Workshop Manual: (4HV1 Model)

2009-2012MY
2009-2012MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE (4HV1 model)

ENGINE
(4HV1 model)
No.LG4HV-WE-0981
LG4HV-WE-0981_64694前書 2010.8.19 0:53 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
2 SUSPENSION 2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D1 Transfer Case (Part Time)
4 BRAKES 4B Brake
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME 11A Frame
LG4HV-WE-0981_64694前書 2010.8.19 0:53 PM ページ 2
LG4HV-WE-0981.book 1 ページ２０１２年１１月１４日　水曜日　午前９時３２分
Engine Mechanical (4HV1-CNG) 1B-1
ENGINE
Engine Mechanical
(4HV1-CNG)
TABLE OF CONTENTS
4HV1-CNG Engine. . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-58
Maintenance Precautions . . . . . . . . . . . . . . . . . 1B-3 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-60
Reading the Engine Type . . . . . . . . . . . . . . . . . 1B-4 Timing Gear Train. . . . . . . . . . . . . . . . . . . . . . . . 1B-61
Description of Function and Operation . . . . . . . 1B-5 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-61
Functional Inspection . . . . . . . . . . . . . . . . . . . 1B-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-61
Malfunction Symptom List . . . . . . . . . . . . . . . . 1B-19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-63
Symptom: Engine Does not Run. . . . . . . . . . . 1B-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-64
Symptom: Fuel Circulates to the Gas Injector List of Tightening Torques . . . . . . . . . . . . . . . . 1B-70
but the Engine Does not Crank . . . . . . . . . . . . 1B-21 Valve Stem Seal and Valve Spring . . . . . . . . . . . 1B-71
Symptom: Fuel Does not Reach Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-71
the Gas Injector. . . . . . . . . . . . . . . . . . . . . . . . 1B-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-71
Symptom: Idling is Unstable . . . . . . . . . . . . . . 1B-23 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-72
Symptom: Engine Output is Decreased . . . . . 1B-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-73
Symptom: Fuel Consumption is Increased . . . 1B-25 Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . 1B-75
Symptom: Oil Consumption is Increased . . . . 1B-26 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-75
Symptom: Overheating Occurs . . . . . . . . . . . . 1B-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-75
Symptom: Oil Pressure Indicator Light does Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-76
not Turn Off . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-28 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-76
Symptom: Engine Sound is Abnormal . . . . . . 1B-29 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-78
Symptom: There is a Sound of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-79
Exhaust Gas Leak. . . . . . . . . . . . . . . . . . . . . . 1B-30 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-80
Symptom: There are Continuous Camshaft Position (CMP) Sensor . . . . . . . . . . . 1B-81
Abnormal Sounds . . . . . . . . . . . . . . . . . . . . . . 1B-31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-81
Symptom: There is an Abnormal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-81
Tapping Sound . . . . . . . . . . . . . . . . . . . . . . . . 1B-32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-81
Symptom: There is a Gas Leak. . . . . . . . . . . . 1B-33 Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 1B-82
Primary Specifications. . . . . . . . . . . . . . . . . . . 1B-33 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-82
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-82
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1B-37 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-83
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-37 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-39 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-85
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-44 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-87
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-44 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-89
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-44 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-90
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-45 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-90
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-45 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-90
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . 1B-46 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-91
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-46 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-94
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-47 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-98
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-47 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-103
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-49 List of Tightening Torques . . . . . . . . . . . . . . . 1B-107
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-50 Crankshaft Position (CKP) Sensor . . . . . . . . . . 1B-108
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-50 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-51 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-108
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-108
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-55 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-109
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1B-56 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-109
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-56 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-56 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-111
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-57 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-112
1B-2 Engine Mechanical (4HV1-CNG)

List of Tightening Torques . . . . . . . . . . . . . . . 1B-115
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-116
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-116
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-116
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-117
Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . 1B-120
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-120
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-120
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-122
Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . 1B-127
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-127
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-127
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-128
Piston and Connecting Rod . . . . . . . . . . . . . . . 1B-131
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-131
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-131
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-132
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-133
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-138
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-140
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-143
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-143
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-143
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-144
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-145
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-149
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-149
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 1B-153
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-153
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-153
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-154
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-155
4HV1-CNG Engine
Maintenance Precautions Precautions for work particular to this engine
To prevent damaging the engine and to ensure the 1. Gas-related matters
reliability of engine performance, be careful of the Natural gas (CNG) is combustible gas with a high
following points when performing engine maintenance. pressure of a maximum of 200 atmospheres approx. 20
For information on working safely, refer to "Precautions MPa(204 kg/cm2/2900 psi). It is necessary to exercise
When Working" in Section 0A, Overview. sufficient caution when performing inspection and
• When lifting or supporting the engine, do not maintenance. Take particular caution with regard to the
directly attach the jack to the oil pan. following when performing maintenance of gas-related
When lowering the engine to the ground, do not let devices.
the oil pan directly contact the ground. Use a 1. Carry out maintenance in a well-ventilated work
wooden frame, etc. to support it on its engine foot area where there is no fire.
or flywheel housing. 2. When removing electrical wiring, etc., confirm that
(There is only a small gap between the oil pan and there is no accumulation of gas.
oil pump strainer, so be careful not to damage the
oil pan and oil pump strainer.) 3. If a gas leak is discovered, do not carelessly
proceed to operate switches such as for lighting
• When the air intake system, such as the air duct or and ventilation fans.
air cleaner, has been removed, cover the air intake
to prevent foreign matter from entering the 4. When removing and installing pipes and
cylinder. components such as CNG container (CNG
cylinder) and gas passages, start the engine after
• To perform maintenance on the engine, always fully closing the manual cylinder valve (at tank) for
remove the battery ground terminals. If the battery all of the CNG container (CNG cylinder). Turn off
ground terminals are not disconnected while the ignition switch OFF after idling the engine and
performing work, there is the possibility of confirming that the gas remaining in the
damaging the wire harness or electrical components and pipes has combusted and that
components. Take adequate precautions for the engine has stopped.
safety, such as short circuits, when inspections
require an energized state. 5. Make sure to use pipes that are equivalent to
those specified by Isuzu.
• To protect and lubricate the sliding surfaces when
running the engine for the first time, apply an 6. When replacing CNG container (CNG cylinder)
adequate amount of engine oil to the sliding and components, securely install them after
surfaces. sufficiently inspecting each fitting section for
damages.
• When the valve-related parts, pistons, piston rings,
control rods, control rod bearings, crankshaft 7. After installation or removal work, force-open the
journal bearings, etc. have been removed, valves and thoroughly confirm that there are no
organize them in order for storage. gas leaks at normal pressure.
• When installing, use the same parts and install 2. Axial-type oil seals
them in the same position as when they were
• Since axial-type front oil seals and rear oil seals
removed.
are used for the crankshaft, exercise caution
• Whenever disassembling the gasket, oil seals and regarding the following points.
O-rings, replace them with new ones.
- When replacing, replace the oil seal and slinger
• Completely wipe off old liquid gaskets from the together.
locations where liquid gaskets were used. After
- Since it is important to set the position of the oil
cleaning to completely remove any oil, moisture
seal and slinger in the front and rear direction
and filth, apply the specified liquid gasket and
accurately, properly use special tools when
reassemble.
doing so.
• After applying the liquid gasket, assemble within
the specified amount of time. If the time of 3. Valve caps
assembly has exceeded the specified amount of
• As valve caps are used for the intake and exhaust
time, wipe away the liquid gasket and reapply it.
valves, exercise great caution in detail when
• When assembling and installing, tighten at the carrying out disassembly and assembly, such as
specified torque value. not to drop valve caps into the gear case or oil
return hole.

4. Oil pan flange 5. Plastic region rotational angle tightening method
• Since only rubber gaskets are used for the seal of • The plastic region rotational angle tightening
oil pan flanges, exercise caution during removal method is adopted when tightening the bolts for
and installation so as not to deform or damage the connecting rods, flywheels, cylinder heads (M14
flange surface. only) and crank cases (M14 only).
Apply the threaded portion and seat surface of
bolts with molybdenum disulfide and tighten the
bolts using the specified method.
Reading the Engine Type
1
2
LNW71BMF005501
Legend
1. Engine type cast ed inscription (4HV1) 2. Engine number stamping (******)

Description of Function and Operation
The CNG engine uses compressed natural gas as fuel.
For the fuel supply method, a multi-point injection (MPI)
method, which reduces the pressure of CNG that is
filled in the CNG container (CNG cylinder) at a
maximum pressure of 20 MPa (204 kg/cm2/2900 psi) to
0.4 MPa (4.1 kg/cm2/58 psi) with a pressure reducing
valve and then injects the CNG from gas injectors
installed for each cylinder, is adopted.
The electric control throttle valve opens and closes in
accordance with operation of the accelerator pedal to
adjust the amount of intake air. The optimal gas
injection amount is determined by the engine control
module (ECM) in accordance with the amount of air
that is calculated from the intake air pressure. At this
time, the gas injection amount is compensated based
on signals from other sensors so that it is always
optimal in accordance with the engine's driving
condition.
The fuel that is injected from the gas injector becomes
an air-fuel mixture together with intake air and flows
into the cylinder. The mixture is exhausted after it is
ignited and combusted by the igniter.
An air-fuel ratio compensation system, which measures
the air-fuel ratio in the exhaust gas using the air-fuel
ratio (A/F) sensor and controls the gas injection amount
so that the exhaust gas purification performance with
the 3-way catalyst can be fully exerted, is adopted. In
addition, the O2 sensor at the backside of the 3-way
catalyst compensates the control based on the air-fuel
ratio (A/F) sensor so that an optimal air-fuel ratio can
be achieved at all times.

except Australia
2 4
3
5
32
31 6
20 14
19 18 17
30
29 21 16 15
28 7
22 13
23 12
27 26 24
11 8
10
25 10
11
LNW91BLF001801
Legend
1. Fuel gauge 17. CNG pressure / temperature sensor
2. Barometric sensor 18. Gas injector
3. Engine control module (ECM) 19. Ignition coil
4. Engine driver unit (EDU) 20. Camshaft position (CMP)sensor
5. Accelerator pedal position (APP) sensor 21. Spark plug
6. Pressure regulator 22. Engine coolant temperature (ECT) sensor
7. Automatic valve (before regulator) 23. Knock sensor
8. CNG pressure sensor 24. Crankshaft position (CKP) sensor
9. Filling unit 25. 3-way catalyst integrated silencer
10. Automatic valve (at tank) and manual cylinder 26. O2 sensor
valve 27. Silencer
11. CNG container (CNG cylinder) 28. Exhaust brake
12. Air cleaner 29. Air-fuel ratio (A/F) sensor
13. Intake throttle valve 30. Exhaust brake magnetic valve
14. Gas filter 31. Vacuum tank
15. Intake air temperature (IAT) sensor 32. Vacuum
16. Intake air pressure (MAP) sensor
for Australia
2 4
3
5
33
32 6
21
20 19 18 16
31
30 22 17 15
29 23 7
14
13
24
8
28 27 25
12 9
11
26 12
8
10
LNW91BLF003601
Legend
1. Fuel gauge 18. CNG pressure sensor
2. Barometric sensor 19. Gas injector
3. Engine control module (ECM) 20. Ignition coil
4. Engine driver unit (EDU) 21. Camshaft position (CMP)sensor
5. Accelerator pedal position (APP) sensor 22. Spark plug
6. Pressure regulator 23. Engine coolant temperature (ECT) sensor
8. Automatic valve (at tank) 25. Crankshaft position (CKP) sensor
9. CNG pressure sensor 26. 3-way catalyst integrated silencer
10. Filling unit 27. O2 sensor
11. Manual cylinder valve (at tank) 28. Silencer
12. CNG container (CNG cylinder) 29. Exhaust brake
13. Air cleaner 30. Air-fuel ratio (A/F) sensor
14. Intake throttle valve 31. Exhaust brake magnetic valve
15. Intake air temperature (IAT) sensor 32. Vacuum tank
16. CNG temperature sensor 33. Vacuum
17. Intake air pressure (MAP) sensor

Layout of CNG-related devices at left side and top side of engine
Left side of engine except Australia
2 3
1
8 7
LNW81BMF005901
Legend
1. Ignition coil (x4) 5. Crankshaft position (CKP) sensor
2. CNG pressure / temperature sensor 6. Intake air temperature (IAT) sensor
3. Gas injector (x4) 7. Intake air pressure (MAP) sensor
4. Intake throttle valve 8. Knock sensor

Left side of engine for Australia
1 2 3 4
LNW61BMF000201
Legend
1. Ignition coil (x4) 5. Intake throttle valve
2. CNG pressure sensor 6. Crankshaft position (CKP) sensor
3. CNG temperature sensor 7. Intake air temperature (IAT) sensor
4. Gas injector (x4) 8. Intake air pressure (MAP) sensor

Top side of engine except Australia
LNW81BMF005701
Legend
1. Camshaft position (CMP) sensor 2. PCV valve

Top side of engine for Australia
LNW61BMF000801
Legend
1. Camshaft position (CMP) sensor 2. PCV valve
Compressed natural CNG container (CNG cylinder)

A container consisting of a high-pressure gas cylinder
made of steel that enables for CNG that has been
compressed to a maximum of 20 MPa (204 kg/cm2/
2900 psi) to be stored in form of gas.
Taking installation in vehicles into consideration, CNG
container (CNG cylinder) are set up so that the
necessary total volume is divided among multiple
containers, and a manual cylinder valve (at tank) that is
equipped with a excess flow valve (EFV) and a
Pressure relief device (PRD) is attached to each CNG
container (CNG cylinder).

Pressure regulator
A device that lowers the pressure of the high pressure
CNG down to 0.4 MPa (4.1 kg/cm2/58 psi) and supplies
the CNG as fuel gas to the gas injector. Heater pipes
are branched off and circulates hot water in order to
stabilize operations.
except Australia
LNW91BLF001901

for Australia
LNW71BLF004901
Gas injector Lubricating system

The ECM makes judgments based on signals from The lubricating system is comprised of a full-flow
each sensor, and injects the optimal fuel gas. bypass integrated oil filter, water cooled oil cooler and
piston coolant oil jet, etc.
Rigid fuel line
A spool lock fitting is used for the rigid fuel line that
connects the filling unit to the pressure reducing valve,
and the torque method is used for tightening control.
Ignition coil
This is equipped with a power switch and is used to
generate high voltage to the spark plug upon receiving
signals from the ECM. It is installed to each of the 4
cylinders, with 12V specification.
Spark plug
Iridium alloy plugs manufactured by Denso are used,
improving abrasion resistance of the electrode.

Functional Inspection
Valve clearance inspection • Sections to inspect when 4th cylinder is at the
compression top dead center.
Valve clearance (while cooling) mm(in)

Intake valve 0.4(0.016)
Exhaust valve 0.4(0.016)
NOTE:
Be sure to work when the engine is cool.
• Inspect valve clearance for the items marked with

{ when the 1st cylinder is at the compression top
dead center, and inspect valve clearance for the
items marked with X in the chart when the 4th
cylinder is at the compression top dead center.
Cylinder No. 1 2 3 4
Valve alignment
Exhaust
Exhaust
Exhaust
Exhaust
Intake
Intake
Intake
Intake
LNW21BSH001201
1. Valve clearance measurement

1st cylinder
a. Remove the cylinder head cover.
compression { { { {
top dead center • Refer to "Cylinder Head Cover" in this
section.
4th cylinder
b. Put the engine 1st cylinder at the compression
compression X X X X
top dead center.
top dead center
• Rotate the crankshaft in the forward
direction and align the crank pulley
• Sections to inspect when 1st cylinder is at the
alignment mark with the front cover BTDC0°
compression top dead center.
mark.
LNW21BSH001101
LNW21BSH015701
REFERENCE
• The compression top dead center of the 1st
cylinder (or 4th cylinder) can be checked at
the instant when the inlet valve of the 4th
cylinder (or 1st cylinder) starts opening.

c. Insert the thickness gauge (1) between the • Refer to "Cylinder Head Cover" in this section.
rocker arm adjust screw and the valve cap, and 7. Install the compression gauge and adaptor.
measure the clearance.
Special Tool
Compression gauge: 5-8840-2675-0
Adaptor: 5-8840-2878-0
8. Force open the throttle portion on the intake
1
throttle valve with your hand.
• Engage the starter to inspect the compression
pressure.
NOTE:
Be careful not to suck any foreign matter such as dust.
Compression
MPa (kg/cm2/psi) / 200 r/min
pressure
Standard value 2.12 - 2.51 (21.6 - 25.6 / 307 - 364)
LNW21BSH066501 Limit 2.12 (21.6 / 307) (reference value)

Cylinder
290 kPa (3.0/42)
difference
d. Put the engine 4th cylinder at the compression
top dead center. 9. Sequentially measure each cylinder.
• Rotate the crankshaft 360° in the forward
direction and align the crank pulley NOTE:
alignment mark with the front cover BTDC0° • To ensure an engine revolution speed of 200 r/min
mark. or more, use a fully charged battery.
e. Measure the other valve clearances.
f. When the measured value is outside the
specified value, adjust the valve clearance.
2. Valve clearance adjustment
a. Loosen the rocker arm adjust screw.
b. Insert a 0.4 mm(0.016 in) thickness gauge
between the rocker arm adjust screw and the
valve cap, tighten the rocker arm adjust screw
until it becomes difficult to insert and remove
the thickness gauge, and then secure the
rocker arm adjust screw nut.
Rocker arm adjust screw nut
Tightening torque: 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Compression pressure inspection

LNW61BSH002601
1. Warm up the engine.
2. Close the manual cylinder valve (at tank) of the
CNG container (CNG cylinder), and wait until the
engine runs out of fuel and stops. 10. Remove the compression gauge and adaptor.
3. Remove the battery negative terminal and remove 11. Disconnect the battery negative terminal.
all ignition coils and spark plugs. 12. Install all of the spark plugs and ignition coils.
4. Connect the battery negative terminal. 13. Install the air intake hose.
5. Turn the starter to discharge foreign matter from • Refer to "Cylinder Head Cover" in this section.
inside the cylinders. 14. Connect the battery negative terminal.
6. Remove the air intake hose.

15. Slowly open the manual cylinder valve (at tank) of
the CNG container (CNG cylinder).
1 2 3 4
5 6 7 8 9
Fuel leak inspection (air-tightness inspection)
NOTE:
When performing maintenance related to fuel devices
of CNG vehicles, it is necessary to conduct an air-
tightness inspection.
Since a gas leak inspection cannot be performed
unless there is nearly full pressure inside the cylinder,
confirm the remaining amount before starting work.
LNW61ASH003401
Valve force-opening method

• The diagram below indicates the relationship
between the PI monitor connector, power supply
and the shutoff valve.
except Australia
Automatic valve
(at tank)
(RH)
LNW81BSH016901 PI monitor
connector
Automatic valve
Method 4 9 (before regulator)
• Force-open the shutoff valve of the fuel circuit, 3 8 Hold-in coil
apply gas leak detection fluid or soap-water to the 7
fitting of the rigid fuel line and flexible fuel line, and 2 6 Pull-in coil
check for gas leaks. 1 5
Battery
Automatic valve
(at tank)
Work sequence (LH)
1. Force-opening of the fuel shutoff valve
• The shutoff valve of the fuel circuit opens only
when the engine is starting or when the engine LNW91BSH009701
is running. But by using the fuel shutoff valve

force-open function, it is possible to force-open
the shutoff valve while the engine is stalling or
while the ignition switch is turned OFF and the
engine is stopped.
• When the shutoff valve is force-opened, the gas
passage from the CNG container (CNG
cylinder) to the gas injector is connected even if
the engine is stopped. It is necessary to
exercise sufficient caution such as to gas leaks.
A PI monitor connector is installed to the upper
section of the accelerator pedal.

for Australia • In this state, apply gas leak detection fluid or
soap-water to the fitting of the rigid fuel line and
the fitting of the flexible fuel line, and check for
Automatic valve
gas leaks.
(at tank) There are no gas leaks if there are no air
(RH) bubbles in the locations where gas leak
PI monitor
detection fluid or soap-water was applied.
connector
Automatic valve except Australia
4 9 (before regulator)
3 8 Hold-in coil
2 6 Pull-in coil
1 5
Battery
Automatic valve
(at tank)
(LH)
LNW91BSH009801
• The valve force-opened condition can be

accomplished by connecting the 7 pin and 8 pin of
the PI connector, connecting the 6 pin and 7 pin for
an instant to open the valve, and then by
separating them.
Since the 7 pin of the PI monitor connector
constantly has battery voltage regardless of the
key switch, exercise sufficient caution when
working.
2. Applying detection fluid
LNW91BMH000201

for Australia
LNW71BMH000201
NOTE:
Use a mirror or flashlight for checking locations that are
difficult to see.
Lastly, thoroughly wipe off the detection fluid or soap-
water that was applied.
Air-tightness inspection is performed on the fitting of
the rigid fuel line and flexible fuel line that was removed
and installed, but make sure to check the fitting of other
rigid fuel line and flexible fuel line as well.
3. Disengaging valve force-opening of the shutoff

valve
• Disconnect the 7 pin and 8 pin of the PI monitor
connector.

Malfunction Symptom List
• Engine Does not Run
• Fuel Circulates to the Gas Injector but the Engine
Does not Crank
• Fuel Does not Reach the Gas Injector
• Idling is Unstable
• Engine Output is Decreased
• Fuel Consumption is Increased
• Oil Consumption is Increased
• Overheating Occurs
• Oil Pressure Indicator Light Does not Turn Off
• Engine Sound is Abnormal
• There is a Sound of Exhaust Gas Leak
• There are Continuous Abnormal Sounds
• There is an Abnormal Tapping Sound
• There is a Gas Leak

Symptom: Engine Does not Run
Condition Possible Cause Correction

Starter does not rotate Loosening of battery terminals, poor Tighten the battery terminals and clean
connection due to corrosion the battery
Battery discharge or decrease in Charge or replace the battery
performance
Slow blow fuse has melted Replace the slow blow fuse
Malfunction of the ignition switch or Replace the ignition switch or starter
starter relay relay
Malfunction of the starter unit Inspect the starter unit and replace if a
failure is found
The starter rotates, but does not rotate Wear of the ring gear Repair or replace the part
the flywheel Improper adjustment of the starter's Adjust or repair
magnetic switch
Starter pinion meshes with the ring Insufficient charging of battery Charge or replace the battery
gear, but the engine does not crank Insufficient tightening of the wiring Repair
circuit terminal
Malfunction of the starter unit Inspect the starter unit and replace if a
failure is found
Seizure or damage inside the engine Overhaul the engine

Symptom: Fuel Circulates to the Gas Injector but the Engine Does not Crank

Fuel circulates to the gas injector but Defective intake throttle valve Replace the intake throttle valve
the engine does not crank Defective spark plug Replace the spark plug
Poor connection of or open circuit in the Replace the ignition coil
ignition coil
Malfunction of the engine control Diagnose the engine control system
system

Symptom: Fuel Does not Reach the Gas Injector

Fuel does not reach the gas injector Defective fuel shutoff valve Replace the fuel shutoff valve
Clogging or damage of the rigid fuel Repair or replace the rigid fuel line, or
line, or looseness of the fitting section tighten the fitting section
Excess flow valve (EFV) is operating Cancel the operation of the excess flow
valve (EFV)
Defective Pressure regulator Replace the Pressure regulator

Symptom: Idling is Unstable

Idling is unstable Defective intake throttle valve Replace the intake throttle valve.
Leakage or clogging of the fuel system Repair or replace the fuel system.
Defective spark plug Replace the spark plug.
Poor connection of or open circuit in the Repair or replace the ignition coil.
ignition coil
Improper adjustment of valve clearance Adjust the valve clearance.
Malfunction of the engine control Diagnose the engine control system.
system

Symptom: Engine Output is Decreased

Engine output is decreased Clogging of the air cleaner element Replace the air cleaner element
Defective intake throttle valve Replace the intake throttle valve
Ignition timing failure Refer to "Engine Control System" in
Section 1A, Engine Control System
(4HV1-CNG)
Defective spark plug Replace the spark plug
Defective gas injector Replace the defective gas injector
Decrease in gas pressure Repair or replace the fuel system
Leakage or clogging of the fuel system Repair or replace the fuel system
Improper adjustment of valve clearance Adjust the valve clearance
Insufficient compression pressure Replace the relevant parts
(cylinder head gasket is blown out,
wear/locking/damage of the piston ring,
defective valve contact)
Clogging of exhaust pipe, damage of Replace the exhaust pipe, catalyst
catalyst converter converter
system

Symptom: Fuel Consumption is Increased

Fuel consumption is increased Leak in fuel system Repair or replace the fuel system
Clogging of the air cleaner element Replace the air cleaner element
Defective spark plug Replace the spark plug
Insufficient compression pressure Replace the relevant parts
(cylinder head gasket is blown out,
wear/locking/damage of the piston ring,
Engine oil deterioration Replace the engine oil
system

Symptom: Oil Consumption is Increased

Oil consumption is increased Defective engine oil Replace the engine oil
Excessive engine oil Adjust the amount of engine oil
Oil leak from oil seal or gasket Replace the oil seal or gasket
Clogging of the air breather Clean the air breather
Defective valve guide oil seal Replace the valve guide oil seal
Wear of valve stem and valve guide Replace the valve stem or valve guide
Worn, locked or broken piston ring Replace the piston ring
Defective PCV Replace the PCV valve

Symptom: Overheating Occurs

Overheating occurs Insufficient amount of coolant Replenish the coolant
Clogging of the cooling system due to Remove foreign matter from the cooling
foreign matter system
Slipping caused by fan clutch oil leak Replace the fan clutch
Slipping caused by loosening of or Adjust or replace the drive belt
cracks in the drive belt
Defective radiator cap or clogging of Replace the radiator cap. Or, clean the
radiator core radiator core
Water leak caused by defective seal Replace the seal cap
cap of the cylinder head or cylinder
block
Defective thermostat Replace the thermostat
Defective water pump Replace the water pump

Symptom: Oil Pressure Indicator Light does not Turn Off

Oil pressure indicator light does not turn Insufficient amount of engine oil or Refill or replace the engine oil
off inappropriate viscosity
Short to ground or malfunction of oil Replace the oil pressure switch or
pressure switch repair the short circuit
Locking of relief valve, fatigue of valve Replace the relief valve
spring
Clogging of oil pump strainer Clean the oil pump strainer
Wear of oil pump-related parts Replace the oil pump-related parts
Wear of the crankshaft and bearing Replace the crankshaft and bearing

Symptom: Engine Sound is Abnormal

Engine sound is abnormal (make sure Insufficient compression pressure Replace the relevant parts
to inspect and confirm after completely (cylinder head gasket is blown out,
warming up the engine) wear/locking/damage of the piston ring,
Insufficient tightening of the rocker arm Tighten the rocker arm bracket
bracket
Malfunction of ignition system Repair or replace the ignition system
Malfunction of engine control system Refer to "Engine Control System" in
(4HV1-CNG)

Symptom: There is a Sound of Exhaust Gas Leak

There is a sound of exhaust gas leak Connection of exhaust pipe is loose Tighten the connection of the exhaust
(make sure to inspect and confirm after pipe
completely warming up the engine) Damage of the exhaust pipe Replace the exhaust pipe
Looseness of the spark plug Tighten the spark plug
Connection of exhaust manifold is loose Tighten the exhaust manifold
Damage of the cylinder head gasket Replace the cylinder head gasket
Damage of exhaust brake assembly Replace the exhaust brake assembly

Symptom: There are Continuous Abnormal Sounds

There are continuous abnormal sounds Loosening of the drive belt Adjust the tension of the drive belt
(make sure to inspect and confirm after Loosening of the cooling fan Tighten the cooling fan
completely warming up the engine)
Wear or damage of the water pump Replace the water pump
bearing
Defective generator or vacuum pump Repair or replace the generator or
vacuum pump

Symptom: There is an Abnormal Tapping Sound

There is an abnormal tapping sound Improper adjustment of valve clearance Adjust the valve clearance
(make sure to inspect and confirm after Damage of the rocker arm Replace the rocker arm
completely warming up the engine)
Wear or damage of the crankshaft and Replace the crankshaft and related
related parts (journal bearing, thrust parts
bearing, connecting rod bearing)
Wear or locking of the connecting rod Replace the connecting rod bushing
bushing and piston and piston
Wear or locking of the piston and Replace the piston and cylinder liner
cylinder liner

Symptom: There is a Gas Leak

There is a gas leak Defective connection or damage of the Reconnect the rigid fuel line. Or,
rigid fuel line replace the rigid fuel line
Defective Pressure regulator Replace the Pressure regulator
Improper tightening or damage of the Tighten or replace the intake manifold
intake manifold
Malfunction of ignition system Refer to "Engine Control System" in
(4HV1-CNG)
Defective catalyst Replace the catalyst
Primary Specifications
Engine type 4HV1-CNG

Total displacement L(cu.in) 4.570 (278.9)
Type 4-cycle, water-cooled inline 4 cylinders
Fuel used Natural gas for automobile
Fuel ignition system Spark ignition system (otto cycle)
Shape of combustion chamber Hemispherical
Valve mechanism OHC, gear-driven
Inner diameter x stroke mm(in) 115 x 110 (4.53 x 4.33)
Compression ratio 12.5
Dimensions mm(in) 847 x 656 x 752 (33.35 x 25.85 x 29.61)
Maintenance weight kg(lb) 365 (805)
No-load revolution speed r/min 650
Lubricating method Force feed method
Type of oil pump, oil filter Gear type, full-flow filter, partial-flow filter combination
Lubricant capacity [reference value] L(lmp⋅gal) 10.5 (2.31)
Oil cooler type Built-in type, water cooled
Cooling method Water cooling
Water pump type Centrifugal type (driven by V belt)
Coolant capacity [reference value] L(lmp⋅gal) 12 (2.64) (including radiator)
Opening BTDC 18°
Intake
Closing ABDC 50°
Valve timing
Opening BBDC 51°
Exhaust
Closing ATDC 17°
Intake (while cool) mm(in) 0.4 (0.016)
Valve clearance
Exhaust (while cool) mm(in) 0.4 (0.016)
Ignition method Full transistor method battery ignition
Ignition timing BTDC° / r/min 12 / 650
Ignition order 1-3-4-2
Spark plug DENSO GX8-1

Plug gap mm(in) 0.7 - 0.8 (0.028 - 0.031)
Spark advancer Electronic type
Fuel supply device, method Multipoint injection (MPI)
Air cleaner type Filter paper type (dry)
Type Alternating current type
Generator Output (V-A) 24 - 60, 24 - 80
Pressure regulator type IC type
Type Reduction type
Starter
Output (V - kW) 24 - 4.5

Special Tool
Illustration Tool Number/ Description Illustration Tool Number/ Description
Tech2 5-8840-2222-0
Scan tool Sealing cup installer
5884022220
5-8840-2230-0 5-8840-0266-0
Crankshaft stopper Angle gauge
5884022300
5-8840-2228-0 5-8840-2360-0
Valve spring compressor Slinger puller
5884022280
8-9439-6815-0 5-8840-2703-0
Valve stem seal installer Oil seal installer kit
8943968150 5884027030
5-8840-2674-1 5-8840-2340-0
Scissors gear spring Connecting rod bushing
wrench replacer
5884026741 5884023400
5-8840-2227-0 8-9439-6818-0
Valve guide replacer Crankshaft gear puller
5884022270 8943968180
Illustration Tool Number/ Description
8-9439-6819-0
Crankshaft gear installer
5-8840-2675-0
Compression gauge
5884026750
5-8840-2878-0
Adaptor
5884028780
5-8840-2862-0
Universal holder
5884028620
1-8522-1097-0
Oil filter wrench
1852210970
Engine Assembly
Removal 6. Remove the flexible fuel line.
except Australia
1. Drain the coolant.
2. Disconnect the starter ground cable.
• Disconnect the front frame harness connector
near the transmission control box and remove
each of the clips fastening the harness.
• Remove the 2 bolts (upper and lower) attached
to the starter, and remove the starter from the
clutch housing.
• Fasten with a wire etc. to a position where it will
not interfere with the removal of the
transmission.
3. Remove the transmission.
• Refer to "Transmission Assembly" in Section
5C, Manual Transmission for details on M/T
vehicles.
Refer to "Smoother Transmission ASM" in
Section 5B, Automatic Transmission for details LNW91BSH004001
on Smoother vehicles.
for Australia
4. Remove the air intake hose.
5. Remove the heater hose.
• Remove the heater hoses at the engine side.
LNW61BSH003301
LNW61BSH001401 7. Remove the radiator upper hose.

