C Relay 11. To Exhaust Brake Solenoid Valve
5. Low Charge Indicator Light 12. Starter Relay
6. Glow Plug Relay 13. Starter
7. Glow Plugs 14. ECM Main Relay
1 1
2 3
4
2
N6B6075E N6B6214E
Legend Legend
1. EGR Duct (EGR cooler (2nd) — EGR valve) 1. EGR Duct (EGR cooler (2nd) — EGR valve)
2. EGR Valve 2. EGR Valve Gasket
3. EGR Valve
4. Remove the glow connector. 4. EGR Valve Gasket
5. Remove the glow plug.
4. Attach the engine harness connectors. Each
composite connector should make a loud click
when it is securely attached.
Service Precautions
Adequate care should be taken as over-tightening the
glow plug could lead to damage.
Functional check
Refer to Section 6E (Glow Control System Check).
N6A6127E
Except the glow plug.
N6A6429E
ENGINE
Exhaust System
TABLE OF CONTENTS
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6F-2
Explanations on Functions and Operation . . . . . 6F-2
EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . . 6F-3
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 6F-6
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-7
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6F-7
Description of function and operation. . . . . . . . . 6F-7
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 6F-7
List of Abnormal Phenomena. . . . . . . . . . . . . . . 6F-7
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6F-8
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-10
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-15
Exhaust Brake System . . . . . . . . . . . . . . . . . . . . 6F-16
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-16
Explanations on Functions and Operation . . . . 6F-16
Functional Check . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Exhaust Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-18
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-19
6F-2 Exhaust System
EGR System
Service Precautions The EGR control starts when the conditions for engine
speed, engine coolant temperature and barometric
Perform EGR related assembly according to the usual
pressure are satisfied. Then, the valve opening is
procedure of temporarily fitting and then permanently
calculated according to the engine speed, and target
tightening the parts so that unnecessary stresses are
fuel injection quantity. Based on this valve opening, the
not applied on the parts.
drive duty of the motor is determined and the motor is
Explanations on Functions and Operation driven accordingly.
The EGR system recirculates a part of exhaust gas A potentiometer type EGR valve position sensor is
back into the intake manifold, which results in reducing employed and installed on the EGR valve body. The
nitrogen oxide (NOx) emissions. The EGR control EGR valve position sensor is supplied with reference
system uses an electronic control system to ensure voltage (5V) and ground at all times from the ECM. The
both driveability and low emission. The control current ECM reads the EGR position sensor voltage input and
from the engine control module (ECM) operates the determines the EGR lift position.
motor to control the lift amount of EGR valve. Also, an
EGR position sensor is provided at the rear of the
motor to feed actual valve lift amount back to the ECM
for more precision control of the EGR amount.
10
7
8 9
8
7
4
6
5
1
3
N6B6111E
Legend
1. Crankshaft Position Sensor 6. EGR Valve
2. Accelerator Pedal Position Sensor 7. EGR Cooler
3. ECM 8. Water Inlet
4. Intake Throttle Valve 9. Water Outlet
5. Intake Air 10. Exhaust Gas
Exhaust System 6F-3
1 2
4 3
N6B6085E
Legend
1. EGR Cooler 5. EGR Duct (EXH)
2. Water Rubber Hose 6. EGR Duct (EGR cooler (1st) – EGR cooler
3. EGR Duct (EGR cooler (2nd) – EGR valve) (2nd))
4. EGR Valve
Removal
1. Drain engine coolant. Refer to Engine Cooling
System section.
2. Remove the fuel filter assembly. Refer to “Fuel
Filter Assembly”.
3. Remove the fuel filter Bracket.
4. Remove the EGR valve connector.
6F-4 Exhaust System
5. Remove the cooling water pipes. Inspection
6. Remove the EGR duct. (EXH) • Gas leak check
7. Remove the EGR cooler. (1st) - Check for gas leak in various parts of the EGR
8. Remove the EGR duct. (EGR cooler (1st) – EGR gas line.
(2nd)) If the results of the check show abnormalities,
9. Remove the cooler. (2nd) repair or replace the defective parts.
10. Remove the EGR duct. (EGR cooler (2nd) – EGR • EGR valve check
valve)
11. Remove the EGR valve. Installation
1. Mount the EGR valve.
2 • Insert the gasket and temporarily fit the EGR
valve.
Notice:
Temporarily tighten the bolts.
5
3 2. Install the EGR duct. (EGR cooler (2nd) – EGR
valve)
• Insert the gasket between the two ends of the
4
EGR duct (EGR cooler (2nd) – EGR valve) and
1
temporarily fit it.
