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Isuzu NHR 4J Series, Workshop Manual

The Isuzu NHR 4J Series Workshop Manual is the ultimate guide for maintaining and repairing your vehicle. Easily download the manual for free from manualshive.com, providing you with all the necessary information to keep your Isuzu NHR 4J Series in top condition. Get your copy now and drive with confidence.

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6A1 – 58  4JB1/4JB1T/4JB1TC/4JG2 - ENGINE

5) Apply a coat of engine oil to the piston pin and the

piston pin hole.
Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.

6) Use your fingers to force the piston pin snap ring into

the piston snap ring groove.
Check that the connecting rod moves smoothly on the
piston pin.

7) Install the piston rings with the piston ring expander.

The compression ring must be set with the 1N, 2N
mark facing up.
Discrimination mark is painted as shown in the
illustration.

8) Use a piston ring replacer to install the three piston

rings.
Piston Ring Replacer
Install the piston rings in the numerical order shown in
the illustration.

!

Oil ring

"

2nd compression ring

#

1st compression ring

NOTE:

Install the compression rings with the stamped side
facing up.

Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.

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Summary of Contents for NHR 4J Series

Page 1: ...WORKSHOP MANUAL NHR NKR NPR ENGINE 4J SERIES SECTION 6...

Page 2: ...MEMO...

Page 3: ...contained in Section 0A under the headings GENERAL REPAIR INSTRUCTIONS and HOW TO USE THIS MANUAL All material contained in this Manual is based on the latest product information available at the tim...

Page 4: ...NG SECTIONS SECTION NO CONTENTS 00 Service Information 6A Engine Mechanical 6A1 4JB1 4JB1T 4JB1 TC 4JG2 Engine 6B Engine Cooling 6C Fuel System 6D Engine Electrical 6E Exhaust Gas Recirculation EGR Sy...

Page 5: ...CE INFORMATION 00 1 SECTION 00 SERVICE INFORMATION CONTENTS PAGE Troubleshooting 00 2 Main Data and Specifications 00 30 Service Standard 00 34 Servicing 00 38 Fixing Torque 00 51 Special Tools 00 60...

Page 6: ...ble Idling 00 6 Insufficient Power 00 7 Excessive Fuel Consumption 00 9 Excessive Oil Consumption 00 9 Overheating 00 10 White Exhaust Smoke 00 10 Dark Exhaust Smoke 00 11 Oil Pressure Does Not Rise 0...

Page 7: ...r starter relay Repair or replace the magnetic switch Starter motor Defective starter motor Repair or replace the starter motor 2 STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER Loose battery cab...

Page 8: ...Defective feed pump Repair or replace the feed pump FUEL IS BEING DELIVERED TO THE INJECTION PUMP Use of the wrong fuel Use the correct fuel Water particles in the fuel Change the fuel Fuel Fuel syste...

Page 9: ...timer Replace the quick on start timer Glow plug indicator light turns on the 0 3 seconds Defective quick on start timer Replace the quick on start timer Return the starter switch to the ON position...

Page 10: ...properly adjusted Adjust the idling Fast idling speed Defective fast idling speed control device Repair or replace the fast idling speed control device Accelerator control system Accelerator control s...

Page 11: ...the valve clearance Compression pressure Blown out cylinder head gasket Worn cylinder liner Piston ring sticking Replace the related parts 3 INSUFFICIENT POWER Checkpoint Possible cause Correction Air...

Page 12: ...epair or replace the injection pump timer Weak governor spring Replace the governor spring Injection pump Worn plunger Replace the plunger assembly Compression pressure Blown out cylinder head gasket...

Page 13: ...is fuel drippage after fuel injection Replace the delivery valve Valve clearance Valve clearance improperly adjusted Adjust the valve clearance Compression pressure Blown out cylinder head gasket Wor...

Page 14: ...tat Defective thermostat Replace the thermostat Cooling system Cooling system clogged by foreign material Clean the foreign material from the cooling system Fuel injection timing Fuel injection timing...

Page 15: ...engine oil Replace the engine oil Correct the engine oil volume Oil pressure gauge or unit Oil pressure indicator light Defective oil pressure gauge or unit Defective indicator light Repair or replac...

Page 16: ...pipes Broken exhaust pipes Tighten the exhaust pipe connections Replace the exhaust pipes Injection nozzles and or glow plugs Loose injection nozzles and or glow plugs Replace the washers Tighten the...

Page 17: ...r damaged crankshaft and or thrust bearings Replace the crankshaft and or the thrust bearings Crankshaft and connecting rod bearings Worn or damaged crankshaft and or connecting rod bearings Replace t...

Page 18: ...ty radiator cap Replace Low engine oil level or use of improper engine oil Replenish or change oil Replenish Damaged cylinder head gasket Replace Clogged exhaust system Clean exhaust system or replace...

Page 19: ...ON HEAD LAMP AND STARTER SWITCH HEAD LAMP DOES NOT COME ON OR IT IS EXTREMELY DARK a LACK OF BATTERY CHARGING b SHORT CIRCUIT IN STARTER OIL c FAULTY STARTER PARTS a DISCONNECT STARTER CIRCUIT b DISCO...

Page 20: ...CONDITION CHECK IF VOLTAGE OF CONNECTOR 3BW ON MAGNETIC SWITCH OF RESTART RELAY IS NORMAL YES NO DISCONNECTION OR FAULTY CONNECTION BETWEEN STARTER SWITCH AND MAGNETIC SWITCH CHECK IF VOLTAGE IS PRES...

Page 21: ...YES YES NO REPAIR OR PINION SLIDING PART DOES NOT MOVE MAGNETIC SWITCH OR COIL IS DISCONNECTED OR BURNED OUT REPAIR OR REPLACE STARTER CHECK IF INDICATOR LAMP ON METER COMES ON NORMALLY YES NO DISCON...

Page 22: ...NOT RUN CHECK GROUND CABLE YES NO REPAIR OR REPLACE GROUND CABLE FAULTY CONNECTION OF BRUSH AND COMMUTATOR BURNED OUT MAGNETIC STARTER SWITCH REPAIR OR REPLACE STARTER DISCONNECTION OR DAMAGE OF FIEL...

Page 23: ...OP THOUGH STARTER SWITCH IS RETURNED TO ON FROM START REPLACE STARTER SWITCH DISCONNECTED STARTER SWITCH WIRING CONNECTOR AND CHECK STARTER SWITCH OPERATION KEY POSITION BATTERY B1 IGNITION IG1 BATTER...

Page 24: ...pe and hose Restricted Clean or replace Compressor Intake manifold Loose Leaking Repair Exhaust manifold turbine inlet Loose Leaking Repair Exhaust piping and silencers Restricted Clean or replace Air...

Page 25: ...int Trouble Cause Countermeasure Compressor wheel Impact damage Replace Turbine wheel Impact damage Replace Carbon build up Replace Rotating assembly Dragging or seized Replace Continued from the prev...

Page 26: ...r replace Turbocharger oil seal Leakage Replace Turbocharger oil drain pipe Restricted Repair or replace Air breather Restricted Clean Boost compensator Injection pump Defective Repair or replace Comp...

Page 27: ...SERVICE INFORMATION 00 23 Checkpoint Trouble Cause Countermeasure Center housing oil drain passage Restricted Clean or replace Continued from the previous page NG OK...

Page 28: ...ost compensator Injection pump Defective Repair or replace Turbocharger oil seal Leakage Replace Turbocharger oil drain pipe Restricted Clean or replace Turbine wheel Impact damage Replace Compressor...

Page 29: ...SERVICE INFORMATION 00 25 Checkpoint Trouble Cause Countermeasure Center housing oil drain passage Restricted Clean or replace Continued from the previous page NG OK...

Page 30: ...r Intake and exhaust system gaskets Damaged Replace Turbocharger rotating parts Rough rotation Replace Rubbing against housing Repair or replace Damaged Replace Rubbing against housing Repair or repla...

Page 31: ...vel Too low Correct Contaminated Replace oil Turbocharger oil feed pipe Restricted Repair or replace Turbine housing Carbon deposits Clean Compressor housing Dirty Clean Turbine shaft bearings Worn Re...

Page 32: ...ange Wrong grade or type Change Turbocharger oil feed pipe Restricted Clean or replace Turbocharger oil seal Defective Replace Center housing oil drain passage Restricted Clean or replace Turbine shaf...

Page 33: ...l filters have on oil cooler It is then delivered to the vital parts of the engine from the cylinder body oil gallery 4JB1 4JB1TC 4JG2 Oil Filter Oil Cooler kPa Kg cm 2 psi Oil filter relief valve ope...

Page 34: ...ion pressure kPa kg cm 2 psi 3 038 31 441 3 334 34 483 8 For EC 2 363 24 1 531 Engine weight Dry N kg lb Approximately 2 245 229 505 4JB1 2 511 256 564 4JB1T 4JB1TC Approximately 2 403 245 540 Fuel in...

Page 35: ...Water cooled Fuel system Injection pump type Bosch distributor Governor type Mechanical Partially variable speed For EC Variable speed Injection nozzle type Hole Pinttle Injection nozzle kPa kg cm 2...

Page 36: ...en C F wax pellet with jiggle valve Without jiggle valve Thailand only 82 180 95 203 Coolant total capacity Iit Imp qt US qt 10 8 80 10 57 For EC 7 3 6 42 7 71 Starting System Manufacturer DENSO Engin...

Page 37: ...LR150 449B DENSO Rated voltage V 12 12 Rated output A 50 40 Rotating direction As viewed from pulley Clockwise Clockwise Pulley effective diameter mm in 80 3 15 82 3 23 Weight with pump kg lb 6 0 13...

Page 38: ...alve Spring Free height Squareness Spring tension N kg lb 48 0 1 891 296 30 2 66 4 47 10 1 856 1 7 0 067 257 9 26 3 57 9 At installed height 38 9 1 531 7 946 7 961 0 3128 0 3134 7 921 7 936 0 3118 0 3...

Page 39: ...de diameter Oil clearance Between rocker arm and rocker shaft Rocker shaft runout 18 98 19 00 0 7472 0 7480 19 036 19 060 0 7494 0 7504 0 06 0 08 0 00235 0 00315 18 90 0 7440 19 10 0 7520 0 10 0 004 0...

Page 40: ...0 0 125 0 0035 0 0049 0 050 0 075 0 0020 0 0030 1 5 0 0591 1 5 0 0591 1 5 0 0591 0 15 0 0059 Oil 0 03 0 07 0 0012 0 0028 0 15 0 0059 Piston pin diameter 33 995 34 000 1 3384 1 3386 30 995 31 000 1 220...

Page 41: ...e Upper surface of the cylinder block 0 20 0 0079 Cylinder bore diameter 97 000 97 040 95 011 95 040 3 8189 3 7406 3 8205 3 7417 Cylinder liner projection 0 0 0 1 0 00 0 0039 Cylinder liner inside 95...

Page 42: ...n of the element Dust fouled Element Rotate the element with your hand while applying compressed air to the inside of the element This will blow the dust free Compressed air pressure kPa kg cm 2 Psi 3...

Page 43: ...ment Replacement Procedure 1 Loosen the used oil filter by turning it counterclockwise with the filter wrench 2 Clean the oil filter fitting face This will allow the new oil filter to seat properly 3...