• Remove the upper hose at the engine side.
8. Remove the reserve tank hose.
• Remove the reserve tank hose at the radiator
side.
1 2 3
LNW71BSH011001 LNW91BSH004901
9. Remove the radiator lower hose at the engine side. Legend

1. Frame side bracket
2. Radiator side bracket
3. Radiator
11. Remove the fan assembly.

• Remove the 4 installation nuts to remove the
fan assembly.
LNW91BSH005101
10. Remove the radiator.

• Remove the brackets on the left and right sides
of the radiator to remove the radiator.
LNW21BSH012201
12. Disconnect the front exhaust pipe.

• Disconnect the parking brake cable and the A/F
sensor connector, and disconnect the front
exhaust pipe from the exhaust manifold side
and the exhaust throttle side.
13. Remove the power steering pump.
• Remove the power steering pump from the
engine side together with the bracket and
fasten it to any suitable position together with
the hoses using a wire, etc. at the same time.

14. A/C compressor
• Remove the A/C compressor drive belt.
• Remove the compressor from the A/C
compressor bracket and fasten it to any
suitable position together with the hoses using
a wire, etc.
15. Vacuum hose
• Remove the hose at the vacuum pump side.
16. Disconnect the connectors and clips of the engine
harness with the ECM, EDU and frame harness.
17. Engine mount
• Before removing the engine mount, use the
hoist to suspend the engine.
• Remove the mounting bolts on the chassis
frame side of the engine mount.
18. Engine assembly LNW71BSH005601
• Slowly operate the hoist to raise the engine
above the surface of the chassis frame.
• Turn the engine 90° and move it from the Installation
chassis frame top surface to remove the engine 1. Install the engine assembly.
assembly.
• Install the hoist wire to the engine hanger and
hoist to lift the engine.
• Operate the hoist to move the engine to the
installation position.
LNW71BSH005501
LNW71BSH005601
• Turn the engine 90° and slowly lower it to the

engine installation position.

• At this time, lower the transmission side and • Install the A/C compressor as shown in the
slowly operate the hoist while pulling the engine diagram and tighten it at the specified torque.
rearward.
LNW71BSH005501
LNW71ESH001501
2. Install the engine mount. • Install the drive belt and adjust its tension using
• Align and install the engine mount to the hole in the adjust bolt of the tension pulley.
the engine mounting cross member, and tighten • Refer to "Drive Belt" in Section 1C, Cooling
it at the specified torque. System (4HV1-CNG) for details on the belt
tension adjustment.
3. Connect the connectors and clips of the engine
harness with the ECM, EDU and frame harness.
4. Install the vacuum hose.
• Install the vacuum hose to the vacuum pump
side.
LNW71BSH006001
6. Install the power steering pump and tighten it at

2 the specified torque.
Flywheel mounting bolt (1)
LNW41ESH000101
Cylinder block mounting bolt (2)

5. Install the A/C compressor. Tightening torque: 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)

Without HBB
LNW61BSH001801
LNW41BSH001501
Legend
1. Flywheel housing section bolt 8. Install the fan assembly.
2. Cylinder block section bolt • Install the fan assembly and tighten it at the
With HBB specified torque.
2
LNW46ASH000801
Legend
1. Flywheel housing section bolt LNW21BSH012201
2. Cylinder block section bolt
9. Install the radiator.

• Install the left and right bracket sections of the
7. Front exhaust pipe
radiator to the frame side bracket as shown in
• Install the front exhaust pipe and tighten it at the diagram.
the specified torque.
Radiator side bracket from frame side bracket
Exhaust manifold side Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
• When removed a frame side bracket, tighten it
Exhaust throttle side by the following torque.
Frame side bracket from frame
Bracket side surface Tightening torque: 55 N⋅m (5.6 kg⋅m/41 lb⋅ft)
2
1 2 3
Legend
2. Radiator side bracket 13. Install the flexible fuel line.
3. Radiator • Make sure that there are no damage or dirt on
the O-ring that is attached to the flexible fuel
10. Install the radiator lower hose. line.
Tightening torque: 5 N⋅m (0.5 kg⋅m/43 lb⋅in) • If there is damage on the O-ring, replace it with
a new O-ring.
• Apply a thin coat of engine oil to the O-ring and
tighten the bolt at the specified torque.
Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
except Australia
LNW91BSH005101
11. Install the reserve tank hose (1).

12. Install the radiator upper hose (2).
LNW91BSH004001

for Australia • Install the starter to the clutch housing with
bolts, and tighten them at the specified torque.
LNW61BSH003301
14. Install the heater hose.

LNW21BSH011601
• Install the hose so that it is not twisted.
18. Connect the front frame harness connector.

19. Refill the coolant.
• Refer to "Cooling System" in Section 1C,
Cooling System (4HV1-CNG).
LNW61BSH001401
15. Install the air intake hose.

Tightening torque: 6.4 N⋅m (0.64 kg⋅m/56 lb⋅in)
NOTE:
Use a new clamp.
16. Install the transmission assembly.

vehicles.
Section 5B, Automatic Transmission for details
on Smoother vehicles.
17. Install the starter.
Engine Mount
Components
LNW71BMF004601
Legend
1. Engine mount 2. Heat protector (NLR,NMR model)
Removal a. Before removing the engine mount, use a hoist

to suspend the engine.
1. Remove the engine mount.
LNW61BSH002701
b. Remove the installation nuts on the chassis


c. Remove the nuts installing the engine foot and NOTE:
engine mount. • A heat protector is assembled to the engine mount
at the right side of NMR vehicles.
Installation
1. Install the engine mount and tighten it at the
specified torque.
Engine foot side nuts
Engine foot side bolts

Chassis frame side nuts

2. After installation, crank the engine to verify
whether there are any abnormalities in the engine
LNW21BSH005501 mount.
d. Slightly raise the engine assembly to remove
the engine mount.
List of Tightening Torques
c
b
LNW71BMF004701
(a) 106 N⋅m (10.8 kg⋅m/78 lb⋅ft)

(b) 51 N⋅m (5.2 kg⋅m/38 lb⋅ft)
(c) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
Cylinder Head Cover

Components
6
3
LNW71BLF004001
Legend
1. Intake duct (NMR,NPR model) 5. Head cover gasket
2. Ignition coil assembly 6. Cylinder head cover
3. Ignition coil bracket 7. Harness bracket (NLR model)
4. Rubber plug 8. Intake duct bracket (NMR,NPR model)

Removal 10. Remove the rubber plugs.
1. Disconnect the ignition coil connector. NOTE:
Do not remove the rubber plugs when there is no need
for removal.
Installation
1. Install the rubber plugs.
• Apply liquid gasket (TB1207B or equivalent)
with a bead diameter of 3 mm(0.12 in) onto the
arch of the rubber plugs.
• Install the rubber plugs to the cylinder head,
and apply liquid gasket (TB1207B or
equivalent) with a bead diameter of 3 mm(0.12
in) onto the upper surface of the cylinder head
and the rubber plugs.
• After applying the liquid gasket, install the
cylinder head cover within 5 minutes.
LNW61BSH002801
2. Remove the ignition coil assembly from the spark

plugs (3).
a
CAUTION: b
Do not disassemble the ignition coils (1) and boots (2)
but remove them together as assembly.
a
a
1
2 LNW91BSH004101
Legend
a. 10 mm(0.39 in)
b. 30 mm(1.18 in)
3
2. Install the gasket to the cylinder head cover.

3. Install the cylinder head cover, harness bracket,
intake duct bracket and the ignition coil bracket.
LNW41BSH004901
• Tighten in the order shown in the diagram.
Tightening torque: 18 N⋅m (1.8 kg⋅m/ 13 lb⋅ft)
3. Remove the PCV hose.
4. Remove the ignition coil bracket. NOTE:
The bolts that install the ignition coil bracket, harness
5. Remove the intake duct (NMR,NPR model).
bracket, and intake duct bracket are tightened together
6. Remove the intake duct bracket with the cylinder head cover. Since the lengths of these
(NMR,NPR model). bolts are different from that of other bolts, make sure
7. Remove the harness bracket (NLR model). not to make mistakes in bolt lengths.
8. Remove the cylinder head cover.
9. Remove the head cover gasket.
5 1 3 7
6 2 4 8
LNW61BSH002001
4. Install the intake duct (NMR,NPR model).

5. Install the PCV hose.
6. Install the ignition coil assembly.
• Insert the ignition coil and the plug boot
assembly in the sleeve, push them in
completely, and tighten them at the specified
torque.
CAUTION:
Install the ignition coil and plug boot assembly without
disassembling them. Disassembly can cause the
danger of poor electric power connection between the
ignition coil and boot.
7. Connect the ignition coil connector.


a
f
e
LNW71BLF004101
(a) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)

(b) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
(c) 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
(d) 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
(e) 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
(f) 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
Intake Manifold
Components
except Australia
2
3 5
4
6
7
13 9 8
10
12
11
LNW91BLF002001
Legend
1. PCV hose 8. Flexible fuel line
2. Air intake hose 9. CNG pressure / temperature sensor
3. Breather hose 10. Intake air temperature (IAT) sensor
4. Intake throttle valve 11. Intake air pressure (MAP) sensor
5. Engine driver unit (EDU) 12. Oil level gauge guide tube
6. Engine control module (ECM) 13. Intake manifold
7. Gas injector connector

for Australia
9 12
10
11
13
6 14
1 2
5
4
LNW61BLF000701
Legend
1. CNG pressure sensor 8. Air intake hose
2. CNG temperature sensor 9. Breather hose
3. Intake air temperature (IAT) sensor 10. Intake throttle valve
4. Intake air pressure (MAP) sensor 11. Engine control module (ECM)
5. Oil level gauge guide tube 12. Engine driver unit (EDU)
6. Inlet manifold 13. Gas injector connector
7. PCV hose 14. Flexible fuel line
Preparatory work 2. Remove the engine control module (ECM) and

• Completely close all manual cylinder valve (at engine driver unit (EDU) together with each
tank). bracket.
• Start the engine to eliminate all fuel gas remaining • Refer to "Engine Control Module (ECM)" and
in the pipes and idle the engine until it stops. When "Engine Driver Unit (EDU)" in Section 1A,
the engine stops, turn the ignition switch OFF. Engine Control System (4HV1-CNG).
3. Remove the PCV hose.
4. Remove the harness connector and mounting bolt
Removal from the intake throttle valve, and remove the
1. Loosen the tightening clamp and remove the air intake throttle valve.
intake hose.

5. Disconnect each connectors of the CNG pressure / 8. Remove the oil level gauge guide tube mounting
temperature sensor (except Australia), CNG bolt, and disconnect the level gauge guide tube.
pressure (for Australia), CNG temperature sensor
(for Australia), intake air temperature (IAT) sensor
and intake air pressure (MAP) sensor. 1
6. Remove the tie wraps (3 locations), and
disconnect the injector connectors (4 locations).
1 2
LNW61BSH003001
Legend
1. Mounting bolt
2. Oil level gauge guide tube
LNW91BSH004201 9. Remove the flexible fuel line.

Legend • Remove the bracket, remove the flexible fuel
1. Connector line mounting bolt, and remove the flexible fuel
2. Tie wrap line from the intake manifold.
7. Disconnect the ground cable at the back side of NOTE:

the second and third gas injectors. There is an O-ring attached to the intake manifold
installation section of the flexible fuel line. Make sure
not to lose the O-ring.
except Australia
LNW61BSH002201
LNW91BSH004001

for Australia • If there is damage on the O-ring, replace it with
a new O-ring.
• Thinly apply engine oil to the O-ring before
installation.
• Install to the intake manifold and tighten it with
a bolt at the specified torque.
• Install the bracket and tighten the bolts.
except Australia
LNW61BSH002301
10. Remove the intake manifold assembly.

• As there are locations where the engine
harness is fixed to the intake manifold with
clips, make sure to completely remove the
engine harness from the intake manifold when
removing the intake manifold assembly.
LNW91BSH004001
Installation for Australia

1. Sandwich the gasket and install the intake
manifold.
7 1 2 5
6 4 3 8
LNW61BSH002301
3. Install the oil level gauge guide tube.

• Make sure that the O-rings are firmly attached
to the lower section of the guide tube. Apply a
thin layer of oil and insert it into the crank case.
Tighten the mounting bolt at the specified
LNW61BSH002401
torque.
2. Install the flexible fuel line.
• There should be no damages or filth on the O-
rings.
1 2
Legend Legend
1. Mounting bolt 1. Connector
2. Oil level gauge guide tube 2. Tie wrap
6. Install the PCV hose.

4. Install the ground cable at the back side of the 7. Install each of the connectors for the CNG
second and third gas injectors. pressure / temperature sensor (except Australia),
CNG pressure (for Australia), CNG temperature
sensor (for Australia), IAT sensor and MAP sensor.
8. Install the intake throttle valve.
• Install the harness connector for the intake
throttle valve.
9. Install the ECM and EDU.
• Refer to "Engine Control Module (ECM)" and
"Engine Driver Unit (EDU)" in Section 1A,
Engine Control System (4HV1-CNG).
10. Install the air intake hose and tighten the tightening
clamp at the specified torque.
NOTE:
LNW61BSH002201
Use a new clamp.
5. Connect the gas injector connectors (4 locations)

and fix the engine harness and the harness for the
gas injector in place using tie wraps (3 locations).
NOTE:
When fixing the harness for the gas injector in place, fix
the tie wraps so that they are on top of the tube.

b c
LNW91BLF001601
(a) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)

(b) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
(c) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
(d) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
(e) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
Exhaust Manifold
Components
2
3
LNW61BLF001101
Legend
1. Gasket 4. Heat protector
2. Exhaust manifold 5. Distance tube
3. Bolt
Removal
1. Remove the A/C compressor drive belt.
2. Remove the A/C compressor.

• Without disconnecting the A/C compressor
hose, remove the compressor from the bracket
and remove the cylinder head from the
compressor bracket.
LNW71ESH001501
LNW61BMH000101
Inspection
Inspect the flatness of the installation surface of the
manifold and cylinder head.
Flatness of the manifold installation mm(in)

Standard value 0.3(0.012) or less
Repair limit 0.5(0.02)
LNW21BSH006301
3. Remove the exhaust pipe.

4. Remove the bolt (3), and remove the heat
protector (4) from the exhaust manifold (2).
5. Remove the exhaust manifold (2).
• Remove 2 nuts and 6 bolts, and remove the
distance tube (5) together with the exhaust
manifold (2).
6. Remove the exhaust manifold gasket (1).
LNW21BSH006601
• Replace if the flatness is beyond the repair limit.


Installation
1. Install the gasket of the exhaust manifold.
• Face the protruding section in the center
towards the outside.
5 3 4 6
1 2 8
7
LNW21BSH063001
3. Install the heat protector.

LNW21BSH062901 • Install the heat protector and tighten it at the
specified torque.
2. Install the exhaust manifold. Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
• Install the distance tube (1), disc spring (2), nut 4. Install the exhaust pipe.
(3), and bolt, in this order, to the stud on the • Tighten the pipe at the specified torque.
cylinder head.
• Exhaust manifold side
5. Install the A/C compressor.
• Install the A/C compressor bracket to the
1 2 cylinder head, and tighten it at the specified
torque.
3
LNW21BSH001701
• Tighten the exhaust manifold in the order

shown in the diagram.
LNW21BSH006301

• Install the A/C compressor to the bracket, and
tighten it at the specified torque.
LNW71ESH001501
6. Install the A/C compressor drive belt.

• Refer to "Drive Belt" in Section 1C, Cooling
System (4HV1-CNG) for details on the belt
tension adjustment.

b
a
LNW71BLF004301
(a) 34 N⋅m (3.5 kg⋅m/25 lb⋅ft)

(b) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
(c) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
Timing Gear Train

Components
14 15
16
17
18
1
7
11 2
5
12 4
3
13 8
9
10
LNW71BMF005201
Legend
1. Power steering pump idle gear 10. Crankshaft position (CKP) sensor
2. Idle gear cover 11. Slinger
3. Clutch pressure plate (M/T vehicles) 12. Oil pump
4. Clutch disk (M/T vehicles) 13. Oil pan
5. Flywheel (M/T vehicles) 14. Cylinder head cover
6. Rear oil seal 15. Idle gear B shaft
7. Flywheel housing 16. Idle gear B
8. Flexible plate (Smoother vehicles) 17. Idle gear A
9. Spacer (Smoother vehicles) 18. Power steering pump
Removal • When removing the flywheel, remove to

prevent interference or damage. This is
sensitive to shocks so do not throw or drop.
• Refer to "Cylinder Head Cover" in this section. 7. Remove the flywheel/flexible plate.
2. Remove the rocker arm shaft assembly . • Install the crankshaft stopper to the installation
• Refer to "Rocker Arm Shaft Assembly " in this section of the flywheel housing starter, and
section. make sure the crankshaft does not rotate.
3. Remove the camshaft assembly . Check that the stopper securely bites into the
• Refer to "Camshaft Assembly " in this section. ring gear and that it is installed.
4. Remove the cylinder head assembly . Special Tool
• Refer to "Cylinder Head" in this section. Crankshaft stopper: 5-8840-2230-0
5. Remove the clutch pressure plate and clutch disk.
6. Remove the crankshaft position (CKP) sensor.

12. Remove the power steering pump idle gear.
LNW21BSH007701
LNW71BSH011901
• Gradually loosen the flywheel mounting bolts in

the order shown in the diagram. 13. Remove the flywheel housing.
• Loosen all of the bolts, remove the stopper, and • Do not forget to remove the bolt indicated by
then remove the flywheel. the arrow in the diagram.
4 7
1 2
6 5
1 3 8
Legend
1. Pilot bearing (M/T vehicles) 14. Remove the idle gear A.
2. Washer
15. Remove the idle gear B.
8. Remove the rear oil seal and slinger.
• Refer to "Crankshaft Rear Oil Seal" in this
section.
9. Remove the oil pan.
11. Remove the power steering pump idle gear cover.

16. Remove the idle gear B shaft.
2. Measurement of the play of the idle gear in the axis
direction
• Insert a thickness gauge into the gap between
the idle gear and thrust collar to measure the
gap.
• Replace the idle gear or thrust collar if the
measured value exceeds the limit.
Play of the idle gear in the axis

direction mm(in)
0.080 - 0.155
Standard value
(0.00315- 0.00610)
Limit 0.20(0.00787)
• Measure the play of the idle gear in the axis

LNW21BSH003201 direction before removing the idle gear B.
Inspection
1. Measurement of idle gear backlash
• Touch the dial gauge to the idle gear tooth to be
measured, and gently move the gear left and
right to read the inconsistency on the dial
gauge. (Always fasten the other connecting
gear.)
• Replace the idle gear if the measured value
exceeds the limit.
Timing gear backlash mm(in)

0.100 - 0.170
Standard value
(0.00393 - 0.00669)
Limit 0.300(0.01181) LNW21BSH003401
• Measure the idle gear backlash before

removing the idle gear A. 3. Outer diameter of the idle gear shaft
• Use a micrometer to measure the outer
diameter of each idle gear shaft.
• Replace the shaft if the measured value
exceeds the limit.
Outer diameter of the idle gear

shaft mm(in)
29.959 - 29.980
Standard value
(1.17949 - 1.18031)
Limit 29.80(1.17323)
LNW21BSH003301

• Tighten the idle gear B shaft at the specified
torque.
• After installing, apply engine oil to the shaft.
LNW21BSH003501
4. Gap between the idle gear and the idle gear shaft
• Measure the inner diameter of the idle gear
bush to calculate the gap between the idle gear LNW21BSH003701
and the idle gear shaft.
• Replace the idle gear or shaft if the measured
value exceeds the limit. 2. Install the idle gear B.
• Install the idle gear B in the direction shown in
the diagram, and tighten the mounting bolt at
Gap between the idle gear
and shaft mm(in)
0.020 - 0.062 Tightening torque: 110 N⋅m (11.2 kg⋅m/81 lb⋅ft)
Standard value
(0.00079 - 0.00244)
Limit 0.200(0.00787)
LNW21BSH003801
Legend
1. Idle gear B
LNW21BSH003601 2. Thrust collar
3. Bolt
Installation
3. Install the idle gear A.
1. Install the idle gear B shaft.
• Rotate the crankshaft in the forward direction to
• Apply Loctite #962T or equivalent to the align the 1st cylinder piston to top dead center.
threaded end of the bolt. (the part of arrow)

• Fit the idle gear shaft at the position shown in • Align the crankshaft gear and idle gear A
the diagram, and apply engine oil to the shaft. alignment marks and install to the cylinder
block.
• Apply the engine oil to the bolt and the both
side of the washer.
• Tighten the mounting bolt at the specified
torque.
LNW21BSH007801
1 2
8 3
0
S 0
5
7 6
LNW61BMF000901
Legend
1. Idle gear C 5. Power steering pump idle gear
2. Camshaft gear 6. Crankshaft gear
3. Idle gear B 7. Oil pump drive gear
4. Power steering pump gear 8. Idle gear A
4. Install the flywheel housing. • As shown in the diagram, uniformly apply liquid
• Clean the back side of the cylinder block gasket (TB1207B or equivalent) to the inside of
thoroughly. In particular, clean the liquid gasket the bolt hole (excluding the bolt hole at the
that oozes out when the crankcase is installed. arrow).
Flywheel housing tightening torque:

N⋅m (kg⋅m/lb⋅ft)
Mark 1 Mark 2 Mark 3
96 (9.8/71) 25 (2.5/18) 38 (3.9/28)
• Tighten Mark 3 from the cylinder block side.
LNW21BSH072401
• Install the flywheel housing by aligning it to the

cylinder block dowel pin.
2
1
1
LNW21BMF008901
• Assemble the idle gear and shaft in the position

5. Install the power steering pump idle gear. shown in the diagram, and tighten at the
specified torque.
• Apply engine oil to the gear assembly sections
of the idle gear shaft. Tightening torque: 134 N⋅m (13.7 kg⋅m/99 lb⋅ft)
7. Install the power steering pump.

Flywheel housing mounting bolt (1)
Cylinder block mounting bolt (2)

Without HBB
LNW21BSH004301
1
6. Install the power steering pump idle gear cover.
• Install the O-ring to the cover, install to the
flywheel housing and tighten the tightening bolt 2
at the specified torque.
LNW41BSH001501
Legend
1. Flywheel housing section bolt
2. Cylinder block installation bolt

With HBB b. Use the flywheel housing, the front cover and
the crankcase stud as a guide to assemble the
gasket (3), and place the oil pan (2) on it.
Next, place the oil pan rubber (1) on the oil pan,
and tighten it with the bolts and nuts.
1
1
2
LNW46ASH000801
Legend
1. Flywheel housing section bolt
8. Install the oil pan.

3 2
a. Apply liquid gasket (TB1207B or equivalent)
with a bead width of 3 mm(0.12 in) to the 1
aligning surfaces of the cylinder block, front
cover and flywheel housing.
LNW21BMH000101
9. Tighten locations (1), (2), (3) and (4) on the oil pan
1 2
LNW21BSH004601
After applying the liquid gasket, install the oil

pan within 5 minutes.
4
3
LNW21BSH013801

• Then, tighten the other bolts and nuts at the
specified torque. (No order of tightening is
specified.)
10. Install the rear slinger and oil seal.

section.
11. Install the flywheel / flexible plate.
• Align with the crankshaft dowel pin, install the
flywheel, and tighten at the specified torque in
the order shown in the diagram.
Tightening torque: M/T vehicles
1st time = 78 N⋅m (8.0 kg⋅m/58 lb⋅ft)
2nd time = 90° - 120°
Tightening torque: Smoother vehicles
2nd time = 120° - 150°
4 7
1 2
6 5
3 8
LNW21BSH072801
12. Install the crankshaft position sensor and tighten

the bolt at the specified torque.
13. Remove the clutch disk and clutch pressure plate.
14. Install the cylinder head assembly.
• Refer to "Cylinder Head" in this section.
15. Install the camshaft assembly.
• Refer to "Camshaft Assembly " in this section.
16. Install the rocker arm shaft assembly.
• Refer to "Rocker Arm Shaft Assembly " in this
section.
17. Install the cylinder head cover.
• Refer to "Cylinder Head Cover" in this section.

a
b
d
c
r f
g k
h i
p j
o
q
m
LNW71BLF004501
Legend
(a) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft) (j) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
(b) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (k) 78 N⋅m (8.0 kg⋅m/58 lb⋅ft) → 90° - 120°
(c) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft) (l) 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
(d) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft) (m) 78 N⋅m (8.0 kg⋅m/58 lb⋅ft) → 120° - 150°
(e) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft) (n) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(f) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft) (o) 110 N⋅m (11.2 kg⋅m/81 lb⋅ft)
(g) 77 N⋅m (7.9 kg⋅m/57 lb⋅ft) (p) 31 N⋅m (3.2 kg⋅m/23 lb⋅ft)
(h) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft) (q) 157 N⋅m (16.0 kg⋅m/116lb⋅ft)
(i) 134 N⋅m (13.7 kg⋅m/99 lb⋅ft) (r) 77 N⋅m (7.9 kg⋅m/57 lb⋅ft)
(j) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
Valve Stem Seal and Valve Spring

Components
10
4
9
8
LNW71BLF005001
Legend
1. Camshaft bearing cap 6. Valve stem oil seal
2. Camshaft bearing 7. Valve spring
3. Camshaft 8. Spring upper seat
4. Rocker arm shaft assembly 9. Split collar
5. Spring lower seat 10. Valve cap
Removal • Compress the valve springs and remove the

split collars using a compressor.
1. Remove the cylinder head.
• Refer to "Cylinder Head" in this section. Special Tool
2. Remove the valve caps. Valve spring compressor: 5-8840-2228-0
• Make sure not to drop the valve cap into the
gear case at the back side of the cylinder head
or into the oil return hole at the front side.
3. Remove the valve springs.

• Remove the special tool and then remove the • Measure the free length of the springs. If it is
upper seats and springs. lower than the specified limit, replace the
Organize the removed valve springs in the spring.
order of the cylinder number.
Free length of valve spring mm(in)
Standard value 62.5(2.461)
Limit 59.4(2.339)
LNW21BSH066701
4. Remove the valve stem oil seals.

• Remove the oil seals using pliers.
NOTE: LNW21BSH017001
Do not reuse the removed oil seals.
2. Degree of perpendicular condition

• Measure the degree of perpendicular condition
with a right-angle gauge. Replace the valve
spring if the measured value exceeds the limit.
Perpendicularity of the valve spring mm(in)

Limit 1.0(0.039)
LNW21BSH066901
5. Remove the spring lower seats.
Inspection
Valve spring inspection
Visually inspect the valve springs and replace them
when damage or abnormal wear is found.
1. Free length
LNW81BSH017101
3. Tension

• Using a spring tester, compress the springs to
the installation height. Measure the
compressed spring tension. If the measured
tension is lower than the limit, replace the
spring.
Valve spring tension

Installed length: 47 mm(1.85 in) N (kg/lb)
Standard value 414 - 477
(42.2 - 48.6/93.0 - 107.0)
Limit 401 (40.9/88.4)
LNW21BSH016601
3. Install the valve springs.

• Install either the side with the paint mark (2) or
the spring's narrower pitch (1) to the lower side
(cylinder head side).
LNW21BSH056701
Installation
1. Install the spring lower seats. 1
2. Install the valve stem oil seals.

• Apply engine oil to the outer circumference of
the valve guide and install the oil seals using
the valve stem seal setting tool. 2
After installing the valve stem oil seals, check that it is
securely inserted all the way in, and that the oil seal is
not inclined or that the garter spring will not come off. 4. Install the spring upper seats.
Special Tool 5. Mount the split collars.
Valve stem seal installer: 8-9439-6815-0 • Using a compressor, compress the valve
springs to install the split collars.
Special Tool
Valve spring compressor: 5-8840-2228-0
6. Install the valve caps.

• Apply engine oil to the inside of the valve caps
and install the valves.

LNW21BSH016201
7. Install the cylinder head.

Rocker Arm Shaft Assembly

Components
3
2
5
1
LNW21BLF000801
Legend
1. Camshaft bracket 4. Rocker arm bracket
2. Rocker arm 5. Valve cap
3. Rocker arm shaft spring 6. Rocker arm shaft
Removal
2. Remove the rocker arm shaft assembly.
• Remove the rocker arm shaft assembly
together with the camshaft bracket.

• The bolt in the diagram is for fastening the • Touch the dial gauge to the center of the shaft
rocker arm shaft and does not need to be and inspect for shaking while rotating the shaft.
removed at this time. • If minor fluctuation is found upon measurement,
correct it using the press (when cooled).
• If the measured value of the fluctuation in the
shaft exceeds the limit, replace the shaft.
Fluctuation of the rocker arm shaft mm(in)

Limit 0.6(0.024)
LNW21BSH066601

Disassembly
1. Remove the camshaft bracket.
2. Remove the rocker arm. LNW21BSH056601
3. Remove the rocker shaft spring.

4. Remove the rocker arm bracket. 2. Inspect the rocker arm shaft for wear.
5. Remove the camshaft bracket. • Use a micrometer to measure the rocker arm
6. Inspect for clogging in the oil hole of the camshaft sliding section at 8 places.
bracket (rear side). • Replace the shaft if the measured value is
under the limit.
Outer diameter of the rocker arm shaft mm(in)

22.0
Standard value
(0.866)
21.85
Limit
(0.860)
LNW21BSH018901
Inspection
1. Inspect the fluctuation of the rocker arm shaft.
• Set the rocker arm shaft on the V block.

a. Pass materials such as a string through the gap
between the rocker arm and roller, and pull
firmly in the direction of the arrows to measure
the level difference between the rocker arm and
roller with the roller raised. Diagram-1
b. After placing a mark at the measurement point,
pull out the string and measure the level of the
mark position with the roller pushed all the way
in. Diagram-2
c. The difference in dimensions measured at a.
and at b. is the gap between the roller and the
rocker arm pin. Replace the rocker arm if the
gap exceeds the limit.
Gap between the roller and rocker arm

pin mm(in)
LNW21BSH019101 0.040 - 0.084
Standard value
(0.00157 - 0.00331)
3. Inspect the gap between the rocker arm and rocker Limit 0.2(0.008)
arm shaft.
• Use a cylinder gauge to measure the inner
diameter of the rocker arm bush and measure
the gap with the shaft outer diameter.
• Replace the rocker arm and shaft if the
Gap between
rocker arm and rocker arm
shaft mm(in)
0.010 - 0.056
Standard value
(0.00039 - 0.00220)
Limit 0.2(0.008)
1 2
LNW21BSH019301
LNW21BSH019201
4. Inspect the gap between the rocker arm roller and

rocker arm pin.

