Engine PDF

WORKSHOP MANUAL
2007MY N-SERIES
ENGINE
4JJ1
SECTION 6
Isuzu Motors Limited
Service Marketing Department

ENGINE MECHANICAL (4JJ1) 6A-1
ENGINE
ENGINE MECHANICAL
(4JJ1)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4JJ1) . . . . . . . . . . . . . . 6A-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6A-3 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-53
Work procedure . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Valve Stem Seal and Valve Spring . . . . . . . . . . . 6A-55
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-56
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-58
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-20 Head Disassembly . . . . . . . . . . . . . . . . . . . . . . 6A-64
Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 6A-21 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Head Reassembly . . . . . . . . . . . . . . . . . . . . . . 6A-70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-72
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-80
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-80
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Piston and Connecting Rod . . . . . . . . . . . . . . . . 6A-82
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-27 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-83
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-87
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6A-28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-90
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-90
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91
Torque specifications . . . . . . . . . . . . . . . . . . . . 6A-33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-95
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . 6A-96
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-37 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-97
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-98
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . 6A-99
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-45 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-102
Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-46 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-102
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46 Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . 6A-103
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-103
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-48 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-103
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-50 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104
6A-2 ENGINE MECHANICAL (4JJ1)
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-105
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-105
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-105
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-106
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-106
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-107
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-112
Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-114
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117
Lubrication System . . . . . . . . . . . . . . . . . . . . . . 6A-119
Service Precautions . . . . . . . . . . . . . . . . . . . . 6A-119
Functional Check . . . . . . . . . . . . . . . . . . . . . . 6A-120
Oil Filter Element. . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Oil Filter Assembly and Oil Cooler . . . . . . . . . . 6A-123
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-123
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-123
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-124
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-124
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-124
Crank Case and Oil Pan . . . . . . . . . . . . . . . . . . 6A-126
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-126
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-126
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-131
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-131
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-131
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-135
Oil Pressure SW . . . . . . . . . . . . . . . . . . . . . . . . 6A-137
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-137
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-137
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-137
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-138
Circuit check. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-138
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . 6A-139
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139
ISUZU DIESEL ENGINE (4JJ1)

Service Precautions Matters that require attention in specifically dealing
with this engine.
Matters that require attention in terms of Holes or clearances in the fuel system, which serve as
maintenance a passage of fuel, including the inside of the injector,
To prevent damage to the engine and ensure reliability are made with extreme precision. For this reason, they
of its performance, pay attention to the following in are highly sensitive to foreign matter and if it gets in, it
maintaining the engine: can lead to an accident on the road, for instance; thus,
• When lifting up or supporting the engine, do not make sure that foreign matter is prevented from getting
apply a jack on the oil pan. in.
When taking down the engine on the ground, do When servicing the fuel system, every precaution must
not make the bearing surface of the oil pan touch be taken to prevent the entry of foreign material into the
the ground directly. Use a wooden frame, for system.
example, to support the engine with the engine • Before beginning the service procedure, wash the
foot and the flywheel housing. fuel line and the surrounding area.
Because there is only a small clearance between • Perform the service procedures with clean hands.
the oil pan and the oil pump strainer, it can damage Do not wear work gloves.
the oil pan and the oil strainer.
• Immediately after removing the fuel hose and/or
• When the air duct or air cleaner is removed, cover fuel pipe, carefully tape vinyl bags over the
the air intake opening to prevent foreign matter exposed ends of the hose or pipe.
from getting into the cylinder. If it gets
• If parts are to be replaced (fuel hose, fuel pipe,
contaminated, it can considerably damage the
etc.) do not open the new part packaging until
cylinder and others while the engine is operating.
installation.
• When maintaining the engine, never fail to remove
the battery earth cable. If not, it may damage the
wire harness or electrical parts. If you need Work procedure
electricity on for the purpose of inspection, for • The fuel opening must be quickly sealed when
instance, watch out for short circuits and others. removing the fuel pipe, injection pipe, fuel injector,
• Apply engine oil to the sliding contact surfaces of fuel supply pump, and fuel rail.
the engine before reassembling it. This ensures • The eyebolts and gasket must be stored in a clean
adequate lubrication when the engine is first parts box with a lid to prevent adhesion of foreign
started. matter.
• When valve train parts, pistons, piston rings, • Fuel leakage could cause fires. Therefore, after
connecting rods, connecting rod bearings or finishing the work, wipe off the fuel that has leaked
crankshaft journal bearings are removed, put them out and make sure there is no fuel leakage after
in order and keep them. starting the engine.
• When installing them, put them back in the same
location they were removed from.
• Gaskets, oil seals, O-rings, etc. must be replaced
with new ones when the engine is reassembled.
• As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust is clinging
to them. Then, apply the designated liquid gasket
to each place anew before assembly.
• Surfaces covered with liquid gasket must be
assembled within 5 minutes of gasket application.
If more than 5 minutes has elapsed, remove the
existing liquid gasket and apply a new liquid
gasket.
• When assembling or installing parts, fasten them
with the prescribed tightening torque so that they
are installed properly.
How to read the model
1
3
LNW71BMF000101
Legend
1. Engine Model (Stamped) 3. Front
2. Engine Number (Stamped)
Explanation of functions and operations EGR system

Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Electronic engine control Control Module (ECM) to purify exhaust by recycling
With the control unit, the range from injection to air part of it.
intake/exhaust, including fuel injection quantity, Its main components include an EGR valve, an EGR
injection timing, intake air restriction, EGR, and idling cooler and various sensors.
rpm, is controlled.
Connecting rod cap bolt
Piston The angular tightening method of the connecting rod
The piston is aluminum-alloy and a thermal flow piston cap bolt further increases reliability and durability.
with a strut cast, while the combustion chamber is a
round reentrant type. Fuel rail-type electronic control injection system
The fuel rail-type electronic control injection system is
Cylinder head composed of a fuel supply pump that sets the target
The cylinder head is aluminum-alloy and there are 4 pressure of high-pressure fuel and supply it, a fuel rail
valves per cylinder. The angular tightening method of that measures such high-pressure fuel and a fuel
the cylinder head bolt further increases reliability and injector that turns it into a fine spray and injects it. Each
durability. is controlled via ECM based upon various signals,
while injection timing or fuel injection quantity is
controlled under every possible driving condition.
Fuel injector
The fuel injector is a 6-hole nozzle that adjusts fuel
injection quantity or injection timing by opening or 2
1
closing an electromagnetic valve on the head of the
fuel injector.
ECM corrects the dispersion of fuel injection quantity
between fuel injector according to ID code data in
memory. At the replacement of fuel injector, ID code 3
data should be stored in ECM.
Fuel filter with sedimenter

It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.
Preheating system
The preheating system consists of the ECM, the glow LNW76ASH001101
relay, glow plugs and the glow indicator lamp. The Legend
preheating system is operated when the engine coolant 1. Crankshaft Damper Pulley
temperature is low, and makes the engine easy to start. 2. Mirror
3. TDC Mark
Lubrication system
It is an oil filter with full-flow bypass, which uses a • Insert a 0.15 mm (0.006 in) thickness gauge
water-cool oil cooler and oil jet to cool the piston. between the roller of the rocker arm and the
camshaft to tighten up the adjusting screw of
Functional inspection the rocker arm. When the movement of the
Inspection/adjustment of valve clearance thickness gauge becomes tight, fasten the
adjusting screw nut of the rocker arm.
1. Inspection of valve clearance
• Remove the injection nozzle harness assembly. Valve clearance
• Remove the leak off hose. mm (in)
• Remove the cylinder head cover. Intake valve 0.15 (0.006)
• Rotate the crankshaft and make the No.1 Exhaust valve 0.15 (0.006)
cylinder compression top dead center (TDC).
• Check TDC using a mirror etc. NOTE:
Adjust while cold.
2. Adjustment of valve clearance

• Loosen each adjusting screw of the rocker arm • Insert a 0.15 mm (0.006 in) thickness gauge
completely. between the roller of the rocker arm and the
camshaft to tighten up the adjusting screw of
the rocker arm. When the movement of the
thickness gauge becomes tight, fasten the
adjusting screw nut of the rocker arm.
1
1 2
3 4 3
RTW56ASH003701
Legend
1. Screwdriver
2. Ring Spanner
LNW71BSH001201
3. Valve Clearance Adjust Nut Wrench
Legend
Special tool 1. Camshaft Assembly (EX)
2. Camshaft Assembly (IN)
Valve clearance adjust nut wrench: 5-8840-2822-0 3. Intake Rocker Arm
4. Exhaust Rocker Arm
Tightening torque:
Rocker arm adjustment Screw nut
18 N⋅m (1.8 kg⋅m/ 13 lb ft)
Adjustment table
Cylinder No. 1 2 3 4
Valve
IN EX IN EX IN EX IN EX
arrangement
No. 1
cylinder
{ { { {
Compression
TDC
No. 4
cylinder
× × ×
Compression
TDC
• If the No.1 cylinder is the compression TDC,

adjust a valve clearance with { mark given on
the table and if the No. 4 cylinder is the
compression TDC, adjust that with × mark.
• Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
• Install the leak off hose.
• Install the fuel injector harness assembly.
Compression pressure inspection • Turn on the starter to inspect compression
• Warm up the engine. pressure.
• Remove a minus terminal of the battery. • Measure each cylinder one by one.
• Remove the all glow plugs. NOTE:
To keep engine speed at 200 rpm or more, use fully
NOTE:
charged batteries.
When the harness connector is removed, ECM judges
that it broke down and DTC is recorded. Upon • Remove the compression gauge with the special
completion of measurement, never fail to clear the tool.
memory of the ECM.
• Remove the minus terminal of the batteries.
(For how to clear the memory of the ECM, refer to
“ENGINE CONTROL SYSTEM” Section) • Install the glow plugs.
• Install the minus terminal of the batteries.
• Install the minus terminal of the battery.
• Turn on the starter to emit foreign matter within the A list of defective phenomena
cylinders. • Engine does not turn over.
• Install an adapter and the gauge of the • Engine turns over but does not start.
compression gauge with the special tool. • Excessive black exhaust smoke.
• Excessive white exhaust smoke.
• Engine knocking.
• Abnormal engine rotation.
• Abnormal battery charging.
• Turbocharger trouble shooting.
Trouble Shooting
LNW76ASH001201
Compression gauge: 5-8840-2675-0

Gauge adapter: 5-8840-2815-0
Engine does not turn over
Condition Possible Cause Correction

Starter motor does not rotate Dead or weak battery Charge battery
Replace battery
Incomplete circuit Connect
Repair
Starter motor brushes stuck, worn, Replace brushes
or broken
Starter motor internal damage Repair motor
Starter motor not meshed with Ring gear abrasion Replace ring gear
flywheel Magnetic switch (starter motor) not Adjust
properly adjusted

Starter motor pinion meshed with Dead or weak battery Charge battery
ring gear but does not rotate Replace battery
Insufficient contact pressure Adjust pressure
between starter motor brushes and
commutator
Armature (starter motor) stuck Repair armature
Engine internal damage (Seizure) Repair engine
Engine turns over but does not start

Fuel is not delivered to fuel supply Air in fuel system Bleed air from fuel system
pump Air entering fuel pipe Replace pipe and bleed air from
fuel system
Empty fuel tank Replenish fuel
Clogged strainer (fuel suction) Clean or replace strainer
Clogged fuel pipe Clean or replace pipe
Feed pump malfunction Replace pump
Use of wrong fuel for prevailing Drain existing fuel and replace with
temperatures appropriate fuel
Clogged fuel filter Replace filter
Fuel is delivered to fuel supply Loose injection pipe connections Tighten connections
pump Loose or broken electrical Tighten and/or replace connectors
connectors
Bad rotational sensor Replace sensor
Engine control system malfunction System diagnosis
Insufficient or unstable fuel delivery Air in fuel system Bleed air from fuel system
volume Feed pump malfunction Repair pump
Loose or broken electrical Tighten and/or replace connectors
connectors
Clogged fuel filter Replace filter
Excessive black exhaust smoke

Bad injection timing Engine control system malfunction System diagnosis
Bad fuel injector condition Carbon deposit at nozzle tip Clean fuel injector assembly
Sticking nozzle Replace fuel injector assembly

Insufficient compression pressure Excessive valve clearance Adjust clearance
Sticking valve stem (valve open) Repair or replace valve
Damaged valve spring Replace spring
Valve seat abrasion Repair valve seat
Compression leakage due to Replace piston ring
damaged piston ring
Damaged gasket Replace gasket
Piston scoring Replace piston
Fuel condition Water in fuel Drain existing fuel and replace with
new fuel
Poor fuel quality Drain existing fuel and replace with
new fuel
Poor engine aspiration Clogged intake pipes Clean or replace pipes
Clogged air cleaner element Clean or replace element
Malfunction detected by engine Defective sensor Replace sensor
control system Engine control system malfunction System diagnosis
EGR valve and/or intake throttle Intake throttle valve sticking Repair or replace valve
valve malfunction EGR valve sticking Repair or replace valve
Exhaust brake valve sticking Repair or replace valve
Turbocharger malfunction Damaged turbocharger blade Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Oil leakage from oil seal Replace turbocharger
Broken actuator Replace turbocharger
Defective booster sensor Replace sensor
Excessive white exhaust smoke