Page 44: ...ilter Wrench 5 8840 0253 0 J 22700 5 Loosen the bleeder plug on the injection pump overflow valve 6 Operate the priming pump until fuel begins to flow from the fuel filter 7 Retighten the bleeder plug...

Page 45: ...on the injection pump overflow valve 2 Operate the priming pump until fuel mixed with foam flows from the bleeder screw 3 Tighten the bleeder screw 4 Operate the priming pump several times and check...

Page 46: ...he system from completely filling up 4 Keep a filling rate of 9 liter min or less Filling over this maximum rate may force air inside the engine and radiator And also the coolant overflow will increas...

Page 47: ...ntain coolant pressure in the cooling system at 1 05 kg cm 2 15 psi 103 kPa Check the radiator filler cap with a radiator filler cap tester The radiator filler cap must be replaced if it fails to hold...

Page 48: ...ey Drive Belt Move the idler pulley as required to adjust the compressor drive belt tension If the vehicle is equipped with power steering move the oil pump as required Depress the drive belt mid port...

Page 49: ...ection pump idling set bolt 2 Adjust the idling speed to the specified range by turning the idling set bolt 3 Lock the idling set bolt with the idling set bolt lock nut 4 Check that the idling control...

Page 50: ...nal positions without fail VALVE CLEARANCE ADJUSTMENT 1 Bring the piston in either the No 1 cylinder or the No 4 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaf...

Page 51: ...ck that the notched line on the injection pump flange is aligned with the front plate or the timing gear case notched line 2 Bring the piston in the No cylinder to TDC 1 on the compression stroke by t...

Page 52: ...ming is outside the specified range continue with the following steps 11 Loosen the injection pump fixing nuts and bracket bolts 12 Adjust the injection pump setting angle When large than standard val...

Page 53: ...3 038 31 441 2 157 22 313 4JG2 3 334 34 484 2 452 25 356 5 Repeat the procedure Steps 3 and 4 for the remaining cylinders If the measured value is less than the specified limit refer to Troubleshooti...

Page 54: ...licking sound within seven seconds after the starter switch is turned on 3 Measure the glow plug terminal voltage with a circuit tester immediately after turning the starter switch to the ON position...

Page 55: ...SERVICE INFORMATION 00 51 FIXING TORQUE CYLINDER HEAD COVER CYLINDER HEAD ROCKER SHAFT BRAKER N m kg m lb ft 011LX002 tif...

Page 56: ...00 52 SERVICE INFORMATION Crankshaft Bearing Cap Connecting Rod Bearing Cap Crankshaft Damper Pulley Flywheel Oil Pan N m kg m lb ft 0051 1 tif...

Page 57: ...SERVICE INFORMATION 00 53 Timing Pulley Housing Timing Pulley Timing Gear Camshaft Oil Seal Retainer N m kg m lb ft 014LX001 tif...

Page 58: ...00 54 SERVICE INFORMATION Cooling System and Lubrication System N m kg m lb ft...

Page 59: ...SERVICE INFORMATION 00 55 Intake Manifold Exhaust Manifold Exhaust Pipe N m kg m lb ft 150LX004 tif...

Page 60: ...00 56 SERVICE INFORMATION N m kg m lb ft 036LX003 tif...

Page 61: ...SERVICE INFORMATION 00 57 Engine Electricals N m kg m lb ft 0056 1 tif...

Page 62: ...00 58 SERVICE INFORMATION Engine Fuel N m kg m lb ft 0057 1 tif...

Page 63: ...SERVICE INFORMATION 00 59 Engine Mounting Bracket N m kg m lb ft 0058 1 tif...

Page 64: ...8840 0202 0 Oil Filter Wrench 106 0 mm 4 2 in 5 8840 2209 0 Oil Filter Wrench 100 6 mm 4 0 in 9 8523 1423 0 J 29760 Valve Spring Compressor 5 8840 2033 0 Oil Seal Installer 5 8840 9018 0 Piston Ring...

Page 65: ...531 7002 0 Gauge Adapter 5 8840 0145 0 Measuring Device 5 8522 0024 0 Crankshaft Timing Pulley Installer 4JG2 Belt Drive only 5 8840 0266 0 Angle Gauge 5 8840 9016 0 Injection Nozzle Tester 5 8840 203...

Page 66: ...2361 0 Front Oil Seal Installer 4JG2 Belt Drive only 5 8840 2360 0 Rear Oil Seal Remover 5 8840 2359 0 Rear Oil Seal Installer 5 8840 2040 0 Cylinder Liner Installer 4JB1 only 5 8840 2313 0 Cylinder L...

Page 67: ...SERVICE INFORMATION 00 63 MEMO...

Page 68: ...ENGINE MECHANICAL CONTENTS PAGE Cylinder Head 6A 2 Valve Spring Valve Guide Oil Seal Valve Guide Push Rod 6A 10 Camshaft Tappet 6A 17 Rocker Arm Assembly 6A 24 Oil Pump 6A 27 Crankshaft 6A 31 Piston a...

Page 69: ...the results DISASSEMBLY 1 Thermostat Housing Assembly 2 Injection Nozzle Holder 4JG2 2a Injection Nozzle Holder 4JB1 4JB1TC 1 Remove the nozzle holder bracket nuts 6A 2 1 tif 6A 2 2 tif 4JB1 Disassemb...

Page 70: ...linder head Carefully remove all varnish soot and carbon to the bare metal Do not use a motorized wire brush on any gasket sealing surface INSPECTION AND REPAIR Make the necessary adjustments repairs...

Page 71: ...cket sealing plugs seating surfaces 6 Use a straight edge and a feeler gauge to measure the manifold cylinder head lifting face warpage Regrind the exhaust manifold cylinder head lifting surfaces if t...

Page 72: ...atches or protuberance on the combustion chamber surfaces which will be in contact with the hot plug after it is installed There flaws will prevent the hot plug from seating correctly Hot plug inspect...

Page 73: ...Heat shield removal 4JG2 only After removing the hot plugs use a hammer and a brass bar to lightly tap the lower side of the heat shield and drive it free Heat shield installation 4JG2 only Install t...

Page 74: ...der head And finally hit the hot plug lightly with a plastic hammer and check it for any excessive sinking protrusion or backlash 2 Valve Seat Insert Installation 1 Carefully place the attachment havi...

Page 75: ...ole to hold the valve in place Install split collar by special tool Valve spring compressor 9 8523 1423 0 J 29760 7 Split Collar Use a spring compressor to push the valve spring into position Install...

Page 76: ...rn one word and one word Set positioning confirmation drilled hole 2 within a nozzle turning angle of 5 against the cylinder head side positioning boss Apply a wrench as illustrated and tighten the ho...

Page 77: ...GUIDE PUSH ROD DISASSEMBLY 1 Rocker Arm Assembly 2 Split Collar Using special Tool compress valve spring Valve spring compressor 9 8523 1423 0 J 29760 3 Valve Spring 4 Valve 5 Valve Guide Oil Seal 6...

Page 78: ...h a steel square Replace the valve springs if the measured value exceeds the specified limit Limit mm in 1 7 0 067 3 Spring tension Use spring tester to compress the springs to the installed height Me...

Page 79: ...st 7 921 7 936 0 3118 0 3124 7 850 0 3091 Measure the inside diameter of the valve guide with a micrometer Subtract the measured outer diameter of the valve stem from the measured inner diameter of th...

Page 80: ...removed both the valve and the valve guide must be replaced as a set Valve Thickness 1 Measure the valve thickness 2 If the measured value is less than the specified limit the valve and the valve guid...

Page 81: ...ct Width mm in Standard Limit Inlet 1 7 0 0670 2 2 0 0866 Exhaust 2 0 0 0788 2 5 0 0984 Valve Seat Insert Replacement Valve Seat Insert Removal 1 Arc weld the tire inside circumference of the valve se...

Page 82: ...inside the valve guide 3 Apply abrasive compound to the valve seat insert surface 4 Insert the valve into the valve guide 5 Turn the valve while tapping it to fit the valve seat insert 6 Check that th...

Page 83: ...5 8840 2033 0 4 Valve Apply engine oil to the outside of the valve stem 3 Valve Spring Attach the valve seat to the upper spring seat The painted area of the valve spring should be facing downward 2...

Page 84: ...ssembly 5 Oil Pump Assembly 6 Camshaft Timing Gear Gear Drive Model Remove the camshaft timing gear bolt from the camshaft NOTE Hold the camshaft stationary to prevent the camshaft from turning Use th...

Page 85: ...y This must be done before removing the camshaft gear If the camshaft end play exceeds the specified limit the thrust plate must be replaced Camshaft End Play mm in Standard Limit 0 08 0 0031 0 2 0 00...

Page 86: ...5 1 9696 50 08 1 9716 Camshaft Bearing Clearance mm in Standard Limit 0 025 0 085 0 0010 0 0033 0 12 0 005 If the clearance between the camshaft bearing inside diameter and the journal exceeds the spe...

Page 87: ...tappet outside diameter with a micrometer If the measured value is less than the specified limit the tappet must be replaced Tappet Outside Diameter mm in Standard Limit 12 97 12 99 0 510 0 511 12 95...

Page 88: ...l Seal Retainer Bolt Torque N m kg m lb ft 19 1 9 14 Align the camshaft timing pulley center with the camshaft key Tighten the timing pulley bolts to the specified torque Timing Pulley Bolt Torque N m...

Page 89: ...heel Apply engine oil to fixing bolts Tighten the flywheel bolts to the specified torque in two steps using the Angular Tightening Method Follow the numerical order shown in the illustration Flywheel...

Page 90: ...insert NOTE The smooth side of the attachment must contact the valve seat insert 2 Use the bench press to gradually apply pressure to the attachment and press the valve seat insert into place NOTE Do...

Page 91: ...t INSPECTION AND REPAIR Make the necessary adjustment repairs and part replacements if excessive wear or damage is discovered during inspection Use a micrometer to measure the rocker shaft outside dia...

Page 92: ...er arm or the rocker arm shaft Rocker Arm and Rocker Shaft Clearance mm in Standard Limit 0 06 0 08 0 0024 0 0031 0 10 0 0039 3 Check that the rocker arm oil port is free is obstructions If necessary...

Page 93: ...haft Run Out mm in Limit 4JB1 4JB1T 4JB1TC 4JG2 0 2 0 008 REASSEMBLY 7 Rocker Arm Shaft Apply a light coat of engine oil to the rocker arm shafts Position the rocker arm shaft with the large oil hole...

Page 94: ...2 Stifner Space Rubber Remove the stiffener from of the oil pan left right side Take out space rubber 3 Oil Pan Assembly 6A 27 2 tif 6A 27 1 tif Disassembly steps 1 Vacuum pump oil hose 2 Stiffener a...

Page 95: ...r Teeth and Body Inner Wall Clearance Use a feeler gauge to measure the clearance between the gear teeth and the body inner wall If the clearance between the gear teeth and the body inner wall exceeds...

Page 96: ...ed torque N m kg m lb ft 19 1 9 14 3 Oil Pan Assembly Apply the recommended liquid gasket or its equivalent to the No 5 bearing cap arches the grooves the cylinder block and the timing gear case filti...

Page 97: ...ener Space Rubber Install the space rubber Install the stiffener tighten to the specified torque Engine Body Side N m kg m lb ft 37 3 8 27 Clutch Housing Side N m kg m lb ft 78 8 0 58 1 Vacuum Pump Oi...

