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Engine

Mechanical

(4HK1)

Table of Contents

Cylinder head cover.........................................................1B-2

removal.......................................................................1B-2
installation...................................................................1B-3

Cylinder head assembly...................................................1B-4

removal.......................................................................1B-4
disassembly...............................................................1B-13
inspection..................................................................1B-19
reassembly................................................................1B-25
installation.................................................................1B-34

Idle gear.........................................................................1B-49

removal.....................................................................1B-49
inspection..................................................................1B-62
installation.................................................................1B-63

Inlet cover......................................................................1B-86

removal.....................................................................1B-86
installation.................................................................1B-90

Cylinder block...............................................................1B-97

removal.....................................................................1B-97
inspection................................................................1B-114
installation...............................................................1B-115

Exhaust manifold.........................................................1B-149

removal...................................................................1B-149
inspection................................................................1B-152
installation...............................................................1B-153

Crankshaft...................................................................1B-157

removal...................................................................1B-157
disassembly.............................................................1B-173
inspection................................................................1B-174
reassembly..............................................................1B-178
installation...............................................................1B-179

Piston...........................................................................1B-212

removal...................................................................1B-212
disassembly.............................................................1B-222
inspection................................................................1B-223
reassembly..............................................................1B-230
installation...............................................................1B-232

Camshaft......................................................................1B-250

removal...................................................................1B-250
disassembly.............................................................1B-252
inspection................................................................1B-253
reassembly..............................................................1B-255

installation...............................................................1B-256

Flywheel......................................................................1B-262

removal...................................................................1B-262
inspection................................................................1B-264
installation...............................................................1B-265

Crankshaft front oil seal..............................................1B-267

removal...................................................................1B-267
installation...............................................................1B-269

Crankshaft rear oil seal................................................1B-272

removal...................................................................1B-272
installation...............................................................1B-274

Rocker arm shaft.........................................................1B-277

removal...................................................................1B-277
disassembly.............................................................1B-279
inspection................................................................1B-280
reassembly..............................................................1B-282
installation...............................................................1B-284

Valve spring................................................................1B-289

removal...................................................................1B-289
inspection................................................................1B-292
installation...............................................................1B-293

Valve stem oil seal......................................................1B-300

removal...................................................................1B-300
installation...............................................................1B-303

CMP sensor.................................................................1B-310

removal...................................................................1B-310
inspection................................................................1B-311
installation...............................................................1B-312

Front cover..................................................................1B-313

removal...................................................................1B-313
installation...............................................................1B-315

CKP sensor..................................................................1B-320

removal...................................................................1B-320
inspection................................................................1B-321
installation...............................................................1B-322

Supplementary Information.........................................1B-323

Mechanical (4HK1) 1B-1

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Содержание 4HK1

Страница 1: ... IN JAPAN K 2015 06 Service Manual consists of the following sections Technical Manual Operational Principle Technical Manual Troubleshooting Workshop Manual Engine Manual EWDCY EN 00 PART NO GB3 EXHAUST EMISSION STANDARDS Engine Manual Workshop Manual URL http www hitachi c m com 4HK1 ...

Страница 2: ...Find manuals at https best manuals com Find manuals at https best manuals com ...

Страница 3: ...iagram FOREWORD This manual describes the service procedures for the 4HK1 diesel engine GB 3 The contents of this manual are current at the date of issue but may differ slightly from your engine due to specification changes or other modifications made thereafter This manual consists of the following sub sections Publication No Publication Name Sub sections IDE 2820 ENGINE 0 Introduction 14A Servic...

Страница 4: ...IDE 2820 前書 4505260 15 1 28 3 19 AM ページ 2 Find manuals at https best manuals com Find manuals at https best manuals com ...

Страница 5: ...Introduction Introduction All Table of Contents Introduction 0 2 safety information 0 2 Introduction All 0 1 Find manuals at https best manuals com Find manuals at https best manuals com ...