Bad injection timing Engine control system malfunction System diagnosis
control system Control unit malfunction Replace unit
Insufficient compression pressure Excessive valve clearance Adjust clearance
Sticking valve stem (valve open) Repair or replace valve
Damaged valve spring Replace spring
Valve seat abrasion Repair valve seat
Compression leakage due to Replace piston ring
damaged piston ring
Damaged gasket Replace gasket
Piston scoring Replace piston
Fuel condition Water in fuel Drain existing fuel and replace with
new fuel

Excessive oil consumption Worn or damaged piston ring(s) Replace ring(s)
Defective valve stem oil seal Replace oil seal
Defective turbocharger oil seal Replace turbocharger
Clogged turbocharger oil return Repair pipe
pipe
Engine knocking

Bad timing Engine control system malfunction System diagnosis
control system Control unit malfunction Replace unit
Fuel condition Poor quality fuel Drain existing fuel and replace with
new fuel
Poor engine aspiration Clogged intake pipes Clean or replace pipes
Engine break-down Foreign material in cylinders Engine overhaul
Scored pistons and/or bearings Replace pistons and/or bearings
Abnormal engine rotation

Engine speed cannot be increased Defective control unit Replace unit
Engine speed unstable Defective control unit Replace unit
Clogged fuel filter element Replace element
Defective fuel injector(s) Replace fuel injector assembly
Water in fuel Drain existing fuel and replace with
new fuel
Air in fuel system Bleed air from fuel system
Exhaust brake valve sticking Repair or replace valve
Turbocharger malfunction Damaged turbocharger blade Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Broken actuator Replace turbocharger
Defective booster sensor Replace sensor
Abnormal battery charging

No charging Open or shorted wiring and/or Repair or replace wiring and/or
connectors connectors
Defective generator Repair or replace generator
Defective battery Replace battery

Insufficient charging Open or shorted wiring and/or Repair or replace wiring and/or
connectors connectors
Loose generator drive belt Adjust belt tension or replace belt
Excessive charging Shorted wiring Repair or replace wiring
Turbocharger Troubleshooting

Engine has less than normal power Air leakage from intake pipe rubber Repair
hose
Air leakage from intake cover Repair
Clogged intercooler cooling section Clean
Clogged air cleaner element Clean or replace
Intake throttle valve stuck Repair or replace
Turbine and housing contact Replace
(Interference)
Excessive carbon deposit near Clean or repair
turbine exhaust port that interferes
with turbine
Rough turbine shaft rotation Repair or replace
Damaged turbine blade Repair or replace
Blue exhaust smoke Oil leakage from turbocharger oil Repair or replace
seal
Clogged turbocharger oil return Repair
pipe
Clogged center housing oil Repair or replace
passages
Engine oil deterioration Change engine oil
Noisy turbocharger operation Gas leakage from intake or exhaust Repair
system
Turbine and housing contact Repair or replace
(Interference)
Damaged turbine blade Replace
Turbine shaft bearing abrasion or Repair or replace
scoring
Excessive rotating part wear Engine oil deterioration Change engine oil
Clogged turbocharger oil feed pipe Repair
Low engine oil pressure Repair
Main Data and specifications
Item Engine model 4JJ1

Type Diesel/4-cycle/water cooling-type in-line DOHC

Combustion chamber type Direct injection type
Cylinder liner type Liner less
Number of cylinders -cylinder mm (in) 4-95.4 (3.76) × 104.9 (4.13)
bore X strokes
Displacement cc (cu.in) 2999 (183)
Compression ratio 17.5
Compression pressure MPa (psi)/rpm 3 (435)/200
Idling speed rpm 700 ± 25
Valve clearance Intake 0.15 (0.006) (cold)
mm (in) Exhaust 0.15 (0.006) (cold)
Ignition type Compressed ignition
Injection order 1-3-4-2
Lubricating system
Lubricating type Pressure delivery type
Oil pump type Gear type
Volume of lubricating oil L (qts) 10 (10.6)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in-type, water cooling
Cooling system
Cooling type Water cooling type
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt drive type
Thermostat type Wax-type units
Thermostat valve-opening temperature °C (°F) 85 (185)
Volume of coolant L (qts) 10 (10.6) (incl. radiator)
Fuel system
Injection pump type Fuel supply pump common rail type
Injection nozzle type Electronic control injector
6-hole
Fuel pump type Into the fuel tank type
Charging system
Generator type AC type
Power output V-A 24 - 50 , 24 - 80
Regulator type IC
Starting system Engage magnet type
Starter type Reduction type
Power output V-kW 24 - 4.0, 24 - 4.5
Preheat system type Glow plug

Glow plug standard voltage/electric current V-A 23 - 3.5
Special Tools
Illustration Tool Number/ Description
5-8840-2822-0
Valve clearance adjust
nut wrench
5884028220
5-8840-2675-0
Compression gauge
5884026750
5-8840-2815-0
Compression gauge
adapter
5884028150
Engine Assembly
Removal
NOTE:
Instructions for engine removal
2
• Be sure to lock the vehicle's wheels in a fixed
position. 1
• Use an engine hoisting attachment that can
adequately sustain the engine's weight.
• Do not get underneath the engine while the engine
is being lifted.
• Do not insert fingers into any location where they
may be caught.
1. Detach the negative cable from the battery.

2. Drain the coolant.
3. Remove the starter.
4. Remove the front exhaust pipe.
LNW76ASH000201
7. Remove the air intake pipe with the hoses.

• Disconnect the hose from the intercooler side.
• Remove the air intake pipe with the hoses from
the turbocharger side.
• Do not disconnect the hoses from the air intake
pipe.
LNW76ASH000101
5. Remove the transmission assembly.

• Refer to Transmission section.
6. Disconnect the air intake hose.
• Disconnect the PCV hose (1) from the air intake
hose (2).
• Disconnect the air intake hose (2) from the LNW76ASH000301
turbocharger side.
8. Disconnect the two connectors from the ECM.
• Do not disconnect the air intake hose from the
air cleaner side. 9. Remove the air intake pipe with the hoses.
• Disconnect the connector from the boost
sensor.
the intake throttle valve.
pipe.
NOTE:
The bracket on the right side of the engine(1) is used
as an engine hanger when the engine is lifted.
2
1
LNW76ASH000501
10. Disconnect the radiator upper hose.

• Disconnect the hose from the radiator side.
11. Detach the A/C compressor. LNW76ASH000701
• Detach the A/C compressor drive belt. 16. Remove the cooling fan assembly.
• Detach the compressor from the A/C • Remove the cooling fan and the fan clutch.
compressor bracket. 17. Disconnect the power steering pump.
• Fix the compressor and hose in an appropriate • Disconnect the power steering pump with its
position with wire etc. hose attached from the engine side.
12. Disconnect the engine ground cable from the • Fix the pump and hose in an appropriate
frame. position with wire etc.
13. Disconnect the vacuum hose. 18. Disconnect the heater hose (1) from the heater
• Disconnect the hose(1) from the vacuum pump pipe (2).
side(2).
1
2
LNW76ASH000801
LNW76ASH000601
19. Install an engine hanger (1).
14. Disconnect the radiator lower hose.
Special tool
• Disconnect the hose from the engine side.
15. Disconnect the fan guide bracket. Engine Hanger: 5-8840-2823-0
• Remove the bolts(3). • Install the engine hanger to the rear left side of
the engine.
NOTE: • Fit hoist wire to the engine hanger and hoist the
The FR engine hanger is not used for this engine. engine.
• Operate the hoist and move the engine into the
installation position.
2. Fit the engine mounts.
• Align the engine mounts to the engine mounting
cross member holes, and once fitted , tighten to
the specified torque.
Tightening torque:
Front independent suspension model
122 N⋅m (12.4 kg⋅m / 90 lb ft)
Front rigid suspension model

94 N⋅m (9.6 kg⋅m / 68 lb ft)
3. Fit the fuel hose.
LNW76ASH000901
20. Engine Mounts

• Before removing the engine mounts, lift the
engine with a hoist.
• Remove the mounting nuts from side of the
engine mount's chassis.
21. Disconnect the fuel hose.
• Disconnect the hose from fuel filter side.
LNW76ASH001001
4. Fit the heater hose to the heater pipe.

5. Fit the power steering pump.
Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)
6. Fit the radiator lower hose.
7. Fit the vacuum hose.
• Connect the hose(1) to the vacuum pump (2).
LNW76ASH001001
22. Engine Assembly

• Operate the hoist slowly, and raise the engine
until it is above and protruding from the chassis
frame.
Installation
1. Fit the engine assembly.
11. Fit the fan guide.
2
2
1
LNW76ASH000601
LNW76ASH000701
8. Attach the engine earth cable to the frame.
9. Fit the A/C compressor. 12. Fit the radiator upper hose.
• Fit the A/C compressor, and tighten to the 13. Fit the air intake pipe and hose.
specified torque. • Fit the pipe and the hose between the intake
throttle valve and the intercooler.
• Connect the boost sensor connector.
• Attach the drive belt, and adjust the belt's
tension with the tension pulley adjustment belt. • Use new clips. Tighten the clip according to the
marking.
• Refer to "Drive Belt" section in the "Cooling
System" chapter for details concerning belt Tightening torque: 6 N⋅m (0.6 kg⋅m / 52 lb in)
tension adjustment.
• By hand, press the center part of the belt with a
force of 98N (10kg / 142psi), and check with a
scale that the degree of deflection is within the
specified range. Also, check that the belt is not
damaged.
A/C Compressor Belt Degree of Deflection:
(5.5 - 7.3 mm / 0.2165 - 0.2874 in) (new belt)
(7.6 - 9.2 mm / 0.2992 - 0.3622 in) (used belt)
• After adjusting belt tension, tighten the tension
pulley's lock nut.
10. Fit the cooling fan Assembly.
• Tighten the fan clutch to the fan pulley at the
specified torque.
LNW76ASH000501
Tightening torque: 8 N⋅m (0.8 kg⋅m / 69 lb in)
14. Connect the ECM harness connector.
15. Fit the air intake pipe and hose.
• Fit the pipe and the hose between the
turbocharger and the intercooler.
• Use new clips. Tighten the clip according to the
marking.
17. Remove the engine hanger.
• Remove the engine hanger from the rear left
side of the engine.
18. Fit the transmission assembly.
• Refer to removal procedure for
"TRANSMISSION".
19. Install the front exhaust pipe and gaskets.
a. Tighten temporarily.
b. Tighten turbocharger side.
c. Tighten the clamp.
d. Tighten DPD side.
LNW76ASH000301
16. Fit the air intake hose (2).

• Fit the hose between the air cleaner and
turbocharger.
• Fit the PCV hose (1) to the air intake hose.
2
1
LNW76ASH000101
20. Fit the starter.

Tightening torque:127 N⋅m (13.0 kg⋅m / 94 lb ft)
21. Replenish the coolant.
22. Reattach the negative cable to the battery.
LNW76ASH000201
Special Tools
5-8840-2823-0
Engine Hanger
5884028230
Engine Mount
Components
LNW76AMF000101
Legend
1. Engine Mount
Removal
1. Remove the engine assembly.
• Refer to “Engine Assembly“.
2. Remove the engine mount.
• Before removing the engine mount, hang the
engine with a hoist.
• Remove the nuts fastened to the engine foot
and engine mount.
• Remove the nuts fastened to the engine mount
on the chassis frame side.
• Hoist the engine assembly slightly to remove
the engine mount.
LNW46ASH002501
Installation
1. Install the engine mount and tighten up with the
specified torque.
The nuts on the chassis frame side
Tightening torque:
Front independent suspension model
122 N⋅m (12.4 kg⋅m / 90 lb ft)
Front rigid suspension model

94 N⋅m (9.6 kg⋅m / 68 lb ft)
The nuts on the engine foot side

LNW76ASH001501
2. Install the engine assembly.