Notice:
Temporarily tighten the bolts.
Notice:
Temporarily tighten the bolts
Notice:
Temporarily tighten the bolts.
N6B6240E
Exhaust System 6F-5
During temporary assembly, tighten the nuts
and bolts to the specified torque in the order
shown in the illustration.
11 7
4
10
6
2
12
13
N6B6136E
Tighten:
Bolts and nuts to
(1): 104 N⋅m (10.6 kgf⋅m/78 lbf⋅ft)
(2), (3), (4): 28 N⋅m (2.9 kgf⋅m/21 lbf⋅ft)
(5), (6), (7), (8): 24 N⋅m (2.4 kgf⋅m/17 lbf⋅ft)
(9), (10), (11): 48 N⋅m (4.9 kgf⋅m/35 lbf⋅ft)
7. Install the cooling water pipes.
8. Install the EGR valve connector.
9. Install the fuel filter bracket.
10. Install the fuel filter assembly.
11. Replenish the engine coolant.
6F-6 Exhaust System
Torque Specifications
48 (4.9 / 35)
24 (2.4 / 17)
28 (2.9 / 21)
48 (4.9 / 35)
48 (4.9 / 35)
28 (2.9 / 21)
24 (2.4 / 17)
28 (2.9 / 21)
24 (2.4 / 17)
24 (2.4 / 17)
24 (2.4 / 17)
Exhaust System
Service Precautions Description of function and operation
Offset in position of the exhaust system during The exhaust brake assembly adjusts exhaust pressure
assembly may sometimes cause vibrations or rattling to serve as supplement brake, Quick Warm-up System
noise. Therefore, temporarily tighten the bolts until all (QWS) for engine, etc. The DPD (diesel particulate
the parts have been positioned, and sequentially diffuser) body consists of a filter and oxidation catalyst,
tighten from the engine side to the rear pipe side. and serves to purify exhaust gas. The tail pipe has the
built-in post silencer that provides silencing effect. The
main components are exhaust brake assembly, front
exhaust pipes A and B, DPD, exhaust throttle
assembly, silencer, and tail pipe.
1 6
2
9
5 7 8
3
4
N6B6089E
Legend
1. Front Exhaust Pipe A 6. Exhaust Throttle Assembly
2. Exhaust Brake Assembly 7. Adapter Pipe
3. Front Exhaust Pipe B 8. Silencer
4. DPD 9. Tail Pipe
5. Extension Pipe
Exhaust Pipe
Removal • Remove the two exhaust temperature sensor
connectors of DPD.
1. Disconnect the tail pipe.
• Remove the clips of the exhaust temperature
sensor connector of DPD.
• Disconnect the two DPD differential pressure
hoses.
• Remove the DPD assembly from the front pipe.
1
2
4
4HK1-TCN
5
2
1
N6B6090E
Legend
1. Tail Pipe 6
2. Post Silencer 7
2
6
3
1
3 4
5 7
N6B6091E
Legend
1. Exhaust Temperature Sensor 2 (catalyst inlet)
2. Exhaust Temperature Sensor 1 (filter inlet)
N6B6215E 3. DPD Assembly
Legend 4. Differential Pressure Hose (F)
1. Extension Pipe 5. Differential Pressure Hose (R)
2. Exhaust Throttle Assembly 6. Differential Pressure Pipe (R)
3. Adapter Pipe 7. Differential Pressure Pipe (F)
4. Silencer
5. DPD Caution:
If you need to remove the differential pressure sensor
7. Remove the DPD.
assembly, take care with the followings.
6F-10 Exhaust System
• Never loosen the four screws (2) that tighten the Disassembly
sensor. If loosened, replace the sensor assembly.
1. Loosen the sleeve nut that secure the differential
• If you drop the sensor assembly, do not reuse it. pressure pipe.
• Never use tools that cause vibrations such as an 2. Remove the clips of the differential pressure pipe.
impact wrench when installing or removing the 3. Disconnect the differential pressure pipe.
differential pressure sensor.
2
1
1
2
N6B6267E
Legend
N6B6092E
1. Hose Clip
Legend 2. Sleeve Nut (R)
1. Differential Pressure Sensor Assembly 3. Clip
2. Tightening Screw 4. Sleeve Nut (F)
8. Disconnect the front exhaust pipes A and B. 4. Disassemble the DPD assembly.
• Remove the clamp and disconnect the front • Loosen the tightening nut on the oxidation
exhaust pipes. catalyst part to remove the oxidation catalyst part.