Страница 6: ... occur 7 Always inspect and prepare in advance the instruments special tools and the tools to be used Also do not use tools such as wrenches that have lost their edge hammers with frayed edges or chipped chisels 8 When performing work using a device such as a grinder crane or welder perform the procedure while paying sufficient attention to the handling precautions Furthermore for work besides thi...

Страница 7: ...ncluded in service information 14A 2 Plastic gauge 14A 4 Recommended liquid gasket 14A 6 Thread locking adhesive agent 14A 8 Term 14A 9 Abbreviations 14A 10 Standard bolts 14A 13 Service Information Guide All 14A 1 Find manuals at https best manuals com Find manuals at https best manuals com ...

Страница 8: ...o each item Disconnection Includes the disconnection procedures for wiring piping etc Connection Includes the connection procedures for wiring piping etc Writing Includes the writing procedure necessary when replacing the ECM or supply pump Setting Includes the setting procedure necessary when replacing the ECM etc Replacement Includes the procedure for replacing parts changing oil etc Prioritized...

Страница 9: ...nsion 7 Arrow indicating a cross section 8 Outside air or cold air 9 Gas or warm air 10 Mixing of outside air and gas or mixing of cold air and warm air 11 Rotational direction 12 Apply oil 13 Apply grease 14 Apply liquid gasket Service Information Guide All 14A 3 Find manuals at https best manuals com Find manuals at https best manuals com ...

Страница 10: ...g rod and measure the width of the flattened PLASTIGAUGE using the scale printed on the packaging Method for measuring clearance between the crank bearing and the crank journal Clean the bearing as well as the cylinder block and crankcase bearing mounting surfaces and assemble to the cylinder block and crankcase Gently place the crankshaft on the cylinder block and settle it by turning it approxim...

Страница 11: ...Service Information Guide All 14A 5 ...

Страница 12: ...the mating parts where the liquid gasket was used using a scraper and clean using a waste cloth etc so that any oil moisture dirt etc is removed After cleaning apply the specified liquid gasket to each location and assemble Note If a gasket remover is used to make the operation during cleaning easier it is better to wait approximately 10 minutes after applying before starting the removal operation...

Страница 13: ...Caution If the workshop manual specifies an application method follow that method Service Information Guide All 14A 7 ...

Страница 14: ...s and screw thread portion of the nuts to which thread locking adhesive agent will be applied Note Verify that the cleaned sections are dry Caution After tightening do not apply excessive torque or vibration for at least 1 hour until the thread locking adhesive agent hardens Apply the thread locking adhesive agent to the end 1 3 of the bolt and tighten to the specified torque 14A 8 Service Informa...

Страница 15: ...s that should not be exceeded during maintenance Parts exceeding these values must be repaired or replaced Warning Refers to a precaution which may lead to injury if not observed Caution Refers to a precaution which may lead to equipment damage if not observed Note Refers to special notes that give instruction guidance or use conditions related to use operation repair etc Service Information Guide...

Страница 16: ... unit CAN Control unit communication method Controller area network CKP Crankshaft position CMP Camshaft position CO Carbon monoxide CPU Central processing unit DC Direct current DI Direct injection type DLC Data link connector DPD Diesel particulate defuser DTC Diagnostic trouble code DMM Digital multimeter ECM Engine control module ECT Engine coolant temperature ECU Electronic control unit EEPRO...

Страница 17: ...INL Intake INJ Injection ISO International Organization for Standardization ISP Intake shutter position ITP Intake throttle position J C Joint connector JIS Japan Industrial Standard KW A communication method Keyword LH Left side LLC Long life coolant M V Magnetic valve MAF Mass air flow MAP Manifold air pressure Max Maximum MIL Malfunction indicator light Diagnostic light Min Minimum MPU Micropro...