• Refer to “Engine Assembly“.
Torque Specifications
51 (5.2/ 38)
40 (4.1 / 30)
94 (9.6/69)
LNW76AMF000201
Cylinder Head Cover

Components
1
3
2
4
9 5
6 6
LNW71BLF000401
Legend
1. Oil Filler Cap 6. Head Cover Mounting Rubber
2. Oil Filler Cap Gasket 7. Oil Seal
3. Engine Cover 8. Head Cover Gasket
4. Cylinder Head Cover 9. Nut
5. Bolt
Removal
1. Remove the engine cover.
• Remove the oil filler cap before removing the
engine cover.
NOTE:
Do not reuse the leak-off hose clips (1).
LNW76ASH002201
2. Remove the fuel injector connector (2) and the

LNW76ASH002101
leak-off hose(1).
3. Disconnect the blow-by hose.
4. Remove the cylinder head cover.
1
RTW76ASH000101
LNW71BSH000401
5. Remove the nozzle seal cover from the cylinder

head cover.
• Remove from the lower side of cylinder head
cover.
6. Remove the cam end gasket (1).
• Remove the liquid gasket that has adhered to
cylinder head completely.
• Apply attaching cam end gasket. Apply the
liquid gasket (ThreeBond TB-1207B or
1
equivalent).
1
1
RTW56ASH020501
Installation RTW56ASH022701
1. Install the nozzle seal cover. Legend

• Insert from the lever side of cylinder head 1. 3.0 - 5.0 mm (0.118 - 0.197 in)
cover. 2. 3.0 - 5.0 mm (0.118 - 0.197 in)
• Apply soapy water or engine oil to the surface
3. Install the cylinder head cover.
of cylinder head cover side.
• Tighten the bolts and a nut in order shown in
• Insert the nozzle seal cover as far as it will go.
the illustration.
2. Install the cam end gasket.
• Apply the liquid gasket (ThreeBond TB-1207B
or equivalent) and mount.
2 12 11 10 2 9 8
3 4
13 7
14 1 5 6
15
LNW76ASH001701
RTW56ASH020601 4. Install the blow-by hose.

Legend 5. Install the leak-off hose and the fuel injector
1. Cam End Gasket connector.
2. Apply The Liquid Gasket 6. Install the engine cover.
3. 2.0 to 3.0 mm (0.079 to 0.118 in) • Install the oil filler cap after installing the engine
cover.
Intake Manifold
Components
LNW71BLF000101
Legend
1. Intake Manifold Gasket 4. EGR Valve Assembly
2. Intake Manifold 5. Intake Throttle Assembly Gasket
3. EGR Valve Assembly Gasket 6. Intake Throttle Assembly
Removal
• Remove the oil filler cap before removing the
engine cover.
6. Remove the intake throttle connector(2) and the
EGR valve connector(1).
LNW76ASH002201 2
LNW71BSH001101
sensor. 7. Remove the injection pipe (No.1 to 4).
• Disconnect the hose from the intercooler side. 1
pipe.
LNW71DSH000101
8. Remove the intake manifold and gasket.

• Remove the intake manifold with the EGR valve
and the intake throttle.
9. Remove the EGR valve (2) from the intake
LNW76ASH000501 manifold (1).
3. Remove the A/C compressor.
• Remove the A/C belt.
• Disconnect the A/C compressor harness
connector.
4. Remove the A/C compressor bracket.
5. Remove the engine oil level guide tube.
10. Remove the intake throttle (3) from the intake 6. Install the engine level guide tube.
manifold (1). 7. Install the A/C compressor bracket.
8. Install the A/C compressor.
1
• Install the A/C belt.
9. Install the intake air pipe and hose.
• Fit the pipe and the hose between the intake
2
marking.
LNW71BSH001001
Installation
1. Install the EGR valve to the intake manifold.
2. Install the intake throttle to the intake manifold.
3. Install the intake manifold. LNW76ASH000501
a. Install the gasket and the intake manifold and 10. Connect the boost sensor connector.
tighten temporarily.
11. Install the engine cover.
b. Tighten the bolts and nuts in the order
• Install the oil filler cap after installing the engine
described in the drawing.
cover.
4
5
1 2
3
8 6 7 9
10
LNW71BSH000901
4. Install the injection pipe (No.1 to 4).

5. Connect the intake throttle connector and EGR
valve connector.
25(2.5/18)
27(2.8/20)
27(2.8/20)
25(2.5/18)
25(2.5/18)
10(1.0/87lb·in)
LNW76ALF000101
Turbocharger
Service Precautions • While carrying out maintenance, take appropriate
measures to prevent foreign materials from
• The turbocharger is a high precision component
entering into the turbine housing, compressor
and cannot be disassembled (spins at approx.
housing, or oil inlets/outlets.
100,000 rpm). If any damage whatsoever, such as
dents and scratches, is discovered on the turbo • After servicing the turbocharger, pour clean engine
charger's fins or housing, the entire turbo charger oil (3-5 cc) into the pipe connecting port before
must be replaced. installing the oil pipe.
Components
1 4
LNW71JLF000101
Legend
1. Turbocharger Assembly 5. Water Feed Pipe
2. Oil Feed Pipe 6. Water Return Pipe
3. Turbocharger Duct 7. Oil Return Pipe
4. Exhaust Adaptor
Removal 6. Remove the heat protector (1).
1
2. Remove the front exhaust pipe and exhaust brake.
LNW71JSH000301
7. Remove the oil feed pipe.

LNW76ASH000101 8. Remove the water return pipe.
3. Remove the following parts. 9. Remove the oil return pipe.
a. Inlet hose (5) 10. Remove the turbocharger assembly from the
exhaust manifold.
b. PCV hose (2)
c. Air duct (1)
d. Right side noise cover (6)
e. Fan guide bracket (3)
f. Water feed pipe and VGS vacuum hose (4)
1 2 3
LNW71JSH000101
6
Inspection
Visual and noise inspection
LNW71BSH000101 The turbine housing outlet's adaptor and the
4. Remove the AC generator. compressor housing inlet's rubber hose must be
removed before a visual inspection on the turbocharger
• Disconnect the generator terminals.
can take place.
5. Remove the exhaust adapter from the The turbocharger can not be disassembled or adjusted.
turbocharger.
• Check the turbocharger for abnormal noise during
• Remove the adapter's bracket (3). operation.
• Remove the exhaust adapter (2).
• Check the compressor cover and turbine housing
for scratches and/or cracks caused by contact with
the fin. 1
• Check the inner surface of the housing for oil
leakage.
• Check the turbine exhaust port for excessive
carbon deposits that may interfere with the fin.
• Turn the turbine shaft by hand and check for
dragging or sticking conditions.
• Move the shaft and check for excessive clearance
in axial and radial directions.
Axial play on the wheel shaft

• Use a dial gauge to measure the axial play on the 2
wheel shaft.
• Alternately, apply a force of approximately 12 N
(1.2 kg / 2.6 lb) to the compressor wheel end. LNW71JSH000501
Legend
Axial Play mm 1. Oil Outlet Port
(in) 2. Oil Inlet Port
Standard 0.03 - 0.08
(0.0012-0.0031)
Waste gate operation (EURO 3 Specification)
Limit 0.09(0.0035)
1. Remove the hose from the waste gate actuator.
2. Install the pressure gauge (general tool). Refer to
the illustration.
1 3
LNW71JSH000401
Clearance between wheel shaft and bearing LNW21BSH022401
• Use a dial gauge to measure the clearance Legend

between wheel shaft and bearing. 1. Waste Gate Actuator
2. Waste Gate Hose
3. Pressure Gauge (General Tool)
Clearance mm
(in) 3. Use the pressure gauge pump to apply pressure
Standard 0.08 - 0.1 (load) to the waste gate actuator (the engine must
(0.0031-0.0039) be off).
Limit 0.17(0.0067)
4. Note the pressure at which the control rod moves 2
mm (0.078 in). This pressure must be within the
specified limit.
Control rod pressure range: kPa (mmHg / psi)

143 - 154 (1068 - 1158 / 20.7 - 22.4)
Actuator operation (EURO 4 Specification)

1. Install a vacuum pump (2) to the actuator (1) as
shown in the illustration.
1 LNW71JSH000101
2. Install the oil return pipe.

• Install the O-rings into both sides of the oil
return pipe, and tighten the bolt to the specified
torque.
Tightening torque
Turbocharger side: 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
Crank case side: 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
3. Install the water return pipe.
• Tighten the water return pipe's eye bolt to the
LNW71JSH000201
specified torque.
2. Operate the vacuum pump and apply vacuum
pressure to the actuator. Tightening torque: 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft)
4. Install the oil feed pipe.
Working kPa (mmHg / psi) • Install the eye bolt to the oil feed pipe on the top
vacuum of turbocharger, and tighten the bolt to the
pressure specified torque.
Reference 44 (330 / 6.38) Tightening torque: 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
5. Install the exhaust adapter to the turbocharger,
3. Place a vernier caliper on the end of the control rod and tighten to the specified torque.
of actuator.
Release the vacuum pressure and check the Tightening torque: 27 N⋅m (2.8kg⋅m / 20 lb⋅ft)
control rod moves.
Measure the length of the control rod moving. 6. Fit the heat protector and tighten with the bolt.
Tightening torque: 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
Standard length 7 mm (0.28 in)
Installation
1. Install the turbocharger assembly.
• Install the gaskets and turbocharger assembly,
and tighten to the specified torque.
Tightening torque
Nut 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
Bolt 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
c. Tighten the clamp.
1 Tightening torque: 41 N⋅m (4.2 kg⋅m / 30 lb ft)
d. Tighten DPD side.
2
LNW71JSH000301
Legend
1. Heat Protector; Turbocharger
2. Exhaust Adapter
3. Exhaust Adapter Bracket
7. Install the AC generator.

8. Install the following parts.
a. Water feed pipe and VGS vacuum hose (4)
b. Fan guide bracket (3)
c. Right side noise cover (6)
d. Air duct (1)
e. PCV hose (2)
f. Inlet hose (5)
1 2 3
LNW71BSH000101
9. Install the front exhaust pipe and gaskets.

a. Tighten temporarily.
b. Tighten turbocharger side.
Torque specifications
10 (1.0/87 lb·in)
10 (1.0/87 lb·in)
22.5 (2.2/16)
27 (2.8/20)
25 (2.5/1.8)
27 (2.8/20) 25 (2.5/1.8)
10 (1.0/87 lb·in)
25 (2.5/1.8)
LNW76ALF001001
Exhaust Manifold
Components
1
2
4
5
7
LNW71BLF000601
Legend
1. EGR Cooler 5. Exhaust Manifold
2. Heat Protector; EGR Cooler 6. Gasket
3. Heat Protector; Exhaust Manifold 7. Turbocharger Assembly
4. Gasket 8. Gasket
Removal
2. Remove the turbocharger assembly.
Refer to "Turbocharger".
3. Remove the EGR cooler heat protector. Limit 0.5 (0.02)
NOTE:
If the plane surface exceeds the limit, replace it.
LNW71FSH000101
4. Remove the EGR cooler.

• Disconnect the rubber hoses of the water
pipe(IN, OUT) from the EGR cooler.
LNW21BSH006601
• Remove the EGR cooler and the gasket from
the exhaust manifold. • Check a crack in the exhaust manifold visually.
Carefully inspect the turbocharger for abrasion
5. Remove the exhaust manifold heat protector.
and/or excessive wear. Make any necessary
adjustments, repairs, and/or part replacements.
Installation
1. Install the exhaust manifold.
• Put the gasket in to install the exhaust manifold.
• Tighten in order described in the drawing.
7 3 1 5
LNW71BSH000701
6. Remove the exhaust manifold.

• Remove the exhaust manifold and gasket. 8 4 2 6
Inspection
• Inspection of the exhaust manifold.
Inspect the plane surface of the plane on which the
manifold and the cylinder head are to be installed. LNW71BSH000801
2. Install the exhaust manifold heat protector.

Manifold installation plane surface mm (in) Tightening torque: 25 N⋅m (2.5 kg⋅m / 18lb ft)
Standard 0.3 (0.01) or lower 3. Install the EGR cooler.
a. Put the gasket in to install the EGR cooler.
b. Temporary tightening order.
1→2→3→4→5→6
c. Fully tightening order.
3→4→5→1→2→6
Tightening torque
Bolt, Nut (1 - 5) : 27 N⋅m (2.8 kg⋅m / 20 lb ft)
Bolt (6) : 52 N⋅m (5.3 kg⋅m / 38 lb ft)
4
1
5
3
2
LNW71FSH000201
4. Connect the rubber hoses to the water pipe(IN,

OUT) of the EGR cooler.
5. Install the EGR cooler heat protector.
6. Install the turbocharger.
Refer to “Turbocharger”.
52(5.3/38)
27(2.8/20)
27(2.8/20)
25(2.5/18) 25(2.5/18)
52(5.3/38)
LNW76ALF000701
Timing Gear Train

Components
4
5
3 8
10
2 11
12
1
13
RTW56ALF001101
Legend
1. Oil Pump Gear 8. Injection Pump Sprocket
2. Crankshaft Gear 9. Injection Pump Gear
3. Idle Gear D 10. Idle Gear A
4. Exhaust Camshaft Gear 11. Vacuum Pump Gear
5. Intake Camshaft Gear 12. Power Steering Oil Pump Gear
6. Idle Gear D Sprocket 13. Idle Gear C
7. Timing Chain
Removal
1. Drain the engine coolant.
2. Remove the radiator upper hose.
3. Remove the fan guide bracket. 9. Remove the cover of the gear case cover(1).
2
1
3
1
LNW76ASH000701 LNW76ASH003201
Legend 10. Remove the gear case cover.