Page 98: ...emove the oil seal Remover 5 8840 2362 0 6A 31 1 tif Disassembly steps 1 Cylinder head Assembly and gasket 2 Oil pan Assembly 3 Timing gear 3a Timing Belt and Pulley 4 Front oil seal 5 Timing gear hou...

Page 99: ...40 2360 0 NOTE Take care not to damage sealing surface of rear plate and crankshaft when removing oil seal 12 Main Bearing Cap 13 Crankshaft INSPECTION AND REPAIR Make the necessary adjustments repair...

Page 100: ...er bearings to the bearing cap original position 7 Apply plastigage to the crankshaft journal unit as shown in the illustration 8 Install the main bearing caps Apply engine oil to the bolt threads and...

Page 101: ...n Inspect the surface of the crankshaft journals and crank pins for excessive wear and damage Inspect the oil seal fitting surfaces for excessive wear and damage Inspect the oil ports for obstructions...

Page 102: ...ately after completing the test NOTE The ammonium cupric chloride solution is highly corrosive Because of this it is imperative that the surfaces being tested be cleaned immediately after completing t...

Page 103: ...0025 1 or 69 927 69 942 2 7530 2 7536 0 031 0 056 0 0012 0 0022 2 or 69 922 69 927 2 7528 2 7530 Green 0 036 0 048 0 0014 0 0019 2 73 975 73 987 2 9124 2 9129 3 or 69 917 69 922 2 7526 2 7528 Black 0...

Page 104: ...tely free of oil before applying the liquid gasket Do not allow the liquid gasket to obstruct the cylinder thread holes and bearings Install the bearing caps with the bearing cap head arrow mark facin...

Page 105: ...the slave 5 After installing the oil seal check the measurement of the oil seal Standard mm in 12 2 12 8 0 48 0 50 10 Cylinder Block Rear Plate Align the rear plate with the cylinder body knock pins...

Page 106: ...ing gear housing gasket to the specified torque N m kg m lb ft 19 1 9 14 3 Cut away the gasket protruding above the fitting surface as shown in the illustration 4 Front Oil Seal Gear Drive Model Insta...

Page 107: ...ng pulley bolts to the specified torque Timing Pulley Bolt Torque N m kg m lb in 8 0 8 69 Prevent the camshaft from turning when tightening the timing center bolt Tighten the timing pulley center bolt...

Page 108: ...amshaft timing pulley the tensioner idler and the injection timing pulley Follow the numerical order Install the timing belt tensioner to the timing pulley housing Temporarily tighten the tensioner bo...

Page 109: ...tensioner bolt to the specified torque Tensioner Bolt Torque N m kg m lb ft 76 7 7 56 14 Tighten the tension adjusting lever nut and bolt NOTE If on vehicle timing belt replacement is performed the c...

Page 110: ...specified torque a little at a time Timing Pulley Cover Bolt Torque N m kg m lb ft 8 0 81 6 Remove the lower cover guide pin Crankshaft Center Pulley Torque N m kg m lb ft 206 21 152 1 Crankshaft Damp...

Page 111: ...ark with the crankshaft timing gear X X setting mark Align the idler gear Y setting mark with the camshaft timing gear Y Y setting mark Install the thrust collar and bolts to the cylinder body through...

Page 112: ...he rear bracket bolts to the injection pump bracket Do not tighten the bolts The rear bracket bolts and will be finally tightened to the specified torque N m kg m lb ft 19 1 9 14 6 Timing Gear Oil Pip...

Page 113: ...Install AC Generator Power Steering pump drive belt and adjust belt tension Depress the drive belt mid portion with a 98 N 10 kg 22 lb force Drive Belt Deflection mm in 8 0 31 12 0 47 Tighten the idle...

Page 114: ...from the upper portion of the cylinder wall with a scraper before removing the piston and connecting rod 6A 47 1 tif Disassembly steps 1 Cylinder head Assembly 2 Oil pan Assembly 3 Oil pump Assembly 4...

Page 115: ...ting Rod INSPECTION AND REPAIR PISTON AND PISTON RING Pistons Carefully clean away all the carbon adhering to the piston head and the piston ring grooves NOTE Never use a wire brush to clean the pisto...

Page 116: ...this Section If the piston clearance does not conform to the specified valve the piston and or cylinder liners must be replaced Piston Clearance mm in 4JB1 4JB1T 4JB1TC 0 061 0 0024 4JG2 0 066 0 0026...

Page 117: ...rk of the piston ring are shown in the illustration 4JB1 4JB1T 4JB1TC mm in Standard Limit 1st 0 20 0 40 0 0079 0 0157 Compression ring 2nd 0 20 0 40 0 0079 0 0157 Oil ring 0 10 0 30 0 0039 0 0118 1 5...

Page 118: ...TC 30 995 31 000 1 2202 1 2204 30 970 1 2190 4JG2 33 995 34 000 1 3384 1 3386 33 970 1 3374 2 Measure the inside diameter of the connecting rod small end If the clearance between the small end and pin...

Page 119: ...hrust clearance Use a feeler gauge to measure the thrust clearance at the big end of the connecting rod If the clearance exceeds the specified limit the connecting rod must be replaced Thrust Clearanc...

Page 120: ...arance mm in Standard Limit 4JB1 4JB1T 4JB1TC 0 029 0 066 0 0011 0 0026 4JG2 0 029 0 083 0 0011 0 0033 0 100 0 0039 REASSEMBLY 11 Connecting Rod 10 Piston 9 Piston Pin Apply a cost of engine oil to th...

Page 121: ...ing Upper side rail Lower side rail 2 2nd compression ring 3 1st compression ring The compression ring must be set with the 1N or 2N mark 4JG2 facing up 1st compression ring 1N 4JG2 N 4JB1 2nd compres...

Page 122: ...the cap nuts check to see that the crankshaft rotates smoothly 4 Piston Cooling Oil Pipe Install the piston cooling oil pipe to the cylinder body Tighten the oil pipe bolts and relief valve to the sp...

Page 123: ...sembly steps 1 Cylinder head Assembly and gasket 2 Oil pan Assembly 3 Timing gear 3a Timing belt and pulley 4 Front oil seal 5 Timing gear housing 5a Timing pulley housing 6 Oil pump Assembly 7 Piston...

Page 124: ...allation surface seal 3 Wipe the cylinder block clean Cylinder Liner Projection Inspection 1 Hold a straight edge along the top edge of the cylinder liner to be measured 2 Use a feeler gauge to measur...

Page 125: ...er liner must be replaced NOTE The inside of the dry type cylinder liner is chrome plated It cannot be rebored or honed If the inside of the cylinder liner is scored or scorched the cylinder liner mus...

Page 126: ...select service parts grade for cylinder liner 1 AX grade and for piston AX grade The stamping grade code on the service parts are For cylinder liner grade stamped on the outside of cylinder liner For...

Page 127: ...to select the correct piston grade will result in engine failure Always measure the cylinder bore and select the correct piston grade Cylinder liner kit clearances are preset However the cylinder lin...

Page 128: ...measure the cylinder liner projection 8 After installing the cylinder liner measure the cylinder liner projection Refer to Cylinder Liner Projection Inspection in this Section Measure the cylinder lin...

Page 129: ...ir of pliers to install the piston pin snap ring to the piston NOTE When changing piston connecting rod combinations do not change the piston piston pin combination 4 Install the piston to the connect...

Page 130: ...numerical order shown in the illustration Oil ring 2nd compression ring 1st compression ring NOTE Install the compression rings with the stamped side facing up Insert the expander coil into the oil r...

Page 131: ...crankpin At the same time rotate the crankshaft until the crankpin is at BDC 16 Position the bearing cap front mark so that it is facing the front of the engine 17 Install the connecting rod bearing c...

Page 132: ...tating crankshaft slowly 6 Oil Pump Assembly Above works refer to OIL PUMP Section in this manual 5a Timing Pulley Housing 5 Timing Gear Housing 4 Front Oil Seal Belt Drive Model 3a Timing Belt and Pu...

Page 133: ...nt Refer to the illustration for the piston head projection measuring positions All measuring positions should be as close as possible to the cylinder liner Measure the points and obtain two differenc...

Page 134: ...linder head gasket with top mark up Clean up cylinder head lower surface and cylinder body upper surface Install the cylinder head as softly Apply molybdenum disulfide grease to screw and seat of cyli...

Page 135: ...HANICAL Tighten the rocker arm shaft bracket bolts to the specified torque in the numerical order shown in the illustration Rocker Arm Shaft Bracket Bolt Torque N m kg m lb ft 54 5 5 40 Valve clearanc...

Page 136: ...mbly 6A1 17 Valvestem Oil Controller and Valve Spring 6A1 20 Timing Gear 6A1 23 Timing Belt 6A1 30 Cylinder Head Assembly and Gasket 6A1 37 Oil Pan 6A1 48 Oil Pump Assembly 6A1 51 Piston Piston Ring a...

Page 137: ...6A1 2 4JB1 4JB1T 4JB1TC 4JG2 ENGINE GENERAL DESCRIPTION 4JB1 TC 6A1 2 1 tif F06LX002 tif F06LX005 tif...

Page 138: ...iding treatment nitriding treatment of the crankshaft for the increased strength eliminates the regrinding of crankpins and journals An oiling jet device for piston cooling is provided in the lubricat...

Page 139: ...ct battery ground cable 1 Fan Shroud Remove reservoir tank hose and fan shroud 2 Fan Belt Remove adjust plate lock bolt Loosen generator fixing bolt then remove fan belt 3 Support Rubber Remove two fi...

Page 140: ...Tighten the fixing nuts to the specified torque Engine foot side N m kg m lb ft 82 8 4 61 Crossmember side N m kg m lb ft 40 4 1 30 2 Fan Belt Install the fan belt Depress the fan belt mid portion wit...

Page 141: ...OVAL Preparation Disconnect battery ground cable 1 Air Intake Duct Remove the intake duct 2 Fan Shroud Remove reservoir tank hose and fan shroud 3 Support Rubber Remove two fixing bolts at the crossme...

Page 142: ...er Install the support rubber while raising the engine Tighten the fixing nuts to the specified torque Engine foot side N m kg m lb ft 82 8 4 61 Crossmember side N m kg m lb ft 40 4 1 30 2 Fan shroud...

Page 143: ...pump side Loosen the flare nut on the injection nozzle side disconnect and put a side the pipe 5 Oil Level Gauge Guide Tube Remove the fixing bolt and remove level gauge guide tube 6A1 8 1 tif 6A1 8...

Page 144: ...del Install the water pipe and tighten the manifold with water pipe Tighten the pipe bracket bolt of cylinder head rear side 5 Oil Level Gauge Guide Tube Install the guide tube and tighten the manifol...

Page 145: ...e 1 Vacuum Hose Exhaust Brake Model Remove the vacuum actuator hose 2 Front Exhaust Pipe Nut Remove the fixing nuts from exhaust manifold side 3 Front Exhaust Pipe Stay Bolt 4 Heat Protector 5 Exhaust...

Page 146: ...r Bolt Torque N m kg m lb ft 19 1 9 14 3 Front Exhaust Pipe Stay Bolt Tighten the fixing bolts to the specified torque Stay Bolt Torque N m kg m lb ft 40 4 1 30 2 Front Exhaust Pipe Nut Tighten the fi...