Страница 18: ...tem QWS Quick warming up system RH Right side R L Relay RAM Random access memory REF Reference ROM Read only memory RP Rail pressure RR Rear Rr Rear RWD Rearward SAE Society of Automotive Engineers SBF Slow blow fuse SCV FRP regulator SIG Signal SLD Shield ST Starter Start STD Standard SW Switch TDC Top dead center TEMP Temperature TP Throttle position VB Battery voltage VGS Turbo Variable geometr...

Страница 19: ... 3 1 to 5 1 kgf m 22 to 37 lb ft M12 x 1 25 49 0 to 73 5 N m 5 0 to 7 5 kgf m 36 to 54 lb ft 54 9 to 82 3 N m 5 6 to 8 4 kgf m 40 to 61 lb ft 60 8 to 91 2 N m 6 2 to 9 3 kgf m 45 to 67 lb ft 68 1 to 102 1 N m 6 9 to 10 4 kgf m 50 to 75 lb ft M12 x 1 75 45 1 to 68 6 N m 4 6 to 7 0 kgf m 33 to 51 lb ft 51 0 to 76 5 N m 5 2 to 7 8 kgf m 38 to 56 lb ft 56 9 to 84 3 N m 5 8 to 8 6 kgf m 42 to 62 lb ft ...

Страница 20: ...o 299 lb ft M20 x 2 5 190 2 to 286 4 N m 19 4 to 29 2 kgf m 140 to 211 lb ft 249 1 to 374 6 N m 25 4 to 38 2 kgf m 184 to 276 lb ft M22 x 1 5 251 1 to 413 8 N m 25 6 to 42 2 kgf m 185 to 305 lb ft 362 8 to 544 3 N m 37 0 to 55 5 kgf m 268 to 401 lb ft M22 x 2 5 217 7 to 327 5 N m 22 2 to 33 4 kgf m 161 to 242 lb ft 338 3 to 507 0 N m 34 5 to 51 7 kgf m 250 to 374 lb ft M24 x 2 358 9 to 539 4 N m 3...

Страница 21: ... N m 8 7 to 13 0 kgf m 63 to 94 lb ft M12 x 1 75 64 8 to 96 1 N m 6 6 to 9 8 kgf m 48 to 71 lb ft 71 4 to 107 2 N m 7 3 to 10 9 kgf m 53 to 79 lb ft 71 6 to 106 9 N m 7 3 to 10 9 kgf m 53 to 79 lb ft 79 5 to 119 2 N m 8 1 to 12 2 kgf m 59 to 88 lb ft M14 x 1 5 106 2 to 158 8 N m 10 8 to 16 2 kgf m 78 to 117 lb ft 114 9 to 172 3 N m 11 7 to 17 6 kgf m 85 to 127 lb ft 113 8 to 170 6 N m 11 6 to 17 4...

Страница 22: ... 29 0 to 48 1 kgf m 209 to 348 lb ft 293 2 to 440 3 N m 29 9 to 44 9 kgf m 216 to 325 lb ft M22 x 1 5 413 6 to 620 5 N m 42 2 to 63 3 kgf m 305 to 458 lb ft 424 6 to 636 5 N m 43 3 to 64 9 kgf m 313 to 469 lb ft M22 x 2 5 385 7 to 578 0 N m 39 3 to 58 9 kgf m 284 to 426 lb ft 394 2 to 592 3 N m 40 2 to 60 4 kgf m 291 to 437 lb ft M24 x 2 490 8 to 810 5 N m 50 0 to 82 6 kgf m 362 to 598 lb ft 554 1...

Страница 23: ... Old New Tightening torque for the flare nut Service standard value 4 6 mm 0 181 in 12 8 to 18 6 N m 1 3 to 1 9 kgf m 9 to 14 lb ft 14 mm 0 55 in 14 mm 0 55 in 6 35 mm 0 25 in 23 5 to 49 0 N m 2 4 to 5 0 kgf m 17 to 36 lb ft 17 mm 0 67 in 17 mm 0 67 in 8 0 mm 0 31 in 23 5 to 49 0 N m 2 4 to 5 0 kgf m 17 to 36 lb ft 19 mm 0 75 in 17 mm 0 67 in 10 0 mm 0 39 in 44 1 to 93 2 N m 4 5 to 9 5 kgf m 33 to...