Reassembly • Insert the turn stopper of the spring securely
into the rocker arm hole.
1. Install the camshaft bracket to one side of the
rocker arm shaft. At this time, temporarily tighten
the bracket. After installing the rocker arm shaft
assembly to the cylinder head, tighten the bracket.
LNW21BSH019701
4. Install the rocker arm bracket.

LNW21BSH033101
• Be careful of the direction of bracket assembly,
and assemble the bracket to the rocker arm
shaft.
2. Install the rocker arm.

• Apply engine oil to the inner diameter of the
rocker arm and to the rocker arm pin, and then
install to the rocker arm shaft.
LNW21BSH019601
5. Install the camshaft bracket.
LNW21BSH019801
3. Install the rocker arm shaft spring.


• Install the camshaft bracket to the rocker arm • Slightly loosen the bolt indicated by the arrow to
shaft. At this time, temporarily tighten the make installation easier.
bracket. After installing the rocker arm shaft
assembly to the cylinder head, tighten the
bracket.
LNW21BSH066601
LNW21BSH019501
• Apply engine oil to the threaded portion of the
bolts marked (1) and the nuts marked (2) in the
diagram.
Installation
Tightening torque: N⋅m(kg⋅m/lb⋅ft)
• If the valve cap falls off, apply engine oil to the
inside of the valve cap and assemble it to the Bolt (1) Nut (2) Bolt (3)
valve. 56 (5.7/41) 27 (2.8/20) 27 (2.8/20)
1 1 1
2 2
2 2
3 3
3 3
LNW21BSH016301
LNW21BSH016201
2. Adjust the valve clearance.
• Loosen the rocker arm adjust screw, apply • Refer to "Cylinder Head Cover" in this section.
engine oil to the rocker arm roller, and then
install to the cylinder head.

LNW71BMF002201
(a) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)

(b) 56 N⋅m (5.7 kg⋅m/41 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(d) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Camshaft Position (CMP) Sensor

Removal
1. Disconnect the negative terminal of the battery
cable.
2. Disconnect the harness connector of the CMP
sensor.
3. Remove the mounting bolt from the CMP sensor,
and remove the CMP sensor. 1
LNW61ASH002101
Legend
1. CMP sensor
2. Connect the harness connector of the CMP

sensor.
3. Connect the negative terminal of the battery cable.
LNW61ASH002101
Legend
1. CMP sensor
Inspection
1. Inspect the sensor for attachment of foreign
matter.
2. If foreign matter is found, clean the sensor.
Installation
1. Install the CMP sensor, and tighten the mounting
bolt of the CMP sensor.
Camshaft Assembly
Components
3
4
5
6
7
8
LNW91BLF002501
Legend
1. Bearing cap 5. Wave washer
2. Bearing 6. Sub gear
3. Dowel pin 7. Spring
4. Snap ring 8. Camshaft gear
Removal 6. Remove the bearing lower.

1. Remove the cylinder head cover. NOTE:
• Refer to "Cylinder Head Cover" in this section. Organize the removed bearings according to the
2. Remove the rocker arm shaft assembly. cylinders using tags, etc.
• Refer to "Rocker Arm Shaft Assembly" in this
section.
3. Remove the camshaft bearing cap.
4. Remove the bearing upper.
5. Remove the camshaft assembly.
1 2 3 4 5
Legend
1. Snap ring
Disassembly 2. Wave washer
1. Remove the sub gear. 3. Sub gear
• Fix the camshaft in a vise, and use snap ring 4. Spring
pliers to remove the sub gear. 5. Camshaft gear
NOTE: 2. Remove the camshaft gear.

Make sure not to damage the cam or the journal • Remove the camshaft gear mounting bolt,
sections of the camshaft. sandwich a wood piece (1) in the puller and
remove the camshaft gear.
LNW21BSH053801
LNW71BSH012601
3. Remove the dowel pin.
Inspection
1. Visually inspect the camshaft.
• Inspect the camshaft journal section and cam
section for wear and damage. Replace if there
are any abnormalities.
3. Inspect the cam lobe for wear.

• Use a micrometer to measure the height of the
cam lobe.
• Replace the camshaft if the cam lobe height is
below the limit.
Cam lobe height mm(in)

Standard value 52.8(2.078)
Limit 51.8(2.039)
LNW21BSH020201
2. Inspect the play of the camshaft in the axis

direction.
• Measure the gap between the camshaft gear
and camshaft bracket in the axis direction using
a thickness gauge.
• Replace the camshaft gear or camshaft if the
Play of the camshaft in the axis

direction mm(in) LNW21BSH020401
0.085 - 0.205
Standard value
(0.00335 - 0.00807) 4. Inspect the camshaft journal for wear.
Limit 0.25(0.0098) • Measure the diameter and uneven wear of the
camshaft journal using a micrometer.
NOTE: • Replace the camshaft if the diameter or uneven
Measure the clearance of the camshaft in the axis wear exceeds the limit.
direction prior to disassembly.
Outer diameter of the camshaft journal
section mm(in)
39.950 - 39.975
Standard value
(1.57283 - 1.57382)
Limit 39.850(1.56889)
Disproportionate wear of the

camshaft journal section mm(in)
Limit 0.05(0.0020)
LNW21BSH020301

b. Read the difference of the inner diameter of the
camshaft bearing and diameter of the camshaft
journal.
Replace the camshaft bearing if the measured
oil clearance exceeds the limit.
Gap of journal section mm(in)

0.025 - 0.087
Standard value
(0.00098 - 0.00343)
Limit 0.15(0.00591)
LNW21BSH020501
5. Inspect the fluctuation of the camshaft.

• Place the camshaft on the V block and
measure the fluctuation using the dial gauge.
• Slowly rotate the camshaft to measure
fluctuation of the dial indicator. Replace the
camshaft if the fluctuation exceeds the limit.
Fluctuation of the camshaft mm(in)

Limit 0.05(0.0020)
LNW21BSH054601
Reassembly
1. Install the dowel pin.
2. Install the camshaft gear.
• Fix the camshaft in a vise, put the side of the
camshaft gear center boss that is projected to
the camshaft side, and align it with the dowel
pin. Then, install the camshaft gear.
NOTE:
When tightening the gear, be careful not to damage the
camshaft cam or journal.
LNW21BSH020601
6. Measure the camshaft journal oil clearance.

a. Measure the inner diameter of the camshaft
bearing using the cylinder gauge.

• Use snap ring pliers to securely assemble the
snap ring and wave washer.
LNW21BSH020301
LNW21BSH053801
3. Install the sub gear. • In order to ensure that the spring force that acts
• Assemble the spring by attaching the left end of on the sub gear may not affect, before installing
the spring (4) to the pin of the camshaft gear (5) the camshaft to the cylinder head, use a special
so as to create a gap on the right. tool to rotate the sub gear. Then, align the hole
• Assemble the sub gear (3) by making it so that of the sub gear with the camshaft gear, and
the pin of the sub gear (3) fits into the gap install the alignment pin from the sub gear side
between the right side of the pin of the so that the teeth match.
camshaft main gear (5) and the right end of the
spring (4). Special Tool
Scissors gear spring wrench: 5-8840-2674-1
1 2 3 4 5
LNW21BSH053901
Legend LNW71BSH010401
1. Snap ring
2. Wave washer
3. Sub gear
4. Spring
5. Camshaft gear

Installation • Face the front mark on the bearing cap to the
engine front side, and assemble in the order of
1. Rotate the crankshaft in the forward direction to
the numbers to the cylinder head.
align the 1st cylinder piston to compression top
dead center.
LNW21BSH015901
LNW21BSH015701
• Apply engine oil to the threaded portion, and

tighten the bearing cap at the specified torque.
2. Install the camshaft bearing lower.
• Apply engine oil to the camshaft bearing lower Tightening torque: 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
and assemble to the cylinder head.
• Assemble the camshaft assembly so that the
"•" mark on the camshaft gear end aligns with
the top surface of the cylinder head.
LNW21BSH016001
• Pull out the alignment pin (1) cautiously so as

not to drop it into the engine.
LNW71BSH011601
4. Install the bearing upper.

5. Install the bearing cap.
• Apply engine oil to the bearing upper.
LNW71BSH010501

section.

LNW91BLF002601
(a) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m20 lb⋅ft)
(c) 142 N⋅m (14.5 kg⋅m/105 lb⋅ft)
Cylinder Head
Components
1
2
3
4
16 5
17 6
7 9
8
10
14
15
11
12
13
LNW71BMF005301
Legend
1. Valve cap 10. Engine hanger rear
2. Split collar 11. Intake and exhaust valves
3. Spring upper seat 12. Cylinder head
4. Valve spring 13. A/C compressor bracket
5. Valve stem oil seal 14. Engine hanger front
6. Spring lower seat 15. Thermostat
7. Valve guide 16. Water outlet pipe
8. Idle gear C 17. Spark plug
9. Idle gear C cover
Preparatory work 4. Remove the A/C compressor drive belt.

• Completely close all manual cylinder valve (at 5. Remove the A/C compressor.
tank) .
• Start the engine to eliminate all fuel gas remaining
in the pipes and idle the engine until it stops. When
the engine stops, turn the ignition switch OFF.
Removal
2. Remove the intake manifold.
• Refer to "Intake Manifold" in this section.
3. Remove the exhaust pipe.
• Refer to "Exhaust Pipe" in Section 1G, Exhaust
System (4HV1-CNG).

• Disconnect the A/C compressor harness • Refer to "Rocker Arm Shaft Assembly" in this
connector and remove the compressor from the section.
A/C compressor bracket. Fasten to any suitable 12. Remove the camshaft assembly.
position together with the hoses using a wire,
• Refer to "Camshaft Assembly" in this section.
etc.
13. Remove the cylinder head assembly.
• Evenly loosen the cylinder head bolts in the
order shown in the diagram.
NOTE:
(1) and (2) are tightened to the flywheel housing by
M10 bolts, so do not overlook them.
• Remove the cylinder head gasket.
NOTE:
Replace the removed head gasket with a new one.
LNW71ESH001501
7 15 18 10
6. Separate the radiator upper hose and the lower 3 11 19 14 6 2
hose from the engine side.
1
7. Remove the water bypass hose. 4 12 20 13 5
• Separate the water bypass hose from the
8 16 17 9
cylinder head.
LNW21BSH002301
Disassembly
1. Remove the A/C compressor bracket and the
engine hanger front.
• Remove the bolts and then remove the bracket.
LNW21BSH008501

9. Remove the rubber plugs.
• Carefully remove the fluid gasket.
10. Remove the spark plug.

6. Remove the thermostat.
LNW71BSH012401
LNW21BSH068401
2. Remove the bolt (3), and remove the heat

protector (4) from the exhaust manifold (2). 7. Remove the idle gear C cover.
3. Remove the exhaust manifold (2) together with the • As shown in the diagram, lightly tap the sealing
distance tube (5). cap outer circumference with the tip of the
4. Remove the exhaust gasket (1). driver, then turn the sealing cap over and pull it
out using pliers.
LNW21BSH054701
5
LNW61BMH000101
5. Remove the water outlet pipe.


8. Remove the idle gear C. 10. Remove the engine hanger rear.
1 2
4
3
Legend 11. Remove the split collars.

1. Idle gear C 12. Remove the spring upper seats.
2. Idle gear shaft
13. Remove the valve springs.
3. Thrust collar
4. Bolt • Compress the valve springs using a valve
spring compressor, and then remove the split
9. Remove the valve caps. collars.
• Make sure not to drop the valve caps into the Special Tool
• Remove the special tool and then remove the
upper seats and springs.
• Organize the removed valve springs in the
order of the cylinder number.
LNW21BSH016201
LNW21BSH066701
14. Remove the inlet and exhaust valves.

• Organize the removed valves by the cylinders
using tags, etc.
15. Remove the valve stem oil seals. 18. Removal of the valve seat
• Remove the oil seals using pliers. • Arc weld the entire inner circumference (1) of
the valve seat (3).
• Cool the valve seat for 2 to 3 minutes. Cooling
makes it easier to remove the valve seat due to
contraction.
• Remove the valve seat using a screwdriver (4).
At this time, be careful not to damage the
cylinder head (2).
3 4
LNW21BSH066901
16. Remove the spring lower seats. 1

17. Remove the valve guides.
2
• Use the valve guide replacer to tap the valve
guides out from the lower side of the cylinder
LNW21BSH068201
head.
Special Tool Inspection

Valve guide replacer: 5-8840-2227-0 1. Inspect the valve guides.
NOTE:
If there are scratches or abnormal wear on the inner
diameter of the valve stem or valve guide, replace it
together with the valve guide.
a. Measure the valve guide clearance.


• Measure the diameter of the valve stem
using the micrometer.
If the diameter of the valve stem is smaller
than the limit, replace the valve and valve
guide together.
Outer diameter of the valve stem mm(in) 1
Standard value Limit a

8.946 - 8.961 8.88
Inlet valve
(0.35220 - 0.35279) (0.3496)
2
8.921 - 8.936 8.80
Exhaust valve
(0.3122 - 0.35180) (0.3465)
BLW51BSH005801
2. Inspect the valve caps for wear.

• Use a dial gauge to measure the contact
surface of the valve cap with the rocker arm.
• Replace the valve cap if wear exceeds the limit
or if there is abnormal wear (band-shaped
wear).
Wear of the valve cap mm(in)

Limit 0.1(0.004)
HCW31BSH039101
• Use a dial indicator to measure the gap

between the valve guide(2) and valve
stem(1) within a range of 10 mm(0.39 in)(a)
from the valve guide.
• Replace the valve and valve guide together
as a set if the measured value exceeds the
limit.
Gap between the valve guide and valve

stem mm(in)
Standard value Limit
0.038 - 0.071 0.20
Inlet valve
(0.00150 - 0.00280) (0.0079) LNW21BSH019401
0.064 - 0.096 0.25

Exhaust valve
(0.00252 - 0.00378) (0.0098) 3. Inspect the valve.
• Measure the thickness of the valve.
• Replace the valve and valve guide together as
a set if the measured value exceeds the limit.

5. Inspect the cylinder head.
Valve thickness mm(in) • Completely remove the varnish-like matter and
soot on the metal surfaces. Use a metal brush
Standard value Limit for the gasket installation surfaces. Be careful
1.88 1.3 not to scratch the seal surface.
Inlet valve
(0.0740) (0.051) • If the cylinder head seal surface is leaking,
corroded or blown out, and the gasket is
1.75 1.3
Exhaust valve defective, check the following possible causes.
(0.0689) (0.051)
- Improper installation
- Improper cylinder head tightening
- Warping of the cylinder block seal
• Investigate damage on the threaded surface
caused by excessive torque and cylinder head
bolts that may have been stretched out.
Replace dubious bolts.
6. Inspect the combustion chamber and spark plug
holes.
1 • Inspect for cracks in the cylinder head of the
2
exhaust port and between the valve seats.
Replace the cylinder head if there are
significant damages or cracks. Perform a color
check as necessary.
HCW31BSH040101
Legend
1. Contact width
2. Thickness
4. Inspect the contract surface of the valve seat.

• If the contact surface of the valve seat is
defective, repair it, or replace the valve, valve
guide and valve seat together as a set.
Contact surface angle: 45°
LNW21BSH021401
7. Inspect the flatness of the cylinder head bottom

surface.
• As shown in the diagram, measure the four
sides and diagonal line with a simple straight
ruler and thickness gauge. Replace if the limit is
exceeded.
Deformation on the bottom surface

of the cylinder head mm(in)
0.05(0.0020)
Standard value
or less
LNW41ESH000201
Limit 0.2(0.008)

9. Inspect the flatness of the exhaust manifold.
• Measure the flatness using a simple straight
ruler and thickness gauge. Replace the exhaust
manifold if the limit is exceeded.
Deformation of the exhaust manifold mm(in)

0.3(0.012)
Standard value
or less
Limit 0.5(0.020)
LNW21BSH021501
8. Inspect the flatness of the installation surface of

the exhaust manifold and inlet cover.
• Measure flatness using a simple straight ruler
and thickness gauge. Replace if the limit is
exceeded.
Deformation on the installation surface of the

manifold and cover.
LNW21BSH001601
mm(in)
0.05(0.0020)
Standard value
or less 10. Inspect the valve seat surface.
Limit 0.2(0.008) • Install the valve to the cylinder head.
Use a depth gauge or simple straight ruler to
measure the sinking amount of the valve from
the bottom surface of the cylinder head.
Replace the valve insert or cylinder head
assembly if it exceeds the limit.
Sinking amount of the valve mm(in)

IN 0.9(0.035) 2.3(0.091)
EX 1.4(0.055) 2.8(0.110)
LNW21BSH021601

NOTE:
Do not apply excessive pressure with the press.
Add compound to the valve seat surface and gently tap
the valve while turning it to check that it is touching
evenly around the entire circumference.
LNW91BSH009501
• Measure the contact width of the valve seat.

Repair or replace if the seat contact surface is
damaged or rough, or if the wear of the contact
surface exceeds the limit.
LNW21BSH018601
Contact width of the valve seat mm(in)

Standard value 2. Repair the seat surface.
• Remove carbon from the valve seat surface.
Intake valve 3.1(0.122)
• Use a seat cutter to minimize the scratches and
Exhaust valve 2.7(0.106) other uneven parts, and restore the contact
width to the standard value.
Legend
1. 89°30'
Reassembly
1. Installation of the valve seat NOTE:
• Place the dolly block (1) (smaller outer diameter Get rid of only the scratches and uneven sections, and
than the valve seat) over the valve seat (2). be careful not to over-cut.
• Use the press (3) to gradually apply pressure to Use an adjustable valve cutter pilot.
the dolly block and push in the valve seat. Do not allow the valve cutter pilot to shake inside the
valve guide.

NOTE:
When replacing the valve guides, replace as a set with
the valve.
LNW21BSH018301
• Add compound to the valve seat and insert the

LNW21BSH018701
valve in the valve guide.
• Gently tap the valve while turning it to check Height from the upper surface of the cylinder head
that it is touching evenly around the entire to the end surface of the valve guide (a): 13.9 mm
circumference. to 14.3 mm(0.547 to 0.563 in)
NOTE:
After fitting, remove all of the compound.
LNW71BSH001701
LNW21BSH018401 4. Install the spring lower seats.

5. Install the valve stem oil seals.
• Apply engine oil to the outer circumference of
3. Install the valve guides. the valve guides and install the oil seals using
• Use the valve guide replacer to tap the valve the valve stem seal setting tool.
guides in from the upper surface side of the Special Tool
cylinder head.
Valve stem seal installer: 8-9439-6815-0
Special Tool
Valve guide replacer: 5-8840-2227-0

NOTE:
After installing the valve stem seals, check that they are
securely inserted all the way in, and that the oil seals
are not inclined or that the garter spring will not come
off.
LNW21BSH016701
8. Install the spring upper seats.

9. Install the split collars.
LNW21BSH016601 • Using a valve spring compressor, compress the
valve springs and install the split collars.
Special Tool
6. Install the inlet and exhaust valves.
• Apply engine oil to the valve stems and install
the valves.
LNW21BSH066701
LNW21BSH018801
NOTE:
After installing the split collars, lightly tap the valve stem
heads with a rubber hammer to stabilize the split
7. Install the valve springs. collars.
• Install either the side with the paint mark (2) or
the spring's narrower pitch (1) to the lower side
(cylinder head side).
Paint mark = yellow
10. Install the valve caps. 12. Install the idle gear C.
• Apply engine oil to the inside of the valve caps • Apply engine oil to the inner diameter of the idle
and install the valves. gear and the idle gear shaft, and install so that
• Make sure not to drop the valve caps into the the side of the gear with the grooves is at the
gear case at the back side of the cylinder head back surface of the engine.
or into the oil return hole at the front side. • Apply engine oil to both surfaces of the thrust
collar, apply molybdenum to the threaded
portion of the bolt and seat surface, and then
assemble.
• Tighten the bolt at the specified torque.
NOTE:
Make sure not to use an impact wrench.
LNW21BSH016201
11. Install the engine hanger rear, and tighten it at the

specified torque.
1 2
4
3
Legend
1. Idle gear C
2. Idle gear shaft 15. Install the water outlet pipe.
3. Thrust collar • Tighten the water outlet pipe at the specified
4. Bolt torque.
13. Install the idle gear C cover. Tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
• Apply liquid gasket (Loctite 262 or equivalent)
to the outer circumference of the idle gear C
cover, and then use the sealing cup setting tool
to tap in to the dimensions(a :1.5 - 2.5 mm
(0.059 - 0.098 in)) shown in the diagram.
Special Tool
Sealing cup installer: 5-8840-2222-0
a
LNW21BSH022001
16. Install the exhaust gasket.

17. Install the exhaust manifold.
• Install the distance tubes (1), disc spring (2)
and nut (3) in this order to the stud on the
MFW81BSH000901 cylinder head.
• Assemble the distance tubes in such a way that
the one with the larger diameter is facing the
14. Install the thermostat. manifold side.
• Install the gasket to the thermostat (1), and • Make sure that the distance tubes do not ride
install it to the position shown in the diagram. up on the manifold spot-faces.
1 2
LNW21BSH001701 1 LNW61BSH003201
Legend
1. Bolt
• Tighten the exhaust manifold in the order
shown in the diagram.
Bolts (1), (2), (3), (4), (5), (6) and nuts (7), (8) 19. Install the A/C compressor bracket and the engine
Tightening torque: 34 N⋅m (3.5 kg⋅m/25 lb⋅ft) hanger front, and tighten the bolts at the specified
torque.
NOTE:
In order to prevent expansion and contraction resulting Tightening torque: 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
from the heat of the manifold, do not over-tighten.
5 3 4 6
1 2 8
7
LNW71BSH012401
LNW21BSH063001
Installation
18. Install the heat protector to the exhaust manifold, 1. Install the cylinder head gasket.
and tighten it at the specified torque. • Apply liquid gasket.
• As shown in the diagram, apply liquid gasket
(TB1207B or equivalent) with a bead width of 3
mm(0.12 in) to the aligning surface (1) of the
cylinder block and flywheel housing.

cylinder head within 5 minutes.
LNW21BSH007901
LNW21BSH015501 NOTE:
When installing the head, check to make sure that the
idle gear C is securely meshed.
• Install the cylinder head gasket.
• Set the side of the head gasket marked with the
part number facing upward, and position and
install the cylinder head rear side gear case
and dowel together.
LNW21BSH068601
• Apply molybdenum disulfide to the seat surface

LNW21BSH015601
and threaded portion of the M14 head bolt, and
apply engine oil to the seat surface and
threaded portion of the M10 head bolt.
2. Install the cylinder head assembly. • Tighten the head bolts in the order shown in the
diagram using a torque wrench and angle
• Position with the cylinder block dowel to install gauge.
the cylinder head.
NOTE:
When installing, be careful not to damage the head
gasket.

Head bolt tightening torque: N⋅m (kg⋅m/lb⋅ft) • Refer to "Rocker Arm Shaft Assembly" in this
section.
M14 (1) - (18) 1st time 98(10.0/72)
5. Install the spark plug and tighten it at the specified
2nd time 147(15.0/108) torque.
3rd time 30° - 60°
Use a stud bolt for (16)
M10 (19, 20) 38 (3.9/28) NOTE:
Be cautious when tightening, as over-tightening will
Special Tool result in the spark plug becoming damaged.
In addition, once dropped, spark plugs may be
Angle gauge: 5-8840-0266-0 damaged internally. Do not reuse them and replace
them with new ones.
14 6 3 11
18 10 2 7 15 19
20
17 9 1 8
16
13 5 4 12
LNW21BSH026601
LNW61ESH000701
• Rotate the crankshaft in the forward direction to

align the 1st cylinder piston to compression top
dead center. 6. Install the rubber plugs.
with a bead width of 3 mm(0.12 in) onto the
arch of the rubber plug.
• Install the rubber plug to the cylinder head, and
apply liquid gasket (TB1207B or equivalent)
with a bead diameter Dia of 3 mm(0.12 in) onto
the upper surface of the cylinder head and the
rubber plug.
cylinder head cover within 5 minutes.
LNW21BSH015701


a
b
a
a
LNW91BSH004101
Legend
a. 10 mm(0.39 in)
b. 30 mm(1.18 in)

8. Install the radiator upper hose and lower hose.
LNW71ESH001501
10. Install the exhaust pipe.

• Refer to "Exhaust Pipe" in Section 1G, Exhaust
System (4HV1-CNG).
11. Install the intake manifold.
• Refer to "Intake Manifold" in this section.

LNW71BLF004601
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
(c) 38 N⋅m (3.9 kg⋅m/28 lb⋅ft)
(d) 95 N⋅m (9.7 kg⋅m/70 lb⋅ft)
(e) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(f) 98 N⋅m (10.0 kg⋅m/72 lb⋅ft) → 147 N⋅m (15.0 kg⋅m/108 lb⋅ft) → 30° - 60°
(g) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
Crankshaft Position (CKP) Sensor

Removal Installation
1. Disconnect the negative terminal of the battery 1. Install the CKP sensor, and tighten the CKP sensor
cable. fixing bolt.
2. Disconnect the harness connector of the CKP Tightening torque: 8.0 N⋅m (0.8 kg⋅m/69 lb⋅in)
sensor.
3. Remove the CKP sensor fixing bolts, and then 2. Connect the harness connector of the CKP sensor.
remove the CKP sensor.
NOTE:
Install the CKP sensor harness connector as shown in
the figure below.
1
LNW71BSH015901
1
Legend
1. CKP sensor
Inspection
1. Inspect the sensor for attachment of foreign
matter.
2. If foreign matter is found, clean the sensor.
3. Measure whether the resistance value is within the
range of standard values.
LNW71BMH000401
108 - 143Ω Legend

Standard value 1. Harness connector
(20°C(68°F))
3. Connect the negative terminal of the battery cable.

4. Replace the sensor if the resistance value is not
within the range of standard value.
Flywheel
Components
1
2
3
4
6
7
8
9
LNW71BMF005401
Legend
1. Crankshaft position (CKP) sensor 6. Clutch disk (M/T vehicles)
2. Flywheel housing 7. Pressure plate (M/T vehicles)
3. Flywheel ASM (M/T vehicles) 8. Flexible plate (Smoother vehicles)
4. Washer 9. Crank end spacer (Smoother vehicles)
5. Pilot bearing (M/T vehicles)
Removal
1. Remove the starter.
• Disconnect the starter ground cable.

• Disconnect the front frame harness connector 3. Install the crankshaft stopper to the installation
near the transmission control box and remove section of the flywheel housing starter, and make
each of the clips fastening the harness. sure the crankshaft does not rotate.
Special Tool
Crankshaft stopper: 5-8840-2230-0
LNW21BSH011501
• Remove the 2 bolts (upper and lower) attached

to the starter, and remove the starter from the
LNW21BSH007701
clutch housing.
• Fasten with a wire etc. to a position where it will
4. Remove the clutch pressure plate and clutch disk
transmission.
(M/T vehicles).
• Insert the clutch aligner in the spline of the
clutch disk.
• Remove the pressure plate mounting bolts in
the order of numbers shown in the diagram.
• Remove the pressure plate from the flywheel.
1 5
7
3
9
10
4
LNW21BSH011601 8
2. Remove the transmission assembly.

• Refer to "Transmission Assembly" in Section 6 2
vehicles. LNW21BSH002501
Section 5B, Automatic Transmission
(Smoother) for details on Smoother vehicles.
• Remove the clutch disk from the flywheel
together with the clutch aligner (1).

• Remove the pilot bearing from the flywheel.
LNW21BSH002601
LNW21BSH029301
Legend
1. Clutch aligner Legend
1. Washer
5. Remove the crankshaft position (CKP) sensor. 2. Pilot bearing
• When removing the flywheel, remove to 3. Flywheel
prevent interference or damage.
8. Remove the ring gear from the flywheel.
• This is sensitive to shocks so do not throw or
drop. • Attach a rod to the ring gear and remove it by
tapping with a hammer.
6. Remove the flywheel / flexible plate.
• Gradually loosen the flywheel mounting bolts in
the order of the numbers shown in the diagram
while making sure that the flywheel does not
rotate.
• After loosening all of the bolts, remove the
crankshaft stopper, and then remove the
washer and flywheel.
• For Smoother vehicles, remove the washer,
flexible plate, and spacer, in this order.
4 7
LNW21BSH012001
1 2
6 5 Inspection
3 8 1. Visual inspection
• Inspect the flywheel friction surface for cracks
and damages. Repair or replace if there are
abnormalities.
• Inspect the ring gear tooth surfaces. Replace
LNW21BSH072801
the ring gear if it shows damage or is
significantly worn.
2. Measurement of friction surface
7. Remove the pilot bearing (M/T vehicles).

• Measure the depth of the flywheel friction
surface.
• If the measurement value allows for polishing or
sanding within the standard value and limit
value, proceed to repair.
• Replace the flywheel if the measured value
exceeds the limit.
Flywheel friction surface depth mm(in)

Standard value 19(0.75)
Limit 20(0.79)
Depth = From pressure plate installation

surface to friction surface
LNW21BSH012101
2. Install the flywheel (M/T vehicles).

• Align to the crankshaft dowel pin, and install the
flywheel.
3. Install the spacer (Smoother vehicles).
• Align to the crankshaft knock pin to install the
spacer.
4. Install the flexible plate. (Smoother vehicles)
• Align to the flexible plate to the spacer center
hole and knock pin, and install it.
LNW21BSH011901
Installation
1. Install the ring gear.
• Tap the ring gear onto the flywheel after
uniformly heating it using a gas burner.
• When shrink-fitting the ring gear and cooling,
apply a load of 68.6 kN (7,000 kg/15,435 lb)
and hold evenly.
NOTE:
• Install it with the chamfered side of the ring gear
facing the front.
• After shrink-fitting, check that the ring gear is airtight
against the flywheel.

for Smoother vehicles
5 4
LNW41BMF001701
Legend
1. Flexible plate 4. Spacer
2. Washer 5. Crankshaft
3. Bolt
5. Install the washer.

• Align the washer to the dowel pin to install.
6. Tighten the bolt.
• Install the crankshaft stopper to the starter
installation section of the flywheel housing.
Special Tool
LNW21BSH007701

and threaded portion of the bolt.

• Tighten at the specified torque in the order • Install the clutch disk to the flywheel using the
shown in the diagram. clutch aligner (1).
Tightening torque: M/T vehicles
2nd time = 90° - 120°
Tightening torque: Smoother vehicles

2nd time = 120° - 150°
1
4 7
1 2
LNW21BSH002601
6 5
Legend
3 8 1. Clutch aligner
10. Install the clutch pressure plate.