1. Fan Guide Bracket(RH)
2. Fan Guide Bracket(LH)
3. Bolt
4. Remove the cooling fan and fan pulley.
RTW56ASH019701
11. Install the M6 bolt to the idle gear A.
RTW56ASH025401
5. Remove the A/C compressor drive belt and fan

belt.
6. Remove the crank pulley.
NOTE:
Do not reuse the crank pulley bolt and washer.
7. Remove the power steering pump with hose.

8. Remove the vacuum pump.
• Remove the vacuum pipe bracket and vacuum
pipe.
• Remove the oil pipe (feed side and return side)
of vacuum pump.
12. Remove the idle gear A and idle gear A flange, idle 14. Remove the crankshaft gear.
gear A shaft.
RTW56ASH021501
RTW56ASH011301
13. Remove the idle gear C and idle gear C shaft.

Disassembly
1. Remove the scissor gear assembly.
• Clamp the vise. Insert soft metal protectors
(aluminum) between the vise and component.
Use snap ring pliers to remove the scissor gear
assembly.
1
RTW56ASH011401
RTW56ASH022001
Legend
1. Snap Ring
2. Sub-gear
3. Spring
4. Idle Gear A
Reassembly
1. Install the scissor gear assembly.
• Clamp the vise. Insert soft metal protectors • If the measurement exceeds the limit, replace
(aluminum) between the vise and component. either the idle gear or the thrust collar.
Press against the pin on the left side of the idle
gear A spring to make a gap on the right side of
the spring. Push the spring into place. End clearance of the idle gear mm (in)
• Align the sub gear pin with the hole in the right Standard 0.080 - 0.155 (0.003 - 0.006)
side of the idle gear A spring. Press the sub- Limit 0.20 (0.008)
gear into place.
• Measure an end clearance of the idle gear
before removing the idle gear B.
4 3. External diameter of the idle gear shaft.
• Use a micrometer to measure an external
3 diameter of each idle gear shaft.
• If the measurement exceeds the limit, replace
2 the shaft.
1 External diameter of the idle gear A shaft mm (in)

Standard 44.950 - 44.975 (1.7697 - 1.7707)
Limit 44.80 (1.764)
External diameter of the idle gear C shaft mm (in)

RTW56ASH022001
Standard 24.959 - 24.980 (0.9826 - 0.9835)
Legend Limit 24.80 (0.976)
1. Snap Ring
2. Sub-gear
3. Spring
4. Idle Gear A
• Use snap ring pliers to snugly install the snap

ring.
Inspection
1. Measurement of idle gear backlash
• Apply a dial gauge on the teeth of the idle gear
to be measured and move the gear to right and
left lightly to read how much the dial gauge
shook (never fail to fix the gear).
the idle gear.
RTW56ASH021601
Backlash of the idle gear mm (in)
Standard 0.10 - 0.17 (0.004 - 0.006) 4. Clearance between the idle gear and the idle gear
shaft
Limit 0.30 (0.01)
• Measure an inside diameter of the idle gear
bush to calculate a clearance between the idle
• Measure backlash of the idle gear before gear and the idle gear shaft.
removing the idle gear A.
2. Measurement of end clearance of the idle gear.
• Insert a thickness gauge between the idle gear
and the thrust collar to measure a clearance.
• If the measurement exceeds the limit, replace • Apply engine oil to the bolt screw thread and
either the idle gear or the shaft. seat, and temporarily tighten together with the
flange (tighten fully in later process).
Clearance between the idle gear A and mm (in)

the shaft
Standard 0.025 - 0.075 (0.0010 - 0.0030)
Limit 0.200 (0.0079)
Clearance between the idle gear C and mm (in)

the shaft
Standard 0.020 - 0.062 (0.0008 - 0.0024)
Limit 0.200 (0.0079)
RTW56ASH011401
3. Install the idle gear A.

4. Tighten sub gear setting bolt.
• Use the M6 bolts and lever to turn sub gear to
right direction until it aligns with the M6 bolt hole
between idle gear A and sub gear.
• Tighten the M6 bolt to a suitable torque to
prevent the sub gear from moving.
LNW21BSH003601
Installation
1. Install the crankshaft gear.
2. Install the idle gear C.
• Apply engine oil over the part where the gear of
the idle gear shaft is to be put together.
RTW56ASH011501
• Apply engine oil over the part where the gear of

the idle gear shaft is to be put together.
• Install the idle gear A and idle gear A flange,
idle gear A shaft at the position shown in the
figure.
• Apply engine oil to the bolt screw thread and
seat, and temporarily tighten together with the
flange (tighten fully in later process).
• Align the oil hole of the cylinder body (2) with • Attach, aligning with the gear crank: idle A and
the oil hole of the idle gear A shaft (3). timing mark.
Install the flange so that the front mark (1) face
toward the front.
LNW71BSH000501
RTW56ALH000301
5. Tighten the bolts of idle gear A and idle gear C to

Tightening torque:
idle gear A: 32 N⋅m (3.3 kg⋅m / 24 lb ft)
idle gear C: 59 N⋅m (6.0 kg⋅m / 44 lb ft)
RTW56ASH011701 RTW56ASH012101
Legend 8. Install the vacuum pump.

1. Idle Gear A Bolt
2. Idle Gear C Bolt
• Install the oil pipe (feed side and return side) of
6. Remove the M6 bolt from the idle gear A. vacuum pump.
7. Install the gear case cover. • Install the vacuum pipe bracket and vacuum
• Apply the liquid gasket (ThreeBond TB-1207B pipe.
or equivalent). 9. Install the power steering pump.
• Tighten the nut to the specified torque.
1
10. Install the cover of the gear case cover
11. Install the crank pulley.
Tightening torque: 294 N⋅m (30 kg⋅m / 217 lb ft)
12. Install the A/C compressor drive belt and fan
belt.Refer to drive belt tension check procedure for
Heating and air conditioning and Engine cooling in
this manual.
13. Install the cooling fan.
14. Install the fan guide bracket.
15. Install the radiator upper hose.
16. Replenish the engine coolant.
RTW56ASH020101
Legend
1. Apply the liquid gasket
• Install the gasket in slot of the gear case cover.

• Tighten the bolts to the specified torque.
130 (13.3 / 96.2)
8 (0.8 / 69lb in) 294 (30 / 217)

32 (3.3 / 24)
59 (6.0 / 43)
LNW76ALF000601
Camshaft Assembly
Components
5
4
2 3
1
RTW56ALF000901
Legend
1. Snap Ring 5. Camshaft Gear and Camshaft
2. Sub Gear 6. Cam Cap
3. Knock Pin 7. Bolt
4. Damper Spring
Removal
1. Rotate the crankshaft to make the No.1 cylinder
compression TDC.
• Check TDC using a mirror etc.
4. Remove the baffle plate.
2
1
1
LNW76ASH001101
RTW56ASH006301
Legend
1. Crankshaft Damper Pulley Legend
2. Mirror 1. Baffle Plate
3. TDC Mark
5. Remove the camshaft bearing cap and camshaft.
2. Remove the cylinder head cover. • Check the engraved making on the camshaft
Refer to "Cylinder Head Cover". bearing caps.
3. Install the M5 lock bolt of fixing sub gear.
1E
2E
3E
4E
1I
5E
2I
3I
4I
5I
RTW56ASH018401
RTW56ASH007101
RTW56ASH013801 LNW76ASH002501
2. Remove the camshaft gear.

Disassembly • Use a press and socket to remove the camshaft
gear.
1. Remove the sub gear assembly.
• Clamp the camshaft in a vise. Insert soft metal
protectors (aluminum) between the vise
surfaces and the camshaft. 1
• Use a camshaft gear tool (5-8840-2591-0) to
turn sub gear to right direction to remove the
M5 bolt.
2
RTW56ASH006501
Legend
1. Press
2. Socket
3. Camshaft Gear
3. Remove the dowel pin.

LNW76ASH002601
4. Inspect the camshaft visually.
• Use snap ring pliers to remove the scissor gear
assembly.
NOTE:
Take care not to damage the camshaft cams and
journals.
• Check if the journal and cam parts of the • Use a micrometer to measure the height of the
camshaft are worn or damaged, if so, replace it. cam lobe.
• If the height of the cam lobe is at the limit or
less, replace the camshaft.
Height of the cam lobe mm (in)

Inlet Exhaust
Standard 40.6 (1.60) 40.6 (1.60)
Limit 39.6 (1.56) 39.6 (1.56)
LNW21BSH020201
5. Inspect an end clearance of the camshaft.

• Use a thickness gauge to measure an end
clearance of the camshaft gear and the
camshaft bracket.
the camshaft gear or the camshaft.
End clearance of the camshaft mm (in)

LNW21BSH020401
Standard 0.050 - 0.170 (0.002 - 0.007)
7. Check if the camshaft journal is worn.
Limit 0.25 (0.009)
• Use a micrometer to measure wear which is not
even with a diameter of the camshaft journal.
NOTE:
• If the measured uneven wear exceeds the limit,
Measure an end clearance of the camshaft before
replace the camshaft.
disassembling.
External diameter of the camshaft journal mm (in)

part
Standard 29.909 - 29.930 (1.1775 - 1.1783)
Limit 29.809 (1.1736)
Partial wear of the camshaft journal part mm (in)

Limit 0.05 (0.0019)
RTW56ASH013901
6. Check if the cam lobe is worn.

b. Read the difference between the inside
diameter of the camshaft bearing and the
diameter of the camshaft journal.
If the measured oil clearance exceeds the limit,
replace the camshaft bearing.
Clearance of the journal part mm (in)

Standard 0.030 - 0.112
(0.0012 - 0.0044 )
Limit 0.15 (0.0059 )
LNW21BSH020501
8. Check if the camshaft is bent.

• Place the camshaft on a V block to measure a
bend with a dial gauge.
• Rotate the camshaft slowly to measure how
much the dial indicator shook. If it exceeds the
limit, replace the camshaft.
Bent of the camshaft mm (in)

Limit 0.05 (0.0019 )
LNW21BSH054601
Reassembly
1. Install the dowel pin.
2. Install the camshaft gear.
LNW21BSH020601
9. Measure a camshaft journal oil clearance.

a. Measure an inside diameter of the camshaft
bearing with a dial gauge.
• Align the knock pin with the slot in the camshaft • Align the sub gear pin (2) with the hole in the
gear. Use a press to install the camshaft gear to right side of the camshaft gear spring (3). Press
the camshaft. the sub-gear into place.
1
2
1 4
Legend Legend
1. Camshaft 1. Snap Ring
2. Dowel Pin 2. Sub Gear
3. Camshaft Gear 3. Spring
4. Camshaft Gear
3. Install the sub gear assembly.
• Clamp the camshaft in a vise. Insert soft metal • Use snap ring pliers to snugly install the snap
protectors (aluminum) between the vise ring.
surfaces and the camshaft. Press against the
pin on the left side of the camshaft gear spring
(3) to make a gap on the right side of the spring.
Push the spring into place.
LNW76ASH002501
4. Tighten sub gear setting bolt.

• Use a camshaft gear tool (5-8840-2591-0) to
turn sub gear to right direction until it aligns with
the M5 bolt hole between camshaft driven gear
and sub gear.
• Tighten the M5 bolt to a suitable torque to
prevent the sub gear from moving.
1 2
RTW56ASH007001
Legend
LNW76ASH002601
1. Exhaust Camshaft Gear
2. Intake Camshaft Gear
3. Idle Gear D
Installation
1. Rotate the crankshaft to make the No.1 cylinder 3. Camshaft bearing caps, tighten ten bolts on one
compression TDC. side bank to the specified torque.
• Check TDC using a mirror etc. • Apply engine oil to camshaft journal and
bearing surface of camshaft bearing caps.
2
1
1E
2E
3E
3
4E
1I
5E
2I
3I
4I
5I
LNW76ASH001101
RTW56ASH018401
Legend
1. Crankshaft Damper Pulley
2. Mirror
3. TDC Mark
2. Install the camshaft assembly.