Страница 24: ...7 to 29 4 N m 1 5 to 3 0 kgf m 11 to 22 lb ft 29 4 to 39 2 N m 3 0 to 4 0 kgf m 22 to 29 lb ft 29 4 to 58 8 N m 3 0 to 6 0 kgf m 22 to 43 lb ft 58 8 to 98 0 N m 6 0 to 10 0 kgf m 43 to 72 lb ft Note The tightening torque for connectors except brass tapered screws is only applied when the mating side is not made of aluminum Note For the elbow type connector tighten it with the minimum torque shown ...

Страница 25: ...23 reassembly 1B 230 installation 1B 232 Camshaft 1B 250 removal 1B 250 disassembly 1B 252 inspection 1B 253 reassembly 1B 255 installation 1B 256 Flywheel 1B 262 removal 1B 262 inspection 1B 264 installation 1B 265 Crankshaft front oil seal 1B 267 removal 1B 267 installation 1B 269 Crankshaft rear oil seal 1B 272 removal 1B 272 installation 1B 274 Rocker arm shaft 1B 277 removal 1B 277 disassembl...

Страница 26: ...om the cylinder head cover 3 Disconnect the oil level gauge guide tube from the cylinder head cover 4 Disconnect the ventilation hose from the air breather 1 Air leak pipe 2 Oil level gauge guide tube 3 Ventilation hose 4 Bracket 2 Cylinder head cover removal 1 Remove the cylinder head cover from the lower cover 2 Remove the head cover gasket from the cylinder head cover 1 Cylinder head cover 2 Ga...

Страница 27: ...the ventilation hose to the air breather 2 Connect the oil level gauge guide tube to the cylinder head cover tightening torque 19 N m 1 9 kgf m 14 lb ft 3 Install the bracket to the cylinder head cover tightening torque 24 N m 2 4 kgf m 18 lb ft 4 Install the air leak pipe to the bracket and EGR cooler Note The existence or nonexistence of the equipment varies depending on the machine manufacturer...

Страница 28: ...ence of the equipment varies depending on the machine manufacturer 2 Disconnect the ventilation hose from the air breather 1 Air leak pipe 2 Oil level gauge guide tube 3 Ventilation hose 4 Bracket 5 Turbocharger assembly removal 1 Remove the exhaust pipe from the turbocharger assembly 2 Remove the air cleaner duct from the air cleaner assembly and turbocharger assembly 3 Remove the air intake duct...

Страница 29: ... pipe 12 Remove the exhaust pipe adapter from the turbocharger assembly 13 Remove the turbocharger assembly from the exhaust manifold Note The turbocharger specification varies depending on the machine manufacturer 1 Exhaust manifold 2 Turbocharger assembly 3 Exhaust pipe adapter 6 EGR cooler assembly removal 1 Disconnect the water rubber hose from the EGR cooler assembly 1 Air leak pipe 2 Water r...

Страница 30: ...al 1 EGR cooler bracket 2 EGR cooler 3 EGR pipe B 7 EGR valve removal 1 Disconnect the harness connector from the EGR valve 2 Remove the EGR valve from EGR pipe C Caution After removing the EGR valve seal to prevent intrusions of foreign material 1 EGR cooler 2 EGR pipe B 3 EGR valve 4 EGR pipe C 8 EGR cooler water pipe removal 1 Remove the fan guide stay from the fan guide and the fan guide brack...

Страница 31: ... from the case 1 Inlet cover 2 Gasket 3 Inlet pipe 4 Boost pressure boost temperature sensor 10 Oil level gauge guide tube removal 1 Remove the oil level gauge from the oil level gauge guide tube 2 Disconnect the oil level gauge guide tube from the cylinder head cover 3 Disconnect the oil level gauge guide tube from the common rail fuel rail assembly 4 Remove the oil level gauge guide tube from th...