• Align the pressure plate installation hole to the
dowel pin in the flywheel and install the
pressure plate to the flywheel.
LNW21BSH072801
• Tighten the pressure plate in the order shown in
the diagram.
7. Install the CKP sensor and tighten it at the
specified torque.
8. Tap in the pilot bearing until it touches the crank
end surface. 1 5
9. Install the clutch disc.
7
3
9
10
4
8
6 2
LNW21BSH002501
11. Install the transmission assembly.

vehicles.
Section 5B, Automatic Transmission
(Smoother) for details on Smoother vehicles.

12. Install the starter to the clutch housing with bolts, • Connect the starter ground cable.
and tighten them at the specified torque. • Connect the front frame harness connector.
LNW21BSH011601
LNW21BSH011501
d
a
LNW71BMF003601
(a) 78 N⋅m (8.0 kg⋅m/58 lb⋅ft) → 90° - 120°

(b) 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
(c) 78 N⋅m (8.0 kg⋅m/58 lb⋅ft) → 120 - 150°
(d) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
Front Cover
Components
3
1
10
6
12
11
8
13
9
LNW91BMF001801
Legend
1. Generator 8. Front oil seal
2. Adjust plate 9. Crankshaft pulley
3. Front cover 10. Water pump assembly
4. Oil pan gasket 11. Drive belt
5. Oil pan 12. Water pump pulley
6. Rubber assembly 13. Fan assembly
7. Front slinger
Removal
1. Remove the front oil seal.
• Refer to "Crankshaft Front Oil Seal" in this
section.
• Refer to "Oil Pan" in Section 1H, Lubricant
System (4HV1-CNG).
3. Remove the water pump.
• Refer to "Water Pump" in Section 1C, Cooling
System (4HV1-CNG).
4. Remove the front cover.

• Remove the generator adjust plate (1). • Pull out the oil thermo valve out of the cylinder
block.
LNW91BSH005301
LNW21BSH058601
• Remove the oil relief valve (arrow) and loosen

the front cover mounting bolt to remove the Installation
front cover. 1. Install the oil thermo valve.
• Insert the oil thermo valve into the cylinder
block. At this time, be careful not to make a
mistake in the insertion direction.
NOTE:
Do not remove the rubber cap.
LNW91BSH005401
5. Remove the oil thermo valve.
LNW21BSH070601
2. Install the front cover.

• Clean the cylinder block front side. In particular,
clean the liquid gasket that oozes out when the
crankcase is installed.

• Install the O-rings (2 pcs.) and apply liquid
gaskets (TB1207B or equivalent) to the groove 1 2
on the front cover installation surface.
1 (1)
Bead width 1.5 - 5 mm(0.039 - 0.197 in) 35
Bead height From aligning surface: 4
(2)
0.3 - 1.5 mm(0.012 - 0.039 in) 5
3 25
• After applying the liquid gasket, install it within 5 1 2
(3)
minutes.
2
65
NOTE: (4)
Apply the liquid gasket without it getting on the O-rings
(1). 30
1
LNW86ASH000301
3. Install the water pump.

1 System (4HV1-CNG).
1 • Refer to "Oil Pan" in Section 1H, Lubricant
System (4HV1-CNG).
5. Install the front oil seal.
section.
LNW21BSH058701
• Align to the cylinder block dowel pin to install

the front cover.
NOTE:
At the same time as the front cover, install the water
pump assembly (before the liquid gasket dries).
• Tighten the bolts indicated by the arrows
together with the generator adjust plate.
• Tighten the oil relief valve (5) at the specified
torque.

c
d
LNW91BLF002101
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(d) 39 N⋅m (4.0 kg⋅m/29 lb⋅ft)
Crankshaft Front Oil Seal

Components
3
1 2
LNW21BMF000901
Legend
1. Crankshaft pulley 3. Slinger
2. Oil seal
Removal • Disconnect the front frame harness connector

near the transmission control box and remove
each of the clips fastening the harness.
2. Remove the starter.
• Disconnect the starter ground cable.
LNW21BSH011501

• Remove the 2 bolts (upper and lower) attaching • Install the crankshaft stopper to the installation
the starter, and remove the starter from the section of the flywheel housing starter, and
clutch housing. loosen the pulley nut while making sure that the
• Fasten with a wire etc. to a position where it will crankshaft does not rotate.
transmission. NOTE:
Check that the stopper securely bites into the ring gear
and that it is installed.
Special Tool
LNW21BSH011601
3. Remove the radiator upper hose at the engine

side.
LNW21BSH012301
4. Remove the coolant reserve tank hose at the
radiator side.
5. Remove the radiator lower hose at the engine side. 10. Remove the oil seal.
6. Remove the brackets at the left and right sides of • Be careful not to damage the front cover oil seal
the radiator (with fan guide) to remove the radiator. installation surface and shaft. Use a
7. Remove the fan assembly. screwdriver to pry only the oil seal to remove it.
• Remove the 4 installation nuts to remove the
fan assembly.
3
LNW21BSH002801
Legend
LNW21BSH012201 1. Felt
2. Slinger
3. Oil seal
8. Remove the fan belt.
11. Remove the slinger.
9. Remove the crankshaft pulley.

• Pull out the slinger using a puller. • Firmly fit the front slinger using the oil seal
installer kit.
Special Tool
Slinger puller: 5-8840-2360-0
4
1
2 5
3 6
LNW21BSH073201
Legend
LNW21BSH012401
1. Front slinger
2. Adaptor (front)
3. Fixing bolt
Installation 4. Sleeve (front)
1. Install the slinger. 5. Washer (front)
6. Center bolt
Special Tool
Oil seal installer kit: 5-8840-2703-0
(Use the parts indicated with a circle in the table below
for the front oil seal.)
Parts
No. Name Slinger Oil seal
No.
5-8840- Sleeve
1 { {
2704-0 (Front)
5-8840- Adaptor
2 { {
2705-0 (Front)
5-8840- Adaptor ring
3 — {
2706-0 (front)
5-8840- Washer
4 { {
2707-0 (Front)
5-8840- Center bolt
5 { {
2713-0
5-8840- Fixing bolt
6 { {
2714-0
• Insert the front slinger into the leading end of

the front adaptor and install the adaptor to the
crankshaft.

• Cover the adaptor with the sleeve, attach the
washer to the center bolt, and tighten and
press-fit them until the sleeve touches the
adaptor.
4
5
1
3 2
LNW71BSH011701
Legend
1. Adaptor
2. Sleeve
LNW81BSH003901
3. Slinger
4. 40.2 - 40.8 mm(1.583 - 1.606 in)
5. 33.9 - 34.1 mm(1.335 - 1.343 in)
• After firmly fitting the front slinger, check the
dimensions in the diagram (depth from the 2. Install the oil seal.
crankshaft end surface to the slinger) and make • Firmly fit the oil seal using the oil seal installer
sure that the slinger does not fluctuate. kit.
NOTE:
Be careful not to mistake the slinger assembly direction
or the front and rear. There is a quadruple right-hand
thread (screw cut) at the rear side, and a quadruple left-
hand thread (screw cut) at the front side. Always 5
replace the slinger and oil seal as a set. 2 4
7
1 3 6
LNW21BSH073301
Legend
1. Oil seal
2. Adaptor (front)
3. Adaptor ring (front)
4. Fixing bolt
5. Sleeve (front)
6. Washer (front)
7. Center bolt

• Install the adaptor (1) to the crankshaft with the
fixing bolt.
LNW81BSH003901
• After firmly fitting the front oil seal, check the

LNW81BSH016701
dimensions in the diagram (depth from the
crankshaft end surface to the oil seal) and
make sure that the oil seal does not fluctuate.
• Apply engine oil to the oil seal (1) lip section,
and set to the front adaptor.
• Put the front adaptor ring (2) into the sleeve (3),
and set the center bolt and washer (4) adaptor.
• Tighten until the sleeve touches the adaptor
and firmly fit the front oil seal. 4 1
2
5
3
1 2 3 4
LNW71BSH011801
Legend
1. Adaptor ring
2. Sleeve
3. Adaptor
4. Oil seal
LNW81BSH016801 5. 30.7 - 31.3 mm(1.209 - 1.232 in)
3. Install the crankshaft pulley.

• Apply engine oil to the threaded portion of the
tightening bolt.
• Align to the crankshaft dowel pin, and install the
crank pulley.

• When removed a frame side bracket, tighten it
by the following torque.
frame side bracket from frame
1
Front rigid suspension vehicle
3 4
1
2
6 2
LNW21BSH013501
3
5
4
4. Install the fan belt.
• Refer to "Drive Belt" in Section 1C, Cooling
System (4HV1-CNG) for details on the belt
LNW21BSH013601
tension adjustment.
5. Install the drive assembly and tighten it at the Legend
specified torque. 1. Stud bolt
2. Rubber
Tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) 3. Washer
4. Flange nut
Front independent suspension vehicle
1
6
2
5
4
LNW21BSH012201
3
6. Be careful not to damage the radiator core with the

LNW21BSH013701
fan blades and install the left and right brackets of
the radiator to the frame side bracket, as shown in Legend
the diagram. 1. Flange nut
2. Rubber
Radiator side bracket from frame side bracket 3. Stud bolt
Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb⋅ft) 4. Frame side bracket
6. Washer

7. Install the radiator lower hose.
8. Install the coolant reserve tank hose.
9. Install the radiator upper hose.
10. Install the starter to the clutch housing with bolts,
and tighten them at the specified torque.
• Connect the starter ground cable.
• Connect the front frame harness connector.
LNW21BSH011601

LNW71BMF004901
(a) 200 N⋅m (20.4 kg⋅m/147 lb⋅ft)

Crankshaft Rear Oil Seal

Components
7
6
9 8
LNW71BLF002801
Legend
1. Starter 6. Crankshaft rear oil seal
2. Transmission ASM 7. Crankshaft rear slinger
3. Clutch pressure plate (M/T vehicle) 8. Flexible plate (Smoother vehicle)
4. Clutch disk (M/T vehicle) 9. Crank end spacer (Smoother vehicle)
5. Flywheel (M/T vehicle)
Removal
1. Remove the flywheel.
• Refer to "Flywheel" in this section.
2. Remove the oil seal.

• Be careful not to damage the shaft and oil seal • Firmly fit the rear slinger using the oil seal
installation surface of the flywheel housing. Use installer kit.
a screwdriver to pry only the oil seal to remove
it.
1 3
3
2
5
6 4
LNW21BSH073401
Legend
LNW21BSH002801
1. Rear slinger
Legend 2. Fixing bolt
1. Felt 3. Center bolt
2. Slinger 4. Sleeve (rear)
3. Oil seal 5. Collar (rear)
6. Adaptor (rear)
3. Remove the crankshaft rear slinger.
• Pull out the slinger using a puller. Special Tool
Special Tool Oil seal installer kit: 5-8840-2703-0
Slinger puller: 5-8840-2360-0
Parts
No. Name Slinger Oil seal
No.
5-8840-
1 Sleeve(rear) { {
2708-0
5-8840-
2 Adaptor(rear) { {
2709-0
5-8840-
3 Collar (rear) { {
2710-0
5-8840- Adaptor ring
4 — {
2711-0 (rear)
5-8840-
5 Center bolt { {
2713-0
5-8840-
6 Fixing bolt { {
2714-0
LNW21BSH002901
NOTE:
A sleeve for engines before '93.5 models (5-8840-
Installation 2712-0) is included in the oil seal installer kit, but it will
not be used with this engine.
1. Install the crankshaft rear slinger.

• Insert the rear slinger to the leading end of the
rear adaptor (3), install the collar (1) to the
fixing bolt (2), and install the adaptor to the
crankshaft.
1
3
1 4
5
6
2
7
3 LNW21BSH014301
Legend
1. Crankshaft rear section
2. Adaptor
LNW21BSH014501
3. 17.0 - 17.6 mm(0.669 - 0.693 in)
4. 10.7 - 10.9 mm(0.421 - 0.429 in)
5. Slinger
• Cover the adaptor with the sleeve, tighten the 6. Sleeve
center bolt until the sleeve touches the adaptor, 7. Collar
and firmly fit the slinger.
2. Install the oil seal.
• Firmly fit the rear oil seal using the oil seal
installer kit.
1 2 3
7 6 5 4
LNW21BSH014701
• After firmly fitting the rear slinger, check the LNW21BSH073501

dimensions in the diagram (depth from the Legend
crankshaft end surface to the slinger) and make 1. Adaptor (rear)
sure that the slinger does not fluctuate. 2. Fixing bolt
3. Center bolt
CAUTION:
4. Sleeve (rear)
Be careful not to mistake the slinger assembly direction
5. Collar (rear)
or the front and rear. There is a quadruple right-hand
6. Adaptor ring (rear)
thread (screw cut) at the rear side, and a quadruple left-
7. Oil seal
hand thread (screw cut) at the front side.
Always replace the slinger and oil seal as a set.

• Install the collar (1) to the fixing bolt (2), and • Tighten the center bolt all the way to the end
install the adaptor (3) to the crankshaft. until the sleeve touches the adaptor, and firmly
fit the oil seal.
LNW21BSH014501
LNW21BSH014701
• Apply engine oil to the rear oil seal lip section,

and set the rear oil seal to the rear adaptor. • After firmly fitting the rear oil seal, confirm the
• Put the rear adaptor ring (2) into the sleeve (1), dimensions in the diagram (depth from the
set to the adaptor and install the center bolt. crankshaft end surface to the oil seal).
1
1 2
7
3
6
5
2 4
Legend
1. Crankshaft rear section
2. Oil seal
3. 7.5 - 8.1 mm(0.253 - 0.319 in)
4. Collar
5. Adaptor ring
6. Sleeve
7. Adaptor
3. Install the flywheel.

• Refer to "Flywheel" in this section.
Piston and Connecting Rod

Components
1
2
7 3
LNW61BMF000401
Legend
1. Piston ring 5. Connecting rod cap
2. Snap ring 6. Connecting rod
3. Piston 7. Snap ring
4. Connecting rod bearing 8. Piston pin
Removal NOTE:
Organize the removed connecting rod caps and
bearings according to the cylinders using tags, etc.
System (4HV1-CNG).
section.
6. Remove the connecting rod cap.

Disassembly
1. Remove the piston ring.
• Remove the piston ring using the ring plier.
NOTE:
When reusing the piston rings, organize them
according to the order of the cylinders so that other
cylinder pistons and piston rings do not get mixed.
LNW21BSH004901
7. Remove the piston and connecting rod.

• Remove carbon from the top of the cylinder
liner using a scraper.
• Pull out the piston and connecting rod out to the
cylinder head side.
When pushing out the connecting rod, be careful not to

damage the oil jet and cylinder liner.
2. Remove the snap ring.
3. Remove the piston pin.
NOTE:
Organize the disassembled piston pins, pistons and
connecting rods according to the order of cylinders.
LNW21BSH005001
8. Remove the connecting rod bearing.
NOTE:
When reusing the bearings, organize them according to
the order of the cylinders so that other cylinder LNW61BSH000701
bearings do not get mixed.
4. Remove the connecting rod from the piston.

5. Remove the connecting rod bush.

• Set the collar (5), connecting rod (2) and collar NOTE:
(4) on the setting bar (1) as shown in the Do not use a wire brush to clean the piston. This may
diagram. cause scratches on the piston.
• Tighten the nut (3).
2. Measure the gap between the piston and the inner
diameter of the cylinder liner.
• Use the cylinder bore gauge to measure the
inner diameter of the liner at the specified
1 positions.
• Measurement position: From the top surface of
the cylinder block,
(1).20 mm(0.79 in) (2).90 mm(3.54 in) (3).160
mm(6.30 in)
2 Thrust direction and radial direction of the
5 above 3 locations for a total of 6 locations
• Determine the inner diameter of the liner based
on the average value of the six locations
measured.
4 Inner diameter of cylinder liner mm(in)

3
LNW21BSH009901 115.031 - 115.060
Standard value
(4.52878 - 4.52991)
• Place the connecting rod bush replacer base

(2) on the bench press and tighten the fixing
bolt (1).
• Use the bench press to remove the bush.
Special Tool 1
Connecting rod bush replacer: 5-8840-2340-0
2
3
LNW21BSH009001

diameter of the piston in the specified position.
2 1 • Measurement position: 86.5 mm(3.406 in)from
the top surface of the piston
(Perpendicular direction to the piston pin)
LNW21BSH010001
Piston outer diameter mm(in)

Inspection
114.930 - 114.960
1. Visually inspect the piston. Standard value
(4.52479 - 4.52597)
• Carefully clean the carbon deposits on the
piston heads and in the piston ring grooves.
• Visually inspect the pistons for cracks, seizure
or other excessive wear. If there is an
abnormality, replace the piston.
Gap between the piston and inner diameter of the

cylinder liner
mm(in)
0.091 - 0.110
Standard value
(0.00394 - 0.00433)
1
NOTE:
If the measurement reveals that the gap in relation to
the piston exceeds the standard values, replace the
piston or cylinder liner.
2
LNW71BSH012501
Legend
1. Grade marking
2. Front mark
4. Inspect the piston ring.

• Measurement of the piston ring joint (remove
carbon from the ring joint)
• Insert the piston ring into the cylinder bore.
• Push the ring down to the lower end of the
cylinder liner using the piston.
LNW21BSH009101
3. Replacing the piston

• As there is only one type for the piston and the
inner diameter of the cylinder liner, there is no
need to select the grade.
However, when replacing the cylinder liner,
there are two types of liner outer diameters (1X,
3X), so it is necessary to select accordingly with
the cylinder blocks (1, 2 and 3).
• Refer to "Cylinder Block" in this section for
information on replacement of the cylinder liner.
NOTE:
Grades A, B and C are marked on the top of the piston
when shipped from the factory. LNW21BSH009301

• Use a thickness gauge to measure the ring joint
gap.
LNW61BSH001001
LNW61BSH000901
5. Inspect the piston pin.
• Visually inspect the piston pin for cracks,
scratches or other damages, and replace it as
• Replace the piston ring if the measured value
necessary.
exceeds the limit.
circumference of the piston pin as indicated in
Piston ring joint gap mm(in) the diagram. Replace the piston pin if the
Standard value Limit measured value exceeds the limit.
0.30 - 0.45 1.50

No. 1 compression ring Piston pin outer diameter mm(in)
(0.0118 - 0.0177) (0.0059)
0.35 - 0.50 1.50 35.995 - 36.000
No. 2 compression ring Standard value
(0.0137 - 0.0197) (0.0059) (1.41712 - 1.41732)
0.15 - 0.35 1.50 35.970

Oil ring Limit
(0.0059 - 0.0137) (0.0059) (1.41614)
• Measure the clearance between the piston ring

groove and the piston ring.
• Remove all carbon in the piston ring groove.
• Insert the piston ring into the piston ring groove,
and measure the gap with the thickness gauge.
• If the clearance between the piston ring groove
and the piston ring exceeds the limit, replace
the piston or piston ring.
Gap between the piston ring and ring

groove mm(in)
No. 1 0.090 - 0.130 0.20
compression ring (0.00354 - 0.00512) (0.0079)
No. 2 0.050 - 0.090 0.15
LNW21BSH009601
compression ring (0.00197 - 0.00354) (0.0059)
• Inspect for a certain degree of resistance when
0.020 - 0.060 0.15
Oil ring the piston pin is lightly pushed in, when the
(0.00079 - 0.00236) (0.0059)
piston is at normal temperature.

• Replace the piston or the piston pin if they feel 6. Measure the clearance between the piston and the
quite loose or slackening at normal piston pin.
temperature. • Apply engine oil to the piston pin, then push it
into the piston hole with your fingers to rotate it.
If the pin rotates smoothly without any
looseness, the clearance is normal. If there is
looseness, measure the clearance. Replace the
piston and piston pin if the clearance exceeds
the limit.
Clearance between piston and piston pin mm(in)

0.004 - 0.017
Standard value
(0.00016 - 0.00067)
Limit 0.04(0.00157)
7. Measure the connecting rod alignment.

• Use the connecting rod aligner to measure the
twisting of the large end hole and small end
LNW61BSH001101 hole, and the degree of parallelization. Replace
if the measured value exceeds the limit.
• Measure the inner diameter of the connecting Connecting rod alignment

rod small end bush. If the clearance between (for 100 mm(3.94)) mm(in)
the bush inner diameter and pin outer diameter
exceeds the limit, replace the bush or the
connecting rod assembly, and pin. 0.05 0.20
Twisting
(0.0020) (0.0079)
Gap between the connecting rod small 0.05 0.20
Degree of parallelization
end and piston pin outer diameter mm(in) (0.0020) (0.0079)
0.012 - 0.027
Standard value
(0.00047 - 0.00106)
0.05
Limit
(0.0020)
LNW21BSH010401
8. Measure the bearing oil clearance.

• Use the following method to measure the oil
LNW21BSH009801 clearance between the connecting rod bearing
and crank pin.

• Remove the connecting rod cap nut and cap. • Remove the plastic gauge from the bearing and
Set the removed caps in the order of the crank pin.
cylinder number.
• Clean the bearing and crankshaft pin.
• Inspect the bearing. Replace the bearing as a
set if there is damage or excessive wear.
• Place the plastic gauge on the crankshaft pin.
• Install the bearing cap, and tighten the cap bolt
Apply molybdenum disulfide to the threaded
portion and seat surface.
Tightening torque:
1st time 39 N⋅m (4.0 kg⋅m/29 lb⋅ft)
2nd time Rotating angle 60°
3rd time Rotating angle 30°
LNW21BSH010601
NOTE:
Do not rotate the crankshaft.
9. Select the connecting rod bearing.
• Select the bearing from the table when
installing a new connecting rod or replacing a
bearing that is in use.
• Select the bearing by carefully considering the
grade of the large end hole diameter of the
connecting rod to install.
LNW21BSH010501 1
2
3
• Remove the cap.
• Measure the section of the plastic gauge where
the width is the largest to determine the oil
clearance. Replace the bearing as a set if the LNW21BSH028401
clearance exceeds the limit.
Legend
1. Front and back side discrimination boss
Pin oil clearance mm(in) 2. Grade mark of the large end hole diameter
3. Cylinder number
0.036 - 0.077
Standard value
(0.00142 - 0.00303)
Limit 0.10(0.0039)

Bearing selection table
Large end hole Bearing
Oil clearance
diameter identification
mm(in)
grade color
0.036 - 0.077
A Green
(0.00142 - 0.00303)
0.036 - 0.077
B Yellow
(0.00142 - 0.00303)
2 1
LNW21BSH010001
• Set the collar (5), new bush (2) and collar (4) on
the setting bar (1) as shown in the diagram.
• Tighten the nut (3).
• Align the connecting rod oil hole with the bush
oil hole, and use the bench press to install the
1 bush.
LNW21BSH010801
Legend
1. Grade identification color 1
Reassembly
1. Installation of the bush
• Place the connecting rod bush replacer base 5
(2) on the bench press, set the connecting rod,
and tighten the fixing bolt (1). 2
Special Tool 4
Connecting rod bush replacer: 5-8840-2340-0

3
LNW21BSH010201

• After assembling the new bush, use a grinder to
finish the pin hole so that the pin and clearance
are at the standard value.
LNW61BSH001201
LNW21BSH010301
6. Install the piston ring using the ring plier.
• Install the oil ring so that the joint of the oil ring
2. Install the piston. and the coil expander will be 180° in the
3. Install the connecting rod. opposite direction.
• Assemble so that the piston head front mark (1) • Place the compression rings so that the "2N" or
and connecting rod cast mark (convex) (2) face "N" mark is facing upward, and install in the
the same direction. order of No. 2 and No. 1 compression rings.
• Install the snap ring for one side using the snap
ring plier.
LNW61BSH000601
NOTE:
LNW71BSH012801
Be cautious, as the shape of the No. 1 and No. 2
compression rings differ. (No. 2 has an undercut)
4. Apply an adequate amount of engine oil on the Check that there is no gap at the position of the arrow
piston pin, then, push it into the piston and in the diagram when the oil ring coil expander is
connecting rod small end. installed.
5. Assemble the snap ring using the snap ring plier.
NOTE:
Check that the snap ring is securely installed in the ring
groove. Check that the connecting rod slides smoothly.
2 3
Installation 3. Install the connecting rod cap.

• Install the bearing to the connecting rod cap
1. Install the connecting rod bearing.
and apply engine oil.
• When replacing the bearing, select the bearing
• Install the cap so that the cap and the
grade upon referring to the selection of the
connecting rod number markings (1, 2, 3, 4)
connecting rod bearing grade.
face the same direction.
• Install the bearing to the connecting rod, and
apply engine oil to the bearing.
2. Install the piston and connecting rod assembly.
• Thoroughly apply engine oil to the piston ring,
ring groove and piston side surface.
• Shift alternately as shown in the diagram for the
piston ring joint to the No. 1 ring for (1), the No.
2 ring for (3), and the oil ring for (2).
• Face the piston front mark (notch) towards the 1
front, and insert the piston into the cylinder liner
using the installer. 1
2
NOTE: 3
When inserting the piston, prevent it from interfering
with the oil jet and cylinder liner.
LNW21BSH028401
Legend
1. Front and back side discrimination boss
2. Grade mark of the large end hole diameter
3. Cylinder number

and threaded portion of the tightening bolts and
tighten them at the specified torque.
Tightening torque:
1st time 39 N⋅m (4.0 kg⋅m/29 lb⋅ft)
2nd time Rotating angle 60°
3rd time Rotating angle 30°
Special Tool
Angle gauge: 5-8840-0266-0
NOTE:
Check that the crankshaft turns smoothly.
LNW21BSH011401

section.
System (4HV1-CNG).

LNW71BMF005001
(a) 39 N⋅m (4.0 kg⋅m/29 lb⋅ft) → 60° → 30°

Crankshaft
Components
1
3
LNW21BLF005301
Legend
1. Upper bearing 5. Lower bearing
2. Thrust bearing upper 6. Thrust bearing lower
3. Gear 7. Crankcase
4. Crankshaft
Removal • Refer to "Camshaft Assembly" in this section.

1. Remove the engine assembly from the vehicle. 5. Remove the cylinder head.
• Refer to "Engine Assembly" in this section. • Refer to "Cylinder Head" in this section.
2. Remove the cylinder head cover. 6. Remove the crankshaft front oil seal.
• Refer to "Cylinder Head Cover" in this section. • Refer to "Crankshaft Front Oil Seal" in this
section.
7. Remove the crankshaft rear oil seal.
section. • Refer to "Crankshaft Rear Oil Seal" in this
section.

System (4HV1-CNG).
9. Remove the water pump.
System (4HV1-CNG).
• Refer to "Front Cover" in this section.
11. Remove the timing gear train.
• Refer to "Timing Gear Train" in this section.
12. Remove the oil pump.
• Refer to "Oil Pump" in Section 1H, Lubricant
System (4HV1-CNG).
• Refer to "Piston and Connecting Rod" in this
section. LNW21BSH023701
14. Remove the crankcase.

• Gradually loosen the crankcase mounting bolts
in the order shown in the diagram, and use the 17. Remove the crankshaft assembly.
three replacer holes (at the arrows in the 18. Remove the thrust bearing upper.
diagram) to remove it. 19. Remove the upper bearing.
3 7 11 15 16 12 8
1
4
18 22 26 25 21
19 23 27 24 20
2 6 10
14 17 13 9 5
15. Remove the thrust bearing lower. Disassembly

16. Remove the lower bearing. 1. Remove the gear.
• Remove the gear using a gear puller.
NOTE:
Remove the crankcase after removing the oil pump and
generator bracket. Special Tool
Puller; Crankshaft gear: 8-9439-6818-0

2. Main bearing clearance
• Remove the crankcase.
The removed main bearings should be lined up
in the order of the number.
• Remove the crankshaft. Remove the main
bearing.
• Clean the crankshaft journal and upper/lower
bearings.
• Inspect the bearing for damage and excessive
wear.
If damage and excessive wear are found during

the inspection, replace the bearing as a set.
• Set the upper bearing and crankshaft to the

cylinder block. Install the crankshaft
LNW21BSH023901
horizontally.
NOTE:
Turn the crankshaft approximately 30° stabilize the
Inspection
bearing.
1. Thrust clearance
• As shown in the diagram, set a dial gauge and
measure the crankshaft thrust clearance.
• Replace the thrust bearing as a set if the thrust
clearance exceeds the limit.
Play of the crankshaft in the axis direction

mm(in)
0.040 - 0.205
Standard value
(0.00157 - 0.00807)
Limit 0.35(0.0138)
NOTE:
Measure the thrust clearance prior to disassembly.
LNW21BSH024101
LNW21BSH024001

• As shown in the diagram, place the plastic
gauge on the crankshaft journal.
25 21 17 13 12 16 20
27
24
10 6 2 3 7
9 5 1 4 8
26 22 18
14 11 15 19 23
LNW21BSH022601
LNW21BSH024201
• Set the lower bearing to the original position of M14 M10

the crankcase. 1st time 2nd time 3rd time 4th time
• Install the crankcase and tighten the bolts at the 1 - 10 1 - 10 1 - 10 11 - 27
specified torque.
98 N⋅m 132 N⋅m 37 N⋅m
• Use a torque wrench and angle gauge to (10.0 kg⋅m (13.5 kg⋅m 30° - 60° (3.8 kg⋅m
tighten the crankcase in the order shown in the /72 lb⋅ft) /98 lb⋅ft) /27 lb⋅ft)
diagram.
• Tighten the bolts in locations 1 to 10 (M14) in
the tightening direction. Check that they are
tightened at a torque of 167 N⋅m (17.0 kg⋅m/
123 lb⋅ft) or higher.
Special Tool
Angle gauge: 5-8840-0266-0
NOTE:
After tightening the crankcase, do not turn the
crankshaft.
• Loosen the bolts and gently remove the

crankcase.
• Measure the maximum width portion of the
plastic gauge crushed by tightening the
LNW21BSH024301 crankcase to determine clearance.
Journal section oil clearance mm(in)

0.039 - 0.070 0.11
No. 1, 2, 4, 5
(0.00154 - 0.00276) (0.0043)
0.053 - 0.084 0.11
No. 3
(0.00209 - 0.00331) (0.0043)
• Measure the journal and crank pin diameter, as

well as for uneven wear.
• Replace all sets of main bearings or the • Use a micrometer to measure the outer
crankshaft if the oil clearance exceeds the limit. diameter of the journal and pin section, and
• Remove the plastic gauge from the bearing and calculate the difference of the maximum and
crankshaft. minimum. Measure in four locations of each
3. Inspection of the crankshaft section of the journals and the pins.
• Inspect the crankshaft journal and crank pin
surface for wear and damage. Inspect the oil
seal installation surface for excessive wear and
damage.
• Inspect the oil port for clogging.
• Carefully set the crankshaft on the V-block.
Slowly rotate the crankshaft to measure
fluctuation. Replace the crankshaft if the
crankshaft fluctuation exceeds the limit.
Fluctuation of the crankshaft mm(in)

0.05(0.0020)
Standard value
or less
Limit 0.30(0.0118)
LNW21BSH024601
Outer diameter of the crankshaft mm(in)

Journal section #1, 81.905 - 81.925 81.85
2, 4, 5 (3.22450 - 3.22539) (3.2224)
Journal section 81.891 - 81.911 81.85
#3 (3.22405 - 3.22484) (3.2224)
65.902 - 65.922 65.85
Pin
(2.59456 - 2.59535) (2.5925)
Limit of uneven 0.005
wear (0.00020)
Selection of the crankshaft bearing

• Refer to the bearing selection table when
installing a new crankshaft bearing or replacing LNW21BSH024801
one that is in use.
• Be careful of the journal hole diameter grade of NOTE:
the cylinder block and the crankshaft journal Be careful of the difference of the bearing shape when
diameter grade when selecting and installing a installing.
new bearing.
• The journal numbers are #1 to #5 from the left
in the direction that the characters are read. 1 2
3
4
6
LNW21BSH024901
Legend
LNW21BSH024701
1. Upper bearing
2. Oil hole
3. Grade identification color
4. Oil groove
5. Lower bearing
6. Grade identification color

Bearing selection table
Grade combination Oil clearance
Cylinder block Crank journal Bearing
#1,2,4,5 #3
Grade Grade identification color
0.041 - 0.068 mm 0.055 - 0.082 mm
1 1 Black
(0.00161 - 0.00268 in) (0.00218 - 0.00323 in)
0.039 - 0.065 mm 0.053 - 0.079 mm
1 2 Brown
(0.00154 - 0.00256 in) (0.00209 - 0.00311 in)
0.043 - 0.070 mm 0.057 - 0.084 mm
2 1 Blue
(0.00169 - 0.00276 in) (0.00224 - 0.00331 in)
0.041 - 0.067 mm 0.055 - 0.081 mm
2 2 Black
(0.00161 - 0.00264 in) (0.00217 - 0.00319 in)
Reassembly Installation
1. Install the gear. 1. Install the crankshaft upper bearing.
• Warm the gear to 170 to 250°C(338 - 482°F), • Install the upper bearing to the cylinder block
align the groove at the gear side with the pin and apply oil.
position at the back side of the crankshaft and
install them. CAUTION:
• When installing, face the alignment mark "S" of When replacing the crankshaft bearing, select the
the gear end surface towards the outside and grade upon referring to the selection of the crankshaft
insert at once up to the brim section. When it is bearing grade. Do not apply oil to the cylinder block
cooling, use the installer to tap it in until it bearing installation surface or to the outer
touches the end. circumference of the bearing.
Special Tool
Installer; crankshaft gear:
8-9439-6819-0
LNW21BSH025201
2. Install the thrust bearing upper.