• Align timing mark on intake camshaft and
exhaust camshaft to idle gear D.
4. Check that the alignment marks (camshaft bearing • Apply engine oil over the screw part and tighten
cap and camshaft) (1) are aligned. up the bearing cap with the prescribed torque.
Tightening torque: 18 N⋅m (1.8kg⋅m / 13 lb ft)
5. Remove the M5 lock bolt of fixing sub gear.
1 6. Adjustment of valve clearance.
Refer to installation procedure for inspection /
adjustment of valve clearance in this manual.
7. Install the baffle plate.
Tighten the bolts to the specified torque.
Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)
Refer to "Cylinder Head Cover".
RTW56ASH006901
N·m(kg·m/lb ft)
18 (1.8/13)
10 (1.0kg·m/87lb in)
Lubricate with engine oil
RTW56AMF001701
Special Tools
5-8840-2591-0
Camshaft gear tool
Valve Stem Seal and Valve Spring

Components
2
3
2 3
1 4
5
6
7
14
13
12
11
10
RTW56ALF001301
Legend
1. Exhaust Rocker Arm Shaft Assembly 8. Pin
2. Bolt (Long) 9. Spring Lower Seat
3. Bolt (Short) 10. Valve Stem Oil Seal
4. Intake Rocker Arm Shaft Assembly 11. Valve Spring
5. Fuel Injector Assembly 12. Spring Upper Seat
6. Fuel Injector Clamp Bolt 13. Split Collar
7. Fuel Injector Clamp 14. Valve Stem End Cap
Removal • To prevent the valve from falling into the

cylinder, move the piston to TDC.
1. Remove the cylinder head assembly.
Refer to "Cylinder Head".
2. Remove the valve stem end cap.
3. Remove the split collar.
• Use a replacer to compress the valve spring to NOTE:
remove the split collar. Do not reuse the oil seal.
Special tool 7. Remove the spring lower seat.
Valve spring replacer: 5-8840-2818-0
Pivot: 5-8840-2819-0 Inspection
Inspect the valve spring
NOTE:
Check the valve spring visually and if there is clear
2 damage or wear, replace it.
1. Free length
• Measure free length of the spring and if it is
shorter than the prescribed limit, replace the
spring.
Free length of the valve spring IN / EX mm (in)

Standard 49.04 (1.93) / 57.57 (2.27)
Limit 48.15 (1.89) / 56.52 (2.23)
1
RTW56ASH012301
Legend
1. Valve spring replacer
2. Pivot
4. Remove the spring upper seat.

• Remove the special tool to remove the upper
seat.
5. Remove the valve spring.
Put the removed valve springs in order by cylinder
number.
6. Remove the valve stem oil seal.
• Use pliers to remove the oil seal.
LNW21BSH017001
2. Valve spring squareness.

• Use a surface plate and a square to measure
the valve spring squareness.If the measured
value exceeds the specified limit, the valve
spring must be replaced.
Valve spring squareness IN / EX mm (in)

Limit 2.1 (0.083) / 2.5 (0.098)
RTW56ASH012401
Installation
1. Install the spring lower seat.
2. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a
valve stem seal installer.
NOTE:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted or
the garter spring has not come off.
Special tool
Valve stem seal installer: 5-8840-2817-0
LNW21BSH017101
3. Tension
• Use a spring tester to compress the spring to
the installation height. Measure tension of the
compressed spring. If the measurement is
lower than the limit, replace the spring.
Installation length mm (in) 37.80 (1.488)
Tension of the valve spring N (kg / lb)

Inlet / Exhaust
Standard 213 (21.7 / 157) / RTW56ASH013701
409 (41.7 / 301)
3. Install the valve spring.
Limit 188 (19.2 / 138) /
4. Install the spring upper seat.
370 (37.7 / 272)
5. Install the split collar.
• Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home
position.
• Use a replacer to compress the valve spring
and install the split collar.
Special tool
Pivot: 5-8840-2819-0
LNW21BSH056701
NOTE:
Move it up and down to check if it moves smoothly.
6. Install the valve stem end cap.

2 7. Install the cylinder head assembly.
RTW56ASH012301
Legend
1. Valve spring replacer
2. Pivot
Special Tools
5-8840-2818-0
Valve spring replacer
5884028180
5-8840-2819-0
Pivot assembly
5884028190
5-8840-2817-0
Valve stem seal installer
5884028170
Cylinder Head
Components
1 2
4
5
6
LNW71BLF000901
Legend
1. Timing Chain Tensioner 5. Fuel Injector Clamp
2. Glow Plug 6. Cylinder Head
3. Intake and Exhaust Valves 7. Timing Chain Guide
4. Fuel Injector Assembly 8. Timing Chain Tension Lever
NOTE: 2. Remove the turbocharger.

To avoid electric shock; Refer to “Turbocharger“.
Set the switch to the 'OFF' position and disconnect
battery negative cable before checking or repairing the
fuel injector, wiring or/and connectors.
Removal
3. Remove the EGR cooler heat protector.
LNW76ASH000501
LNW71FSH000101
7. Remove the LH noise cover.
4. Remove the EGR cooler. 8. Remove the radiator upper hose.
5. Remove the water by pass pipe (1). 9. Remove the A/C compressor drive belt.
10. Remove the A/C compressor.
• Remove the compressor from the A/C
compressor bracket.
• Fix the compressor and hose in an appropriate
position with wire etc.
11. Remove the A/C compressor bracket.
12. Remove the A/C compressor adjust pulley.
RTW56ASH008401

sensor.
the intake throttle valve. 2 1
• Do not disconnect the hoses from the air intake LNW76CSH001101
pipe. Legend
1. Bolt
2. Nut

Refer to “Cylinder Head Cover“.
14. Remove the oil level gauge tube.
15. Remove the injection pipes (NO.1 to 4). 19. Remove the harness connector of camshaft
position sensor (1), water temperature sensor (2).
1
LNW71DSH000101
LNW76CSH001801
16. Disconnect the heater hose.
• Disconnect the heater hose from the cylinder 20. Remove the timing chain cover.
block side. a. Remove the lower cover (2).
17. Remove the fan guide bracket (LH). b. Remove the upper cover (1).
18. Remove the noise shield cover (1) from the lower
timing chain cover.
1
1
2
LNW76CSH001001
21. Remove the fuel injector.

RTW56CSH001401 Refer to “Fuel Injector“ in “FUEL SYSTEM“
section.
22. Remove the glow plug connector.
23. Remove the glow plug .
24. Install M5 bolts to the sub gear of the camshaft. 26. Remove the camshaft bearing cap.
1E
2E
3E
4E
1I
5E
2I
3I
4I
5I
25. Remove the baffle plate (1). 27. Remove the camshaft.
28. Remove the timing chain tensioner (1) and gasket 30. Remove the timing chain tension lever pivot.
(2).
2
1
RTW56ASH019401
LNW71BSH001401
31. Remove the timing chain from the supply pump
29. Remove the idle gear D. sprocket.
• Timing chain is dropped behind. 32. Remove the chain guide bolt from the cylinder
head.
RTW56ASH022101
RTW56ASH019501
33. Remove the rocker arm shaft assembly.
NOTE:
Keep the removed rocker arm shaft assembly properly
so that they may be put back to the original place.
2
3
2 3
2 6 10 14 18 15 11 7 3
1 4
5 9 13 17 16 12 8 4
5
Legend 36. Remove the cylinder head assembly.

1. Exhaust Rocker Arm Shaft Assembly • Remove the cylinder head assembly with the
2. Bolt (Long) exhaust manifold and the intake manifold.
3. Bolt (Short)
• Remove the cylinder head gasket.
4. Intake Rocker Arm Shaft Assembly
5. Front NOTE:
Replace the head gasket with a new one once it is
NOTE: removed.
Pay full attention so as not to drop the parts in the gear
case of the front part of the cylinder head or a hole into
which oil pours back in the front. Head Disassembly
1. Remove the intake manifold assembly.
34. Remove the cylinder head gear case bolts (2) and 2. Remove the exhaust manifold assembly.
nuts (1).
3. Remove the water outlet pipe.
4. Remove the valve stem cap.
2 5. Remove the split collar.
• Use a replacer to compress the valve spring to
1
remove the split collar.
Special tool
1
Pivot: 5-8840-2819-0
RTW56ASH020801
35. Remove the cylinder head bolts.

• Loosen the cylinder head bolts in the order
described in the drawing.
NOTE:
Do not reuse the cylinder head bolts.
9. Remove the valve stem oil seal.
RTW56ASH012301
RTW56ASH012401
Legend
1. Valve spring replacer 10. Remove the spring lower seat.
2. Pivot 11. Remove the valve guide.
6. Remove the spring upper seat • Use the valve guide replacer to press out the
valve guides from the bottom side of the
7. Remove the valve spring. cylinder head.
• Put the removed valve springs in order by
cylinder number. Special tool
8. Remove the intake and exhaust valve. Valve guide remover and installer:
• Put the removed valves in order by cylinder 5-8840-2816-0
number.
RTW56ASH008701
LNW21BSH016801
12. Remove the cam end gasket (1). 2. The cylinder head lower surface warpage is more
than the limit, it should be replaced.
1
RTW56ASH020501
RTW56ASH008901
13. Remove the oil seal.
Cylinder Head Lower Face Warpage mm (in)

Standard 0.05 (0.002) or less
Limit 0.20 (0.0079)
NOTE:
The cylinder head lower face cannot be reground.
A
RTW56ASH008801
E F
C D
Inspection B
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Cylinder Head Lower Face Warpage

1. Use a straight edge and a thickness gauge to LNW61ASH003901
measure the four sides and the two diagonals of

the cylinder head lower face.
Cylinder Head Height (H) (Reference) mm (in)
Standard 143.4 (5.646)
Exhaust Manifold Warpage
Use a straight edge and a thickness gauge to measure
the manifold cylinder head fitting face warpage.If the
measured values exceed the specified limit, the
manifold must be replaced.
Exhaust Manifold Warpage mm (in)

H
Limit 0.20 (0.008)
RTW56ASH017401
Manifold Fitting Face Warpage

Use a straight edge and a thickness gauge to measure
the manifold cylinder head fitting face warpage.Regrind
the manifold cylinder head fitting surfaces if the
measured values are greater than the specified limit
but less than the maximum grinding allowance.If the
measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.
LNW21BSH001601
Manifold Fitting Face Warpage mm (in)
Valve Stem Cap
Limit 0.20 (0.008)
Make the necessary part replacements.If excessive
Maximum Grinding Allowance 0.40 (0.016) wear or damage is discovered during inspection.
Valve Stem Outside Diameter

Measure the valve stem diameter at three points.If the
measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Valve Stem Outside Diameter mm (in)

Intake Valve Exhaust Valve
6.955 - 6.970 6.939 - 6.949
Standard
(0.2738 - 0.2744) (0.2732 - 0.2736)
6.935 6.920
Limit
(0.2730) (0.2724)
RTW56ASH017501
Valve Thickness
Measure the valve thickness.If the measured value is
less than the specified limit, the valve and the valve
guide must be replaced as a set.
Intake and Exhaust Valve Thickness mm (in)

Standard 1.3 (0.051)
Limit 1.1 (0.045)
LNW21BSH017301
Valve Stem and Valve Guide Clearance

1. Measure the valve stem outside diameter.Refer to
the item "Valve Stem Outside Diameter".
2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.
If the measured values exceed the specified limit,
the valve and the valve guide must be replaced as
a set.
LNW21BSH017801
Valve Stem Clearance mm (in)

Valve Depression
Intake Valve Exhaust Valve
1. Install the valve (1) to the cylinder head (2).
0.030 - 0.060 0.038 - 0.068
Standard 2. Use a depth gauge or a straight edge with steel
(0.0012 - 0.0023) (0.0015 - 0.0027)
rule to measure the valve depression from the
0.200 0.250 cylinder head lower surface.
Limit
(0.008) (0.0098) If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
Valve Depression mm (in)

Standard 0.5 (0.02)
Limit 2.5 (0.098)
LNW61ASH004001
• Use a seat cutter to minimize the scratch and other
roughness (15/45/75 degree-blade), thereby
returning the contact width to the standard value.
150
90
30
LNW61ASH004101
Valve Contact Width

LNW21BSH018201
1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact
NOTE:
surfaces.
Remove only scratches and roughness, and do not cut
2. Measure the valve contact width. the surface too much.
If the measured value exceeds the specified limit, Use the free adjustment valve cutter pilot.
the valve seat insert must be replaced. Do not let the valve cutter pilot waver inside the valve
guide.
Valve Contact Width mm (in)
Intake Exhaust Valve Seat Angle Degree
Standard 2.26 (0.089) 2.12 (0.083) 45
Limit 2.2 (0.087) 2.5 (0.078)
LNW21BSH056101
LNW61ASH004201 • Attach compound in the valve insert seat.

• Insert the valve into the valve guide.
Repair of the seat surface • Attach compound on the valve seat surface, rotate
• Remove carbon from the surface of the valve the valve and hit it lightly to grind it, and confirm
insert seat. that it has even contact all round.
NOTE: Install the valve seat insert
Remove compound completely after grinding. • Carefully place a washer (the outer diameter is
smaller than the valve seat insert) on the valve
seat insert.
• Use the press to apply pressure gradually on the
washer, thereby pushing the valve seat insert.
NOTE:
Do not apply too much pressure with the press. Attach
compound on the valve seat surface, rotate the valve
and hit it lightly to grind it, and confirm that it has even
contact all round.
1
LNW21BSH031801
Replace the valve seat insert.