Страница 32: ... Do not reuse the gasket 14 Fuel leak off pipe assembly removal 1 Disconnect the fuel leak off pipe from the cylinder head assembly 2 Remove the fuel leak off pipe from the fuel supply pump Note Remove the eyebolt tightened together with the fuel feed pipe 3 Disconnect the fuel leak off pipe from the common rail assembly 4 Remove the fuel leak off pipe from the case Note Remove the clip 1 Common r...

Страница 33: ...n Be careful not to damage the injector side stud bolts 3 Remove the injector harness from the cylinder head assembly Note Remove the bracket tightening bolts and then remove the injector harness together with the bracket 4 Remove the lower cover from the cylinder head assembly 1 Lower cover 2 Connector 5 Remove the gasket from the lower cover 6 Remove the rubber plug from the cylinder head assemb...

Страница 34: ...eeve has not been removed as well 1 Injector 2 Injector sleeve Caution Store each ID code plate on the injector head with the cylinder number tag attached to avoid a mix up Be extremely careful not to damage the injector nozzle 19 Rocker arm shaft removal 1 Loosen the adjust screw using the wrench Note Loosen all valve clearance adjustment screws 1B 10 Mechanical 4HK1 ...

Страница 35: ...earing from the camshaft bearing cap 3 Remove the camshaft from the cylinder head 4 Remove the camshaft bearing from the cylinder head assembly Note Temporarily assemble the removed caps and bearings in the original position to avoid a mix up after the bearings have been inspected 21 Bridge removal 1 Remove the bridge cap from the bridge Caution Be careful not to drop the bridge cap into the engin...

Страница 36: ...ote Loosening order of the head bolts Caution Since the idle gear C protrudes from the bottom surface of the cylinder head be careful not to damage the gear 1 Idle gear C 2 Remove the cylinder head gasket from the cylinder block Caution Do not reuse the cylinder head gasket 1B 12 Mechanical 4HK1 ...

Страница 37: ...ront engine hanger 2 Front engine hanger bracket 3 Rear engine hanger 2 Bracket removal 1 Remove the EGR cooler bracket from the bracket 2 Remove the bracket from the cylinder head assembly 1 EGR cooler bracket 2 Bracket 3 Inlet cover removal 1 Remove EGR pipe C from the case 2 Remove the case from the inlet cover 3 Remove the inlet cover from the cylinder head assembly Mechanical 4HK1 1B 13 ...

Страница 38: ... Thermostat removal 1 Remove the fan guide bracket from the water outlet pipe 2 Remove the water outlet pipe from the cylinder head assembly 3 Remove the thermostat from the cylinder head assembly 4 Remove the gasket from the thermostat 6 Overheat switch removal 1 Remove the overheat switch from the cylinder head assembly 7 Engine coolant temperature sensor removal 1 Remove the engine coolant temp...

Страница 39: ...e gear C cover using the driver Note Lightly tap the outer perimeter of the cover using a screwdriver and tilt the cover 2 Remove the idle gear C cover from the cylinder head assembly using the pliers 3 Remove the idle gear C from the cylinder head assembly 1 Idle gear C 2 Idle gear shaft 10 Valve spring removal 1 Press the valve spring using the special tool SST 5 8840 2621 0 valve spring replace...

Страница 40: ...e according to the cylinders 12 Exhaust valve removal 1 Remove the exhaust valve from the cylinder head assembly Note Organize the removed valve according to the cylinders 13 Valve stem oil seal removal 1 Remove the valve stem oil seal from the valve guide using the pliers Caution Do not reuse the valve stem oil seal 2 Remove the valve spring seat from the cylinder head assembly 14 Valve guide rem...

Страница 41: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com ...

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