Page 147: ...Oil Cooler Model REMOVAL Preparation Disconnect battery ground cable Drain coolant Put rag to beneath side of oil cooler to prevent oil leaking 1 Water Hose Disconnect water inlet and outlet hose 2 O...

Page 148: ...heck for water leakage at the water passage 1 Plug one side of the oil cooler water passage 2 Submerge the oil cooler in water 3 Apply compressed air 2 kg cm 2 28 5psi 196 0kPa to the other side of th...

Page 149: ...ng filter wrench Filter wrench 5 8840 0200 0 INSTALLATION Lightly oil the O ring of oil filter cartridge Turn in the new oil filter cartridge by hand until the sealing face is fiffted against the O ri...

Page 150: ...over Apply engine oil to the rocker arms and the valve springs Install the cylinder head cover gasket to the cylinder head cover The gasket must be perfectly smooth with no loose areas Tighten the cyl...

Page 151: ...6A1 16 4JB1 4JB1T 4JB1TC 4JG2 ENGINE 1 PCV Hose Connect the PCV hose to the intake pipe Connect battery ground cable...

Page 152: ...ocker shaft assembly INSTALLATION 3 Rocker Arm Shaft Assembly Install rocker arm shaft with larger oil hole 4 to the front of engine Align fixing bolt with nut of rocker arm shaft and tighten fixing b...

Page 153: ...sion stroke If the No 1 cylinder intake and exhaust valve push rods are depressed the No 4 piston is at TDC on the compression stroke Adjust the No 1 or the No 4 cylinder valve clearances while their...

Page 154: ...4JB1 4JB1T 4JB1TC 4JG2 ENGINE 6A1 19 2 Cylinder Head Cover Install cylinder head cover and tighten bolts to the specified torque N m kg m lb in 13 1 3 113 1 PCV Hose Connect battery ground cable...

Page 155: ...e Spring Apply compressed air to cylinder from the glow plug hole hold the valve in place Using special tool compress valve spring and removal split collar Valve spring compressor 9 8523 1423 0 J 2976...

Page 156: ...g seat CAUTION The painted area of the valve spring should be facing toward Apply compressed air to cylinder from the glow plug hole to hold the valve in place Install split collar by special tool Val...

Page 157: ...pply engine oil to the rocker arms and the valve spring Install the cylinder head cover gasket to the cylinder head cover The gasket must be perfectly smooth with no loose areas Install cylinder head...

Page 158: ...Belt P S Model Loosen power steering pump mounting bolt and adjust bolt and remove the drive belt 3 AC Generator Drive Belt Loosen AC Generator mounting bolt under side and adjust plate lock bolt and...

Page 159: ...both the gear to be checked and the adjoining gear stationary 2 Move the gear to be checked as far as possible to both the right and the left Take the dial indicator reading If the measured value exce...

Page 160: ...caps or the equivalent to prevent the entry of foreign material 13 Camshaft Timing Gear 1 Use a dial indicator to measure the camshaft end play This must be done before removing the camshaft gear If t...

Page 161: ...e N m kg m lb ft 18 1 8 13 3 Install the camshaft timing gear to the camshaft The timing gear mark Y Y must be facing outward 4 Tighten the timing gear to the specified torque N m kg m lb ft 64 6 5 47...

Page 162: ...b ft 19 1 9 14 11 Idler Gear 1 Apply engine oil to the idler gear and the idler gear shaft The idler gear shaft oil hole must be facing up 2 Position the idler gear setting marks X and Y so that they...

Page 163: ...Align the gear case with the timing gear case knock pin and then install the timing gear case cover 2 Tighten the gear case cover bolts to the specified torque 7 Noise Cover Spacer 6 Noise Shield Cov...

Page 164: ...to the specified torque N m kg m lb ft 27 2 8 20 2 Power Steering Pump Drive Belt P S Model Install Power Steering pump drive belt and adjust belt tension Depress the drive belt mid portion with a 98N...

Page 165: ...fan asm distant pipe and fan pulley 2 Fan Shroud Removal reservoir tank hose and fan shroud 3 Power Steering Pump Drive Belt P S Model Loosen power steering pump idle pulley lock nut and adjust bolt...

Page 166: ...belt 6 Power Steering Pump Bracket Assembly P S Model Loosen power steering oil pipe bracket and clip Remove power steering pump bracket assembly and hang the power steering pump bracket assembly 7 Cr...

Page 167: ...enter give another turn Remove tensioner and timing belt WARNING IF CRANKSHAFT AND CAMSHAFT AND TURNED WITH TIMING BELT BEING NOT MOUNTED PISTON AND VALVE WILL INTERFERE WITH EACH OTHER THEREFORE THE...

Page 168: ...he belt passing Remove tension adjust lever mounting bolt and loosen the fulcrum bolt to such extent that the lever is movable Hung a spring balance from the end hole of tension adjust lever and with...

Page 169: ...he camshaft timing pulley Flange Bolts Torque N m kg m lb ft 19 1 9 14 9 Timing Pulley Lower Cover Install timing pulley lower cover and tighten bolt to the specified torque Cover Bolts Torque N m kg...

Page 170: ...Install AC Generator drive belt and adjust belt tension Depress the drive belt mid portion with a 98N 10kg 22lb force Drive Belt Deflection mm in 8 0 31 12 0 47 Install fixing bolt and tighten bolts...

Page 171: ...m in 8 0 31 12 0 47 Tighten the idler lock nut to the specified torque N m kg m lb ft 27 2 8 20 2 Fan Shroud Install the fan shroud and reservoir tank hose 1 Cooling Fan Assembly Mount fan pulley dist...

Page 172: ...ose upper 2 Heater hose 3 A C Compressor drive belt 4 Engine harness 5 Air intake duct 6 Injection pipe 7 Leak off pipe 8 PCV hose 9 Glow plug harness 10 Oil level gauge guide tube 11 Oil cooler water...

Page 173: ...ing 5 Air Intake Duct Remove the clip and air intake duct 6 Injection Pipe Release injection pipe clip Remove flare nut injection pump side Remove flare nut injection nozzle side and remove injection...

Page 174: ...t from inlet manifold 12 A C Compressor Assembly A C Model Remove the clutch harness connector Remove the A C compressor fixing bolts and temporally tighten the A C compressor to chassis frame side us...

Page 175: ...a little at a time in numerical order will adversely effect the rocker arm shaft 18 Push Rod 19 Cylinder Head Assembly Loosen the cylinder head bolts a little at a time in the numerical order shown i...

Page 176: ...piston head projection measuring positions All measuring positions should be as close as possible to the cylinder liner 3 Measure the points and obtain two differences and on each cylinder Calculate t...

Page 177: ...l the cylinder head gasket with top mark up 3 Clean up cylinder head lower surface and cylinder body upper surface 4 Install the cylinder head as softly 5 Apply engine oil to screw and seat of cylinde...

Page 178: ...E 6A1 43 3 Tighten the rocker arm shaft bracket bolts to the specified torque in the numerical order shown in the illustration Rocker Arm Shaft Bracket Bolt Torque N m kg m lb ft 54 5 5 40 Valve clear...

Page 179: ...inder Head Cover Torque N m kg m lb in 13 1 3 113 15 By Pass Hose 14 Front Exhaust Pipe Install the pipe to manifold and tighten bolts and nuts to the specified torque W Exhaust Brake Manifold Nut Tor...

Page 180: ...stall the guide tube bolt and tighten bolt to the specified torque Guide Tube Bolt Torque N m kg m lb ft 19 1 9 14 9 Glow Plug Harness 8 PCV Hose 7 Leak Off Pipe Mount using a new copper washer 6 Inje...

Page 181: ...for deflection Standard deflection mm in Initial tension AC generator fan pulley drive belt A C compressor drive belt P S pump drive belt 8 12 0 31 0 47 TENSION ADJUSTMENT P S oil pump and A C compre...

Page 182: ...A1 47 2 Heater Hose Connect the heater hose them tighten clip securely 1 Radiator Hose Upper Connect the radiator hose them tighten clip securely Pour coolant Connect battery ground cable Start the en...

Page 183: ...NOTE Install drain plug with new gasket N m kg m lb ft 44 4 5 33 1 Vacuum Pump Oil Hose Remove oil hose from oil pan 6A1 48 1 tif 6A1 48 2 tif Removal steps 1 Vacuum pump oil hose 2 Engine mount bolt...

Page 184: ...ount bolts right left side 3 Stiffener Space Rubber Remove the exhaust pipe bracket Remove the stiffener from of the oil pan left right side Take out space rubber 4 Oil Pan Assembly Raising the engine...

Page 185: ...il pan bolts to the specified torque Oil Pan Bolt Torque N m kg m lb ft 19 1 9 14 3 Stiffener and Space Rubber Install the space rubber Install the stiffener left side and right side tighten bolt to t...

Page 186: ...nstall drain plug with new washer N m kg m lb ft 44 4 5 33 1 Vacuum Pump Oil Hose Remove the oil hose from oil pan 6A1 51 2 tif 6A1 51 1 tif Removal steps 1 Vacuum pump oil hose 2 Engine mount bolts 3...

Page 187: ...Stiffener Space Rubber Remove the exhaust pipe bracket Remove the stiffener from of the oil pan left right side Take out space rubber 4 Oil Pan Assembly Raise the engine about 50mm Remove the oil pan...

Page 188: ...to oil pipe O ring and insert the O ring in O ring hold on cylinder block Install oil pump asm with oil pipe in cylinder block and tighten fixing bolts to the specified torque N m kg m lb ft 19 1 9 1...

Page 189: ...AL Preparation Disconnect battery ground cable Drain coolant Drain engine oil NOTE Install drain plug with new washer N m kg m lb ft 44 4 5 33 1 Cylinder Head Assembly 1 Radiator hose upper 2 Heater h...

Page 190: ...ssembly 20 Cylinder head gasket Above works refer to CYLINDER HEAD ASSEMBLY AND GASKET Section in this manual 2 Oil Pan Assembly 1 Vacuum pump oil hose 2 Engine mount bolt 3 Stiffener and spacer rubbe...

Page 191: ...ecting rod upper bearings are to be reinstalled mark their fitting positions by tagging each bearing with the cylinder number from which it was removed 4 Clamp the connecting rod in a vise Take care n...

Page 192: ...embly Select piston and connecting rod combinations so that the weight variation of the different assemblies is held within the specified limits g oz Variance in weight Less than after assembly 3 0 10...

Page 193: ...der The compression ring must be set with the 1N 2N mark facing up Discrimination mark is painted as shown in the illustration 8 Use a piston ring replacer to install the three piston rings Piston Rin...

Page 194: ...er wall 14 Position the piston head front mark so that it is facing the front of the engine Use the piston ring compressor to compress the piston rings Piston Ring Compressor 5 8840 9018 0 J 8037 15 U...

Page 195: ...ng oil pipe to the cylinder body 2 Tighten the oil pipe bolts and relief valve to the specified torque Oil Pipe Bolt Torque N m kg m lb ft M8x1 25 19 1 9 14 N m kg m lb in M6x1 00 8 0 8 69 Oil Pressur...

Page 196: ...t 19 1 9 14 4 Install the space rubber and stiffener right left side then tighten bolts to the specified torque Engine Body Side Stiffener Bolts Torque N m kg m lb ft 37 3 8 27 Clutch Housing Side Sti...