2
Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve seat
insert.
• Cool the valve seat insert for two to three minutes.
Contraction due to cooling makes it easier to
remove the valve seat insert.
LNW21BSH018601
• Remove the valve seat insert, using a screw driver.
Be sure not to harm the cylinder head. Legend
1. Washer
2. Valve Seat Insert
3. Press
2
Head Reassembly
3 1. Install the oil seal.
• Install on the surface of the injection pipe insert.
• Hammer it in so that the seal does not incline.
NOTE:
Be sure not to harm the Lip.
1
Special tool
Injection pipe oil seal installer: 5-8840-2820-0
LNW21BSH056001
Legend
1. Arc-Weld
2. Valve Seat Insert
3. Screw Driver
Height from the upper surface of the cylinder head

to the edge surface of the valve guide;
1 NOTE:
2 When replacing the valve guide, it must be replaced
together with the valve.
RTW56ASH009101
Legend
1. Cylinder Head
2. Injection Pipe Oil Seal Installer
2. Install the valve guide.

• Hammer in the valve guide from the upper
surface of the cylinder head, using the valve RTW56ASH023001
guide installer. Legend

Special tool 1. 12.6 ± 0.1 mm (0.50 ± 0.0039 in)
2. Cylinder Head
Valve guide remover and installer:
5-8840-2816-0 3. Install the valve spring lower seat.
4. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a
valve stem seal installer.
NOTE: • Use a replacer to compress the valve spring
After installing the valve stem oil seal, check if it is and install the split collar.
inserted nice and deep and the oil seal is not tilted or
Special tool
the garter spring has not come off.
Special tool
Pivot: 5-8840-2819-0
Valve stem seal installer: 5-8840-2817-0
RTW56ASH012301
RTW56ASH013701
Legend
5. Install the intake and exhaust valve. 1. Valve spring replacer
• Apply engine oil on the valve stem part and 2. Pivot
install the valve.
NOTE:
Move it up and down to check if it moves smoothly.
9. Install the valve stem end cap.

10. Install the exhaust manifold assembly.
Refer to “Exhaust Manifold”.
11. Install the intake manifold assembly.
Refer to “Intake Manifold”.
Installation
1. Select the cylinder head gasket.
LNW21BSH018801
6. Install the valve spring.

7. Install the valve spring upper seat.
8. Install the split collar.
• Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home
position.
Cylinder Head Gasket Selection 4. Obtain the maximum value in the four cylinders.
Cylinder head gasket is determined by the piston head 5. Determine the gasket grade required to the
projection from the cylinder body upper surface, in maximum value described above in accordance
order to improve engine performance. with the following table.
Three types of gasket are provided with difference of
thickness. Select the appropriate one out of three
grades of gasket, according to the following procedure.
Before measurement, clear off carbon from the piston
head and cylinder body surface and also clean the
2 1 3 4
place where the gasket was installed.
LNW61ASH004301
Cylinder Head Gasket Combination mm(in)
LNW21BSH068001
1. Use a dial indicator to measure the piston Gasket Grade Mark Piston Projection Gasket Thickness
projection amount.
2. Refer to the illustration for the piston head 0.067-0.117 0.95
A (0.0026-0.0046) (0.0374)
projection measuring positions. All measuring
positions should be as close as possible to the 0.117-0.167 1.00
cylinder block. B (0.0046-0.0066) (0.0394)
C 0.167-0.217 1.05
(0.0066-0.0085) (0.0413)
RTW76ASH000301
2 4
1 3
RTW36ASH001701
3. Measure the points 1, 2, 3, 4 and obtain two

differences 1-2 and 3-4 on each cylinder. Calculate
the average value of the piston head projection on
each cylinder.
• Use a torque wrench and angle gauge to
tighten the head bolts in the order described in
the drawing.
Tightening torque:
1st step = 70 N⋅m (7.1 kg⋅m / 51 lb ft)
2nd step = 70 N⋅m (7.1 kg⋅m / 51 lb ft)
3rd step = 60° (degrees)
4th step = 60° (degrees)
17 13 9 5 1 4 8 12 16
RTW56ASH009501
18
NOTE:
Difference of each piston projection must be equal or
within 0.05 mm (0.002 in).
6. Select the gear case gasket.

14 10 6 2 3 7 11 15
• This should be of the same grade as cylinder
gasket is chosen.
7. Apply liquid gasket (ThreeBond 1207B or
equivalent) at the two locations . RTW56ASH009701
Special tool
2 Angle gauge: 5-8840-0266-0

11. Install the cylinder head gear case bolts (2) and
1 nuts (1).
• Tighten the bolts and nuts to the specified
torque.
1
RTW56ASH020901
8. Install the cylinder head gasket and gear case

gasket within 5 minutes of application of the liquid
gasket.
9. Install the cylinder head assembly.
• Wipe the cylinder head assembly lower face.
• Install the cylinder head assembly, adjusting the
dowel of the cylinder block.
10. Install the cylinder head bolt. RTW56ASH020801
• Please use new cylinder head bolt. 12. Install the rocker arm shaft assembly.
• Apply the engine oil.
• Attach the rocker arm shaft assembly in 16. Rotate the crankshaft to make the No.1 cylinder
sequence from No.1 to No.4. compression top dead center (TDC).
2
2 1
3
2 3
1 4
3
LNW76ASH001101
5
RTW56ASH012201 Legend
Legend
2. Mirror
1. Exhaust Rocker Arm Shaft Assembly
3. TDC Mark
2. Bolt (Long)
3. Bolt (Short)
17. Install the timing chain with idle gear D.
4. Intake Rocker Arm Shaft Assembly
5. Front • Apply the engine oil bolt thread and seat.
Tightening torque: 59 N⋅m (6.0 kg⋅m/43 lb ft)
13. Install the water by pass pipe.Apply soapy water to
the O-ring.Tighten the bolt to the specified torque.
14. Install the chain guide bolt from cylinder
head.Tighten the bolt to the specified torque.
RTW56ASH021801
RTW56ASH019501
15. Install the tension lever.

• Align the timing marks at two locations as 19. Hold the latch(3) depressed.
shown. Insert the plunger(2).
Attach the hook(4) to the pin(1) to hold the plunger
3 in place.
1
2
2
2
4 RTW56ASH020301
Legend
LNW71BSH001501
1. Timing Chain
2. Timing Mark 20. Install the timing chain tensioner (1) and gasket
3. Blue Link (2). Tighten the bolt to the specified torque.
4. Yellow Link
18. Install the timing chain tension lever pivot.Tighten
the bolt to the specified torque.
2
1
LNW71BSH001401
21. Unlock the tensioner hook.

• Press the place of the arrow in the figure.
RTW56ASH019401 • The hook is opened. The plunger pushes the
tension lever.
22. Install the camshaft assembly. 24. Align mark (1) on camshaft to mark on camshaft
• Align timing mark on intake camshaft and bearing cap.
exhaust camshaft to idle gear D. • Align mark on intake camshaft and exhaust
camshaft to mark of bearing cap.
1 2
RTW56ASH007001
RTW56ASH006901
Legend
1. Exhaust Camshaft Gear 25. Remove the M5 lock bolt from the camshaft Gear.
2. Intake Camshaft Gear 26. Turn the crank pulley two rotation (720°CA)
3. Idle Gear D
• Align mark on camshaft to mark on camshaft
23. Install the camshaft bearing cap. bearing cap.
• Apply engine oil to all of the cylinder head
journals.
31. Install the noise cover.
Refer to procedure for fuel system in this manual.
32. Inspection and adjustment of valve clearance.
Refer to procedure for service precautions in this
manual.
33. Install the fuel injector.Refer to procedure for fuel
system in this manual.
34. Install the baffle cover.Refer to procedure for
camshaft in this manual.
35. Install the cam end gasket.
• Apply the liquid gasket (ThreeBond TB-1207B
1 2 or equivalent).
3
2
RTW56ASH020701
Legend 1
1. Exhaust Camshaft Gear
2. Intake Camshaft Gear
3. Idle Gear D
3
1
2
RTW56ASH020601
Legend
1. Cam End Gasket
2. 2.0 to 3.0 mm (0.078 to 0.118 in)

37. Install the glow plug. Tighten the glow plug to the
specified torque.
2
4 RTW56ASH020301
38. Install the glow plug connector. Tighten the nuts to
Legend
1. Timing Chain
2. Timing Mark Tightening torque: 2 N⋅m (0.2 kg⋅m / 17 lb in)
3. Dark Plate 39. Install the fuel injection pipe.
4. Yellow Plate
Attachment order No.2→No.1→No.3→No.4
27. Apply liquid gasket to timing chain cover upper. 40. Tighten the fuel injector clamp bolt to the specified
Refer to procedure for fuel system in this manual. torque.
28. Install the timing chain cover upper. Tightening torque: 26 N⋅m (2.7 kg⋅m / 20 lb ft)
Refer to procedure for fuel system in this manual.
41. Tighten the injection pipe to the specified torque.
29. Apply liquid gasket to timing chain cover lower.
Refer to procedure for fuel system in this manual. Tightening torque: 30 N⋅m (3.1 kg⋅m / 22 lb ft)
30. Install the timing chain cover lower. 42. Install the fuel injection pipe clip .Tighten the nut to
Refer to procedure for fuel system in this manual. the specified torque.
43. Install the engine oil level gauge guide. 52. Install the cooling fan.
• Apply engine oil to the O-ring. Tighten the bolt Refer to procedure for Engine cooling in this
to the specified torque. manual.
53. Install the A/C drive belt.
Refer to Procedure for Intake Manifold in this
44. Install the A/C compressor bracket.Tighten the bolt manual.
to the specified torque.
Tightening torque: 25 N⋅m (2.6 kg⋅m / 19 lb ft) 55. Install the radiator upper hose.
45. Install the A/C compressor adjust pulley. Tighten 56. Install the Turbocharger.
the bolt (1) and nut (2) to the specified torque. Refer to “Turbocharger“.
Tightening torque: bolt 25 N⋅m (2.6 kg⋅m/19 lb ft) (Dry) 57. Replenish the coolant.
Tightening torque: nut 41 N⋅m (4.2 kg⋅m/30 lb ft)
2 1
LNW76CSH001101
46. Install the A/C compressor and connector.

Tighten the bolt to the specified torque.
47. Connect each connector.
• Barometric Sensor
• EGR Valve
• Glow plug
• Water temperature sensor
• Camshaft Position sensor
• Throttle Assembly
48. Install the exhaust front pipe.
Refer to procedure for exhaust system in this
manual.
49. Install the EGR cooler.
manual.
50. Install the EGR cooler water pipe.
manual.
51. Install the EGR cooler heat protector.
manual.
25(2.5/18) 70(7.1/51)
70(7.1/51)
18(1.8/13)
60
60
2(0.2/17lb in)
25(2.5/18)
10(1.0/87lb in)
26(2.7/20)
25(2.5/18)
27(2.8/20)
LNW76ALF000801
Special Tools
Illustration Tool Number/ Description Illustration Tool Number/ Description
5-8840-2820-0 5-8840-2816-0
Injection pipe oil seal Valve guide remover and
installer installer
5884028200 5884028160
5-8840-2817-0
Valve stem seal installer
5884028170
5-8840-2818-0
Valve spring replacer
5884028180
5-8840-2819-0
Pivot
5884028190
5-8840-0266-0
Angle gauge
Piston and Connecting Rod

Components
RTW56ALF001601
Legend
1. Piston Pin Snap Ring 4. Piston
2. Piston Pin 5. Connecting Rod
3. Piston Ring 6. Bearing
Removal 5. Remove the gear case assembly.

Refer to "Gear Case Assembly".
1. Demount the engine assembly.
Refer to "Engine Assembly". 6. Remove the oil pan.
Refer to "Oil Pan and Crank Case" .
Refer to "Cylinder Head Cover". 7. Remove the connecting rod cap.
3. Remove the camshaft assembly. NOTE:
Refer to "Camshaft Assembly". Sort the removed bearings according to cylinders by
4. Remove the cylinder head. using tags.
LNW21BSH004901 LNW21BSH005101
8. Remove the piston and connecting rod. 2. Remove the snap ring.
• Remove carbon on the upper side of the 3. Remove the piston pin.
cylinder block with a scraper.
• Pull out the piston and connecting rod towards NOTE:
the cylinder head. Sort the disassembled piston pins, pistons and
connecting rods together in the same order as the
NOTE: cylinders.
Be sure not to damage the oil jet and cylinder block
when pushing out the connecting rod.
9. Remove the connecting rod bearing.
NOTE:
Sort the bearings in the order of cylinders when reusing
them so that they are not confused with the bearings of
other cylinders.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
NOTE:
Sort the piston rings in the same order as the cylinders
when reusing them so that they are not confused with
the pistons and piston rings of other cylinders. LNW21BSH005201
4. Remove the connecting rods from the piston.