• Install the thrust bearing upper to the front side
LNW21BSH025101
of the cylinder block No. 5 journal section.
Legend When doing so, it is acceptable to use grease
1. Alignment mark to adhere the thrust bearing upper to the
cylinder block. However, wipe away any excess
grease.

NOTE: 5. Install the thrust bearing lower.
Install so that the oil groove of the thrust bearing • Install the thrust bearing lower to the rear side
touches the crankshaft. of the crankcase No. 5 journal.
• Install so that the oil groove of the thrust
bearing touches the crankshaft.
LNW21BSH025301
LNW21BSH025501
3. Install the crankshaft assembly.

• Apply engine oil to the crankshaft journal 6. Install the crankcase.
section and gently install it on the cylinder
block. • Apply liquid gasket (TB1207B or equivalent)
with a bead diameter of 3 to 4 mm(0.12 - 0.16
• Push the installed crankshaft against the rear in) on the crankcase.
side, and insert the thrust bearing upper to the
rear side of the cylinder block No. 5 journal • After applying the liquid gasket, install it within 5
section. minutes.
• Gently place the crankcase on the cylinder
NOTE: block.
Install so that the oil groove of the thrust bearing
touches the crankshaft.
LNW71BSH012001
LNW21BSH025401
and threaded portion of the M14 bolts, and
tighten them at the specified torque in the order
4. Install the crankshaft lower bearing. shown in the diagram.

• It is not necessary to apply engine oil to the • Refer to "Oil Pan" in Section 1H, Lubricant
M10 bolts. System (4HV1-CNG).
13. Install the crankshaft rear oil seal.
M14 M10
section.
1st time 2nd time 3rd time 4th time
14. Install the crankshaft front oil seal.
1 - 10 1 - 10 1 - 10 11 - 27 • Refer to "Crankshaft Front Oil Seal" in this
98 N⋅m 132 N⋅m 37 N⋅m section.
(10.0 kg⋅m (13.5 kg⋅m 30° - 60° (3.8 kg⋅m 15. Install the cylinder head.
/72 lb⋅ft) /98 lb⋅ft) /27 lb⋅ft)
• Tighten the bolts in locations 1 to 10 (M14) in
the tightening direction. Check that they are • Refer to "Camshaft Assembly" in this section.
tightened at a torque of 167 N⋅m (17.0 kg⋅m/ 17. Install the rocker arm shaft assembly.
123 lb⋅ft) or higher. • Refer to "Rocker Arm Shaft Assembly" in this
Special Tool section.
Angle gauge: 5-8840-0266-0
NOTE: 19. Install the engine assembly to the vehicle.
Check that the crankshaft turns smoothly. • Refer to "Engine Assembly" in this section.
25 21 17 13 12 16 20
27
24
10 6 2 3 7
9 5 1 4 8
26 22 18
14 11 15 19 23
LNW21BSH022601
7. Install the piston and connecting rod.

section.
8. Install the oil pump.
System (4HV1-CNG).
9. Install the timing gear train.
System (4HV1-CNG).

LNW71BLF002201
(a) M14; 98 N⋅m (10.0 kg⋅m/72 lb⋅ft) → 132 N⋅m (13.5 kg⋅m/132 lb⋅ft) → 30° - 60°
M10; 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
Cylinder Block
Components
LNW61BLF001401
Legend
1. Cylinder liner 2. Cylinder block
Removal • Refer to "Cylinder Head" in this section.

1. Remove the engine assembly from the vehicle. 6. Remove the crankshaft front oil seal.
• Refer to "Engine Assembly" in this section. • Refer to "Crankshaft Front Oil Seal" in this
section.
7. Remove the crankshaft rear oil seal.
section.
8. Remove the oil cooler.
section.
• Refer to "Oil Cooler" in Section 1H, Lubricant
System (4HV1-CNG).

• Refer to "Oil Pan" in Section 1H, Lubricant • Perform a color check and water pressure (or
System (4HV1-CNG). air pressure) test, and repair or replace the
10. Remove the water pump. cylinder block if it is cracked or damaged.
System (4HV1-CNG).
12. Remove the timing gear train.
13. Remove the oil pump.
System (4HV1-CNG).
section.
15. Remove the crankshaft.
• Refer to "Crankshaft" in this section.
16. Remove the piston oil jet. LNW21BSH026701
5. Measurement of cylinder liner wear

• Inspect the inner surface of the liner for
scratches or damage.
• For the liner inner diameter, measure the
maximum wear (larger wear in rotational
direction) at a position (a) approximately 15 to
20 mm(0.59 to 0.79 in)from the upper surface
of the liner with the cylinder block installed.
Replace the liner if the measured value
exceeds the limit for use.
LNW21BSH026401
a
17. Remove the cylinder liner.
Inspection
1. Gently remove foreign matter, such as water
deposit, from the top surface of the cylinder block.
• Be careful not to damage the cylinder block.
2. Gently remove the liquid gasket on the crankcase
installation surface.
LNW61BSH004001
3. Clean the cylinder block.
4. Visually inspect the cylinder block.
Inner diameter of cylinder liner mm(in)
112.041 - 112.060
Standard value
(4.41105 - 4.4118)
Limit 112.20(4.41731)

6. Measure the flatness. • The cylinder block inner diameter grade 1, 2 or
• Pull out the cylinder liner and remove all water 3 is marked as indicated in the diagram (1).
deposits on the top surface of the cylinder Select the liner in accordance with the
block. markings.
• Use a simple straight ruler and thickness gauge
to measure the 4 sides of the cylinder block top 1
surface and 2 locations in a diagonal line.
Replace the cylinder block if the measured
value exceeds the limit.
Deformation of the cylinder block top

surface mm(in)
Standard value 0.05(0.0020) or less
Limit 0.20(0.0079)
LNW71BSH011301
When the cylinder block inner diameter grade

is 1 or 2: Select liner outer diameter grade 1X
When the cylinder block inner diameter grade

is 3: Select liner outer diameter grade 3X
NOTE:
• As there is only one type of replacement cylinder
inner diameter, it is not necessary to select the liner
inner diameter grade.
LNW21BSH026901
• For replenishment with "liner set," the piston that
matches the liner inner diameter is replenished
together.
Installation
1. Selection of the cylinder liner grade REFERENCE
Cylinder Liner outer
Grade
block inner diameter diameter
118.001 - 117.991 -
118.020 mm 118.000 mm
1,2 / 1X
(4.64570 - (4.64531 -
4.64645 in) 4.64566 in)
118.021 - 118.001 -
118.030 mm 118.010 mm
3 / 3X
(4.64649 - (4.64570 -
4.64684 in) 4.64605 in)
2. Install the cylinder liner.

• Install straight into the cylinder block.
• Do not tap or apply excessive force when
inserting the liner.
• Thoroughly clean the cylinder block and
cylinder liner, and install them after air-blowing.

• Align the oil jet dowel pin to the cylinder block
pin hole and tighten with a check valve.
NOTE:
Be careful not to deform or damage the oil jet nozzle.
LNW71BSH011401
3. Protrusion amount of the cylinder liner

Use a dial gauge to measure the protrusion
amount of each cylinder liner.
The difference in the protrusion amounts with the
adjacent cylinder liner should not exceed 0.03 LNW21BSH065701
mm(0.0012 in).
5. Install the crankshaft.

Protrusion amount of the cylinder liner mm(in)
• Refer to "Crankshaft" in this section.
0.09 - 0.14 6. Install the piston and connecting rod.
Standard value
(0.0035 - 0.0055)
section.
NOTE: 7. Install the oil pump.
After replacing the cylinder liner, always measure the
protrusion amount of the cylinder liner.
System (4HV1-CNG).
8. Install the timing gear train.
System (4HV1-CNG).
11. Install the oil cooler.
• Refer to "Oil Cooler" in Section 1H, Lubricant
System (4HV1-CNG).
System (4HV1-CNG).
13. Install the crankshaft rear oil seal.
LNW21BSH026801 section.
14. Install the crankshaft front oil seal.
4. Install the piston oil jet. section.

section.
19. Install the engine assembly to the vehicle.
• Refer to "Engine Assembly" in this section.
MEMO
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Engine Cooling (4HV1-CNG) 1C-1
ENGINE
Engine Cooling
(4HV1-CNG)
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1C-2
Description of Function and Operation . . . . . . . 1C-2
Functional Inspection . . . . . . . . . . . . . . . . . . . . 1C-6
Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-7
Malfunction Symptom List . . . . . . . . . . . . . . . . . 1C-9
Symptom: Engine has Overheated . . . . . . . . . 1C-10
Symptom: Engine has Overcooled . . . . . . . . . 1C-11
Primary Specifications. . . . . . . . . . . . . . . . . . . 1C-11
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14
List of Tightening Torques . . . . . . . . . . . . . . . . 1C-16
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-17
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Engine Coolant Temperature (ECT) Sensor . . . 1C-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-24
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-24
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-25
List of Tightening Torques . . . . . . . . . . . . . . . . 1C-26
1C-2 Engine Cooling (4HV1-CNG)
Cooling System
Maintenance Precautions Description of Function and Operation
WARNING: Cooling system
Do not loosen or remove the radiator cap when the The cooling system is a forced-circulation system, and
coolant is hot. Steam and boiling liquids can burst out its main components are a water pump, thermostat and
from the radiator and possibly cause burns or heat radiator.
related injuries. When opening the radiator cap, place a
thick cloth over the cap when the coolant is cooled, and
turn it gradually to release the pressure before opening
it.
11
10 12
8 13
9
14
15
7
6 1
4
2
5 3
LNW21CLF000901
Legend
1. Water jacket 9. Heater core
2. Drain plug 10. Pressure regulator
3. Oil cooler 11. Reserve tank
4. Water pump 12. Water outlet pipe
5. Drain plug 13. Thermostat (2 pcs.)
6. Radiator 14. Engine coolant temperature sensor
7. Cooling fan 15. Bypass pathway
8. Radiator cap

Water pump
The water pump is a centrifugal impeller type pump and
is driven by the engine fan belt.
2
1
6
LNW46BMF000401
Legend
1. Fan center 4. Seal unit
2. Fan pulley 5. Impeller
3. Bearing 6. Liquid gasket application groove

Thermostat
The thermostat is a wax pellet type and the structure
uses a total of 2 thermostats. One has an open valve
temperature of 82°C(180°F) (bottom bypass type), and
the other has an open valve temperature of
85°C(185°F) (inline type), enabling fine water
temperature adjustments. The thermostat is installed in
the thermostat housing.
2 2
5
5
4 4
3
3
LNW71CMF001501
Legend
1. Jiggle valve 4. Gasket
2. Open valve temperature marking 5. Piston
3. Valve

Radiator
The radiator is a tube type radiator with a corrugate
fins. A pressurized radiator cap is attached to raise the
boiling point of the coolant.
LNW71CSH003401

Engine coolant level inspection
• Inspect the coolant level in the reserve tank. The
amount is appropriate if the level is within its MAX
(upper limit) and MIN (lower limit). Note that if
there is insufficient coolant, remove the reserve
tank cap, refill a mixture of tap water and engine
coolant at a proportion of 1:1 and fill the tank to the
MAX line. For long life coolants, use genuine Isuzu
engine coolant.
Reference value
Coolant amount 12(2.64)
L(lmp⋅gal) (Within MIN to MAX level)
Replacement period Every 2 years
LNW21BSH000301
Coolant concentration inspection

1. Engine coolant concentration
• Since the concentration of the engine coolant
affects its freezing temperature, the
concentration should conform to the lowest
atmospheric temperature.
• Use genuine Isuzu engine coolant.
• Since overheating may easily occur when the
2
mixture ratio of engine coolant is 60% or higher
3 and corrosion prevention will be insufficient at
30% or lower, use a mixture ratio between 30%
and 60%.
1
LNW21BSH000101
Legend
Coolant density( )
1. Reserve tank
Frozen temperature ( F)
2. MAX line (upper limit)

)
0 10 20 30 40 50
3. MIN line (lower limit)

Frozen temperature(
-10 14
Coolant leakage inspection -20 -4
• Apply 200 kPa (2.0 kg/cm2/29 psi) pressure using -30 -22
the radiator cap tester to inspect for leaks in the

-40 -40
following locations.
- Radiator assembly -50 -58
- Water pump assembly

- Radiator hose
- Heater hose HCW61CSH000101
• Inspect the radiator hose and heater hose for

damage or deterioration and that hose clamps are
not loose.
Mixture ratio 1.100

Freezing L(imp⋅gal) Engine 1.090 60%
temperature coolant
reference Engine
Tap water concentration
1.080 50%
coolant 1.070
SPECIFIC GRAVITY
-18°C 4.2 7.8 1.060 40%
35%
(-0.4°F) (0.94) (1.72)
1.050 30%
-25°C 5.0 7.0
42% 1.040
(-25°F) (1.10) (1.54) 20%
1.030
-35°C 6.0 6.0
(-31°F) (1.32) (1.32)
50% 1.020 10%
1.010
-40°C 6.4 5.6
(-40°F) (1.41) (1.23)
53% 1.000
0 10 20 30 40 50 60 70
2. Measurement of engine coolant concentration TEMPERATURE (°C) LNW71CSH004601
Specific gravity measurement method
• Use an antifreeze hydrometer and thermometer
to measure the specific gravity and coolant Refractometer method
temperature. • Measure the concentration using a
If the cap is removed when the coolant is hot, refractometer.
the boiled coolant will burst out, so be careful.
• Use a container that is deeper than the length
of the hydrometer. Reference
WARNING:
Do not loosen or remove the radiator cap when the
coolant is hot. Steam and boiling liquids can burst out
from the radiator and possibly cause burns or heat
related injuries. When opening the radiator cap, place a
2 thick cloth over the cap when the coolant is cooled, and
turn it gradually to release the pressure before opening
it.
1 1. Check that the engine is cool.

2. Open the radiator cap.
3. Loosen the air removal plug of the water outlet
pipe.
4. Refill coolant up to the filler neck.
LNW21CSH000501
Legend
1. Radiator
2. Anti-freeze hydrometer
• The temperature of the coolant to be measured

is to be between 0 and 50°C(32 and 122°F).
• After measuring the temperature and specific
gravity, obtain the concentration from the table
below.

5. After refill, press the radiator upper hose two or 8. Close the radiator cap and start the engine. Run
three times. Then, if the level has dropped the engine for two to three minutes in idling
because of removal of air from the hose, add an revolution speed, then stop the engine, open the
equivalent amount of coolant. radiator cap again and refill more coolant into the
radiator if the coolant level has dropped.
9. After securely tightening the radiator cap, warm up
the engine at approximately 2000 r/min.
1 2 10. When it is verified that the thermostat has opened
after the water temperature gauge indicator has
passed the center, idle the engine for
approximately five more minutes, then stop the
engine and let the vehicle stand.
11. After the engine has adequately cooled, check the
coolant level again at the filler neck and add more
coolant when necessary. If the coolant level is
excessively low, check the coolant path and
reserve tank hose for leaks.
12. refill coolant up to the "MAX" line of the reserve
3
tank again.
LNW71CSH001701
Legend
1. Radiator cap
2. Air removal plug
3. Upper hose
6. refill coolant up to the "MAX" line of the reserve

tank.
2
3
LNW21BSH000101
Legend
1. Reserve tank
2. MAX line (upper limit)
7. Tighten the air removal plug of the water outlet

pipe.

• The Engine has Overheated
• The Engine has Overcooled

Symptom: Engine has Overheated

The engine has overheated Insufficient amount of coolant Replenish the coolant
Clogging of the cooling system due to Remove foreign matter from the cooling
foreign matter system
Slipping caused by loosening or cracks Adjust or replace the drive belt
in the drive belt
Slipping caused by fan clutch oil leak Replace the fan clutch
Defective radiator cap or clogging of Replace the radiator cap. Or, clean the
radiator core radiator core
Defective thermostat Replace the thermostat
Improper adjustment of the timing Adjust the timing
Water leak caused by defective seal Replace the seal cap
cap of the cylinder head or cylinder
block
Defective water pump Replace the water pump

Symptom: Engine has Overcooled

The engine has overcooled Defective thermostat Replace
Cooling system method Force circulation method

Radiator NLR,NMR NPR
Heat dissipation capacity kW (kcal/h) 91.2 (78000) 103.8 (89000)
Heat dissipation surface area m2 2
(ft ) 10.93 (117.6) 13.92 (149.8)
Front surface area m2(ft2) 0.242 (2.60) 0.279 (3.00)
Dry mass kg(lb) 8.1 (17.9) 9.0 (19.8)
Coolant capacity L(lmp⋅gal) 2.5 (0.55) 2.6 (0.57)
Radiator cap
Open valve pressure kPa (kg/cm2/psi) 88 - 118 (0.9 - 1.2/12.8 - 17.1)
Water pump Centrifugal impeller method
Thermostat Wax pellet type
Open valve temperature 85(185) (With jiggle valve)
°C(°F) 82(180) (Without jiggle valve)
Full-open temperature 100(212) (With jiggle valve)
°C(°F) 95(203) (Without jiggle valve)
Coolant total capacity
12 (2.64)(including radiator)
[reference value] L(lmp⋅gal)
Water Pump
Components
3
4
LNW61CMF000101
Legend
1. Water pump 4. Set plate
2. Drive belt 5. Fan assembly
3. Water pump pulley 6. Fan guide
Removal Legend
1. Radiator drain plug
2. Drain plug; cylinder block
2. Loosen the tightening screw of the fan guide.

2
LNW21CSH000601

3. Remove the 4 installation nuts to remove the fan 6. Remove the water pump assembly bolt and insert
assembly. At that time, loosen the 4 water pump a screwdriver into the position shown in the
pulley and set plate tightening bolts. diagram to remove the water pump assembly while
twisting the screwdriver.
1
1
2
3
2
4
LNW21CSH001901
LNW21CSH002001
Legend
1. Fan assembly Legend
2. Fan assembly tightening nut 1. Water pump
3. Set plate 2. Water pump pulley
4. Water pump pulley 3. Set plate
5. Set plate and water pump pulley tightening bolts
4. Loosen the nuts (2) and (3). Loosen the generator

adjust bolt (1) to remove the fan belt.
Inspection
1. External inspection.
• Inspect the pump body for cracks and damage.
• Inspect the impeller for cracks and corrosion.
• Inspect the seal unit for water leak.
• When an abnormality is found, replace the
water pump assembly.
3
1
LNW21CSH000101
Legend
1. Adjust bolt
2. Adjust plate lock nut
3. Generator tightening nut
5. Remove the set plate and water pump pulley.

LNW21CSH000901
2. Inspection of the bearing unit.


• Rotate the fan while pushing the fan center to 2. Temporarily tighten the bolt until the water pump
the radius direction and inspect for any pulley (1) is seated together with the set plate (2)
significant looseness or abnormal sounds. on the water pump assembly.
• When an abnormality is found, replace the
water pump assembly.
LNW21BSH026101
Legend
LNW21CSH001001 1. Fan pulley
2. Set plate
Installation 3. Install the drive belt and adjust its tension using the
1. Install the water pump assembly. adjust bolt of the generator.
• Apply liquid gasket (TB1207B or equivalent) in • For details on the adjustment of the fan belt,
bead width of approximately 3 to 5 mm(0.12 to refer to "Drive Belt" in this section.
0.20 in)in alignment to the groove of the water 4. After adjusting the drive belt, tighten the generator
pump installation surface. at the specified torque.
• Refer to the diagram for the application position Tightening torque:
of the liquid gasket.
Nut (2) = 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
• After applying the liquid gasket, install it within 5 Nut (3) = 62 N⋅m (6.3 kg⋅m/46 lb⋅ft)
minutes.
• Install the water pump by aligning it to the front
cover stud.
mm (in.)
3
1
3-5
(0.12-0.20) 1(0.04) or more
LNW21CSH000101
(0.02-0.06)
Legend
0.5-1.5
1. Adjust bolt
2. Adjust plate lock nut
LNW71CSH002901
3. Generator tightening nut

5. After adjusting the drive belt, tighten the
temporarily tightened fan pulley and set plate at
6. Install the fan assembly and tighten it at the
specified torque.
1
2
3
LNW21CSH001901
Legend
1. Fan assembly
2. Fan tightening nut (4 pcs.)
3. Set plate
4. Fan pulley
5. Water pump pulley and set plate tightening bolts
7. Install the fan guide.

8. refill the coolant.
• Reference, refer to "Cooling System" in this
section.

f
c
LNW71CMF001701
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(c) 62 N⋅m (6.3 kg⋅m/46 lb⋅ft)
(d) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(e) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(g) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Thermostat
Components
LNW71CMF001401
Legend
1. Radiator upper hose 3. Thermostat
2. Water outlet pipe 4. Gasket
Removal
1. Drain the coolant. Prepare a container for
discharge and use it for refilling when installing the Temperature when it starts opening
thermostat. The amount of coolant to be
discharged should be enough to avoid coolant (Without jiggle valve) 82°C(180°F)
from spilling from the thermostat housing. (With jiggle valve) 85°C(185°F)
2. Remove the radiator upper hose at the radiator Full-open temperature
side.
95°C(203°F)
3. Remove the water outlet pipe. (Without jiggle valve)
or more
4. Remove the thermostat. 100°C(212°F)
5. Remove the gasket from the thermostat. (With jiggle valve)
or more
8 mm(0.31 in)
Lift amount
Inspection or higher
• Place the thermostat in water, and raise the water

temperature while thoroughly stirring it.
• Measure the temperatures when the valve starts
opening and when it is fully opened.

LNW21CSH003401
LNW21CSH000401
4. Refill the coolant that was stored when discharged,

Installation and check the coolant level.
1. Install the gasket to the thermostat and install to • Reference, refer to "Cooling System" in this
the position in the diagram. section.
• There are 2 types of thermostats of different
shapes. Install them to the positions shown in
the diagram.
• Securely insert the thermostat so that the
thermostat gasket does not ride up outside of
the cylinder head side housing.
2
3
LNW21BSH000101
Legend
1. Reserve tank
1 2 2. MAX line (upper limit)
LNW21CSH000201
Legend
1. Thermostat
2. Cylinder head
2. Install the water outlet pipe.

Engine Coolant Temperature (ECT) Sensor

Removal
1. Turn OFF the ignition switch.
2. Disconnect the harness connector of the engine
coolant temperature (ECT) sensor.
4. Remove the engine coolant temperature (ECT)
sensor.
MFW71KSH000201
1 Resistance value at a certain temperature

(approximate value):
2.45 kΩ (when the water is 20°C(98°F))
0.81 kΩ (when the water is 50°C(122°F))
2 0.245 kΩ (when the water is 90°C(194°F))
LNW61CSH000101
Thermistor characteristic
Legend 30
1. Engine coolant temperature (ECT) sensor 20
2. Adhesive agent application area

10
7.0
)
5.0
Resistance value(k
Inspection 3.0
2.0
• Place the temperature sensor section of the
engine coolant temperature (ECT) sensor into 1.0
water. Measure the resistance value while 0.7
changing the water temperature and check that it 0.5
corresponds to the values in the thermistor 0.3
characteristics graph. 0.2
Replace it if any abnormality is found during the

0.1
inspection. -20 0 20 40 60 80 100 120
Engine coolant temperature( )
MFW81CSH000901
Installation
1. Clean up the threaded portion of engine coolant
temperature (ECT) sensor, apply adhesive agent
(Loctite 262 or equivalent) to the threaded portion,
then tighten it at the specified torque.
LNW61CSH000101
Legend
1. engine coolant temperature (ECT) sensor
2. Adhesive agent application area
2. Connect the harness connector of the engine

coolant temperature (ECT) sensor.
section.
Radiator
Components
3
LNW71CMF001301
Legend
1. Fan guide 4. Upper hose
2. Radiator 5. Reserve tank hose
3. Lower hose
Removal
1. Loosen the water drain plug (on the rear right side
of the engine) and radiator drain plug, and
completely drain the coolant.

• After draining, securely tighten the drain plug. Inspection
Radiator cap
2 1. Use the radiator cap tester to inspect the open
valve pressure. Replace the radiator cap if the
open valve pressure exceeds the standard value.
1 Open valve pressure: 88 - 118 kPa (0.9 - 1.2 kg/cm2/
12.8 - 17.1 psi)
LNW21CSH000601
Legend
1. Radiator drain plug
2. Drain plug: cylinder block
2. Remove the upper hose at the radiator side.

3. Remove the lower hose at the radiator side.
LNW21BSH000201
4. Remove the reserve tank hose from the radiator
side. 2. Inspect the condition of the negative pressure
5. Pull out the fan guide from the bottom side. valve at the center of the cap valve seat side. If the
valve seat is not operating smoothly because of
rust, filth, etc., clean or replace the radiator cap.
fan blades. Remove the brackets on the left and
Radiator core
right sides of the radiator to remove the radiator.
• Repair the radiator fins if they are deformed as it
can lead to a decrease in heat dissipation effect,
causing overheating. When repairing, take
sufficient care not to damage the base of the fins.
• Remove filth or other foreign matter.
Washing the radiator
• Wash the inside of the radiator and coolant path
with water and a mild detergent. Wash away boil
residue and rust.
Installation
fan blades. Install the left and right brackets of the
radiator to the frame side bracket as shown in the
diagram.
1 2 3
Radiator side bracket from frame side bracket
LNW91BSH004901
Legend
1. Frame side bracket • When removed a frame side bracket, tighten it
2. Radiator side bracket by the following torque.
3. Radiator
Frame from frame side bracket

Front rigid suspension vehicles 4. Install the radiator lower hose.
1
section.
6 2
3
5
4
LNW21BSH013601
Legend
1. Stud bolt
2. Rubber
3. Washer
4. Flange nut
Front independent suspension vehicles
1
6
2
5
4
3
LNW21BSH013701
Legend
1. Flange nut
2. Rubber
3. Stud bolt
6. Washer

3. Install the coolant reserve tank hose to the
radiator.
Drive Belt
Components
1 2
3
4
5
6
7
8
13
12
4 10
11
10
4 10
LNW71CMF001801
Legend
1. A/C compressor 8. Tension pulley adjust bolt
2. Adjust plate lock nut 9. Crank pulley
3. Adjust plate 10. Drive belt
4. A/C compressor drive belt 11. Nut
5. Water pump pulley (fan pulley) 12. Generator
6. Tension pulley lock nut 13. Adjust bolt
7. Tension pulley
Inspection
Inspect the drive belt for wear or damage and replace it A/C compressor drive belt (1)
when necessary.
16 - 20 mm(0.63 - 0.79 in)
Also inspect the belt tension and adjust the tension if
(new belt)
necessary. Belt flex amount
18 - 22 mm(0.71 - 0.87 in)
Inspection guidelines (reused belt)
Press the mid-point of the longest span of each belt
with a pressure of 98 N (10 kg/22 lb) to inspect the
amount of belt flex.
Drive belt (2)
8 - 12 mm(0.31 - 0.47 in)
(new belt)
Belt flex amount
10 - 14 mm(0.39 - 0.55 in)
(reused belt)
5 12
7
1 8
9
2 10
4
2
11
1
LNW71CSH003501 LNW71CSH002701
Legend
1. Crank pulley
Adjustment 2. Generator tightening nut
When adjusting the belt tension, do so for both the fan 3. Generator
belt and the A/C compressor drive belt. 4. Adjust bolt
After adjusting the fan belt, adjust the A/C compressor 5. A/C compressor
drive belt. 6. Adjust plate lock nut
1. Loosen the tension pulley lock nut (8) and adjust 7. Water pump pulley (fan pulley)
bolt (10) of the A/C compressor drive belt to free 8. Tension pulley lock nut
the belt. 9. Tension pulley
10. Tension pulley adjust bolt
2. Loosen the adjust plate lock nut (6) of the
11. Drive belt
generator and the tightening nut (2) at the bottom
12. A/C compressor drive belt
side of the generator.
3. Turn the adjust bolt (4) to adjust (or remove/attach,
replace) the drive belt.
• When replacing the belts, replace both of the 2
belts.
4. After adjustment, tighten the adjust plate lock nut
(6) and the tightening nut (2) at the bottom side.
Tightening torque:
Nut (6) = 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Nut (2) = 62 N⋅m (6.3 kg⋅m/46 lb⋅ft)
5. Adjust the tension of the A/C compressor drive
belt.
a. Turn the tension pulley adjust bolt (10) to adjust
(or remove/attach, replace) the belt.
b. After adjusting, tighten the lock nut (8) at the
specified torque.

b
C
LNW71CSF000201
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(c) 62 N⋅m (6.3 kg⋅m/46 lb⋅ft)
Engine Fuel (4HV1-CNG) 1D-1
ENGINE
Engine Fuel
(4HV1-CNG)
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 List of Tightening Torques . . . . . . . . . . . . . . . . 1D-41
Maintenance Precautions . . . . . . . . . . . . . . . . . 1D-2 Gas Filter except Australia . . . . . . . . . . . . . . . . . 1D-42
Description of Function and Operation . . . . . . . 1D-2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-42
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-42
Gas Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-42
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-10 Filling Unit except Australia . . . . . . . . . . . . . . . . 1D-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-44
CNG Pressure / Temperature Sensor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-45
except Australia . . . . . . . . . . . . . . . . . . . . . . . . . 1D-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-12 Filling Unit for Australia . . . . . . . . . . . . . . . . . . . 1D-46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-46
CNG Temperature Sensor for Australia . . . . . . . 1D-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13
CNG Pressure Sensor for Australia . . . . . . . . . . 1D-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-14
Pressure Regulator except Australia . . . . . . . . . 1D-15
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
List of Tightening Torques . . . . . . . . . . . . . . . . 1D-18
Pressure Regulator for Australia . . . . . . . . . . . . 1D-19
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-20
Automatic Valve (before Regulator) except
Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-22
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-23
Automatic Valve (before Regulator) for Australia 1D-25
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-26
Automatic Valve (at Tank) for Australia . . . . . . . 1D-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-28
CNG Container (CNG Cylinder) except Australia1D-30
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-32
CNG Container (CNG Cylinder) for Australia . . . 1D-35
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-38
1D-2 Engine Fuel (4HV1-CNG)
Fuel System
Maintenance Precautions
• When the battery is not being used, remove its
ground cable.
• Do this in a maintenance garage where there is no
presence of flames and with good ventilation.
Confirm that there is no accumulation of gas when
removing the electric wiring.
• If a gas leak is discovered, do not carelessly
proceed to operate switches such as for lighting
and ventilation fans.
• When removing and installing components such as
CNG container (CNG cylinder) and gas passages,
start the engine after fully closing the manual
cylinder valve (at tank) of all CNG container (CNG
cylinder) in order to eliminate any residual gases.
Idle the engine to burn any residual gas and turn
the ignition switch OFF after the engine stops.
• Make sure to use parts such as pipes that are
equivalent to those specified by Isuzu.
When replacing CNG container (CNG cylinder)
and components, securely install them after
sufficiently inspecting each connection for
damages.
• After installation or removal work, force-open the
valves and thoroughly confirm that there are no
gas leaks at normal pressure.
• For details on trouble diagnosis of the fuel system,
check the fuel system upon refer to the "Engine
Control System" in Section 1A, Engine Control
System (4HV1-CNG).
• The tightening torque for the Dia of 6.35 mm(0.23
in) rigid fuel line coupler is 29 N⋅m (3.0 kg⋅m/22
lb⋅ft).