Page 197: ...t exhaust pipe 9 Vacuum actuator hose Exhaust Brake Model 10 A C compressor assembly A C Model 11 Oil cooler water pipe Oil Cooler Model 12 Oil level gauge guide tube 13 Glow plug harness 14 PCV hose...

Page 198: ...ug with new washer Drain Plug Torque N m kg m lb ft 83 8 5 61 6A1 63 1 tif Removal steps 1 Transmission and clutch Assembly 2 Engine Assembly 3 Cylinder head Assembly and gasket 4 Timing gear Gear dri...

Page 199: ...assembly Above works refer to ENGINE ASSEMBLY Section in this manual 3 Cylinder Head Assembly and Gasket 1 Injection pipe 2 Leak off pipe 3 PCV hose 4 Glow plug harness 5 Oil level gauge guide tube 6...

Page 200: ...pulley Use a dial indicator to measure the camshaft end play This must be done before removing the oil pump If the camshaft end play exceeds the specified limit the camshaft and or the driven gear mu...

Page 201: ...etainer 5 Oil Pan Assembly Disconnect vacuum pump oil hose from oil pan Remove the stiffener and space rubber from oil pan both side Remove the oil pan bolts and remove oil pan from cylinder body 6 Oi...

Page 202: ...4JB1T 4JB1TC 4JG2 ENGINE 6A1 67 7 Camshaft and Tappets Remove the camshaft from cylinder body Take care not to damage the camshaft bearings Take out the tappets from cylinder body 6A1 67 1 tif 6A1 67...

Page 203: ...the solution to the teeth of the oil pump pinion Apply engine oil to oil pipe O ring and insert the O ring in O ring hold on cylinder block Install oil pump asm with oil pipe in cylinder block and tig...

Page 204: ...learance Adjustment 8 Cylinder head cover 7 By pass hose 6 Oil cooler water pipe Oil cooler Model 5 Oil level gauge guide tube 4 Glow plug harness 3 PCV hose 2 Fuel leak off pipe 1 Injection pipe Abov...

Page 205: ...ENGINE 1 Transmission and Clutch Assembly 2 Clutch 1 Transmission Above works refer to ENGINE ASSEMBLY Section in this manual Connect the battery ground cable Pour coolant Pour engine oil Start the en...

Page 206: ...rator Drive Belt Loosen AC Generator mounting bolt under side and adjust plate lock bolt and remove the drive belt 4 Cooling Fan Assembly Remove clamp nut and remove cooling fan assembly distant pipe...

Page 207: ...el ring gear stationary to prevent the crankshaft from turning when tightening the damper pulley Pulley Boss Bolt Torque N m kg m lb ft 206 21 152 4 Cooling Fan Assembly Mount fan pulley distance piec...

Page 208: ...Fan Shroud 3 Power Steering Pump Drive Belt P S Model 4 A C Compressor Drive Belt A C Model 5 AC Generator Drive Belt 6 Power Steering Pump Bracket Assembly P S Model 7 Crankshaft Damper Pulley 8 Timi...

Page 209: ...sleeve attached to the oil seal put it in the front end of the crankshaft 2 With the edge portion of the oil seal attached securely to the crankshaft tighten it with the center bolt until the sleeve h...

Page 210: ...ng Pulley Upper Cover 7 Crankshaft Damper Pulley 6 Power Steering Pump Bracket Assembly P S Model 5 AC Generator Drive Belt 4 A C Compressor Drive Belt A C Model 3 Power Steering Pump Drive Belt P S p...

Page 211: ...arking brake drum Disconnect the propeller shaft at flange yoke Put aside the propeller shaft and tie it to the frame so that it does not interface with servicing work Parking Brake Cable Move the joi...

Page 212: ...e shift cable and select cable on the transmission side Clutch Slave Cylinder Remove the clutch pipe fixing clips and the clip bracket Right hand drive models only Remove the slave cylinder assembly w...

Page 213: ...mission tie it firmly to the jack with a chain or belt Do not allow transmission to hang unsupported from clutch Damage to the clutch assembly will result Remove the nuts of the transmission mounting...

Page 214: ...ven plate assembly from falling free Pilot Aligner 5 5825 3001 0 Mark the flywheel and pressure plate lug for alignment when installing Loosen the pressure plate assembly fixing bolts 2 Flywheel 3 Rea...

Page 215: ...12x1 75L 70 until the adapter section hits the sleeve 4 Remove the adapter and the sleeve 5 After installing the oil seal check the measurement of the oil seal Standard mm in 12 2 12 8 0 48 0 50 2 Fly...

Page 216: ...ing Bracket Nuts Torque N m kg m lb ft 69 7 0 51 Transmission Assembly Support the transmission with mission jack CAUTION To prevent the falling of the transmission tie it securely to the jack with a...

Page 217: ...the return spring a Loosen the lock nut of the push rod b Turn the adjust nut until it reaches the shift fork c Back off the adjust nut 1 5 turns shift fork free play Approximately 2 mm 0 1 in d Tigh...

Page 218: ...LY Section in this manual 2 Pilot Bearing Remove pilot bearing using remover Pilot Bearing Puller 5 8840 2000 0 Sliding hammer 5 8840 0019 0 3 Flywheel Set the flywheel stopper Loosen flywheel fixing...

Page 219: ...htening Method Follow the numerical order shown in the illustration Flywheel Bolt Torque N m kg m lb ft 1st Step 2nd Step 59 6 0 43 60 90 2 Pilot Bearing Install the pilot bearing using installer Pilo...

Page 220: ...r drive model 4a Timing belt Belt drive model 5 Oil pan Assembly 6 Oil pump Assembly 7 Piston cooling oil pipe 8 Piston and connecting rod Assembly 9 Front oil seal 10 Timing gear housing 10a Timing p...

Page 221: ...embly 9 Power steering pump bracket assembly Power Steering Model 10 Actuator vacuum hose Exh Brake Model 11 Vacuum pump hose Exh Brake Model 12 Front exhaust pipe 13 Support rubber 14 Engine assembly...

Page 222: ...aft timing gear remover to remove the crankshaft gear Crankshaft Timing Gear Remover 5 8840 2057 0 4a Timing Belt Belt Drive Model 1 Cooling fan assembly 2 Crankshaft damper pulley 3 Timing pulley upp...

Page 223: ...AMSHAFT AND TAPPET Section in this manual 7 Piston Cooling Oil Pipe Remove the oil pipe from cylinder block 8 Piston and Connecting Rod Assembly If the connecting rod lower bearings are to be reinstal...

Page 224: ...12 Flywheel and Cylinder Body Rear Plate Set the flywheel stopper Loosen the flywheel fixing bolts then remove the flywheel Remove the cylinder block rear plate 13 Rear Oil Seal Gear and Belt Drive Mo...

Page 225: ...g back faces and the cylinder body bearing fitting surfaces Be sure that they are positioned correctly Apply new engine oil to the upper and lower main bearing faces Carefully mount the crankshaft App...

Page 226: ...scraps clean from the press in portion of the oil seal Take note of the press in direction of the oil seal 1 Install the adapter of the special tool to the rear end of the crankshaft with two bolts 2...

Page 227: ...he cylinder body Take care not to twist the front oil seal Tighten the timing pulley housing together with the timing pulley housing gasket to the specified torque Timing Pulley Housing Bolt Torque N...

Page 228: ...y Above works refer to CAMSHAFT AND TAPPET Section in this manual 11 Injection pump 10 Injection pump timing pulley Above works refer to CYLINDER BLOCK ASSEMBLY Section in this manual 9 Crankshaft tim...

Page 229: ...shaft 7 Idle gear 6 Timing gear oil pipe 5 Timing gear case cover 4 Noise cover spacer 3 Noise shield cover 2 Crankshaft damper pulley 1 Cooling fan assembly Above works refer to TIMING GEAR Gear Typ...

Page 230: ...ket assembly Power Steering Model 8 A C compressor assembly A C Model 7 Oil pressure switch harness 6 Fuel hose 5 Glow plug harness 4 Engine control cable 3 Heater hose 2 Intake air duct 1 Radiator as...

Page 231: ...ke air duct 4 Heater hose 5 Engine control cable 6 Glow plug harness 7 Fuel hose 8 Oil pressure switch harness 9 A C Compressor Assembly A C model 10 Power steering pump bracket Assembly Power steerin...

Page 232: ...ller shaft and tie it to the frame so that it does not interface with servicing work Parking Brake Cable Move the joint cover Disconnect the joint bolt Remove the clip then disconnect the cable from t...

Page 233: ...mission Assembly NOTE The exhaust pipe bracket the gear control bracket and the clips are sometimes installed in the wrong position or direction confusedly To prevent incorrect installation of these p...

Page 234: ...oil pan Remove transmission fastening bolts Pull out the transmission assembly rearward Mounting Bracket 2 Clutch Raise vehicle and support with suitable safety stands CAUTION Do not let clutch fluid...

Page 235: ...disconnect accelerator cable from injection pump control lever 6 Glow Plug Harness 7 Fuel Hose Remove the fuel inlet hose and fuel return hose 8 Oil Pressure Switch Harness 9 A C Compressor Assembly...

Page 236: ...e the wire 11 Actuator Vacuum Hose Exh Brake Model Disconnect the vacuum hose from actuator side 12 Vacuum Pump Hose Exh Brake Model Disconnect the vacuum hose from vacuum tank side and magnetic valve...

Page 237: ...ve two fixing nuts at the crossmember side 15 Engine Assembly 1 Lift engine carefully by using hoist 2 Lift front part of engine higher than rear part of it 3 Take out engine assembly taking care not...

Page 238: ...30 13 Front Exhaust Pipe Connect the exhaust pipe and tighten nut to the specified torque Exhaust Pipe Nut Torque N m kg m lb ft 69 7 0 51 Install the exhaust pipe stay and tighten bolt nut to the sp...

Page 239: ...nd replace with new ones as necessary Check belts for tension and adjust as necessary Push the middle of belts with a force of 10kg and check each bolt for deflection Standard deflection mm in Initial...

Page 240: ...ust belt tension with adjuster s adjust bolt Idler Lock Nut Torque N m kg m lb ft 27 2 8 20 8 Oil Pressure Switch Harness Connect the oil pressure switch harness connector 7 Fuel Hose Connect the fuel...

Page 241: ...ven Plate Assembly Apply multi purpose with MOS2 type grease to the driven plate hub spline Use the pilot aligner to install the driven plate assembly Pilot Aligner 5 5825 3001 0 Pressure Plate Assemb...

Page 242: ...t securely to the jack with a chain or belt Shift transmission into high gear Align transmission with engine slope Turn output parking brake drum to aid clutch spring engagement Clutch Housing to Flyw...

Page 243: ...he lock nut of the push rod b Turn the adjust nut until it reaches the shift fork c Back off the adjust nut 1 5 turns shift fork free play Approximately 2 mm 0 1 in d Tighten the lock nut Push Rod Loc...

Page 244: ...LING 6B 1 SECTION 6B ENGINE COOLING CONTENTS PAGE General Description 6B 1 On Vehicle Service 6B 6 Water Pump 6B 6 Thermostat 6B 10 Radiator 6B 12 Drive Belt Adjustment 6B 15 GENERAL DESCRIPTION 6B 1...

Page 245: ...driven by V type drive belt The water pump is not disassembled type THERMOSTAT The thermostat is a wax pellet type with a juggle valve and is installed in the thermostat housing RADIATOR The radiator...