5. Piston
• Carefully clean carbon that is adhered to the
head of the piston and the groove of the piston
ring.
NOTE:
Do not use a wire brush to clean the piston because it
scratches the piston.
Visually inspect the piston for cracks, burns and other
excessive wear, and replace it if there is any
abnormality.
6. Measure the gap between the piston and the inner • Measurement position (from the bottom surface
diameter of the cylinder bore. of the piston) 11.00 mm (0.43 in).
Inner diameter of the cylinder block.
• Use a cylinder bore dial indicator to measure
the cylinder block inner diameter both in the
thrust and radial directions in the designated
position.
• Measurement position (from the upper surface 1
of the cylinder block) 20 mm (0.79 in)
• Measure the cylinder block inner diameter
based on the average value of the actual
measurement values on 2 positions.
Cylinder block inner diameter mm (in)

95.421 - 95.450 (3.75673 - 3.75787)
RTW56ASH023101
Legend
1. 11 mm (0.43 in)
1
Gap between the piston and the inner mm (in)
diameter of the cylinder block
2 Standard 0.082 - 0.100 (0.0032 - 0.0039)
3
3
NOTE:
2
If it is found that the gap between the cylinder block
inner diameter and the piston exceeds the standard
value, replace the piston or cylinder block.
7. Piston replacement
LNW21BSH039801
• The head of the piston has a marking of grade
Legend A, B or C.
1. 20 mm (0.79 in) The mark shows the grade of the piston.
2. Radial • If oversize pistons are installed, rebore the
3. Thrust cylinder block.
Refer to "Cylinder Block".
Piston outside diameter
• Use a micrometer to measure the outside Piston Grade (Service Part) mm (in)
diameter of the piston in the right angle to the
piston pin in the designated position. A 95.340 - 95.369 (3.75354 - 3.75469)
B 95.350 - 95.379 (3.75394 - 3.75508)
C 95.360 - 95.389 (3.75433 - 3.75547)
• Push the piston ring into the cylinder bore until
it reaches the measuring point 1 or 2 where the
cylinder liner bore is the smallest.Do not allow
the piston ring to slant to one side or the other.
1 It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or
Measuring Point 2 20 mm (0.8 in)
LNW76ASH001401
Legend
1. Grade
2. Front Mark Cut
1
8. Inspect the piston ring.
• Insert the piston ring horizontally (in the position
it would assume if it were installed to the piston)
LNW61ASH004401
into the cylinder liner.
LNW21BSH034801 LNW61ASH004501
• Use a thickness gauge to measure the piston

ring gap.
If the measured value exceeds the specified
limit, the piston ring must be replaced.
Piston ring gap mm (in)

Standard Limit
0.27 - 0.51 1.50
1st compression ring
(0.0106 - 0.0200) (0.059)
0.42 - 0.66 1.50
2nd compression ring
(0.0165 - 0.0260) (0.059)
0.27 - 0.56 1.50

Oil ring
(0.0106 - 0.220) (0.059)
Measure the clearance between the piston ring

groove and the piston.
• Remove carbon in the piston ring groove.
• Put the piston ring in the piston ring groove, use
a thickness gauge to measure the gap between
them.
• If the clearance between the piston ring groove
and the piston exceeds the limit, replace the
piston and the piston ring.
Piston ring and piston ring groove mm (in)

clearance
Standard Limit LNW21BSH009601
1st compression ring —* —* • Inspect to make sure that there is a resistance

0.05 - 0.09 1.50 to the extent which the piston can push the
2nd compression ring
(0.0020 - 0.0035) (0.059) piston pin lightly in normal temperatures.
0.03 - 0.07 1.50 • If it feels a large looseness or instability in
Oil ring normal temperatures, replace the piston or
(0.0012- 0.0028) (0.059)
piston pin.
*Measurement is impossible
LNW21BSH009701
LNW21BSH009501 • Measure the bush of the small edge of the

9. Inspect the piston pin. connecting rod. If the clearance of the bush
inner diameter and the pin diameter exceeds
• Visually inspect the piston pin for cracks, the limit, replace the bush or connecting rod
scratches and other damages, and replace it if assembly, and the pin.
necessary.
• Use a micrometer to measure the outer
diameter of the piston pin. If the measured Piston pin and connecting rod small end mm (in)
value exceeds the limit, replace the piston pin. bushing clearance
Standard 0.008 - 0.020 (0.0003 - 0.0008)
Piston pin outer diameter mm (in) Limit 0.05 (0.0020)
Standard 33.995 - 34.000 (1.33838 - 1.33858)
Limit 33.970 (1.33740)
10. Measure the clearance between the piston and the 12. Measure the bearing oil clearance.
piston pin. • Install the bearing to the connecting rod big
• Apply engine oil on the piston pin. Use your end.
finger to push it in the piston hole and rotate it. • Tighten the bearing cap to the two step of
If the pin smoothly rotates without instability, the angular tightening method.
clearance is normal. If there is instability,
• Use an inside dial indicator to measure the
measure the clearance. If the clearance
connecting rod bearing inside diameter.
exceeds the limit, replace the piston and the
piston pin.
Connecting rod bearing cap bolt torque: mm (in)
Piston pin and piston pin hole clearance mm (in) 1st step 29.4 (3.0 / 22)
Standard 0.008 - 0.019 (0.0003 - 0.0007) 2nd step 45 deg
Limit 0.04 (0.0016)
If the clearance between the measured bearing
inside diameter and the crank pin exceeds the
11. Measure the connecting rod alignment.
specified limit, the bearing and/or the
• Use a connecting rod aligner to measure the crankshaft must be replaced.
torsion and parallel level of the big end hole and
the small end hole. If the measured value
exceeds the limit, replace it. Crank pin and bearing clearance mm (in)
Standard 0.029 - 0.083 (0.0011 - 0.0026)
Connecting rod alignment Limit 0.10 (0.0039)
(par length of 100 mm (3.94 in)) mm (in)
Standard Limit
Reassembly
Distortion 0.08 (0.003) or less 0.20 (0.008)
1. Install the piston.
Parallelism 0.05 (0.002) or less 1.50 (0.006)
2. Install the connecting rod.
• Install it so that the front mark of the head of the
piston, and the connecting rod forging mark
(projecting) on the connecting rod, both face in
the same direction.
• Install the snap ring of one side.
• 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.
3 1
2 4
1
2
3
LNW41BSH003701
4
Legend
1. Front Mark
RTW56ASH023201
2. Forging Mark (Projecting)
Legend
3. Apply enough engine oil on the piston pin, push it 1. Compression Ring 1st
in the piston and the connecting rod small edge. 2. Compression Ring 2nd
4. Use snap ring pliers to install the snap ring. 3. Oil Ring
4. Expander
NOTE:
Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
Installation
moves smoothly.
1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, and
apply engine oil on the bearing.
2. Install the piston and connecting rod assembly.
• Apply enough engine oil on the piston ring, ring
groove and piston side surface.
• Dislocate the piston ring end gap so that (1) is
1st ring, (3) is 2nd ring and (2) is oil ring, as
shown in the drawing.
• With the piston front mark cut facing forward,
use the piston ring compressor to insert the
piston in the cylinder liner.
NOTE:
• Be sure not to make the connecting rod touch the oil
jet when pushing in the piston.
• Be sure not to harm the inside of the cylinder block
LNW61ASH004601 when pushing in the piston.
5. Use ring pliers to install the piston ring.
• Install the piston rings in the order shown in the
illustration.
• Install 2nd and 1st compression rings in this
order so that the marks "2N" and "N" face
upward.
Special tool
Piston ring compressor: 5-8840-9018-0
LNW21BSH011401
4. Install the oil pan.

LNW21BSH072201
Refer to "Oil Pan and Crank Case".
3. Install the connecting rod cap. 5. Install the gear case assembly.
• Install the bearing on the connecting rod cap Refer to "Gear Case Assembly".
and apply engine oil. 6. Install the cylinder head.
• Install the cap, matching the numbers (1, 2, 3, Refer to "Cylinder Head".
and 4) of the caps and connecting rods. 7. Install the camshaft assembly.
Refer to "Camshaft Assembly".
LNW61ASH004801
• Apply engine oil on the screw part and the

setting face of the tightening bolt and tighten it
with the designated torque.
Tightening torque:
1st step = 29.4 N⋅m (3.0 kg⋅m / 22 lb ft)
2nd step = 45° (degrees)
Special tool
Angle gauge: 5-8840-0266-0
NOTE:
Make sure that the crankshaft smoothly rotates.
N·m(kg·m/lb ft)
1st STEP 2nd STEP
29.4(3.0/22) 45
Lubricate with engine oil
RTW56AMF001801
Special Tools
5-8840-9018-0
Piston ring compressor
5884090180
5-8840-0266-0
Angle gauge
Flywheel
Components
5 6
4
3
2
1
10
8
9
LNW71BMF000601
Legend
1. Pressure Plate Assembly 6. Bearing Stopper
2. Driven Plate 7. Flywheel Housing
3. Pilot Bearing 8. Flywheel (Smoother E)
4. Washer 9. Flexible Plate
5. Flywheel
Removal
1. Remove the starter.
2. Remove the transmission assembly.
Refer to "transmission assembly removal and
installation".
3. Remove the clutch pressure plate.
• Remove the pressure plate installation bolts in
the order shown in the drawing.
• Remove the pressure plate from the flywheel.
• In the case of A/T car, after loosening the
flywheel installation bolts, remove the washer,
flexible plate, flywheel and sleeve in this order.
1 5
7
3
9
10 4 7
4
8 1 2
6 5
3 8
6 2
LNW21BSH002501
4. Remove the driven plate.

• Remove the driven plate from the flywheel LNW21BSH072801
along with the clutch aligner (1).
7. Remove the pilot bearing.
5. Install the crankshaft stopper in the starter
installation part of the flywheel housing. • Remove the pilot bearing from the flywheel.
NOTE:
Make sure that the stopper is applied with the ring gear
and installed properly.
1
Special tool
Crankshaft stopper: 5-8840-0214-0
LNW21BSH029301
Special tool
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0
8. Remove the ring gear.
• Put a bar on the ring gear and hit it with a
LNW21BSH007701
hammer to remove it.
6. Remove the flywheel.
• Gradually loosen the flywheel installation bolts
in the order shown in the drawing so that the
flywheel does not rotate.
• After loosening the bolts, remove the stopper
and remove the flywheel.
Depth = From the pressure installation surface to
the friction surface.
LNW21BSH012001
LNW21BSH011901
Inspection 3. Flywheel installation bolts.
1. Visual inspection • There is no damage in appearance.
• Inspect the flywheel friction surface for cracks • Exchange for a new part if damage is
and damages, and replace it if it has extensive.
abnormality.
• Inspect the tooth part of the ring gear, replace
the ring gear if it has damage or serious wear. Installation
2. Measurement of the friction surface 1. Install the pilot bearing
• Measure the depth of the friction surface of the • Place the crankshaft pilot bearing right angle
flywheel. across the crankshaft bearing installation hole.
• Adjust it if the measured value is within the • Tap around the edges of the crankshaft pilot
standard value and the limit. bearing outer races with a brass hammer to
• If the measured value exceeds the limit, replace drive the bearing into the crankshaft bearing
the flywheel. installation hole.
2. Install the ring gear.
• Heat the ring gear evenly with a gas burner to
Depth of the friction surface of the flywheel mm (in) invite thermal expansion. Do not allow the
Standard 12 (0.4724) temperature of the gas burner to exceed 200°C
Limit 13 (0.5118) (390°F).
• Install the ring gear when it is sufficiently
heated. The ring gear must be installed with the
chamfer facing the clutch.
NOTE:
• Install the ring gear so that the side with a pattern
faces forward.
• Shrink fit the ring gear to the flywheel.Make sure
that flywheel and ring gear adhesion is complete.
3. Install the flywheel. Legend

• Install the flywheel of the crankshaft, tighten 1. Clutch Aligner
them in the order shown in the illustration.
5. Install the clutch pressure plate.
• Apply molybdenum disulfide on the screw part
and setting face of the bolt. • Install the pressure plate on the flywheel so that
the installation hole of the pressure plate
• Install the crankshaft stopper on the starter matches with the dowel pins of the flywheel.
installation part of the flywheel housing.
• Tighten the pressure plate in the order shown in
Tightening torque: the drawing.
1st step = 59 N⋅m (6.0 kg⋅m / 43 lb ft) Tightening torque: 51N⋅m (5.2 kg⋅m / 38 lb ft)
2nd step = 60° - 90° (degrees)
Special tool
Crankshaft stopper: 5-8840-0214-0
1 5
9
1 7
3
5 3 9
10
4
8
7 8
6 2
4 6
2 LNW21BSH002501
6. Install the transmission assembly.