Compressed natural gas (CNG) is compressed to 20
MPa (204 kg/cm2/2900 psi) and stored in the high
pressure CNG container (CNG cylinder). After passing
the gas through the rigid fuel line to the pressure
regulator, where it is reduced to 0.4 MPa (4.1 kg/cm2/
158 psi), the gas is guided to the flexible fuel line,
where it is mixed with air by the opening of the gas
injector, to become a fuel mixed gas. Then, it is sucked
into the combustion chamber and ignited by a spark
from the spark plug.

Components
except Australia
4
2 3
13 12
11 5
10
8
LNW91DMF000401
Legend
1. Spark plug 8. Filling unit
2. Gas injector 9. Automatic valve (at tank) and manual cylinder
3. Gas filter valves
4. Pressure regulator 10. CNG container (CNG cylinder)
5. Fuel gauge 11. Throttle valve
6. Engine control module (ECM) 12. Intake pipe
7. Automatic valve (before regulator) 13. Exhaust pipe

for Australia
3
2
12 11
10 4
9
8 7
LNW71DMF001601
Legend
1. Spark plug 7. Filling unit
2. Gas injector 8. Automatic valve (at tank)
3. Pressure regulator 9. CNG container (CNG cylinder)
4. Fuel gauge 10. Throttle valve
5. Engine control module (ECM) 11. Intake pipe
6. Automatic valve (before regulator) 12. Exhaust pipe

Manual cylinder valve with excess flow valve (EFV) and automatic valve (at tank) except Australia
2 3 4 5 6
1 7 8
20 19 18
17 11 10
16
12
15 13
14
LNW91DLF000901
Legend
1. O-ring 11. O-ring
2. Spring 12. Excess flow valve (EFV)
3. Gasket 13. Body
4. Sleeve 14. Pressure relief device (PRD)
5. O-ring 15. Solenoid
6. Gasket 16. Internal excess flow shutter
7. O-ring 17. Spring
8. Pin 18. Compensation ring
9. Handle 19. Nut
10. Shaft 20. Nut

Automatic valve (at tank) for Australia
1
12
11 10
9
4
8
7 5
6
LNW21DMF001901
Legend
1. Coil 7. Rubber material
2. Plunger 8. Filter
3. Spring 9. Black lead wire (GND)
4. O-ring 10. Red lead wire (for suction)
5. Main valve 11. White lead wire (for retention)
6. Body 12. PVC tube black color

Manual cylinder valve (at tank) with excess flow valve (EFV) for Australia
5 LNW71DMF001501
Legend
1. Rigid fuel line 3. Fusible alloy
2. Pressure relief device (PRD) bursts through 4. Excess flow valve (EFV)
the fusible alloy of the pressure relief device 5. CNG container (CNG cylinder) side
(PRD) to discharge gas. (fusible alloy melting
point 105 °C(221°F))

Operating status of the excess flow valve (EFV) for Australia
4 5
1 2 3
LNW21DSF000701
Legend
1. Normal use status 4. Valve seat is closely attached, cutting off the gas
2. excess flow valve operation 5. Removed by tightening the handle
3. When the excess flow valve operation is
cancelled
Check valve except Australia
1 2
4 3
LNW91DSF000101
Legend
1. Valve 3. CNG container (CNG cylinder) side
2. Spring 4. Filling unit side

Check valve for Australia
2
4
3
LNW71DMF001701
Legend
1. Spring 3. Filling unit side
2. Valve 4. CNG container (CNG cylinder) side
Ignition cut switch for Australia NOTE:

If the filling unit door is open, the starter will not operate
1 even if the ignition switch is engaged.
3
2
LNW61CSH000201
Legend
1. Filling unit
2. Filling unit cap
3. Ignition cut switch (interlock switch)
Gas Injector
Components
except Australia
1 2
4 3
LNW91DMF000301
Legend
1. Connector 3. Gas injector
2. Clip 4. Plate (Until December, 2012)

for Australia
1
2
4
5
LNW61DMF000301
Legend
1. Connector 4. Plate (Until December, 2012)
2. Clip 5. Bolt
3. Gas injector
Removal NOTE:
If the bolt is tightened when the rubber seal's outer
1. Loosen the clip.
circumference protruding section is not securely
2. Disconnect the connector. inserted into the intake manifold hole, the seal rubber
3. Remove the gas injector installation bolt. will protrude out from between the intake manifold and
4. Remove the gas injector. plate, which will cause gas leaks.
3. Connect the connector.

Installation • Pass the gas injector harness through the clip
1. Install the gas injector. and connect the connector.
• Apply a thin layer of engine oil to the seal 4. Fasten the clip.
rubber side surface and to the tip of the O-ring. 5. When the gas injector is replaced, use the scan
• Insert straight in to the insert direction without tool to learning the different kind fuel learning to
tilting, until it hits the end. the ECM. Refer to the “Engine Control System” in
Section 1A, Engine Control System(4HV1-CNG).
• Ensure that the harness is facing towards the
front of the engine.
2. Install the gas injector installation bolt.
• After securely inserting the protruding section
into the hole of the intake manifold, attach the
plate (Until December, 2012) and tighten the
bolt at the specified torque.
CNG Pressure / Temperature Sensor except Australia

Removal
1. Remove the battery ground.
2. Disconnect the harness connector.
3. Remove the CNG pressure / temperature sensor.
LNW91DSH000701
Installation
1. Install the CNG pressure / temperature sensor and
• Make sure to apply a thin layer of engine oil to
the O-ring.
• Make sure to place the sensor parallel and
insert it while rotating (30° or less).
2. Connect the harness connector.
3. Install the battery ground.
CNG Temperature Sensor for Australia

Removal • Tighten the sensor at a torque of 17 N⋅m (1.7
kg⋅m/12 lb⋅ft).
1. Disconnect the negative side terminal of the
battery cable.
2. Remove the harness connector of the CNG
1
temperature sensor.
3. Remove the CNG temperature sensor.
LNW61ASH002401
Legend
1. CNG temperature sensor
2. Connect the harness connector of the CNG

LNW61ASH002401
temperature sensor.
Legend 3. Connect the negative side terminal of the battery
1. CNG temperature sensor cable.
Installation
1. Install the CNG temperature sensor.
NOTE:
Check to make sure that the copper washers are firmly
attached.
CNG Pressure Sensor for Australia

Removal • Tighten the sensor at a torque of 23 N⋅m (2.3
kg⋅m/17 lb⋅ft).
battery cable.
2. Disconnect the harness connector of the CNG 1
pressure sensor.
3. Remove the CNG pressure sensor.
LNW61ASH002501
Legend
1. CNG pressure sensor
2. Connect the harness connector of the fuel

LNW61ASH002501
pressure sensor.
Legend 3. Connect the negative side terminal of the battery
1. CNG pressure sensor cable.
Installation
1. Install the CNG pressure sensor.
NOTE:
Check to make sure that the O-rings are firmly
attached.
Pressure Regulator except Australia

Components
LNW91DLF000301
Legend
1. Bracket 4. Pressure regulator
2. Automatic valve (before regulator) 5. Service valve
3. Pressure regulator cover
Removal Work
Preparation 1. Remove the pressure regulator cover.
1. Completely close all manual cylinder valve (at 2. Disconnect each harness connector (2) and clip.
tank). 3. Remove the flexible fuel line (3).
2. Start the engine to eliminate all fuel gas that
NOTE:
remain in the pipes and idle the engine until it
There is an O-ring attached in the flexible fuel line
stops. When the engine stops, turn the ignition
installation section. Be careful not to lose it. Also, cover
switch off.
the open section of the hose so that foreign matter do
3. Remove the battery ground. not enter.

4. Remove each heater hose (4). 9. Remove the pressure regulator from the bracket.
5. Remove each rigid fuel line (1).
NOTE:
Installation
• Before removing, adequately clean the removal
section of the rigid fuel line. 1. Install the pressure regulator to the bracket.
• Use two wrenches to fasten one side, and to 2. Install the vinyl pipe(1).
loosen the other side. 3. Install the rigid fuel line(2).
• Keep the removed rigid fuel line away from
attachment of filth or dust.
1 2
LNW91DSH001801
4 3
Tightening torque: 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)→90°

LNW91DSH000101
4. Install the pressure regulator, automatic valve
Legend (before regulator) and service valve to the frame
1. Rigid fuel line along with the bracket.
2. Harness connector 5. Tighten each rigid fuel line (1) at the specified
3. Flexible fuel line torque.
4. Heater hose
6. Remove the pressure regulator, automatic valve
(before regulator) and service valve along with the NOTE:
bracket. • With reference to the coupler, insert the pipe
7. Remove the rigid fuel line(2). straight in to install it.
8. Remove the vinyl pipe(1). • When inserting, check that there is no attachment
of foreign matter or scratches on the inside of the
coupler or seal surface, then assemble.
6. Install each heater hose (4).

7. Install the flexible fuel line (3).
• There should be no scratches or filth on the O-
rings.
Replace the O-ring if it is damaged.
1
• Apply a thin layer of engine oil on the O-ring,
2 and
tighten the mounting bolt at the specified
torque.
LNW91DSH001801

8. Connect each harness connector (2) and clip.
1 2
4 3
LNW91DSH000101
Legend
1. Rigid fuel line
2. Harness connector
3. Flexible fuel line
4. Heater hose
9. Install the pressure regulator cover.


LNW91DLF000401
(a) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)

(b) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(c) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(d) 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)→90°
(e) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
Pressure Regulator for Australia

Components
5 4
LNW71DLF002001
Legend
1. Fuel manifold 4. Air valve
2. Automatic valve (before regulator) 5. Pressure regulator
3. Fuel filler inlet 6. Pressure regulator cover
Removal 4. Disconnect the connector from the chassis

harness.
Preparation
1. Completely close all manual cylinder valve (at Work
tank).
1. Remove the pressure regulator cover.
2. Disconnect each harness connector (1).
stops. When the engine stops, turn the ignition 3. Remove the flexible fuel line (2).
switch off.

NOTE: • There should be no scratches or filth on the O-
There is an O-ring attached in the fuel hose installation rings.
section. Be careful not to lose it. Also, cover the open Replace the O-ring if it is damaged.
section of the hose so that foreign matter do not enter. • Apply a thin layer of engine oil on the O-ring,
and
4. Remove each heater hose (3). tighten the mounting bolt at the specified
5. Remove each rigid fuel line (4). torque.
NOTE: Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb⋅in)

• Before removing, adequately clean the removal 6. Connect each harness connector (1).
section of the rigid fuel line.
• Use two wrenches to fasten one side, and to
loosen the other side.
4 14
4 14
3
1
2 3
LNW71DSH004001
3
2 3
LNW71DSH004001
6. Remove the pressure regulator, fuel manifold and

air valve along with the bracket.
7. Remove the pressure regulator from the bracket.
Installation
1. Install the pressure regulator to the bracket.
2. Install the pressure regulator, fuel manifold and air
valve to the frame along with the bracket.
3. Tighten each rigid fuel line (4) at the specified
torque.
NOTE:
• With reference to the coupler, insert the pipe
straight in to install it.
• When inserting, check that there is no attachment
of foreign matter or scratches on the inside of the
4. Install each heater hose (3).

5. Install the flexible fuel line (2).

a b
e c
LNW71DLF001801
(a) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)

(b) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(c) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(d) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(e) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(f) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
Automatic Valve (before Regulator) except Australia

Components
LNW91DLF000301
Legend
1. Bracket 4. Pressure regulator
2. Automatic valve (before regulator) 5. Service valve
3. Pressure regulator cover
Removal Work
Preparation 1. Remove the pressure regulator cover.
1. Completely close all manual cylinder valve (at 2. Disconnect each harness connector (2) and clip.
tank). 3. Remove the flexible fuel line (3).
NOTE:
There is an O-ring attached in the flexible fuel line
installation section. Be careful not to lose it. Also, cover
switch off.
the open section of the hose so that foreign matter do
3. Remove the battery ground. not enter.

4. Remove each heater hose (4). 4. Tighten each rigid fuel line (1) at the specified
5. Remove each rigid fuel line (1). torque.
NOTE:
• Before removing, adequately clean the removal NOTE:
• Use two wrenches to fasten one side, and to straight in to install it.
• When inserting, check that there is no attachment
• Keep the removed rigid fuel line away from of foreign matter or scratches on the inside of the
attachment of filth or dust. coupler or seal surface, then assemble.
5. Install the heater hose (4).

6. Install each flexible fuel line (3).
• There should be no scratches or filth on the O-
1 2 rings.
Replace the O-ring if it is damaged.
• Apply a thin layer of engine oil on the O-ring,
and
tighten the mounting bolt at the specified
torque.
7. Connect each harness connector (2) and clip.
4 3
1 2
LNW91DSH000101
Legend
1. Rigid fuel line
4. Heater hose
6. Remove the pressure regulator, automatic valve

(before regulator) and service valve along with the
bracket.
4 3
7. Remove the harness clip.
8. Remove the rigid fuel line.
9. Remove the automatic valve (before regulator) LNW91DSH000101
from the bracket. Legend

1. Rigid fuel line
Installation 4. Heater hose
1. Install the automatic valve (before regulator) to the
bracket.
2. Install the rigid fuel line. 8. Install the pressure regulator cover.
3. Install the pressure regulator, automatic valve
(before regulator) and service valve to the frame
along with the bracket.

LNW91DLF000401
(a) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)

(b) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(c) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(d) 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)→90°
(e) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
Automatic Valve (before Regulator) for Australia

Components
1 5
LNW71ALF001601
Legend
1. Rigid fuel line 3. CNG pressure sensor harness connector
2. Automatic valve (before regulator) harness 4. Pressure regulator cover
connector 5. Automatic valve (before regulator)
Removal Removal
Preparation 1. Remove the CNG container front cover.
1. Completely close all manual cylinder valve (at 2. Remove the pressure regulator cover.
tank). 3. Remove each rigid fuel line.
NOTE:
stops. When the engine stops, turn the ignition • Before removing, adequately clean the removal
switch off. section of the rigid fuel line.
3. Disconnect the connector from the chassis • Use two wrenches to fasten one side, and to
harness. loosen the other side.

4. Disconnect the harness connector from the

automatic valve (before regulator) and CNG
pressure sensor.
5. Remove the automatic valve (before regulator).
Installation
1. Install the automatic valve (before regulator).
2. Connect the harness connector to the automatic
valve (before regulator) and CNG pressure sensor.
3. Install each rigid fuel line, and tighten at the
specified torque.
NOTE:
• With reference to the coupler, insert the pipe straight
in to install it.
• When inserting, check that there is no attachment of
foreign matter or scratches on the inside of the

5. Install the CNG container front cover.
Automatic Valve (at Tank) for Australia

Removal NOTE:
Preparation • Before removing, adequately clean the removal
1. Completely close all manual cylinder valve (at
tank). • Use two wrenches to fasten one side, and to loosen
the other side.
remain in the pipes and idle the engine until it • Keep the removed rigid fuel line away from
stops. When the engine stops, turn the ignition attachment of filth or dust.
switch OFF.
4. Remove the automatic valve (at tank) bracket
3. Remove the battery ground. fixing bolts (2 pcs.) and remove the automatic
4. Disconnect the connector from the chassis valve (at tank) bracket (with automatic valve (at
harness. tank)) from the CNG container bracket.
[RH]
Removal
1. Remove the side cover bracket (1). 3
2
1
A
LNW61ASH003201
Legend
LNW91DSH001001 1. Automatic valve (at tank)(RH)
2. Automatic valve (at tank) bracket
2. Remove the CNG container cover 3. CNG container (CNG cylinder) (RH)
LNW91DSH001101
3. Remove the rigid fuel line from the automatic valve

(at tank).

[LH] 2. Install the automatic valve (at tank) bracket (with
automatic valve (at tank)) to the CNG container
bracket and tighten the automatic valve (at tank)
2 3 fixing bolts (2 pcs.).
1 [RH]
A
A 2
1
A
A
LNW61ASH003301
Legend
1. Automatic valve (at tank) (LH)
LNW61ASH003201
3. CNG container (CNG cylinder) (LH)
Legend
5. Remove the automatic valve (at tank) fixing bolts 1. Automatic valve (at tank) (RH)
(2 pcs.) and remove the automatic valve (at tank) 2. Automatic valve (at tank) bracket
from the bracket. 3. CNG container (CNG cylinder) (RH)
[LH]
Installation
1. Install the automatic valve (at tank) to the bracket
2 3
and tighten the automatic valve (at tank) fixing
bolts (2 pcs.). 1
A
LNW61ASH003301
Legend
1. Automatic valve (at tank) (LH)
3. CNG container (CNG cylinder) (LH)
3. Install the rigid fuel line to the automatic valve (at

tank), and tighten at the specified torque.
NOTE:
straight in to install it.

• Check that there are no attachment of foreign
matter or scratches to the inside of the coupler and
seal surface when inserting.
• Measures taken when leaks occur
- Check the removed coupler.
- Remove any foreign matter and replace with a
new part if scratched or damaged.
Do not simply over-tighten.
4. Install the CNG container cover and tighten at the

specified torque.
LNW91DSH001101
5. Install the side cover bracket (1) and tighten at the

specified torque.
LNW91DSH001001
CNG Container (CNG Cylinder) except Australia

Components
2
1
10 3
6 5
8 7
LNW91DLF000501
Legend
1. Side cover bracket 6. Out support bracket
2. Rear cover 7. Filling unit
3. CNG container (CNG cylinder) 8. Lower cover
4. CNG container band 9. Front cover
5. Side cover 10. Rigid fuel line
Removal 3. Remove the battery ground.

Preparation
Work
1. Remove the CNG container cover (front, rear and
tank).
side).
remain in the pipes and idle the engine until it NOTE:
stops. When the engine stops, turn the ignition When removing the front cover, remove the harness
switch off. clip.

6. Remove the CNG container lower cover.
2. Disconnect the harness connector. 7. Remove the side cover brackets.
3. Remove the pressure regulator cover.
4. Remove the rigid fuel line with the bracket

assembly.
NOTE:
• Use two wrenches to fasten one side, and to loosen
the other side.
LNW61DSH001401
8. Remove the stopper plate mounting bolt for fixing

the CNG container (CNG cylinder).
LNW91DSH000201
5. Remove the filling unit and check valve with the

bracket assembly.
LNW91DSH000401
LNW91DSH000301

9. Remove the CNG container band installation nut 2. Tighten the stopper plate mounting bolt for fixing
and remove the CNG container band. the CNG container (CNG cylinder) and tighten at
LNW91DSH000501
10. Remove the out support bracket. LNW91DSH000401
11. Remove the CNG container (CNG cylinder).
NOTE: 3. Tighten the CNG container band with the

• Lay the removed CNG container (CNG cylinder) to installation self-lock nut.
its side and set it so that it will not roll away. • When installing, check that the rigid fuel line is
• Be careful not to apply an impact to the CNG smoothly installed, and tightened at the
container (CNG cylinder) and manual cylinder valve specified torque.
(at tank).
NOTE:
• Use a new self-lock nut.
LNW91DSH001301
Installation
LNW91DSH000501
1. Install the CNG container (CNG cylinder) .

4. Install the out support bracket, and tighten the
bolts at the specified torque. 8. Install the rigid fuel line with the bracket assembly,
Tightening torque: 41 N⋅m (4.2 kg⋅m/30 lb⋅ft) and tighten the rigid fuel line installation nut at the
specified torque.
5. Install the side cover bracket, and tighten the bolts
at the specified torque. NOTE:
Tightening torque: 20 N⋅m (2.0 kg⋅m/14 lb⋅ft) • With reference to the coupler, insert the pipe straight
in.
matter or scratches to the inside of the coupler and
- Check the removed coupler.
LNW61DSH001401
6. Install the CNG container lower cover and tighten

the bolts at the specified torque.
7. Install the filling unit and check valve with the

bracket assembly, and tighten the rigid fuel line LNW91DSH000201
installation nut at the specified torque.
9. Install the pressure regulator cover .
11. Install the CNG container cover.

• Install the front, rear and side covers and
tighten them at the specified torque.
• Install the harness clip
LNW91DSH000301

k
j i
b
c
g
e
d
h
f
LNW91DLF000601
(a) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

(b) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(c) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
(d) 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
(e) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(f) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(g) 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)→90°
(h) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(i) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(j) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(k) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
CNG Container (CNG Cylinder) for Australia

Components
2
3
4
5
9
6
8
LNW61DMF000501
Legend
1. Manual cylinder valve (at tank) 6. Filling unit
2. CNG container band 7. Side cover
3. CNG container (CNG cylinder) 8. Lower cover
4. Automatic valve (at tank) 9. Front cover
5. Rigid fuel line
Removal NOTE:
When removing the front cover, remove the harness
Preparation
clip.
tank).
switch off.
4. Disconnect the connector from the chassis
harness.
5. Remove the side cover.
Work
1. Remove the CNG container cover (front, left and
right).
LNW61DSH000901 LNW61DSH001101
2. Remove the pressure regulator cover. 4. Remove the filling unit and ignition cut switch ASM.
3. Remove the rigid fuel line with the bracket ASM. 5. Remove the rigid fuel line with the automatic valve
(at tank).
NOTE:
• Before removing, adequately clean the removal NOTE:
section of the rigid fuel line. • Before removing, adequately clean the removal
• Use two wrenches to fasten one side, and to loosen section of the rigid fuel line.
the other side. • Use two wrenches to fasten one side, and loosen at
• Keep the removed rigid fuel line away from the other side.
attachment of filth or dust. • Keep the removed rigid fuel line away from

8. Remove the stopper plate mounting bolt for fixing
the CNG container (CNG cylinder) .
LNW61DSH001301
LNW61DSH001501
6. Remove the CNG container lower cover.

7. Remove the side cover brackets.
9. Remove the CNG container band installation nut
and remove the CNG container band.
LNW61DSH001401
LNW61DSH001601
10. Remove the CNG container (CNG cylinder) .
NOTE:
• Lay the removed CNG container (CNG cylinder) to
its side and set it so that it will not roll away.
• Be careful not to apply an impact to the CNG
container (CNG cylinder) and manual cylinder valve
(at tank).
4
3
2
1
11. Remove the CNG container (CNG cylinder) (3) 2. Install the CNG container (CNG cylinder) so that
ring nuts (2) using the special tool (4), and remove the rigid fuel line installation section of the manual
the stopper plate (1). cylinder valve (at tank) faces directly downward.
Special tools
Universal holder:
5-8840-2862-0
4
3
2
1
LNW61DSH001701
3. Tighten the CNG container band with the

LNW61DSH002101 installation self-lock nut.
• When installing, check that the rigid fuel line is
smoothly installed, and tightened at the
Installation specified torque.
1. Install the stopper plate (1) to the CNG container Tightening torque: 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
(CNG cylinder) (3) with the ring nut (2), and tighten
at the specified torque with the special tool (4). NOTE:
Special tools • Use a new self-lock nut.
Universal holder:
5-8840-2862-0
4. Tighten the stopper plate mounting bolt for fixing 6. Install the CNG container lower cover and tighten
the CNG container (CNG cylinder) and tighten at the bolts at the specified torque.
7. Install the rigid fuel line with the Automatic valve
(at tank) and tighten the rigid fuel line installation
nut at the specified torque.
NOTE:
• With reference to the fitting, insert the pipe straight
in.
matter or scratches to the inside of the fitting and
- Check the removed fitting.
LNW61DSH001501
5. Install the side cover bracket, and tighten the bolts


- Check the removed fitting.
LNW61DSH001301
8. Tighten the filling unit and ignition cut switch ASM

with the mounting bolts and tighten at the specified
torque. LNW61DSH001101

10. Install the pressure regulator cover and tighten the
bolts at the specified torque.
Tightening torque: 52 N⋅m (5.3 kg⋅m/38lb⋅ft)
LNW61DSH001201
9. Install the rigid fuel line with the bracket ASM, and
tighten the rigid fuel line installation nut at the LNW71DSH003801
specified torque.
11. Install the CNG container cover.
NOTE: • Install the front and left/right covers and tighten
them at the specified torque.
• With reference to the fitting, insert the pipe straight
in. Tightening torque: 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
matter or scratches to the inside of the fitting and

e
d
g
f
c
LNW71DMF001401
(a) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
(c) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(d) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(e) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(f) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
(g) 82 N⋅m (8.4 kg⋅m/61 lb⋅ft)
Gas Filter except Australia

Components
1
2
LNW91DMF000201
Legend
1. Straight connector 3. Gas filter
2. Elbow connector 4. Filter body
Preparation 1. Install the filter body.
1. Completely close all manual cylinder valve (at 2. Install the elbow connector.
tank). • Apply sealing agent (Loctite 575 or equivalent)
2. Start the engine to eliminate all fuel gas that to the tip of the circumference of the taper
remain in the pipes and idle the engine until it threaded portion (1 thread).
stops. • After temporarily tightening at 30 N⋅m(3.1 kg⋅m/
When the engine stops, turn the ignition switch 22 lb⋅ft), tighten in the tightening direction and
"OFF". position at the angle shown in the diagram "a
3. Remove the battery ground. "(30°).
Work
1. Remove the gas filter.
2. Remove the flexible fuel line.
3. Remove the straight connector.
4. Remove the elbow connector.
5. Remove the filter body.
LNW91DSH000601
3. Install the straight connector.

• Apply sealing agent (Loctite 575 or equivalent)
to the tip of the circumference of the taper
threaded portion (1 thread).
4. Install the flexible fuel line and tighten it at the
specified torque.
5. Install the gas filter.
• Apply grease or engine oil to the seal section of
the gas filter and install it.
or
After touching the seal, tighten with a 3/4 to 1 turn.
Filling Unit except Australia

Removal • Place marks on the check valve and the flare nut
before removing the rigid fuel line.
Preparation
tank).
switch off.
1
Work
1. Remove the CNG container cover (front).
NOTE:
When removing the front cover, remove the harness
clip.

LNW91DSH002401
Legend
1. Marks
3. Remove the filling unit.
NOTE:
Disassembly
LNW91DSH002301
1. Remove the O-ring (3).
2. Remove the coupler assembly (2).
NOTE: 3. Remove the O-ring (1).
the other side.

b. Install the rigid fuel line with the specified
torque.
1 2 3
NOTE:
When tightening the rigid fuel line, make sure to tighten
in the tightening direction from the marked position.
LNW91DSH002701
Reassembly
1. Install the O-ring (1).
2. Install the coupler assembly (2).
Tightening torque: 70 N⋅m (7.1 kg⋅m/51 lb⋅ft) LNW91DSH002501
3. Install the O-ring (3). Legend

1. Marks
3. Install the the CNG container cover (front).
1 2 3
LNW91DSH002701
Installation
1. Install the filling unit.
• Install the filling unit with the specified torque.
2. Install the rigid fuel line.
a. Blow air onto the joint of the filling unit and rigid
fuel line.
Filling Unit for Australia

Preparation 1. Install the filling unit.
1. Completely close all manual cylinder valve (at • Install the filling unit with the specified torque.
tank).
remain in the pipes and idle the engine until it 2. Install the rigid fuel line.
stops. When the engine stops, turn the ignition a. Blow air onto the joint of the filling unit and rigid
switch off. fuel line.
3. Remove the battery ground. b. Install the rigid fuel line with the specified
torque.
Work
1. Remove the CNG container cover (front).
3. Install the the CNG container cover (front).
NOTE:
When removing the front cover, remove the harness Tightening torque: 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
clip.
LNW91DSH002601
NOTE:
the other side.
3. Remove the filling unit.
NOTE:
Engine Electrical (4HV1-CNG) 1E-1
ENGINE
Engine Electrical
(4HV1-CNG)
TABLE OF CONTENTS
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-33
Maintenance Precautions . . . . . . . . . . . . . . . . . 1E-2 List of Tightening Torques . . . . . . . . . . . . . . . . 1E-34
Description of Function and Operation . . . . . . . 1E-2 Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
Malfunction Symptom List . . . . . . . . . . . . . . . . . 1E-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
Symptom: Starter Does not Work Even Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
When the Ignition Switch is Turned On . . . . . . . 1E-6 DC-DC Converter . . . . . . . . . . . . . . . . . . . . . . . . 1E-36
Symptom: Pinion Moves Forward but Does not Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-36
Mesh with the Ring Gear. . . . . . . . . . . . . . . . . . 1E-7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-36
Symptom: Pinion Meshes and the Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-37
Turns, but the Engine Does not Crank . . . . . . . 1E-8
Symptom: Pinion Meshes, but the Engine
Does not Crank . . . . . . . . . . . . . . . . . . . . . . . . . 1E-9
Symptom: After the Engine Starts,
the Starter Does not Stop Even if
the Ignition Switch is Turned Off . . . . . . . . . . . 1E-10
Primary Specifications. . . . . . . . . . . . . . . . . . . 1E-10
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-12
List of Tightening Torques . . . . . . . . . . . . . . . . 1E-13
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-14
Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1E-15
Maintenance Precautions . . . . . . . . . . . . . . . . 1E-15
Description of Function and Operation . . . . . . 1E-15
Primary Specifications. . . . . . . . . . . . . . . . . . . 1E-16
Functional Inspection . . . . . . . . . . . . . . . . . . . 1E-17
Malfunction Symptom List . . . . . . . . . . . . . . . . 1E-18
Symptom: Does not Charge at All. . . . . . . . . . 1E-19
Symptom: Charge is Insufficient . . . . . . . . . . . 1E-20
Symptom: Overcharged . . . . . . . . . . . . . . . . . 1E-21
Symptom: Charge Current is Unstable . . . . . . 1E-22
Symptom: Abnormal Noises from the
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-23
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-24
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-25
List of Tightening Torques . . . . . . . . . . . . . . . . 1E-27
Ignition System. . . . . . . . . . . . . . . . . . . . . . . . . . 1E-28
Maintenance Precautions . . . . . . . . . . . . . . . . 1E-28
Description of Function and Operation . . . . . . 1E-28
Ignition Coil & Spark Plug. . . . . . . . . . . . . . . . . . 1E-31
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-32
1E-2 Engine Electrical (4HV1-CNG)
Starting System
When performing maintenance on the electrical The ignition system is composed of the battery, starter,
system, confirm that the ignition switch and lighting ignition switch, and starter relay. Each of these main
switch are OFF, and always disconnect the negative (-) components is wired as shown in the diagram.
battery terminal before working.
4 5
ST
8
3
B
2
10
1
9
LNW21EMF001901
Legend
1. Pinion clutch 6. "B" terminal
2. Ring gear 7. Starter relay
3. Shift lever 8. Ignition switch
4. Magnetic switch 9. Battery
5. "S" terminal 10. Armature
Starter
The starter is a magnetic shift type starter and an outer
gearing mesh method reduction starter.
The contact point of the magnetic switch closes and the
armature rotates when the ignition switch is turned ON.
At the same time, the plunger is drawn in and the pinion
is pushed forward via the shift lever to mesh with the
ring gear, and when the ring gear rotates, the engine
starts. After the engine starts, the plunger returns, the
pinion separates from the ring gear, and the armature
stops rotating when the ignition switch is turned OFF.
When the engine rotation increases faster than the
pinion, the pinion will be caused to turn in reverse, but
because the pinion is rotating without contact, it does
not drive the armature.