Page 246: ...N A failure to correctly fill the engine cooling system in changing or topping up coolant may sometimes cause the coolant to overflow from the filler neck even before the engine and radiator are compl...

Page 247: ...reduce the pressure when the coolant has become cooler 8 After tightening radiator cap warm up the engine at about 2 000 rpm Set heater adjustment to the highest temperature position and let the cool...

Page 248: ...solution Water 10 lit Total cooling system capacity In case of 6 8 lit total cooling system capacity Mixing ratio Anti freeze solution lit imp qt U S qt Water lit imp qt U S qt 0 5 10 15 20 25 30 35...

Page 249: ...nut and loosen adjust bolt and remove the drive belt 4 A C Compressor Drive Belt Loosen A C compressor idler pulley lock nut and adjust bolt and remove the drive belt 6B 5 2 tif 6B 5 3 tif 6B 5 1 tif...

Page 250: ...Lower Cover 9 Water Pump Assembly Remove the O ring INSPECTION Make necessary parts replacement if extreme wear or damage is found during inspection Should any of the following problems occur the ent...

Page 251: ...m lb in 8 0 8 69 6 Crankshaft Damper Pulley Install crankshaft damper pulley and tighten to specified torque Pulley Bolt Torque N m Kg m lb in 19 1 9 14 5 AC Generator Drive Belt 4 A C Compressor Dri...

Page 252: ...Pulley Lock Nut Torque N m Kg m lb ft 27 2 8 20 2 Cooling Fan Assembly Mount fan pulley and cooling fan assembly on the water pump and tighten to the specified torque Fan Pulley Nut Torque N m Kg m lb...

Page 253: ...blocks on the bottom of the water container Not to directly heat the thermostat Gradually increase the water temperature Stir the water so that the entire water is same temperature Make sure that pri...

Page 254: ...3 Gasket 2 Outlet Pipe Connect outlet pipe and tighten bolts to the specified torque N m Kg m lb ft 19 1 9 14 1 Switch Harness Install switch harness Install battery ground cable Pour coolant Start th...

Page 255: ...s Hose Disconnect the hose from radiator 2 Radiator Hose Disconnect lower hose and upper hose from the engine 3 Air Intake Duct 4 Radiator Stay 5 Condenser Remove the condenser from radiator and tempo...

Page 256: ...valve fixing torque N m kg m lb ft 6 0 6 4 Conduct cooling system leakage check after reinstalling the radiator valve Radiator Core Deformed radiator fins could reduce radiation effects resulting in...

Page 257: ...e the radiator core by a fan blade 5 Condenser 4 Radiator Stay 3 Air Intake Duct Connect the Duct and tighten clip securely 2 Radiator Hose Connect inlet hose and outlet hose to the engine Connect bat...

Page 258: ...ts for tension and adjust as necessary Check drive belts tension Push the middle of belts with a force of 98 N 10 kg 22 lb and check each bolt for deflection Standard deflection mm in Tension at readj...

Page 259: ...just bolt Tighten bolt to the specified torque Generator Fixing Bolt Torque N m Kg m lb ft 40 4 1 30 Adjust Plate Fixing Bolt Torque N m Kg m lb ft 19 1 9 14 2 P S Oil Pump and A C Compressor Pulley B...

Page 260: ...ly Gear Drive Type 6C 26 Injection Pump Assembly Belt Drive Type 6C 31 Injection Timing Adjustment 6C 41 Adjustment of Idling Speed 6C 42 Injection Pump Data 6C 43 Injection Volume and Governor Perfor...

Page 261: ...attery voltage is required Always keep a dry chemical Class B fire extinguisher near the work area Replace all pipes with the same pipe and fittings that were removed Clean and inspect O rings Replace...

Page 262: ...ection nozzle The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other foreign material are removed from the fuel Fuel fed by the injection pu...

Page 263: ...ardless of the number of cylinders The governor the injection timer and the feed pump are all contained in the injection pump housing The injection pump is compact light weight and provides reliable h...

Page 264: ...l filter and the water separator remove water particles and other foreign material from the fuel before it reaches the injection pump The water separator has an internal float When the float reaches t...

Page 265: ...from the injection pump into the combustion chamber through the injection nozzle orifices 4JB1 engines employ a hole type nozzle with four injection orifices The nozzle is made up of the nozzle body a...

Page 266: ...e hose ends to prevent fuel spillage 3 Fuel Filter Assembly Remove the fixing bolts on fuel filter bracket INSTALLATION 3 Fuel Filter Assembly Install the fuel filter bracket then tighten fixing bolt...

Page 267: ...pump to send the air in the fuel system to the injection pump Loosen injection pump bleeding plug and operate the priming pump until no bubble is made Tighten the bleeding plug Start the engine and if...

Page 268: ...ion nozzle side disconnect and put aside the pipe 2 Leak off Pipe or Hose 3 Injection Nozzle INSPECTION Set the nozzle in a nozzle tester Check there is no fuel leak in the nozzle seal when a fuel pre...

Page 269: ...CAUTION Wash all the parts removed and arrange them on a cylinder basis care should be taken not to miss any parts Soak the nozzle assembly in a parts receptacle filled with light oil Care should be t...

Page 270: ...fter lapping Nozzle body needle Check nozzle body and end for seizure If significantly seized replace as a nozzle assembly basis Also replace as a nozzle assembly basis if needle valve end is deformed...

Page 271: ...m CAUTION The spray condition when judged with a nozzle tester is deemed as normal so long as the spray form is not excessively deformed Oil tight test 4JG2 Engine 1 After completion of the adjustment...

Page 272: ...orque using a special tool CAUTION After tightening the holder nut make sure that the drilled hole makes 5 or smaller with the cylinder head side positioning boss When mounting leak off pipe injection...

Page 273: ...at 6 Push rod 7 Shim Second nozzle opening pressure adjustment 8 Second spring 9 Collar 10 Spring seat 11 First spring 12 Shim First nozzle opening pressure adjustment 13 Nozzle holder body 14 Eye bol...

Page 274: ...n matter REASSEMBLY AND ADJUSTMENT PROCEDURE 1 First nozzle opening pressure adjustment Adjust the first nozzle opening pressure using the shim 2 Full needle valve lift confirmation Confirm the full n...

Page 275: ...ring and spring seat in the nozzle holder 3 Install the collar second spring shim spring seat and pushrod in the nozzle holder 4 Install the pins lift piece and spacer in the nozzle holder 5 Install t...

Page 276: ...ter and measure the first nozzle opening pressure 11 If the first nozzle opening pressure is not as specified disassemble the nozzle holder and replace the shim until the pressure is as specified CAUT...

Page 277: ...with the nozzle facing down and install the dial gauge holder on the nozzle holder Dial gauge holder 5 8677 7142 0 3 Install the nut on the dial gauge holder Nut 5 8677 7143 0 4 Install the pin to the...

Page 278: ...holder to the nozzle tester and put needle to zero on the dial gauge 7 Operate the nozzle tester to bleed any air from inside the retaining nut and to confirm that no fuel leaks 8 Operate the nozzle...

Page 279: ...when the second spring has stopped operating Refer to the pre lift measuring point for liter Pre lift measuring point Read the dial gauge at first nozzle opening pressure approx 1 MPa 10 kg cm 2 Note...

Page 280: ...full lift 2 Release the nozzle tester handle so that in line pressure decreases Note The in line pressure will decrease and needle valve lift as indicated on the dial gauge will also decrease a littl...

Page 281: ...041 0 0 56 8 9711 6043 0 0 58 8 9711 6044 0 0 59 Final inspection 1 Remove the dial gauge nut and dial gauge holder 2 Remove the adjustment retaining nut and gasket 3 Install the original retaining nu...

Page 282: ...t them from dust 3 Spacer 4 Spring Seat 5 Spring 6 Adjusting Shim 7 Nozzle Holder INSPECTION AND REPAIR 4JB1 4JB1 T Engine Make the necessary adjustments repairs and part replacements if excessive wea...

Page 283: ...y cavity to wear excessively 2 Carefully wash the needle valve and the nozzle body in clean diesel fuel after lapping Nozzle Body and Needle Valve Inspection Check the nozzle body and the needle valve...

Page 284: ...ncrease of decrease the nozzle opening pressure approximately 369 46 kPa 3 77 kg cm 2 53 6 psi WARNING TEST FLUID FROM THE INJECTION NOZZLE WILL SPRAY OUT UNDER GREAT PRESSURE IT CAN EASILY PUNCTURE A...

Page 285: ...mbly Remove clamp nut and remove cooling fan assembly distant pipe and fan pulley 2 Fan Shroud 3 Power Steering Pump Drive Belt P S Model Loosen Power Steering pump mounting bolt and adjust bolt and r...

Page 286: ...achometer sensor with tachometer CSD solenoid fuel cut solenoid 13 Injection Pipe Release pipe clip Remove the flare nut on the pump side Remove the flare nut on the injection nozzle side and remove t...

Page 287: ...e with the pointer of the check hole 4 In the condition above with the injection pump gear mark O set to the pointer of the check hole install the injection pump assembly Install the injection pump fi...

Page 288: ...o remove any slack 3 Tighten the accelerator cable bracket bolt 8 Air Intake Duct 7 Noise Cover Spacer 6 Noise Shield Cover 5 AC Generator Drive Belt Install AC generator drive belt and adjust belt te...

Page 289: ...S Model Install P S pump drive belt and adjust belt tension Depress the drive belt mid portion with a 98 N 10 kg 22 lb force Drive Belt Deflection mm in 8 0 31 10 0 39 Tighten the idler lock nut to t...

Page 290: ...the drive belt 6C 30 1 tif 6C 30 2 tif Removal steps 1 Cooling fan Assembly 2 Fan shroud 3 Power steering pump drive belt 4 A C compressor drive belt 5 AC generator drive belt 6 Power steering pump b...

Page 291: ...Drive Belt Loosen AC generator mounting bolt under side and adjust plate lock bolt and remove the drive belt 6 Power Steering Pump Bracket Assembly P S Model Loosen power steering oil pipe bracket and...

Page 292: ...injection timing pulley fixing bolt holes are set to each other Then Fit in a fixing bolt and lightly tighten No 1 cylinder should be at top dead center If the fixing bolt holes are not set No 4 cylin...

Page 293: ...olt 13 Air Intake Duct 14 Injection Pump Control Cable Remove the control cable bracket bolt and remove the control lever side 15 Fuel Hose Disconnect the fuel feed hose and fuel return hose 16 CSD Wa...

Page 294: ...he pipe and tighten securely Install clip where it was Sleeve Nut Torque N m Kg m lb ft 29 3 0 22 17 Injection Pump Harness Mount engine harness and connect it to switches 16 CSD Water Hose Connect th...

Page 295: ...Injection Pump Timing Pulley Nut Torque N m Kg m lb ft 64 6 5 47 Remove the stopper bolt from the injection timing pulley 11 Timing Belt When removing the belt make sure the marks on the bolt fixed ca...

Page 296: ...Remove tension adjust lever mounting bolt and loosen the fulcrum bolt to such extent that the lever is movable Hung a spring balance from the end hole of tension adjust lever and with the balance pul...

Page 297: ...1 9 14 9 Timing Pulley Lower Cover Install timing pulley lower cover and tighten bolt to the specified torque N m Kg m lb in 8 0 8 69 8 Timing Pulley Upper Cover Install timing pulley upper cover and...