• Remove the exhaust brake assembly. • Loosen the tightening nut of the filter part to
remove the filter part and the rear case.
Caution:
Do not have a strong impact on or drop the DPD
assembly.
1
3
N6B6093E
Legend
1. Front Exhaust Pipe A
2. Exhaust brake Assembly
3. Front Exhaust Pipe B
Exhaust System 6F-11
4 5
3
1
2
N6B6216E N6B6217E
Legend Legend
1. Oxidation Catalyst Part 1. Filter
2. Gasket 2. Filter Case
3. Filter Part
4. Gasket 3. If the differential pressure sensor assembly has
5. Rear Case been replaced, do the followings (on the vehicle):
• Turn the starter switch from key OFF to key ON
(do not start the engine).
Inspection • The DPD lamp comes on then goes off in
approx. 30 seconds.
1. Check the appearance of the exhaust pipe-related
parts. • After checking the DPD lamp is OFF, leave it for
more than 15 seconds with key OFF.
• Take care that damage due to heat or vibration
of the body panel may cause exhaust gas to Caution:
enter into the room.
• Check the connection for looseness, damage 4. Check the oxidation catalyst.
or exhaust gas leakage.
• Visually check the oxidation catalyst for melt,
• Check the clamp and the rubber for damage or clogging.
deterioration, crack or damage.
• Check the pipe and the silencer for dent or Assembly
crack due to corrosion, and repair or replace if Assemble the DPD assembly.
damaged. 1. Insert the gaskets between the filter part and the
2. Check the parts related to the DPD. rear case, and temporarily tighten the nut.
• Visually check the filter for melt, damage or 2. Insert the gaskets between the filter part and the
clogging. oxidation catalyst, and temporarily tighten with the
• Shine a light on the backside of the filter. If the bolt and nut.
light penetrates through the filter, replace the
Caution:
filter part.
• Check the assembled portions between the filter
Caution: part and the rear case, and between the filter part
Before disassembling the DPD assembly, always check and the oxidation catalyst part, and tighten
the differential pressure of DPD and its status using a together with the pipe brackets at the two portions.
scan tool, and confirm the procedure of check and 3. Tighten the bolts and nuts to the specified torque.
service. Refer to “Engine Control” chapter for details.
• Tighten all the blots and nuts twice.
Tighten:
Bolts and nuts to 25 N⋅m (2.5 kgf⋅m/18 lbf⋅ft)
6F-12 Exhaust System
Caution:
After tightening all the bolts and nuts, tighten again to
the same torque (double tightening).
3
4
4 5
3 1
2
1
N6B6094E
Legend
1. Differential Pressure Pipe (F)
N6B6216E 2. Differential Pressure Pipe (R)
Legend 3. Sleeve Nut (R)
1. Oxidation Catalyst Part 4. Clip
2. Gasket 5. Sleeve Nut (F)
3. Filter Part
4. Gasket Installation
5. Rear Case
Caution:
4. Insert the differential pressure pipes (F), (R), and • Vibration or play in the exhaust system may be
tighten the sleeve nut by hand. caused by misalignment at assembly. Tighten the
5. Secure the differential pressure pipes with clips. bolts temporarily until the positioning of all parts
are finished and then fully tighten them from the
Tighten:
engine side to the tail pipe side in order.
Clips to 10 N⋅m (1.0 kgf⋅m/87 lbf⋅in)
• Do not reuse the removed gasket and nut.
6. Tighten the sleeve nuts of differential pressure
pipes to the specified torque. 1. Install the front exhaust pipe A.
• Install the front exhaust pipe A to the exhaust
Tighten: manifold, and tighten to the specified torque.
Sleeve nut to 35 N⋅m (3.6 kgf⋅m/26 lbf⋅ft)
Tighten:
Caution: 67 N⋅m (6.8 kgf⋅m/49 lbf⋅ft)
• Clean off the old anti-seize compound on the
sleeve nuts, and apply new one. Caution:
Tighten the front exhaust pipe A evenly to prevent gas
• Make sure to install the differential pressure pipes leakage.
according to the procedure. Failure to follow the
procedure may cause the nut to be loose. 2. Install the exhaust brake assembly.
• When the DPD has been disassembled, do not • Install the exhaust brake assembly and the
reuse the old gasket, bolt and nut (use gasket, front exhaust pipe B to the front exhaust pipe A,
fixing kit). and tighten to the specified torque.