Starter motor
24V 4.5kW(S25-505G)
3
4
5
6
2
1
LNW71EMF000801
Legend
1. Brush 5. Clutch
2. Yoke 6. Pinion
3. Magnetic switch 7. Armature
4. Torsion spring
Output characteristics
S25-505G
OUTPUT(kw)
TORQUE(N m)
SPEED(r/min)
VOLTAGE(v)
STARTER PERFORMANCE JIS D1607 24-B

(STANDARD)
OUTPUT
4.8 118 6000 24 VOLTAGE
4.0 98 5000 20
3.2 78 4000 16
2.4 59 3000 12
TORQUE
1.6 39 2000 8
SPEED
0.8 20 1000 4
0 0 0 0
0 100 200 300 400 500 600 700 800 900 1000 1100
CURRENT (A)
LNW91ESF000101

Ignition switch
IG1 B2
ACC ST
B1 IG2
OFF ACC ON ST
B2
IG2
ST
B1
ACC
IG1
LNW71ESF000501
Idling stop and start system (ISS) for Australia

ISS is a system to automatically stop the engine, which
is in idling state when the vehicle is parked or stopped,
and to restart the engine when the vehicle is started. It
also utilizes the idling stop function to stop the engine
from the rear mounted equipment/body such as of an
aerial platform vehicle, etc. When the condition to stop
the engine is satisfied based on the inputs from
sensors, switches and CAN, the BCM will send the
engine stop request to the ECM through the CAN and
the ECM will perform the engine stop control. When the
condition to restart the engine is satisfied, the BCM will
energize the starter and perform the engine start
control.
For details, refer to "Body Control System" in Section
10B Vehicle Control.

• The Starter Does not Work Even When the Ignition
Switch is Turned On.
• The Pinion is Pushed Forward but Does not Mesh
with the Ring Gear.
• The Pinion Meshes and the Motor Turns, but the
Engine Does not Crank.
• The Pinion Meshes, but the Engine Does not
Crank.
• After the Engine Starts, the Starter Does not Stop
Even if the Ignition Switch is Turned Off.

Symptom: Starter Does not Work Even When the Ignition Switch is Turned On

Starter does not work even when the Complete battery discharge Replace the battery
ignition switch is turned on Wiring circuit open circuit, improper Repair
connection
Defective contact of the ignition switch Repair or replace the part
contact point, or improper tightening of
the terminal
Defective contact of the starter relay Repair or replace the part
contact point or defective contact of the
insertion terminals
Short circuit or open circuit of magnetic Replace
switch coil

Symptom: Pinion Moves Forward but Does not Mesh with the Ring Gear

Pinion moves forward but does not Insufficient charge of battery Charge or replace the battery
mesh with the ring gear Wear of the pinion or ring gear teeth Replace the pinion or ring gear
Dust adhesion on pinion shaft Clean

Symptom: Pinion Meshes and the Motor Turns, but the Engine Does not Crank

Pinion meshes and the motor turns, but Slipping of the clutch Replace the clutch or starter
the engine does not crank Damage of the deceleration gear Replace the gear or starter

Symptom: Pinion Meshes, but the Engine Does not Crank

Pinion meshes, but the engine does not Insufficient charge of battery Charge or replace the battery
crank Improper tightening of the wiring circuit Repair
terminal
Armature or field coil short circuit Replace the starter
Filth damaged commutator Repair or replace the starter
Fatigue of the brush spring or wear of Replace the brush spring or brush
the brush
Seizure of the bearings Replace the bearing or starter
Defective contact of the magnetic Replace the magnetic switch
switch contact point

Symptom: After the Engine Starts, the Starter Does not Stop Even if the Ignition Switch is
Turned Off

After the engine starts, the starter does Improper return of the ignition switch Replace the ignition switch
not stop even if the ignition switch is contact point
turned off Improper return of the starter relay Replace the starter relay
contact point
Short circuit of magnetic switch coil Replace the magnetic switch
Type (Hitachi, Ltd.) S25-505G

Rating
Voltage V 24
Output kW 4.5
Time second 30
Number of pinion teeth 11
Rotational direction (when seen from the pinion side) Left
Weight (Approx.) kg(lb) 7.5(16.5)
No-load characteristics
Voltage/Current V/A 23/120 or less
Revolution speed r/min 3,500 or more
Load characteristics
Voltage/Current V/A 14.3/400 or less
Torque N⋅m (kg⋅m/lb⋅ft) 25 (2.5/18) or more
Revolution speed r/min 1,000 or more
Locking characteristics
Voltage/Current V/A 10/1,200 or less
Torque N⋅m (kg⋅m/lb⋅ft) 47 (4.8/35) or more
Starter Motor
Components • Disconnect the magnetic switch B terminal (1)
harness.
1
2
3
LNW21ESH001401
1
2. Remove the starter assembly.
• Remove the two bolts at the top and bottom,
2 and remove the starter from the clutch housing.
LNW41EMH000101
Legend
1. Starter B terminal
2. Starter Assembly
3. Starter S terminal
Removal
1. Disconnect the harness terminal.
• Disconnect the magnetic switch S terminal (2)
harness.
LNW21ESH001001
Inspection
Inspection of the pinion protrusion position
• The pinion moves forward to the cranking position
to rotate the armature when the M terminal lead
wire is disconnected and the battery cable positive
(+) side is connected to the S terminal, the
negative (-) side is connected to the M terminal
and the switch is turned to ON. Then, disconnect
the negative (-) side to stop the rotation of the
armature.

• Manually, lightly push the leading end of the clutch • Replace if there is an abnormality in the pull-in,
shaft and measure the movement dimension of the hold-in, or return tests.
clutch shaft.
• When the amount of movement is outside of the
specified value, insert or remove spacers (1)
between the magnetic switch and gear case to 1 2
adjust the amount of movement. 3
Pinion movement amount : 4

0.1 to 0.3 mm(0.0039 - 0.0118 in)
+
-
5
LNW21ESH001301
1
Installation
1. Install the starter assembly.
• Install the starter to the clutch housing with
mounting bolts, and tighten them at the
specified torque.
LNW21ESH001201
Magnetic switch inspection
Pull-in test
• Check whether the pinion protrudes outward when
the negative (-) cables (2) and (5) are connected to
the terminal "M" of the magnetic switch and the
body, and when the positive (+) cable (1) is
connected to the terminal "S".
Hold-in test
• Check whether the pinion remains protruded when
the negative (-) cable (2) is disconnected from the
terminal "M" after the pull-in test above is
completed.
Return test
• Check whether the pinion (plunger) returns
immediately when the negative (-) cable (5) of the
LNW21ESH001001
switch body is disconnected (with the negative (-)
cable (2) remaining disconnected) after the hold-in
test above is completed. 2. Connect the harness terminal.
• Tighten the S terminal (2) at the specified
torque.
Tightening torque:
1 to 1.5 N⋅m (10 to 15 kg⋅cm/9 to 13 lb⋅in)

• Tighten the B terminal (1) at the specified
torque.
Tightening torque: 1
2
7.5 to 10 N⋅m (75 to 100 kg⋅cm/65 to 87 lb⋅in)
LNW21ESH001401
a b
c
d
MFW71EMF000201
(a) 7.5 to 10 N⋅m (75 to 100 kg⋅cm/65 to 87 lb⋅in)

(b) 1 to 1.5 N⋅m (10 to 15 kg⋅cm/9 to 13 lb⋅in)
(c) 127 N⋅m (12.9 kg⋅m/94 lb⋅ft)
(d) 127 N⋅m (12.9 kg⋅m/94 lb⋅ft)
Starter Switch
Removal Inspection
1. Remove the steering cowl (1). Inspect the continuity between the ignition switch
• Remove the screws to remove the cowl. connector terminals.
If any abnormality is found in the inspection results,
2. Disconnect the ignition switch connector (2).
repair or replace it.
LNW71ESH001001
IG1 B2
ACC ST
B1 IG2
OFF ACC ON ST
B2
IG2
ST
B1
ACC
IG1
LNW71ESF000501
Installation
Perform installation in the reverse order of the removal.
Charging System
When performing maintenance on the electrical The charging system is an IC integral regulator
system, confirm that the ignition switch and lighting charging method and the main components are
switch are OFF, and always disconnect the negative (-) connected as shown in the circuit diagram.
battery terminal before working. The regulator is an integrated solid-state type regulator,
which is installed into the rear end cover together with
the brush holder assembly and is built-in to the
generator.
Generator maintenance, such as voltage adjustment is
unnecessary. There are six diodes in the rectifier
connected to the stator coil that converts alternating
current voltage into direct current voltage. The direct
current voltage is connected to the generator output
terminal.
3 4 5 6 7 8
1 2
10
12
14 13 11
LNW21EMF000201
Legend
1. Pulley 8. Ball bearing
2. Ball bearing 9. Oil seal
3. Fan 10. Vacuum pump
4. Stator 11. Rear cover
5. Rotor 12. Slip ring
6. Brush 13. Through bolt
7. IC regulator 14. Front cover

Output characteristics
Generator 60A (LR260-512)/Generator 80A (LR280-
508B)
80 80A
70
60
60A
OUTPUT CURRENT
50
40
30
(A)
20
10
27V CONST
0 2000 4000 6000 8000 10000 12000

SPEED(r/min)
LNW91EMH000101
Specifications Generator 60A Generator 80A

Type (Hitachi, Ltd.) LR260-512 LR280-508
Rated voltage V 24 24
Rated output A 60 80
Rotational direction (when seen from the pulley side) Right Right
Effective diameter of pulley mm(in) 80(3.15) 80(3.15)
Weight kg(lb) 9.0(19.8) 9.6(21.2)

General on-board inspection
The charging system indicates abnormalities in
operations by the charge warning light. If the warning
light illuminates when the ignition switch is "ON" and
turns off after the engine is running, operations are
normal. If the warning light does not illuminate,
disconnect the generator wiring connector, and ground
the connector side terminal "L." If the light illuminates
by this grounding, repair or replace the generator. If the
battery is insufficiently charged or overcharged,
perform trouble diagnosis according to the malfunction
symptom list.

• Does not Charge at All
• Charge is Insufficient
• Overcharged
• Charge Current is Unstable
• Abnormal Noises from the Eenerator

Symptom: Does not Charge at All

Does not charge at all Defective battery Replace
Open circuit, short circuit or Repair
disconnection of connections of wiring
or current meter
Open circuit in each coil, damage to Replace
ground, short circuit, or diode of the
generator.
Defective regulator Replace
Defective contact of the regulator Repair
terminal

Symptom: Charge is Insufficient

Charge is insufficient Defective battery Replace
Open circuit, short circuit or Repair
disconnection of connecting section of
wiring
Loose generator drive belt Adjust belt tension
Stator coil layer short circuit Replace
Diode failure Replace
Defective terminal contact Repair
terminal

Symptom: Overcharged

Overcharged Defective regulator Perform a repair

Symptom: Charge Current is Unstable

Charge current is unstable Open connection or defective contact of Repair
the wiring
Loose generator drive belt Adjust belt tension
Stator coil short, or defective contact Repair
Defective contact of each terminal Repair
terminal

Symptom: Abnormal Noises from the Generator

Abnormal noises from the generator Belt tension is loose Adjust belt tension
Defective bearing Replace the bearing
Contact of rotor core and stator core Repair
Defective diode Replace
Stator coil short, or defective contact Replace
Generator
Components
1 2
3
4
5
8
LNW61ELF000101
Legend
1. A/C compressor 5. Harness
2. Drive belt 6. Drive belt
3. Oil pipe 7. Adjust plate
4. Vacuum hose 8. Generator
Removal
1. Remove the A/C compressor drive belt.
• Loosen the tension pulley nut (2) and adjust
bolt (3), and remove the drive belt.

• Disconnect the B terminal cable and harness
connector from the generator.
1
3 1
2
LNW71ESH001301
Legend
LNW61ESH000201
1. A/C compressor
2. Tension pulley nut
3. Adjust bolt
7. Remove the drive belt.
• Loosen the nuts (2) and (3).
2. Remove the A/C compressor. • Loosen the AC generator adjust bolt (1) to
remove the belt.
• Disconnect the A/C compressor harness
connector, remove the compressor from the A/
C compressor bracket, and fasten to any
suitable position together with the hoses using
a wire, etc.
3
1
LNW21CSH000101
8. Remove the generator.

• Remove the nuts at 2 locations, pull out the
bolts, and remove the generator.
LNW61ESH000101
Installation
3. Remove the vacuum pump oil pipe (1). 1. Install the generator.
4. Remove the vacuum pump oil return rubber hose. • Install the generator to the bracket and adjust
5. Remove the vacuum hose. plate, and temporarily tighten the installation
nut.
• Remove the hose at the vacuum pump side.
6. Disconnect the generator harness (2).

NOTE:
Tighten the generator after adjusting the fan belt.
Insert the lower side mounting bolt from the backside to
the front as indicated in the diagram, and use a nut for
its back.
3
1
LNW21CSH000101
4. Connect the generator harness.

• Connect the harness connector (1 pole) and B
terminal to the generator.
5. Install the vacuum hose.
LNW21ESH000601
6. Install the vacuum pump oil return rubber hose.
• When installing, install with the clip knob facing
2. Install the drive belt. upward so that it does not interfere with the
• Install the drive belt and adjust belt tension. engine foot.
Refer to "Drive Belt" in Section 1C Cooling 7. Install the vacuum pump oil pump.
System (4HV1-CNG) for an outline of the
Tightening torque:
adjustment procedures.
Eyebolt (1) = 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Eyebolt (2) = 23 N⋅m (2.3 kg⋅m/17 lb⋅ft)
1 2
LNW21ESH000501
3. Tighten the generator at the specified torque.

LNW61ESH000301
• Tighten in the order of 2 to 3.
Tightening torque:
(2) Part = 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) • Install the A/C compressor as shown in the
diagram and tighten at the specified torque.
(3) Part = 62 N⋅m (6.3 kg⋅m/46 lb⋅ft)

• After adjusting the belt tension, tighten the lock
nut (2) of the tension pulley.
LNW61ESH000101
9. Install the A/C compressor drive belt.

• Place the drive belt into position and adjust its LNW71ESH001301
tension.
Refer to "Drive Belt" in Section 1C Cooling
System (4HV1-CNG) for an outline of the
adjustment procedures.
c
LNW71ESF000701
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(c) 62 N⋅m (6.3 kg⋅m/46 lb⋅ft)
Ignition System
Maintenance Precautions
When repairing the electrical system, always close the
manual cylinder valve (at tank), run the engine until it
stops and start work after burning off fuel gas remaining
in the pipes.

Employs a full-transistor type direct-ignition system.
The direct ignition method enables a precise and
strong ignition spark because there are no moving
parts such as a distributor, and because the high-
voltage circuit can be minimized. The ignition coil has a
built-in power switch and receives the ignition signal
from the engine control module to generate a high-
voltage charge to the spark plug. The ignition coil is
installed for each of the four cylinders. For spark plugs,
iridium alloy spark plugs are employed. In order to
improve durability of the electrodes and to prevent
premature sparking and to improve durability, the plug
heat value is equivalent to #22.

except Australia
1 2
22
7 6 5
4
8
21
20 15
14
13
19
16
17
12 10
11
18
LNW91ELF000701
Legend
1. Engine control module (ECM) 12. Air-fuel ratio (A/F) sensor
2. Accelerator pedal position (APP) sensor 13. Camshaft position (CMP) sensor
3. Automatic valve (at tank) (RH) 14. Ignition coil
4. CNG container (CNG cylinder) 15. Gas injector
5. Automatic valve (at tank) (LH) 16. Engine coolant temperature (ECT) sensor
7. Pressure regulator 18. Crankshaft position (CKP) sensor
8. Gas filter 19. Intake air pressure (MAP) sensor
9. CNG pressure / temperature sensor 20. Intake air temperature (IAT) sensor
10. O2 sensor 21. Intake throttle valve
11. Exhaust brake vacuum switching valve (VSV) 22. Engine driver unit (EDU)

for Australia
1 2
20
7 6 5
4
21
9 8
20 15
14
13
19
16
17 12 10
11
18
LNW91ELF000801
Legend
1. Engine control module (ECM) 12. Air-fuel ratio (A/F) sensor
2. Accelerator pedal position (APP) sensor 13. Camshaft position (CMP) sensor
3. Automatic valve (at tank) (RH) 14. Ignition coil
4. CNG container (CNG cylinder) 15. Gas injector
5. Automatic valve (at tank) (LH) 16. Engine coolant temperature (ECT) sensor
7. Pressure regulator 18. Crankshaft position (CKP) sensor
8. CNG pressure sensor 19. Intake air pressure (MAP) sensor
9. CNG temperature sensor 20. Intake air temperature (IAT) sensor
10. O2 sensor 21. Intake throttle valve
11. Exhaust brake vacuum switching valve (VSV) 22. Engine driver unit (EDU)
Ignition Coil & Spark Plug

Components
2
1
LNW61EMF000101
Legend
1. Ignition coil connector 4. Spark plug
2. Ignition coil 5. Bracket
3. Spark plug boot
Removal 2. Remove the mounting bolt and remove the ignition

coil assembly.
1. Disconnect the ignition coil connector.
NOTE:
Remove the ignition coil and spark plug boot as one
part. Disassembly can cause the danger of poor
electric power connection between the ignition coil and
spark plug boot.
LNW61ESH000501

3. Remove the spark plug (3) with the plug wrench.
LNW61ASH003801
LNW41BSH004901
2. Check for abnormalities in the internal structure of
the ignition coil using the resistance value between
the terminals.
Inspection
a. Disconnect the ignition coil assembly
Follow the procedures below to inspect the ignition coil connector.
assembly with the built-in igniter and spark plug.
b. Measure the resistance value between the
1. Checking the operation of the ignition coil terminals on the coil assembly unit side
• Remove the ignition coil assembly and spark mentioned above using a DMM.
plugs from the engine. If the resistance value between the terminals is
• Disconnect the wiring connector of the fuel within the standard values, it can be judged that
injector of all cylinders. there are no functional problems.
• Join the wiring connector to the removed Standard value
ignition coil assembly and install the spark Measured terminal Resistance value
plugs.
1-2 10 - 15 MΩ
• Ground the threaded portion of the spark plug
to the engine, and crank the engine with the 1-3 10 - 15 MΩ
ignition switch. 2-3 1 - 2 kΩ
• A good spark should be jumping from the spark
plugs of each cylinder.
CAUTION:
Perform this work in a well-ventilated location with no
flammable materials (CNG etc.).
While cranking the engine, high-voltage electrical
power is generated in the ignition coil assembly. It is
extremely dangerous because you could receive a
serious electric shock if it comes into contact with your
body. Use rubber gloves and absolutely never touch
the section of the ignition coil assembly where it will be
mounted the engine with bolts (section with an arrow
mark).
1 2 3
1 2 3
LNW41ASH004801 LNW61ESH000601
Legend
1. Battery
2. GND Installation
3. Ignition signal 1. Install the spark plug.
• Tighten at the specified torque.
c. Replace the ignition coil if the resistance value
is not within the standard value. Tightening torque: 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
3. Spark plug inspection
NOTE:
• If the plug gap (3) in not within the limit value,
replace it with a new one. • If over-tightened, the spark plug will be damaged, so
Standard value: always observe the tightening torque.
0.7 to 0.8 mm(0.028 to 0.031 in) • Dropped spark plugs can be damaged internally, so
replace them with new parts without reusing them.
Limit value:
1.0 mm (0.040 in)
NOTE:
• Do not remove other than when periodically
replacing 100,000 km (62,000 mile) or inspecting for
engine trouble.
• Iridium alloy plugs are used for spark plugs, so there
is the danger of the iridium alloy chip falling off when
a thickness gauge is forced inside or when it is
cleaned with a wire brush, therefore, do not adjust
the thickness.
• Measure the plug insulation resistance between

(1) and (2). If the value is not unlimited, the plug
is damaged.
• If the electrode surface is spherical by sight,
and if the glass is damaged, replace with a new
part. LNW61ESH000701
2. Install the ignition coil.

• Insert the ignition coil and spark plug boot as
one part, then tighten the mounting bolt at the
specified torque.

3. Install the ignition coil connector.
LNW41BSH006301
LNW61ESH000501
LNW71EMF001001
(a) 5 N⋅m (0.5 kg⋅m/43 lb⋅in)

(b) 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
Knock Sensor
Removal
1. Disconnect the harness connector of the knock
sensor.
2. Remove the knock sensor and adaptor.
1 2 3
LNW91BSH006501
Legend
1. Adaptor
2. Knock sensor
3. Bolt
Installation
1. Install the knock sensor and adaptor.
• Tighten the sensor at a torque of 23.5N⋅m (2.4
kg⋅m/17 lb⋅ft).
2. Connect the harness connector of the knock
sensor.
DC-DC Converter
Removal 4. Remove the DC-DC converter(1).
RHD Model
1. Disconnect the harness connector(5) and clip(4).
1
2. Remove the bracket(3) with DC-DC converter(1).
3. Remove the DC-DC converter(1).
2
2
3
1
5
5
4
LNW91ESH000701
Legend
1. DC-DC converter
4 2. Bracket
3. Intermittent relay
LNW91ESH000501 4. Door lock relay
Legend 5. DRM (Data recording module)
1. DC-DC converter
2. Nut
3. Bracket Inspection
4. Clip
1. Confirm that 13.5V is outputted from the out put
5. Connector
when 24V is applied to the in put.
LHD Model
1
1. Remove the blower ASM.
Refer to "Blower ASM" in Section 7A, Heating and 2
Ventilation
2. Disconnect the harness connector.
3. Remove the bracket(2).
4 3
LNW91ESH000601
Legend
1. Out put -
2. In put -
3. In put +24V
4. Out put +13.5V

Installation
RHD Model
1. Install the DC-DC converter(1).
2. Install the DC-DC converter(1) with bracket(3).
3. Connect the harness connector(5) and clip(4).
LHD Model
1. Install the DC-DC converter.
2. Install the bracket.
4. Install the blower ASM.
Refer to "Blower ASM" in Section 7A, Heating and
Ventilation
MEMO
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Engine Exhaust (4HV1-CNG) 1G-1
ENGINE
Engine Exhaust
(4HV1-CNG)
TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1G-2
Description of Function and Operation . . . . . . . 1G-2
Malfunction Symptom List . . . . . . . . . . . . . . . . . 1G-3
Symptom: Vibrations and Rattling Sounds
from the Exhaust System . . . . . . . . . . . . . . . . . 1G-4
Symptom: Clogging of the Exhaust System . . . 1G-5
Symptom: Exhaust Gas Leak, Noise . . . . . . . . 1G-6
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-7
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-8
List of Tightening Torques . . . . . . . . . . . . . . . . 1G-10
Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-11
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-11
Functional Inspection: . . . . . . . . . . . . . . . . . . . 1G-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-13
List of Tightening Torques . . . . . . . . . . . . . . . . 1G-14
Air-fuel ratio (A/F) sensor . . . . . . . . . . . . . . . . . . 1G-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-15
O2 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-16
Magnetic Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
1G-2 Engine Exhaust (4HV1-CNG)
Exhaust System
Maintenance Precautions • Replace if the clamp or mount rubber (bushing) is
deteriorated, cracked or damaged.
• Vibrations and looseness of the exhaust system
can be caused by mis-positioning of exhaust • If pipes or the silencer are damaged or dented,
system components during their assembly. repair or replace them.
Temporarily tighten the bolts and nuts until all parts • Inspect for dents or damage, or holes and
are placed into position. After being placed into fractures caused by corrosion, and abnormal noise
position, tighten the parts starting from the engine when driving the vehicle.
side to the rear side.
• When inspecting or repairing, make sure that there
is an adequate gap between the floor and body.
• Be cautious, as damage caused by heat from the The main components of the exhaust system are: a
body panel or vibrations can cause exhaust gas to front exhaust pipe, air-fuel ratio (A/F) sensor, exhaust
enter the cabin. brake, O2 sensor, 3-way catalyst integrated silencer,
and tail pipe.
• There should be no loose or damaged
Exhaust brake assembly uses exhaust pressure to
connections, or exhaust gas leaks.
assist braking.
1 3
2
5 6 7 8
4
LNW71GSF000401
Legend
1. Air-fuel ratio (A/F) sensor 5. O2 sensor
2. Front exhaust pipe 6. 3-way catalyst integrated silencer
3. Exhaust brake assembly 7. Rear exhaust pipe
4. Center exhaust pipe 8. Tail pipe

• Vibrations and Rattling Sounds from the Exhaust
System
• Clogging of the Exhaust System
• Exhaust Gas Leak, Noise

Symptom: Vibrations and Rattling Sounds from the Exhaust System

Vibrations and rattling sounds from the Looseness of joint sections, or Retighten after aligning the joint
exhaust system maladjustment section. Also, inspect the hanger,
mounting brackets and clamps for
damage
Deterioration, crack and damage of Replace the clamp or mount rubber
clamp or mount rubber (bushing) (bushing)

Symptom: Clogging of the Exhaust System

Clogging of the exhaust system The exhaust brake is ON. For details on the electrical system that
activates the exhaust brake, check the
exhaust system upon refer to the
"Engine Control System" in Section 1A,
Engine Control System (4HV1-CNG). If
there is any abnormality, repair it.
Inspect the exhaust brake shaft for
sluggishness and replace it if there is
an abnormality
Internal damage on the 3-way catalyst Replace the 3-way catalyst integrated
integrated silencer silencer
Deformation of the exhaust pipe Repair or replace the exhaust pipe

Symptom: Exhaust Gas Leak, Noise

Exhaust gas leak, noise Improper installation or maladjustment Retighten after aligning the joint section
Exhaust pipe or silencer damage, burn Replace the damaged parts
damage
Defective exhaust system components Replace the defective parts
(clamps, pipes, silencer)
Internal damage on silencer Replace the silencer
Exhaust Pipe
Components
7
5
4
2
3
1 8
9
LNW71GLF000801
Legend
1. Front exhaust pipe 6. O2 sensor
2. Air-fuel ratio (A/F) sensor 7. 3-way catalyst integrated silencer
3. Exhaust pipe clamp 8. Tail pipe
4. Exhaust brake assembly 9. Rear exhaust pipe
5. Center exhaust pipe
Removal 7. Remove the air-fuel ratio (A/F) sensor

1. Remove the tail pipe. 8. Remove the front exhaust pipe.
• Remove the clamps and tail pipe. • Remove the clamp, and remove the front
exhaust pipe.
2. Remove the rear exhaust pipe.
3. Remove the O2 sensor.
4. Remove the silencer.
5. Remove the center exhaust pipe.
6. Remove the exhaust brake assembly.

Inspection
• When inspecting or repairing the exhaust system,
check that there is an adequate gap between the
floor and body.
• Be cautious, as damage caused by heat from the
body panel or vibrations can cause exhaust gas to
enter the cabin.
• Inspect for loose or damaged connections and
exhaust gas leaks.
• Replace if the clamp or mount rubber (bushing) is
deteriorated, cracked or damaged.
• Inspect the pipe or silencer for dents, or cracks
caused by corrosion. If damaged, repair or replace
them.
Installation LNW71GSH002201
NOTE:
• Vibrations and looseness of the exhaust system
can be caused by mis-positioning of exhaust 2. Install the air-fuel ratio (A/F) sensor.
system components during their assembly. • Install the air-fuel ratio (A/F) sensor, tighten it at
Temporarily tighten all the bolts until all the specified torque and connect the harness.
components are placed into position, then
completely tighten the parts starting from the Tightening torque: 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
engine side to the tail pipe side.
NOTE:
• Do not reuse the removed gasket or nuts.
If the air-fuel ratio (A/F) sensor is to be reused, apply
1. Install the front exhaust pipe. anti-seize to the threaded portion of the bolts.
If the screw thread is damaged, do not reuse it.
• Assemble the gasket, install the front exhaust
pipe to the exhaust manifold and tighten them
NOTE:
Uniformly tighten the front exhaust pipe with caution so
that there is no gas leak.
• Install the front exhaust pipe to the bracket and

tighten the clamp at the specified torque.
LNW61GSH000301
3. Install the exhaust brake.
NOTE:
The gasket has a pre-defined direction. Install the
surface with brim section to the exhaust brake side (1).
LNW71GSH002301 LNW71GSH001501
4. Install the center exhaust pipe. 8. Install the tail pipe.