Page 298: ...force Drive Belt Deflection mm in 8 0 31 10 0 39 Install fixing bolt and tighten bolts to the specified torque Generator fixing Bolt N m Kg m lb ft 40 4 1 30 Adjust Plate Fixing Bolt N m Kg m lb ft 19...

Page 299: ...0 31 10 0 39 Tighten the idler lock nut to the specified torque N m Kg m lb ft 27 2 8 20 2 Fan Shroud Install the fan shroud and reservoir tank hose 1 Cooling Fan Assembly Mount fan pulley distance pi...

Page 300: ...14 BTDC 12 91 542A 4JB1T BTDC11 4JB1TC BTDC4 4JG2 Belt Drive Type ATDC 1 91 542A TDC 0 91 542B Gear Drive Type ATDC 2 91 542A Measuring Device s Indication mm in Standard 0 5 0 0197 If it reads abnor...

Page 301: ...rom the control lever injection pump 5 Set the engine tachometer 6 Check the idling rotation When the idling rotation is outside the range of the specified value adjust it correctly Specified value rp...

Page 302: ...Nozzle MPa kg cm2 psi 14 7 150 2 133 13 0 133 1 891 Opening Pressure Injection Line dimensions mm in Inside Diameter 2 0 079 Outside Diameter 6 0 236 Length 840 33 1 450 17 7 Fuel delivery Pressure k...

Page 303: ...6C 44 ENGINE FUEL IDENTIFICATION PLATE AND NUMBER Use the data following the injection pump identification number to adjust the injection volume F06LV002 tif F06LV001 tif F06LW002 tif...

Page 304: ...ump assembly No 8943616830 104741 6410 8943616850 104741 6430 Adjustment specification of timer and pump case pressure Timer piston stroke mm Air pressure of pump kPa kg cm2 Solenoid timer Solenoid ti...

Page 305: ...re C Remarks 500 38 6 48 2 700 34 9 2 5 50 2 1000 42 1 1 0 4 0 50 2 Standard 1450 44 5 2 5 50 2 1800 47 6 3 0 50 2 2100 12 9 3 0 4 0 52 2 390 6 7 2 0 2 0 48 2 100 60 100 48 2 Engine 4JB1 Injection pum...

Page 306: ...en amplitude mm3 ST Remarks 100 78 12 350 64 6 0 500 52 3 0 720 55 9 3 4 1000 62 6 1 0 4 0 1250 60 9 3 5 1700 574 3 5 4 0 2100 13 5 0 2250 Below 5 0 360 15 9 3 0 2 5 550 Below 3 0 Engine 4JG2 For 91 5...

Page 307: ...ent Timer adjustment Adjustment specification of injection volume Pump rotation rpm Average injection quantity mm3 ST Uneven amplitude mm3 ST Oil temperature C Remarks 500 29 7 4 5 48 2 1000 46 4 3 5...

Page 308: ...ection pump identification No 104742 1480 1490 Injection volume adjustment 0 4 0 3 F06LV023 tif Adjustment specification of injection volume Pump rotation rpm Average injection quantity mm3 ST Uneven...

Page 309: ...8 0 4 Adjustment specification of injection volume Pump rotation rpm Average injection quantity mm3 ST Uneven amplitude mm3 ST Oil temperature C Remarks 500 51 6 48 2 1000 52 0 1 0 50 2 Standard 1440...

Page 310: ...n of injection volume Pump rotation rpm Average injection quantity mm3 ST Uneven amplitude mm3 ST Oil temperature C Remarks 500 53 7 48 2 1000 56 0 1 0 3 5 50 2 Standard 1440 53 3 50 2 1800 54 3 50 2...

Page 311: ...ion of injection volume Pump rotation rpm Average injection quantity mm3 ST Uneven amplitude mm3 ST Boost pressure kPa kg cm2 Oil temperature C Remarks 500 37 0 4 0 0 48 2 750 46 9 1 0 3 5 33 3 0 34 5...

Page 312: ...justment specification of injection volume Pump rotation rpm Average injection quantity mm3 ST Uneven amplitude mm3 ST Boost pressure kPa kg cm2 Oil temperature C Remarks 500 33 9 4 0 0 48 2 750 43 8...

Page 313: ...0 48 2 Standard 100 60 0 48 2 Engine 4JB1TC Injection pump identification No 104746 6601 Injection volume adjustment 40 0 Adjustment specification of timer and pump case pressure Pump rotation rpm Tim...

Page 314: ...to the specified torque N m Kg m lb ft 29 3 22 1 Evapo Fuel Hose 2 Fuel Feed Hose 3 Fuel Return Hose Plug the hose to prevent fuel from getting spilt and tie it to the frame with the plugged end up 4...

Page 315: ...and tighten it to the specified torque N m Kg m lb ft 55 5 6 41 When mounting the fuel tank on the bracket be sure to place the packing section pasted on the fuel tank securely on the bracket 5 Band...

Page 316: ...gauge unit connector from fuel gauge unit 2 Fuel Gauge Unit Remove fuel gauge unit fixing screw and fuel gauge unit NOTE After removing fuel gauge unit cover fuel tank with waste to prevent any dust e...

Page 317: ...emove the control wire from injection pump control lever 3 Accelerator Control Wire Accelerator Pedal Side Remove the accelerator control wire from accelerator pedal 4 Accelerator Control Cable Remove...

Page 318: ...lt up the cab 2 Accelerator Control Wire Injection pump side Install the tip end of the wire to the engine control lever 1 Lock Bolt With the accelerator control lever attached to the stopper bolt pul...

Page 319: ...move accelerator pedal assembly from brake pedal bracket INSTALLATION 4 Accelerator Pedal Assembly Apply the sliding section with grease and install it to the brake pedal bracket 3 Idling Control Cabl...

Page 320: ...9 in and tighten the lock nut to the specified torque N m Kg m lb ft 7 4 0 75 65 Check to see if the accelerator pedal play is in the range of 5 10 mm 0 2 0 4 in above the pedal pad Press down on the...

Page 321: ...Wave Washer 4 Idling Control Cable Remove control cable from accelerator pedal bracket INSTALLATION 4 Idling Control Cable Install Control Cable to Accelerator pedal bracket 3 Wave Washer 2 Idling Con...

Page 322: ...ghten the screw Inspection With the idling control knob not in use check to see if the injection pump lever is at the idle position with the lever in contact with the stopper bolt With the idling cont...

Page 323: ...lter with a light for fears rears or holes Cleaning Method Dust Fouled Element Rotate the element with your hand while applying compressed air to the inside of the element This will blow the dust free...

Page 324: ...must not exceed 274 Kpa 2 8 kg cm 2 40 psi 4 Dry the element in a well ventilated area An electric fan will hasten drying NOTE Do not use compressed air or an open flame to dry the element quickly Dam...

Page 325: ...6C 66 ENGINE FUEL MEMO...

Page 326: ...rging System 6D3 QOS II Preheating System 6D6 QOS III Preheating System 6D7 SECTION 6D1 BATTERY CONTENTS PAGE General Description 6D1 2 Diagnosis 6D1 2 On Vehicle Service 6D1 4 Battery Charging 6D1 4...

Page 327: ...te loss Replace the battery if obvious physical damage is discovered during inspection Check for any other physical damage and correct it as necessary If not proceed to Step 2 2 FLUID LEVEL CHECK The...

Page 328: ...nd Specifications in this section Read voltage after 15 seconds then remove load a VOLTAGE DOES NOT DROP BELOW THE MINIMUM LISTED IN FOLLOWING TABLE The battery is good and should be returned to servi...

Page 329: ...reduced if the battery feels hot to the touch Battery charging should be discontinued or the rate of charge reduced if the battery begins to gas or spew electrolyte from the vent holes 3 In order to m...

Page 330: ...ponents of one or both vehicles particularly Never expose the battery to an open flame or electrical spark Gas generated by the battery may catch fire or explode Remove any rings watches or other jewe...

Page 331: ...er end of the same cable to the positive terminal of the discharged battery Attach the end of one jumper cable to the positive terminal of the booster battery Do not allow the vehicles to touch each o...

Page 332: ...ion 2 Disconnect the battery ground cable 3 Disconnect the battery positive cable 4 Disconnect the battery cable CAUTION It is important that the battery ground cable be disconnected first Disconnecti...

Page 333: ...6D1 8 ENGINE ELECTRICAL MEMO...

Page 334: ...duction starter in which the motor shaft is also used as a pinion shaft When the starter switch is turned on the contacts of magnetic switch are closed and the armature rotates At the same time the pl...

Page 335: ...6D2 2 STARTING SYSTEM STARTING CIRCUIT 6D2 2 1 tif...

Page 336: ...arth Cable Terminal 4 Starter Assembly 5 Spacer 4JB1 Except cold area INSTALLATION 5 Spacer 4JB1 Except cold area 4 Starter Assembly Tighten the fixing bolt and nut to the specified torque Starter Bol...

Page 337: ...minal Connect the harness connector 1 50 Terminal Connect the battery cable terminal with starter switch harness terminal then tighten nut to the specified torque Fixing Nut Torque N m Kg m lb in 9 0...

Page 338: ...STARTING SYSTEM 6D2 5 UNIT REPAIR DISASSEMBLY 1 Lead Wire Disconnect the lead wire from the magnetic switch 2 Through Bolt Remove the through bolts from the yoke 6D2 5 1 tif 6D2 5 2 tif 6D2 5 3 tif...

Page 339: ...Separate the yoke from the solenoid switch 4 Yoke Cover 5 Brush and Brush Holder Remove pull out the brushes and the brush holder from the armature with a pair of long nose pliers 6 Armature 7 Drive...

Page 340: ...pring Remove the return spring from magnetic switch 10 Steel Ball Remove the steel ball from the overrunning clutch 11 Idle Pinion Remove the idle pinion from housing 12 Retainer Remove the retainer f...

Page 341: ...andard Limit 2 2 2 0 0 7 0 9 0 028 0 035 0 20 0 008 Check the commutator outer diameter Commutator outer diameter mm in kw Standard Limit 2 2 2 0 35 00 1 378 34 00 1 339 Armature short circuit test Ch...

Page 342: ...nuity at any test points Replace if it is open circuited YOKE Field winding ground test Using circuit tester touch one probe to the field winding end or brush and the other to the bare surface of yoke...

Page 343: ...one probe to the holder plate and the other to the positive brush holder There should be no continuity OVERRUNNING CLUTCH Inspect the teeth of pinion for wear and damage Replace if it damaged Rotate...

Page 344: ...owing points Magnetic Switch Idle Gear Clutch assembly Housing 1 Install the clutch asm to the magnetic switch 2 Install the idle gear and housing Note Do not fail to assemble the steel ball and the s...

Page 345: ...t the M terminal The pinion should continue to flutter 3 Return test Connect the battery negative terminal to the 50 terminal and the body Connect the battery positive terminal to the M terminal The p...

Page 346: ...main components are connected as shown in Figure The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator installed on the rear end cover The gen...

Page 347: ...6D3 2 CHARGING SYSTEM Generator 6D3 2 1 tif 6D3 2 2 tif...

Page 348: ...CHARGING SYSTEM 6D3 3 CHARGING CIRCUIT 6D3 3 1 tif...