Tighten:
27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft)
Exhaust System 6F-13
8 1
2 2 2
7 7
6 3
1 5 4
3
N6B6093E N6B6268E
Legend Legend
1. Front Exhaust Pipe A 1. Differential Pressure Sensor
2. Exhaust Brake Assembly 2. Clip
3. Front Exhaust Pipe B 3. Differential Pressure Hose
4. The Normal Hose Assembly
3. Install the DPD assembly to the front pipe. 5. The Revers Hose Assembly
6. Differential Pressure Hose
Tighten:
7. Clip
S spec: 85 N⋅m (8.7 kgf⋅m/63 lbf⋅ft)
8. Differential Pressure Sensor
N spec: 22 N⋅m (2.2 kgf⋅m/16 lbf⋅ft)
4. Install the differential pressure hose to the DPD 5. Connect the DPD exhaust temperature sensor
differential pressure pipe. connector.
• Insert the differential pressure hose securely till
it reaches the bulge of the pipe. Caution:
Do not confuse its front and rear directions.
• Attach the hose clip properly.
Caution:
• Do not confuse its front and rear directions.
• Do not use the hose that have cracks.
• Do not further tighten nor remove the tightening
screw of the differential pressure sensor assembly.
• Gas leakage from the joint can cause malfunction
of the sensor.
Be sure to check for gas leakage after starting the
engine.
6F-14 Exhaust System
4
4HK1-TCN
5
2
1 2
1
3 4
5
6
7
N6B6215E
Legend
1. Extension Pipe
5 4 2. Exhaust Throttle Assembly
4HK1-TCS
2 3. Adapter Pipe
1 4. Silencer
5. DPD
7
1
N6B6091E
2
Legend
1. Exhaust temperature sensor 2 (catalyst inlet)
2. Exhaust temperature sensor 1 (filter inlet)
3. DPD assembly
4. Differential pressure hose (F)
5. Differential pressure hose (R)
6. Differential pressure pipe (R)
7. Differential pressure pipe (F)
67 (6.8 / 49)
27 (2.8 / 20)
N6B6098E
6F-16 Exhaust System
N6A6439E
Functional Check
Operational check
• Confirm the sound of the valve touching the
stopper when the exhaust brake is operated in the
idling condition.
Exhaust System 6F-17
Exhaust Brake
Components
7 N6B6099E
Legend
1. Power Chamber, Insulator, Gasket and Bearing 5. Front Exhaust Pipe B
2. Lock Nuts and Clevis Joint 6. Exhaust Brake Assembly
3. Split Pin and Washer 7. Front Exhaust Pipe A
4. Exhaust Brake Valve
Removal
1. Remove the vacuum hose and clips.
2. Remove the nut.
3. Remove the exhaust pipe.
4. Remove the exhaust brake assembly.
Disassembly
1. Remove the split pin.
2. Remove the lock nuts.
3. Remove the clevis joint.
4. Remove the power chamber.
Reassembly
1. Mount the power chamber.
N6A6441E
Tighten:
2. Mount the lock nuts.
Nut to 14 N⋅m (1.4 kgf⋅m/122 lbf⋅in)
6F-18 Exhaust System
3. After mounting the clevis joint, tighten the lock nuts Unit check
to the specified torque. • Negative pressure in the power chamber caused
Tighten: by the vacuum pump
Lock nut to 13 N⋅m (1.3 kgf⋅m/113 lbf⋅in) When a pressure of 53.3 - 93.3 kPa (0.54 - 0.95
kg/cm2 / 7.7 - 13.5 psi) is applied, the exhaust
brake valve should open or close smoothly.
Special tool
Vacuum pump: 5-8840-0279-0 (J-23738-A)
N6A6442E
Inspection
N6A6443E
Check for damage or degradation in the parts
mentioned below.
• Exhaust brake valve
Installation
• Exhaust brake shaft 1. Mount the exhaust brake assembly.
• Butterfly valve Tighten:
• Bush Bolt and nut to 27 N⋅m (2.8 kgf⋅m/20 lbf⋅ft)
• Power chamber
N6B6218E
Exhaust System 6F-19
2. Mount the exhaust pipe. 3. Mount the nuts.
Tighten:
Nut to 67 N⋅m (6.8 kgf⋅m/49 lbf⋅ft)
4. Mount the vacuum hose and the clips.
N6A6445E
Torque Specifications
N6B6100E
6F-20 Exhaust System
Tool Number /
Illustration
Description
5-8840-0279-0
(J-23738-A)
Vacuum Pump
5884002790
LG4HK-WE-0761
Issued by
Tokyo, Japan