• Assemble the gasket, attach it to the exhaust • Insert the tail hanger section into the rubber
brake, then tighten it at the specified torque. hanger, assemble the gasket, attach it to the
silencer, then tighten it.
• Install the pipe rear side to the bracket, and
tighten it at the specified torque. • Tighten the clamp.
Tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) Tightening torque: 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
5. Install the 3-way catalyst integrated silencer. • Start the engine after assembling each part,
• Assemble the gasket, attach it to the center and check for gas leaks from each joint and for
exhaust pipe, then tighten it at the specified abnormal vibration.
torque.
6. Install the O2 sensor.
• Install the O2 sensor to the 3-way catalyst
integrated silencer, tighten it at the specified
torque, and connect the harness.
NOTE:
If the O2 sensor is to be reused, apply anti-seize to the
threaded portion of the bolts.
If the screw thread is damaged, do not reuse it.
• Install the rear side of 3-way catalyst integrated

silencer to the bracket, and tighten it at the
specified torque.
7. Install the rear exhaust pipe.
• Assemble the gasket, attach it to the silencer,
then tighten it at the specified torque.

g
h
b
d
k
l
a
LNW71GLF001101
Legend
(a) 67 N⋅m (6.8 kg⋅m/49 lb⋅ft) (h) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(b) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft) (i) 50 N⋅m (5.1 kg⋅m/37 lb⋅ft)
(c) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft) (j) 50 N⋅m (5.1 kg⋅m/37 lb⋅ft)
(d) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft) (k) 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
(e) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (l) 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(g) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
Exhaust Brake
Components
3 6 5
7 8
2
9
10
11
13
12
11
LNW71GMF000201
Legend
1. Exhaust brake assembly 8. Bearing
2. Bolt 9. Nut
3. Cover 10. Pin
4. Power chamber 11. Gasket
5. Gasket 12. Exhaust brake valve
6. Clevis joint 13. Nut
7. Split pin

Functional Inspection:
Operation inspection Individual inspections
• Check for the sound of the valve hitting the stopper • When negative pressure is actuated from the
when the exhaust brake is operated while the vacuum pump to the power chamber
vehicle is idling. at 66.7 to 93.3 kPa (500 to 700 mmHg/9.7 to 13.5
psi), the exhaust brake valve should open and
close smoothly.
Removal
1. Remove the vacuum hose and clip from the
exhaust brake assembly.
2. Remove the front exhaust pipe A and exhaust
brake assembly.
• Remove the front exhaust pipe A and manifold
installation nut (1).
• Remove the front exhaust pipe A and exhaust
brake assembly installation nut (3).
At this time, the exhaust brake assembly will
also be removed simultaneously.
• Remove the exhaust pipe clamp installation
bolt (2) to the right side of the transmission.
LNW21GSH000401
3
• When negative pressure is actuated from the
vacuum pump to the power chamber at 86.7 to
2 93.3 kPa (650 to 700 mmHg/12.5 to 13.5 psi), the
average of gap ((1) and (2)) between the valve and
the body should be as listed below.
If the gap is outside the standard value, loosen the
nut (4) and adjust it with the adjust bolt (3).
Average gap mm(in) Min. gap mm(in)

0.1 to 0.25 0.1
1
(0.00394 to 0.00984) (0.00394)
LNW71GSH002001
Tightening torque:
M6 nut (4) = 6 N⋅m (0.6 kg⋅m/52 lb⋅in)
Disassembly
1. Remove the split pin.
2. Remove the lock nut.
3. Remove the clevis joint.
4. Remove the power chamber.
Inspection
Inspect the following parts for damage and
deterioration.
• Exhaust brake valve
• Exhaust brake shaft
• Butterfly valve
• Bushing
• Power chamber
3
1
2
4
LNW76FSH000801 LNW21GSH002201
Reassembly 4. Install the split pin.
1. Install the power chamber.

Installation
1. Install and temporarily tighten the front exhaust
pipe A and exhaust brake assembly.
2. Tighten the mounting bolt and nut at the specified
torque.
• After temporary fitting, tighten them in the order
of the numbers in the diagram.
Tightening torque:
Exhaust manifold side nut (1)
67 N⋅m (6.8 kg⋅m/49 lb⋅ft)
Exhaust pipe clamp bolt (2)
41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Exhaust brake side nut (3)
27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
LNW41GSH001101
3
2. Install the lock nut.

3. After installing the clevis joint, tighten the lock nut 2
LNW71GSH002001

3. Install the vacuum hose and clip.
d
LNW71GMF000601
(a) 14 N⋅m (1.4 kg⋅m/122 lb⋅in)

(b) 13 N⋅m (1.3 kg⋅m/113 lb⋅in)
(c) 6 N⋅m (0.6 kg⋅m/52 lb⋅in)
(d) 67 N⋅m (6.8 kg⋅m/49 lb⋅ft)
(e) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
(f) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Air-fuel ratio (A/F) sensor

Removal
battery cable.
2. Disconnect the harness connector of the air-fuel
ratio (A/F) sensor.
3. Remove the air-fuel ratio (A/F) sensor.
1
LNW61ASH002701
Legend
1. Air-fuel ratio (A/F) sensor
2. Connect the harness connector of the air-fuel ratio

(A/F) sensor.
1
3. Connect the negative side terminal of the battery
LNW61ASH002701
cable.
Legend
4. When the air-fuel ratio (A/F) sensor is replaced,
1. Air-fuel ratio (A/F) sensor
use the scan tool to learning the different kind fuel
learning to the ECM. Refer to the “Engine Control
System” in Section 1A, Engine Control System
Installation (4HV1-CNG).
1. Install the air-fuel ratio (A/F) sensor.
• Tighten the sensor at a torque of 44 N⋅m (4.5
kg⋅m/33 lb⋅ft).
NOTE:
• If the air-fuel ratio (A/F) sensor is to be reused,
apply anti-seize to the threaded portion of the bolts.
• If the screw thread is damaged, do not reuse it.
O2 Sensor
Removal
battery cable.
2. Disconnect the harness connector of the O2 1
sensor.
3. Remove the O2 sensor.
LNW61ASH002801
Legend
1. O2 sensor
2. Connect the harness connector of the O2 sensor.

cable.
LNW61ASH002801
Legend
1. O2 sensor
Installation
1. Install the O2 sensor.
kg⋅m/33 lb⋅ft).
NOTE:
• If the O2 sensor is to be reused, apply anti-seize to
the threaded portion of the bolts.
• If the screw thread is damaged, do not reuse it.
Magnetic Valve
Removal
1. Disconnect the magnetic valve harness connector.
2. Disconnect the vacuum hose.
3. Remove the magnetic valve.
Inspection
1. Perform a continuity test between terminals (1)
and (2), and confirm that continuity exists.
2. Confirm that air exits from (5) when blowing your
breath from (4). At this time, confirm that air does
not exit from (3).
3. Confirm that an operation sound is made when
providing power supply voltage to the connector.
4. While providing power supply voltage to the
connector, confirm that air exits from (3) when
blowing your breath from (4).
At this time, confirm that air does not exit from (5).
3 4 2 1
LNW86FSH000101
Installation
1. Install the magnetic valve.
2. Connect the vacuum hose.
3. Connect the magnetic valve harness connector.
MEMO
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Engine Lubrication (4HV1-CNG) 1H-1
ENGINE
Engine Lubrication
(4HV1-CNG)
TABLE OF CONTENTS
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . 1H-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1H-2
Description of Function and Operation . . . . . . . 1H-2
Functional Inspection . . . . . . . . . . . . . . . . . . . . 1H-3
Oil filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1H-5
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-6
List of Tightening Torques . . . . . . . . . . . . . . . . . 1H-7
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-8
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-10
List of Tightening Torques . . . . . . . . . . . . . . . . 1H-12
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-13
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-13
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-16
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-19
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . 1H-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-24
1H-2 Engine Lubrication (4HV1-CNG)
Lubrication System
• Use a scraper to completely scrape off old liquid A full-flow bypass integrated oil filter, water cooling oil
gasket from the locations where liquid gasket is cooler, and piston coolant oil jet are adopted for the
used and apply the specified liquid gasket after lubrication system.
cleaning off any oil, moisture and filth with a rag,
etc.
Apply a proper amount of the liquid gasket,
avoiding excessive or lack in application. If an
excessive amount is applied, it will cause seizures
from clogging of the oil gallery and oil jet head, and
an insufficient amount will cause the oil and water
leaks.
Perform overlapping applications at the beginning
and end.
Lubricant system diagram
Oil pressure switch

39 (0.4/6)
Fuse
Oil pressure Engine control Battery

98 (1.0/14)
indicator lamp switch
Safety valve
(Filter installed)
Full flow filter Oil cooler Oil gallery
Thermo valve
441 (4.5/64)
Relief valve
Crankshaft Check valve Vacuum
Valve train (Front cover
bearing 196 (2.0/28) pump
installed)
785 (8.0/114)
Relief valve
(Oil pump Con-rod
Oil pump Gear train Oil jet
internal bearing
organs)
Oil strainer
Oil pan
2
kPa(kg/cm /psi)
LNW91HLF000401

Engine oil level inspection Inspection of the oil pressure
• Upon parking the vehicle on a level area, perform 1. Inspect for filth and mixture of water in the engine
inspections prior to starting the engine or following oil. If the engine oil is filthy, or is mixed with water,
20 to 30 minutes after stopping the engine, using (after investigating the causes and taking
the oil level gauge (2). At the same time, inspect appropriate measures for water mixture), change
the engine oil for filth. the oil.
If it is below the lower limit, refill the engine oil from 2. Inspect the engine oil level. The oil level should be
the oil filler (1). in between the two holes of the level gauge. If the
oil level is low, replenish the engine oil.
3. Install the oil pressure gauge.
2
1 4. Warm-up the engine.
5. Measure and confirm that the oil pressure is 340
kPa (3.5 kg/cm2/49.3 psi) or more at 3200 r/min.
6. Stop the engine.
7. Remove the oil pressure gauge.
8. Install the oil pressure switch.
9. Start the engine and check that there are no oil
leaks.
Inspection for engine oil leaks

• Inspect for oil leaks from the cylinder head cover,
oil pan, etc. while the vehicle is lifted up.
LNW61HSH000101
• If the engine oil is sticking between the upper limit

and lower limit (1) – (2), the amount is appropriate.
1 2
LNW61HSH000401
Legend
1. Upper limit
2. Lower limit
Oil filter Cartridge

Components
1
LNW21HSF000101
Legend
1. Oil filter cartridge
Removal • Tighten it at the specified torque using the oil

filter wrench.
1. Place a pan under the oil filter cartridge.
2. Use the oil filter wrench to remove the oil filter Tightening torque: 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
cartridge. Or
Special tool After touching the oil seal, further tighten with a 1 and
1/4 turn
Oil filter wrench: 1-8522-1097-0
Special tool
LNW21HSH000601
Installation
1. Install the oil filter cartridge.
cartridge.
Oil Filter Assembly

Components
LNW61HMF000201
Legend
1. Oil pressure switch 3. Oil filter cartridge
2. Oil filter body 4. O-ring
Removal
1. Place a pan under the oil filter cartridge.
2. Remove the oil filter cartridge.
• Use the oil filter wrench to remove it.
Special tool
LNW21HSH000601

3. Remove the oil pressure switch. 5. Remove O-rings (1) and (2).
• For inspection, refer to "Oil Pressure Switch" of
this section.
LNW21HSH000201
LNW21HSH000401
Installation
1. Install the O-rings to the oil filter body.
4. Remove the oil filter body. 2. Install the oil filter body to the cylinder block and
3. Install the oil pressure switch to the oil filter body.
• Apply liquid gasket (Loctite No. 262 or
equivalent) to 2 or 3 threads from the leading
end of the threaded portion of the oil pressure
switch, and install it to the position shown in the
diagram.
4. Install the oil filter cartridge.
cartridge, and then install it.
• Tighten it at the specified torque using the oil
filter wrench.
LNW21HSH000301
Or
After touching the oil seal, further tighten with a 1 and
1/4 turn
Special tool

LNW71HMF000201
(a) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)

(b) 13 N⋅m (1.3 kg⋅m/113 lb⋅in)
Oil Cooler
Components
1 2
6
5 4 3
LNW61HMF000101
Legend
1. Oil cooler 4. Heater pipe
2. Intake manifold assembly 5. Water suction pipe
3. Oil level gauge guide tube 6. Bypass hose
Removal 4. Remove the water hose (bypass) head-side.

2. Drain the engine oil.
3. Remove the intake manifold assembly.
• Refer to "Intake Manifold" in Section 1B Engine
Mechanics (4HV1-CNG).
LNW21BSH008501

5. Remove the heater hoses at the engine side. 8. Remove the water suction pipe.
LNW61BSH001401 LNW61HSH000201
6. Remove the radiator lower hose at the engine side. 9. Remove the knock sensor.
• Refer to "Knock Sensor" in Section 1E Engine
Electrical (4HV1-CNG).
10. Remove the oil cooler assembly.
• Carefully peel off the liquid gasket from the oil
cooler groove.
LNW91BSH005101
7. Remove the heater pipe.
LNW21HSH005701
11. Remove the O-ring.
Disassembly
1. Remove the element mounting bolts.
2. Remove the element (1).

3. Remove the O-rings (2). • Refer to the diagram for the position to apply
the liquid gasket.
1
2 3
1
5 6
4
LNW21HSH001201
LNW81HSH000201
Legend
Reassembly 1. O-Ring
1. Install O-rings (2) to the oil cooler case. 2. Liquid gasket
2. Install the element (1). 3. O-Ring
4. 0.1 mm - 2.0 mm(0.004 in - 0.079 in)
3. Tighten the element mounting bolt at the specified
5. 2 mm - 4 mm(0.08 in - 0.16 in)
torque.
6. 1 mm(0.04 in)
2. Install the oil cooler assembly.

• Align to the cylinder block stud (13), install the
1 oil cooler, and tighten it at the specified torque
in the order shown in the diagram.
12 9 4 1 5 10 13
14
LNW21HSH001201 8
7 3 2 6 11 15
Installation
1. Install the O-rings (1) and (2).
along the groove of the flange surface (3).
LNW21HSH005801
• Install the O-ring to the oil path entrance/exit
areas. The liquid gasket should not adhere to
the O-ring.
• After applying the liquid gasket, install it within 5
minutes.

3. Install the knock sensor.
• Refer to "Knock Sensor" in Section 1E Engine
Electrical (4HV1-CNG).
4. Install the water suction pipe.
• Align to the groove of the water suction pipe 1
flange surface, and apply liquid gasket
(TB1207B or equivalent).
• Refer to the diagram for the application position
2
of the liquid gasket.
1
1
LNW61HSH000301
5. Install the heater pipe.

• Sandwich the gasket, and attach the heater
3 4 pipe.
• Attach it to the position shown in the diagram,
2 and tighten it at the specified torque.
LNW81HSH000301
Legend
1. Liquid gasket
2. 0.5 mm - 2.0 mm(0.020 in - 0.079 in)
3. 2 mm - 5 mm(0.08 in - 0.20 in)
4. 1 mm(0.04 in)
• Attach it to the position shown in the diagram,

and tighten it together with the oil cooler.
• (1) shows the nut, and (2) shows the bolt.
NOTE:
Perform installation of the water suction pipe
immediately after installing the oil cooler (because
liquid gasket is used with the tightening).
LNW61HSH000201
6. Install the radiator lower hose.
7. Install the heater hoses.


8. Install the water hose (bypass).
9. Install the intake manifold assembly.
• Refer to "Intake Manifold" in Section 1B Engine
10. Refill the engine oil.
• For how to fill the coolant, refer to "Cooling
System" in Section 1C Cooling System (4HV1-
CNG).
12. Start the engine and check that there is no coolant
leak or oil leak.
LNW21BSH008501
b
c
a
d
LNW71HMF000601
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(c) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(d) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(e) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Oil Pan
Components
2 3
4
1
5 6
LNW71HLF000501
Legend
1. Fan guide 5. Oil pan rubber
2. Engine mount 6. Gasket
3. Oil pan gasket 7. Drain plug
4. Oil pan
Removal • Before removing the engine mount, use a hoist

to suspend the engine.
• Remove the mounting bolts on the chassis
• After draining the oil, tighten the drain plug at
• Suspend the engine assembly.
Tightening torque: 83 N⋅m (8.5 kg⋅m/61 lb⋅ft) 4. Remove the oil pan.
2. Remove the fan guide from the radiator and place
it on the fan side.
Installation
3. Remove the engine mount.

a. Apply liquid gasket (TB1207B or equivalent)
with bead width of 3 mm(0.12 in) to the aligning 2. Tighten the positions (1), (2), (3), and (4) in the
surfaces of the cylinder block, front cover and diagram.
flywheel housing.
1 2
4
3
LNW21BSH004601
LNW21BSH013801
After applying the liquid gasket, install the oil
pan within 5 minutes. • Then, tighten other places. (No order of
b. Use the flywheel housing, the front cover and tightening is specified.)
the crankcase stud as a guide to assemble the
gasket (3) and place the oil pan (2). Next, place 3. Install the engine mount.
the oil pan rubber (1) on the oil pan, and tighten • Install the engine mount and tighten it at the
it with the bolts and nuts. specified torque.
3 5. Refill the engine oil.
3 2
LNW21BMH000101

LNW71HMF000501
(a) 11 N⋅m (1.1 kg⋅m/95 lb⋅in)

(b) 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
Oil Pump
Components
3
5
4
1
LNW21HMF000701
Legend
1. Idle gear A 5. Split pin
2. Oil pump assembly 6. Driven gear & shaft
3. Spring 7. Oil pump body
4. Ball
Removal • Refer to "Flywheel" in Section 1B Engine

• Refer to "Oil Pan" in this section.
• Refer to "Cylinder Head Cover" in Section 1B
Engine Mechanics (4HV1-CNG). 10. Remove the power steering pump idle gear cover.
• Refer to "Rocker Arm Shaft Assembly" in
Section 1B Engine Mechanics (4HV1-CNG).
• Refer to "Camshaft Assembly" in Section 1B
Engine Mechanics (4HV1-CNG).
6. Remove the cylinder head assembly.
• Refer to "Cylinder Head" in Section 1B Engine
7. Remove the flywheel.

11. Remove the power steering pump idle gear.
LNW21BSH068801
LNW71BSH011901
14. Remove the rear slinger.

12. Remove the flywheel housing. • Refer to "Crankshaft Rear Oil Seal" in Section
• Do not forget to remove the bolt shown in the 1B Engine Mechanics (4HV1-CNG).
diagram. 15. Remove the idle gear A (1).
16. Remove the oil pump assembly (2).
LNW21BSH072301
2
LNW21BSH069301
13. Remove the rear oil seal.

• As shown in the diagram, remove the oil seal by
tapping it lightly at the left and right side
alternately from the back side of the flywheel
housing.

Disassembly
1. Remove the driven gear and shaft.
LNW21HSH001901
2. Measure the gap between the drive gear shaft and

LNW21HSH002401 bush.
diameter of the driven gear shaft.
2. Remove the split pin.
3. Remove the spring. Outer diameter of the drive gear shaft mm(in)
4. Remove the ball.
15.989 - 16.000
Standard values
(0.62949-0.62992)
Inspection Limit 15.900(0.62598)
1. Measure the gap between the gear and the inner
wall of the oil pump body.
• Use a thickness gauge to measure the gap
between the gear and the inner wall of the oil
pump body.
• If the gap between the gear and the body wall
exceeds the limit, replace the gear assembly or
driven gear assembly.
Gap between gear and body wall mm(in)

0.125 – 0.220
Standard values
(0.00492-0.00866)
Limit 0.30(0.0118)
LNW21HSH002101
• Use a dial gauge to measure the inner diameter

of the oil pump body and cylinder block bush.
• If the gap between the driven gear shaft and the
bushing exceeds the limit, replace the driven
gear assembly.

4. Apply engine oil to the driven gear and shaft, and
install these to the oil pump body.
Gap between the driven gear shaft and
bush mm(in)
0.04 - 0.07
Standard values
(0.0016-0.0028)
Limit 0.20(0.0079)
LNW21HSH002401
Installation
1. Install the oil pump assembly.
• Apply liquid gasket (TB1141E or equivalent) as
LNW21HSH002201 shown in the diagram, install it to the cylinder
block within one hour and tighten it at the
specified torque.
Reassembly Tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
1. Install the ball.
2. Install the spring. NOTE:
Apply liquid gasket so that it does not enter the hole at
3. Install the split pin (2) and bend as shown at (1).
the arrow in the diagram, the gear, or inside the oil
• Always use new parts and firmly bend its legs. pump body.
LNW81HSH001201
LNW21HSH002501
2. Install the idle gear A.

• Fit the idle gear shaft at the position shown in
the diagram, and apply engine oil to the shaft.

• Rotate the crankshaft in the forward direction to • After applying the liquid gasket, install it within 5
align the first cylinder piston to the top dead minutes.
center.
LNW21BSH072401
LNW21BSH007801
• Install the flywheel housing by aligning it to the
• Align the crankshaft gear and idle gear A cylinder block dowel pin.
alignment marks and install to the cylinder
block.
Flywheel housing tightening
torque: N⋅m (kg⋅m/lb⋅ft)
Mark 1 Mark 2 Mark 3
96 (9.8/71) 25 (2.6/18) 38 (3.9/28)
• Tighten Mark 3 from the cylinder block side.
LNW21BSH069801
• Apply the engine oil to the bolt and the both

side of the washer.
• Tighten the mounting bolt at the specified
torque.
3. Install the flywheel housing.
• Clean the cylinder block back side thoroughly.
Especially, clean the liquid gasket that oozes
out when the crankcase is installed.
• As shown in the diagram, uniformly apply liquid
gasket (TB1207B or equivalent) to the inside of
the bolt hole (excluding the bolt hole at the
arrow).
2
1
1
LNW21BMF008901
4. Install the power steering pump idle gear.

• Apply engine oil to the gear assembly sections
of the idle gear shaft.
• Assemble the idle gear and shaft as shown in
the diagram, install these to the flywheel
housing and tighten these at the specified
torque.
LNW21BSH072501
5. Install the power steering pump idle gear cover.

• Install the O-ring to the cover, install to the
flywheel housing and tighten the tightening bolt
LNW21BSH004301

With HBB
LNW71BSH010101 2
LNW46ASH000801
Legend
6. Install the power steering pump and tighten it at 1. Flywheel housing section bolt
the specified torque. 2. Cylinder block installation bolt
Flywheel housing mounting bolt (1)

Cylinder block mounting bolt (2) • Refer to "Oil Pan" in this section.
8. After attaching the rear slinger to the crankshaft,
Without HBB attach the rear oil seal.
• Refer to "Crankshaft Rear Oil Seal" in Section
1B Engine Mechanics (4HV1-CNG).
9. Install the flywheel.
• Refer to "Flywheel" in Section 1B Engine
10. Install the cylinder head assembly.
• Refer to "Cylinder Head" in Section 1B Engine
1 11. Install the camshaft assembly.
• Refer to "Camshaft Assembly" in Section 1B
Engine Mechanics (4HV1-CNG).
2 12. Install the rocker arm shaft assembly.
• Refer to "Rocker Arm Shaft Assembly" in
Section 1B Engine Mechanics (4HV1-CNG).
13. Tighten the cylinder head cover.
LNW41BSH001501
• Refer to "Cylinder Head Cover" in Section 1B
Legend Engine Mechanics (4HV1-CNG).
1. Flywheel housing section bolt 14. Fill the engine oil.
15. Fill the coolant.
• Refer to "Cooling System" in Section 1C

LNW71HMF000701
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 157 N⋅m (16.0 kg⋅m/116 lb⋅ft)
Oil Pressure Switch

Inspection 3. Disconnect the oil pressure switch connector, and
inspect that the oil pressure warning light lights
Inspect the continuity between the switch terminal and
when the harness side connector is connected to
body ground without a load applied.
the ground.
Replace with a normal part if there is no continuity in
the inspection.
If it does not light, inspect the circuit between the
meter and the oil pressure switch. Repair any open
circuit.
LNW21HSH003301
Inspection of the circuit LNW21HSH003401

1. Turn the ignition switch ON.
2. Disconnect the oil pressure switch connector, and
inspect that the oil pressure warning light turns off
at the time of the disconnection.
• If it does not turn off, inspect the circuit between
the meter and the oil pressure switch. Repair
any open circuit.
LNW71HSH002101
Engine Speed Control System (4HV1-CNG) 1I-1
ENGINE
Engine Speed Control System
(4HV1-CNG)
TABLE OF CONTENTS
Accelerator Pedal Sensor . . . . . . . . . . . . . . . . . . . 1I-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-3
1I-2 Engine Speed Control System (4HV1-CNG)
Accelerator Pedal Sensor

Components
1
2
LNW41ILF000101
Legend
1. Nut 4. Accelerator pedal
2. Accelerator pedal position (APP) sensor 5. Bolt
3. Control link & bracket assembly
Removal
1. Turn OFF the ignition switch.
Engine Speed Control System (4HV1-CNG) 1I-3

2. Remove the installation nuts of control link &
bracket assembly.
LNW71FSH002601
Installation
1. Install the control link & bracket assembly.
2. After installing the pedal, check that the gap (a) is
at the specified value when the pedal is depressed
all the way to the end.
Gap (a) (reference value): 0 - 2.0 mm(0 - 0.0787 in)
• If it needs adjustment, loosen the nut (2), turn
the bolt (1) to adjust, and then fix the nut (2).
1
2
a
LNW71ISH000101
MEMO
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Induction (4HV1-CNG) 1J-1
ENGINE
Induction
(4HV1-CNG)
TABLE OF CONTENTS
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-3
IAT Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-4
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-5
Throttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-6
1J-2 Induction (4HV1-CNG)
Air Cleaner Element

Removal Cleaning
1. Remove three clips to remove the air cleaner <When dry dust such as from dust sand is
cover. adhering>
2. Remove the air cleaner element from the body. • Blow air at pressures of 690 kPa(7 kg/cm2/100 psi)
NLR model or below from the direction shown in the diagram
to remove dust.
NLR model
LNW71JSH000901
NMR,NPR model
LNW71BSH000201
NMR,NPR model
LNW71JSH001001
LNW71JSH001701
Inspection
• Inspect the element for damage and for clogging
caused by filth.
If clogging is found, clean the element. If damage
is found, replace the element.
Cleaning period: once every 10,000 km(6,000 mile)
Replacement period: Every 40,000 km(24,000 mile) or
once every two years

• When the element is blackened by oily smoke NMR,NPR model
such as soot.
Dissolve a mild detergent with water and soak the
element for approximately 30 minutes. Then,
thoroughly rinse the element with water and allow
it to dry naturally (for two to three days).
Do not use compressed air or fire to dry.
LNW71JSH001001
HCW31BSH057501
NOTE:
If the element is excessively dirty, replace it.
Installation
1. Install the air cleaner element.
2. Carefully align the air cleaner cover claw and notch
on the body, and securely fasten the clips at three
locations.
NLR model
LNW71JSH000901
IAT Sensor
Removal
battery cable.
2. Remove the throttle valve.
Refer to "Throttle Valve" in this section.
3. Disconnect the harness connector of the IAT
sensor.
4. Remove the IAT sensor.
1
LNW61ASH002301
1 Legend
1. IAT sensor
2. Connect the harness connector of the IAT sensor.

3. Install the throttle valve.
Refer to "Throttle Valve" in this section.
cable.
LNW61ASH002301
Legend
1. IAT sensor
Installation
1. Install the IAT sensor.
kg⋅m/113 lb⋅in).
MAP Sensor
Removal
battery cable. 2
2. Disconnect the harness connector of the MAP
1
sensor.
3. Remove the MAP sensor bracket fixing bolt, and
then remove the MAP sensor bracket.
4. Remove the MAP sensor.
2
1
LNW61ASH002601
Legend
1. MAP sensor
2. MAP sensor bracket
2. Connect the harness connector of the MAP

sensor.
3. Install the MAP sensor bracket and tighten the
MAP sensor bracket fixing bolt.
LNW61ASH002601
Legend cable.
1. MAP sensor
2. MAP sensor bracket
Installation
1. Install the MAP sensor.
• Tighten the sensor at a torque of 8.0 N⋅m (0.8
kg⋅m/69 lb⋅in).
Throttle Valve
Removal
battery cable.
1
2. Remove the intake hose (air cleaner - throttle
valve).
3. Remove the blow-by hose from the PCV. 2
4. Remove four throttle valve fixing bolts and remove

the throttle valve.
LNW61ASH002901
Legend
1. Throttle valve
2. Gasket
4. Install the blow-by hose to the PCV.

5. Install the intake hose of the throttle valve.
LNW61ASH002901
NOTE:
Legend
Use a new clamp.
1. Throttle valve
2. Gasket 6. Connect the negative side terminal of the battery
cable.
5. Disconnect the harness connector of the throttle
valve.
6. Remove the gasket.
Installation
1. Install the gasket.
2. Connect the harness connector of the throttle
valve.
3. Install the throttle valve and tighten the four fixing
bolts.
LG4HV-WE-0981_4305501奥付 2012.11.1 3:08 PM ページ 1
Published: Nov., 2012 All rights reserved.

Sixth Edition
WORKSHOP MANUAL
ENGINE
(4HV1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
LG4HV-WE-0981_4305501奥付 2012.11.1 3:08 PM ページ 2
2009-2012MY
2009-2012MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE (4HV1 model)

ENGINE
(4HV1 model)
No.LG4HV-WE-0981

Workshop Manual: (4HV1 Model)

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WORKSHOP MANUAL ENGINE (4HV1 model)

Engine Mechanical (4HV1-CNG) 1B-1

1B-2 Engine Mechanical (4HV1-CNG)

Engine Mechanical (4HV1-CNG) 1B-3

1B-4 Engine Mechanical (4HV1-CNG)

Reading the Engine Type

Engine Mechanical (4HV1-CNG) 1B-5

1B-6 Engine Mechanical (4HV1-CNG)

Engine Mechanical (4HV1-CNG) 1B-7

1B-8 Engine Mechanical (4HV1-CNG)

Engine Mechanical (4HV1-CNG) 1B-9

1B-10 Engine Mechanical (4HV1-CNG)

Engine Mechanical (4HV1-CNG) 1B-11

Compressed natural CNG container (CNG cylinder)

1B-12 Engine Mechanical (4HV1-CNG)

Engine Mechanical (4HV1-CNG) 1B-13

Gas injector Lubricating system

1B-14 Engine Mechanical (4HV1-CNG)

Valve clearance (while cooling) mm(in)

• Inspect valve clearance for the items marked with

1. Valve clearance measurement

Engine Mechanical (4HV1-CNG) 1B-15

LNW21BSH066501 Limit 2.12 (21.6 / 307) (reference value)

Compression pressure inspection

1B-16 Engine Mechanical (4HV1-CNG)

Valve force-opening method

• Force-open the shutoff valve of the fuel circuit, 3 8 Hold-in coil

apply gas leak detection fluid or soap-water to the 7

is running. But by using the fuel shutoff valve

Engine Mechanical (4HV1-CNG) 1B-17

• The valve force-opened condition can be

1B-18 Engine Mechanical (4HV1-CNG)

3. Disengaging valve force-opening of the shutoff

Engine Mechanical (4HV1-CNG) 1B-19

1B-20 Engine Mechanical (4HV1-CNG)

Condition Possible Cause Correction

Engine Mechanical (4HV1-CNG) 1B-21

Condition Possible Cause Correction

1B-22 Engine Mechanical (4HV1-CNG)

Condition Possible Cause Correction

Engine Mechanical (4HV1-CNG) 1B-23

Condition Possible Cause Correction

1B-24 Engine Mechanical (4HV1-CNG)

Condition Possible Cause Correction

Engine Mechanical (4HV1-CNG) 1B-25

Condition Possible Cause Correction

1B-26 Engine Mechanical (4HV1-CNG)

Condition Possible Cause Correction

Engine Mechanical (4HV1-CNG) 1B-27

Condition Possible Cause Correction

1B-28 Engine Mechanical (4HV1-CNG)

Condition Possible Cause Correction

Engine Mechanical (4HV1-CNG) 1B-29

Condition Possible Cause Correction

1B-30 Engine Mechanical (4HV1-CNG)

Condition Possible Cause Correction

Engine Mechanical (4HV1-CNG) 1B-31

Condition Possible Cause Correction

1B-32 Engine Mechanical (4HV1-CNG)

Condition Possible Cause Correction

Engine Mechanical (4HV1-CNG) 1B-33

Condition Possible Cause Correction