Page 349: ...e starts If the warning lamp shows abnormality or if undercharged or overcharged battery condition is suspected perform diagnosis by checking the charging system as follows 1 Check visually the belt a...

Page 350: ...essor Drive Belt A C Model Loosen the idler pulley lock nut Loosen the adjust bolt and remove the drive belt 2 A C Compressor Assembly A C Model Disconnect the clutch harness connector Remove the A C...

Page 351: ...enerator fixing bolt then remove the fan belt 7 Power Steering Oil Pipe Bracket P S Model Remove the oil pressure pipe bracket fixing bolt and pipe clip bolt Remove the oil suction pipe clip bolt 8 AC...

Page 352: ...n Depress the drive belt mid portion with a 98N 10kg 22lb force Drive Belt Deflection mm in 8 0 31 10 0 39 Install the fixing bolt and tighten bolt to the specified torque Generator Fixing Bolt Torque...

Page 353: ...itch harness connector 1 A C compressor Drive Belt A C Model Install A C compressor drive belt and adjust belt tension Depress the drive belt and mid portion with a 98N 10 kg 22 lb force Drive Belt De...

Page 354: ...2 Read Wire 3 Through Bolts 4 Rotor and Front Cover Assembly 5 Stator and Rear Cover Assembly Insert a driver into the clearance between the front cover and the stator core and remove the assembly NO...

Page 355: ...n stator coil and diode When melting solder hold the lead wire with long nose pliers to prevent heat from being transferred to the diodes 12 IC Regulator Assembly Separate the IC regulator from the di...

Page 356: ...g and rotor shaft In case of continuity replace the rotor assembly Rear Ball Bearing Check to see if the ball bearing rotates smoothly with no noises When it does not rotate smoothly or any noises are...

Page 357: ...ive and should be replaced Auxiliary diodes are not provided with the terminal and continuity test should be made across the terminals of the conventional diodes side diode check Across terminals BAT...

Page 358: ...cross the intermediate tap on variable resistor and E terminal without actuating the variable resistor V Standard voltage at 20 C 68 F 14 0 14 9 If measured value deviates from the standard replace th...

Page 359: ...5 13 5 0 492 0 531 Check Valve 1 Apply a light pressure onto the B side of valve with a screw driver and check that valve operates smoothly 2 Apply compressed air 1 5 kg cm 2 onto A side of valve and...

Page 360: ...by fixing the rivet at 1 and soldering the terminal at 2 10 Stator When connecting stator coil leads and diode leads using solder use long nose pliers and finish the work as quickly as possible to pre...

Page 361: ...h Bolts Torque N m kg m lb in 3 5 0 36 31 2 Read wire 1 Vacuum Pump Install and mount the housing to the generator using 3 bolts Pour engine oil 5 cc or so in through the filler port then check that g...

Page 362: ...d Frame and Rear End Frame Stator As illustrated put a screw driver into the notched part of the drive end frame and separate the rear end frame and stator from the drive end frame NOTE Be careful not...

Page 363: ...frame parallel to a block and then push out the bearing with a press through a jig 5 Separation of Rear End Frame and Rectifier Stator Remove the nuts M5 and M6 and separate the rectifier and stator f...

Page 364: ...smooth and noiseless turning 3 Stator Resistance between phases neutral point and each phase lead wire should be 1 or less Insulation resistance between the core and stator coil should be 0 1M or more...

Page 365: ...r by the resistance in the direction of easy flow Because of diode s characteristics the current in the direction of easy flow changes greatly depending on the power source voltage Therefore a tester...

Page 366: ...he holder Rotor Be sure to fit it after brush is supported by the brush holder Otherwise the rotor cannot be fitted or the brush may be broken Output Characteristic As alternator speed increases the o...

Page 367: ...6D3 22 CHARGING SYSTEM MEMO...

Page 368: ...oting 6D6 4 GENERAL DESCRIPTION QOS II preheating system features a quick on glow plug with thermometer control of the glowing time and the afterglow time function The system consists of a controller...

Page 369: ...6D6 2 QOSII PREHEATING SYSTEM SYSTEM DIAGRAM QOS II Timing Chart 6D6 2 1 tif 6D6 2 2 tif...

Page 370: ...circuit tester to check the thermo switch for continuity OFF ON 7 13 C 44 6 55 4 F ON OFF Below 3 C 37 4 F 10 C ON OFF 3 C GLOW PLUG Use a circuit tester to test the glow plugs for continuity Glow Pl...

Page 371: ...r disconnection Malfunction of other of Fuse No 8 circuits occurred simultaneously Bad starter awitch Bad connection of glow plug relay terminal Disconnection of glow plug relay excitation coil Discon...

Page 372: ...of the engine is 0 C or above Condition Cause Circuit Indicator lamp is not lit Bad timer Burning out of bulb 8 Turn glow relay ON Bad thermoswitch or disconnection of thermo SW circuit Indicator will...

Page 373: ...6D6 6 QOSII PREHEATING SYSTEM MEMO...

Page 374: ...lowing time and the afterglow time function The system consists of a controller indicator lamp thermosensor vehicle speedsensor dropping resistor relay 2 pcs and temperature self control type glow plu...

Page 375: ...6D7 2 QOSIII PREHEATING SYSTEM SYSTEM DIAGRAM QOS II Timing Chart 6D7 2 1 tif 6D7 2 2 tif...

Page 376: ...QOSIII PREHEATING SYSTEM 6D7 3 QOS III FLOW CHART 6D7 3 1 tif...

Page 377: ...6D7 4 QOSIII PREHEATING SYSTEM QOS III BLOCK CHART 6D7 4 1 tif...

Page 378: ...and thermo sensor If satisfied inspect glow plug II Inspection on Quick Heating Afterglow Operation 1 Disconnect thermo sensor connection on the thermostat housing 2 Connect the circuit tester betwee...

Page 379: ...r relay No 2 and charge relay THERMO SENSOR Measure the resistance depending on the water temperature as shown in the left figure Measuring range 10 C 50 C Temperature Current mA Resistance KW 20 1 1...

Page 380: ...mperature m 225 255 GLOW PLUG RELAY Inspect the continuity No Continuity If apply the battery voltage to terminal between Continuity CHARGE RELAY Inspect the continuity Continuity No Continuity If app...

Page 381: ...6D7 8 QOSIII PREHEATING SYSTEM MEMO...

Page 382: ...CIRCULATION EGR SYSTEM 6E 1 SECTION 6E EXHAUST GAS RECIRCULATION EGR SYSTEM CONTENTS PAGE General Description 6E 2 EGR System Wiring Diagram 6E 3 EGR System Operation 6E 3 EGR System Check 6E 4 Inspec...

Page 383: ...culating the exhaust gas into the combustion chamber through the intake manifold The EGR valve are controlled by VSV also VSV are controlled by EGR controller according to signals from RPM sensor and...

Page 384: ...11 Potentio Meter 12 13 VSV EGR SYSTEM OPERATION 1 On the input side of engine speed there is provided a hysteresis of 50 rpm on the speed rising side 2 It does not work until 70 sec pass after engin...

Page 385: ...ve pintle valve passages and adapter for excessive deposits obstructions or any restrictions Does the EGR valve have excessive deposits obstructions or any restrictions Go to Step 6 Go to Step 7 6 Cle...

Page 386: ...With negative pressure applied to the diaphragm chamber make sure that the valve is smoothly actuated to make the area between 1 and 2 ventilated Startup About 18 66 2 67 Kpa 140 20 mmHg Check to see...

Page 387: ...6E 6 EXHAUST GAS RECIRCULATION EGR SYSTEM MEMO...

Page 388: ...from the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials CONTENTS PAGE General Description 6F 2 Three Way Catalytic Co...

Page 389: ...s Check complete exhaust system and nearby body areas and rear compartment lid for broken damaged missing or mispositioned parts open seams holes loose connections or other deterioration which could p...

Page 390: ...aust system is not required If the vehicle is raised for other service it is advisable to check the condition of the complete exhaust system A dual bed monolith catalytic converter is used in combinat...

Page 391: ...age 3 If any part of the converter heat shield is damaged or dented to the extent that it contacts the catalyst repair or replace 4 Check for dents or damage and for any holes or cracks caused by corr...

Page 392: ...h connection Exhaust Brake Unit INSPECTION Operational inspection With the engine idling operate the exhaust brake to check for the sound of the valve hitting against the stopper Unit inspection Check...

Page 393: ...6F 6 ENGINE EXHAUST MEMO...

Page 394: ...S PAGE Turbocharger 6G 2 Main Data and Specifications 6G 2 General Description 6G 3 Identification of Unit 6G 4 Turbocharger Servicing 6G 4 Precautions 6G 4 Disassembly 6G 5 Inspection and Repair 6G 7...

Page 395: ...ine type Compressor type Maximum permissible speed rpm Wastegate opening pressure kPa mmHg Weight N kg lb Centrifugal 180 000 IHI Ishikawajima Harima Heavy Industries Ltd IHI RHF 4H Mixed flow 109 4 4...

Page 396: ...st port The turbocharger increases air intake efficiency This results in increased engine power reduced fuel consumption and minimal engine noise The turbocharger operates at very high speeds and temp...

Page 397: ...overhaul is required Visual checks Clearance measurements End play measurements Refer to INSPECTION AND REPAIR 3 The turbocharger compressor and turbine housing may be removed from the center housing...

Page 398: ...TURBOCHARGER 6G 5 DISASSEMBLY Disassembly Steps 1 Bolt 4 Compressor housing 2 Turbine housing 5 Center housing and rotating assembly 3 Bolt 036LW001 tif...

Page 399: ...Housing 5 Center Housing and Rotating Assembly 1 Loosen the bolts 2 Disassembly the parts Handle the parts with extreme care Be particularly careful not to damage the turbine wheel blades and the comp...

Page 400: ...tationary with no load applied to the engine 4 Check to see that turbocharger pressure rises to approximately 500 mmHg Pressure Gauge 5 8840 0075 0 Waste gate operation check 1 Remove the hose between...

Page 401: ...a force of 1 2 kg 2 6 lb 11 8N alternately to the compressor wheel end and the turbine wheel end Wheel Shaft End Play mm in Standard Limit 0 02 0 08 0 0008 0 0031 0 09 0 0035 Wheel Shaft and Bearing C...

Page 402: ...TURBOCHARGER 6G 9 REASSEMBLY Reassembly Steps 1 Center housing and rotating assembly 4 Turbine housing 2 Compressor housing 5 Bolt 3 Bolt 036LW002 tif...

Page 403: ...he new bolt threads 4 Install the new bolts to the compressor housing 5 Tighten the bolts to the specified torque Compressor Housing Bolt Torque N m kg m lb ft 4 7 0 5 3 5 4 Turbine Housing 5 Lock Pla...

Page 404: ...c of CHINA TEL 86 1 505 4997 0408 FAX 86 1 505 4350 TLX 210343 IHIPK CN TAIWAN IHI TAIPEI OFFICE Room 1202 Chia Hsin Building No 96 Chung Shan North Road Section 2 Taipei TAIWAN TEL 886 2 542 5520 552...

Page 405: ...applicable for vehicles in all countries except the USA and Canada All rights reserved This manual may not be reproduced in whole or in part without the permission in writing of ISUZU MOTORS LIMITED...

Page 406: ...No HGSTG WE 661 PRINTED IN JAPAN...

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