Refer to "transmission assembly removal and
LNW71BSH001301 installation".
4. Install the driven plate. 7. Install the starter.
• Use a clutch aligner to install the driven plate on Tightening torque: 127 N⋅m (13 kg⋅m / 94 lb ft)
the flywheel.
59(6.0/43) 60 to 90
51(5.2/38)
59(6.0/43) 60 to 90
LNW76AMF000301
Special Tools
5-8840-2230-0
Crankshaft stopper
5884022300
5-8840-0266-0
Angle gauge
Gear Case Assembly

Components
LNW76ALF000301
Legend
1. Adjust Plate 3. Gasket
2. Generator 4. Gear Case Assembly
Removal 5. Remove the power steering pump.

Refer to removal procedure for power steering in
this manual.
Refer to “Engine Assembly”.
6. Remove the water pump.
2. Remove the cylinder head.
Refer to removal procedure for water pump in this
Refer to “Cylinder Head”.
manual.
3. Remove the adjustment bracket of generator.
7. Remove the fuel supply pump.
4. Remove the vacuum pump and pipe. Refer to removal procedure for fuel supply pump in
Refer to removal procedure for brake in this this manual.
manual.
8. Remove the crankshaft pulley. • Install the timing gear case to match with the
Refer to removal procedure for crankshaft front oil dowel pins, install bolts them in the order shown
seal in this manual. in the illustration.
9. Remove the gear case cover. • Do not remove the bolts(11) when maintaining.
Refer to removal procedure for gear case cover in
this manual. 1
11 10
10. Remove the idle gear A and idle gear A shaft, idle 11
gear C and idle gear C shaft. 3
11 5
Refer to “Timing Gear Train”.
11. Remove the oil pump. 2
Refer to “Oil Pump”. 4
12. Remove the timing gear case (1) and gasket (2). 2
2
2 2
2 2
2
8
6 4
2 7
2 2
9 2 9 LNW76ASH002701
Legend
1. Gear Case Assembly
2. Bolt L = 20 mm (0.79 in)
3. Bolt L = 60 mm (2.36 in)
4. Bolt L = 45 mm (1.77 in)
2 5. Bolt L = 35 mm (1.38 in)
1 6. Bolt L = 16 mm (0.63 in)
RTW76ASH001201
7. Bolt L = 20 mm (0.79 in)
8. Bolt L = 25 mm (0.98 in)
9. Nut
Installation 10. UP
10. Bolt
1. Install the gasket of the timing gear case.
• Apply liquid gasket (ThreeBond 1207B or • Tighten the bolts and nuts to the specified
equivalent) on the joint (1) of the cylinder block torque.
and the crank case.
3. Install the oil pump.
1 Refer to “Oil Pump”.
4. Install the idle gear C shaft and idle gear C, idle
gear A shaft and idle gear A.
Refer to “Timing Gear Train”.
5. Install the gear case cover.
Refer to removal procedure for gear case cover in
this manual.
6. Install the crankshaft pulley.
Refer to removal procedure for crankshaft front oil
seal in this manual.
7. Install the fuel supply pump.
Refer to installation procedure for fuel supply
pump in this manual.
8. Install the water pump.
Refer to installation procedure for water pump in
RTW56ASH016301
this manual.
2. Install the timing gear case.
9. Install the power steering pump. 11. Install the adjustment bracket of generator.
Refer to removal procedure for power steering in Tighten the bolts to the specified torque.
this manual.
10. Install the vacuum pump and pipe.
12. Install the cylinder head.
Refer to removal procedure for brake in this
manual.
Refer to “Engine Assembly”.
25 (2.5/18)
51 (5.2/38)
25 (2.5/18)
25 (2.5/18)
LNW76ALF000401
Crankshaft Front Oil Seal

Components
6
5
4
3
LNW76AMF000401
Legend
1. Bolt 5. Gear Case Cover
2. Washer 6. Slinger
3. Crankshaft Damper Pulley 7. Crankshaft Gear
4. Crankshaft Front Oil Seal
Removal
1. Remove the radiator.
Refer to “Radiator“ in ENGINE COOLING section.
2. Remove the fan assembly.
• Remove the fan assembly unscrewing four
mounting nuts.
LNW61BSH003601
3. Remove the fan belt. • Tighten the bolt as far as it will go.
4. Remove the crankshaft pulley. Special tool
NOTE: Oil seal and slinger installer: 5-8840-2855-0
Do not reuse the crankshaft pulley bolt and the washer.
5. Remove the crankshaft front oil seal. The length from the surface of the crankshaft gear to
• Use the special tool to remove the front oil seal. the surface of the slinger:
Special tool
Remover: 5-8840-0027-0 5.8 - 6.2 mm (0.228 - 0.244 in)
• Put a rod and a wooden piece etc. as shown in
the illustration. And pull the rod to the front
slowly, and remove the crankshaft front oil seal. 5 6
3 4
2
1
2
3
LNW76ASH002901
Legend
LNW76ASH002801 1. Bolt
Legend 2. Washer
1. Rod 3. Slinger Installer
2. Remover 4. Slinger
3. Wooden Piece 5. Crankshaft Gear
6. Crankshaft
6. Remove the gear case cover.
2. Install the gear case cover.
7. Remove the slinger.
3. Install the crankshaft front oil seal.
• Remove the slinger with a screwdriver etc.
avoiding damage to the surface of the • Use the special tool to install the front oil seal.
crankshaft gear. Use only one of the special tools when the oil
seal is installed.
NOTE: Special tool
The slinger does not need to be replaced if there are no
scratches nor damages. Oil seal and slinger installer: 5-8840-2855-0
Installation The length from the surface of the crankshaft gear to

1. Install the slinger. the surface of the oil seal:
• Use the special tool to install the slinger.
14.75 - 15.25 mm (0.581 - 0.600 in)
4 5 6 7 8
3
2
1
LNW76ASH003001
Legend
1. Bolt
2. Washer
3. Front Oil Seal Installer
4. Gear Case Cover
5. Front Oil Seal
6. Slinger
7. Crankshaft Gear
8. Crankshaft
• Apply engine oil to the lip of the oil seal.

4. Install the crankshaft damper pulley.
• Install the crankshaft pulley aligning with the
key on the crankshaft.
• Hold the flywheel ring gear stationary to prevent
the crankshaft from turning when tightening the
damper pulley bolt.
• Tighten in the sequence shown.
• Take care not to damage the crankshaft
damper pulley boss.
Tightening torque: 294 N⋅m (30 kg⋅m/217 lb ft)
5. Install the fan belt.
Refer to "Engine Cooling"
6. Install the radiator.
Refer to “Radiator“ in ENGINE COOLING section.
294(30/217)
LNW76AMF000501
Special Tool
5-8840-0027-0
Remover
5-8840-2855-0
Oil seal and slinger
installer
5884028550
Crankshaft Rear Oil Seal

Components
5
3 4
2
LNW71BLF000501
Legend
1. Starter 5. Flywheel
2. Transmission Assembly 6. Crankshaft Rear Oil Seal
3. Clutch Pressure Plate 7. Transmission Assembly
4. Driven Plate 8. Flexible Plate
Removal
1. Remove the flywheel.
Refer to "Flywheel".
• With the oil seal pushed in deep, install the
special tool as shown in the illustration and
remove the oil seal.Oil Seal Remover: 5-8840-
2360-0
• Use an oil seal install to install the crankshaft
rear oil seal.
Oil Seal Installer: 5-8840-2359-0
12.5±0.3mm
(0.49±0.01in)
LNW76ASH002301
Installation RTW56ASH022901
1. Install the crankshaft rear oil seal. 2. Install the flywheel.

Refer to "Flywheel".
Special Tools
5-8840-2359-0
Oil seal installer
5-8840-2360-0
Oil seal remover
Crankshaft
Components
4 1
RTW56ALF002601
Legend
1. Upper Bearing 4. Crankshaft
2. Thrust Bearing 5. Lower Bearing
3. Gear 6. Bearing Cap
Removal 5. Remove the fuel supply pump and common rail.

Refer to "Fuel Supply Pump and Common Rail" in
the fuel system section.
Refer to "Engine Assembly".
6. Remove the front cover.
Refer to "Front Cover".
7. Remove the crankshaft rear oil seal.
3. Remove the camshaft.
Refer to "Crankshaft Rear Oil Seal".
8. Remove the water pump. 18. Remove the thrust bearing.
Refer to "Water Pump" in the Cooling System 19. Remove the upper crankshaft bearings.
Section.
9. Remove the timing gear train.
Refer to "Timing Gear Train". Disassembly
10. Remove the oil pump. 1. Remove the crank angle sensor rotor.
Refer to "Oil Pump".
11. Remove the gear case assembly.
12. Remove the crankshaft gear. 1
RTW56ASH016801
Legend
1. Crank Angle Sensor Rotor
2. Bolt
LNW61ASH005501
13. Remove the crank case.

Refer to "Crank Case and Oil Pan". Reassembly
14. Remove pistons and connecting rods. 1. Install the crank angle sensor rotor
Refer to "Pistons and Connecting Rods". • Attach by making a rotor tooth's running out
15. Remove the bearing cap. side into a front side.
• Loosen the crankshaft bearing cap bolts in • Apply Loctite #262 or the equivalent to the bolt
numerical order a little at a time. threads (if a new bolt is used, Loctite
application is not required).
3 6 2
7 10
4 8 9 5 1
LNW21BSH037601
16. Remove the lower crankshaft bearings.

17. Remove the crankshaft assembly.
2
1
Legend 2. Main bearing clearance

1. Crank Angle Sensor Rotor • Remove the crankcase.Set out disassembled
2. Bolt main bearings in the order of the numbers.
• Remove the crankshaft. Remove the main
bearings.
Inspection • Clean the crankshaft journal and upper and
1. Thrust clearance lower bearings.
• Measure the crankshaft end play at the center • Check the bearings for damage or excessive
journal of the crankshaft. wear.
• Do this before removing the crankshaft bearing If you find damage or excessive wear, replace
caps. If the measured value exceeds the the bearings in pairs.
specified limit, the crankshaft thrust bearing • Place the upper bearings and the crankshaft on
must be replaced. the cylinder block. Install the crankshaft so that
it is horizontal.
Axial play of the crankshaft mm (in) NOTE:

Turn the crankshaft about 30 degrees to allow the
Standard 0.10 (0.004)
bearings to settle in.
NOTE: • Place Plastigage on the crankshaft journal as

Measure the thrust clearance before dismounting. shown.
• Place the lower bearings at original positions on #1,#2,#4,#5 0.030 - 0.054 (0.0012 - 0.0021)
the bearing cap.
#3 0.042 - 0.066 (0.0016 - 0.0026)
LNW61ASH005801
• Install the bearing cap and tighten bolts to the LNW21BSH024401

specified tightening torque.
• If the journal oil clearance exceeds the limit,
• Tighten the bearing cap in the sequence shown
replace the main bearings altogether or the
using a torque wrench and an angle gauge.
crankshaft.
• Remove the Plastigage from the bearings and
the crankshaft.
Inspection of the crankshaft
• Check the crankshaft journal and crank pin
1 5 9 surfaces for wear and damage. Check the oil
8 4
seal contact surface for excessive wear and
damage.
• Check the oil port for clogging.
3 2 6
7 10 3. Crankshaft run-out
Carefully set the crankshaft on the V block. Slowly
turn the crankshaft to measure the run-out. If the
crankshaft run-out exceeds the limit, replace the
crankshaft.
Crankshaft run-out mm (in)

LNW21BSH038701 Standard 0.05 or less (0.0020 or less)
NOTE:
Do not turn the crankshaft after you have tightened the
bearing cap.
• Loosen the bolts and gently remove the bearing

cap.
• Measure the widest part of the Plastigage
flattened by tightening the bearing cap to
determine the clearance.
Journal oil clearance mm (in)

NOTE:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
should not polish the surface of the crankshaft.
Crankshaft bearing selection

• Crankshaft bearing selection is based on the
measured diameters of the crankshaft journals
and the bearing inserts.
• Match the crankshaft bearing housing grade
marks and the crankshaft journal grade marks
in the table below to determine the correct
crankshaft bearing size.
• Crankshaft bearing housing grade marks 1, 2 or
3 are stamped on the rear right hand side of the
cylinder body.
LNW21BSH024501
4. Measure the journal and the crank pin diameters

and uneven wear.
1 2 3 4 5
• Measure outer diameters of the journal and the
pin and calculate differences between the
maximum and the minimum values. Take
measurements at four positions for both the
journal and the pin.
1 2 1 1 2
LNW76ASH003101
Legend
1. No.1
2. No.2
3. No.3
4. No.4
5. No.5
• The crankshaft journal grade marks (1 or -, 2 or

LNW21BSH024601
--, 3 or ---) are stamped on each crankshaft
journal web. The crankshaft journal and bearing
clearance must be the same for each position
Crankshaft Outside Diameter mm (in) after installation of the crankshaft and the
crankshaft bearings.
Standard Limit
69.917 - 69.932 69.91 NOTE:
Journal The crankshaft journal mark No. 4 is stamped on
(2.7526 - 2.7532) (2.7524)
crankshaft No. 4 journal web front side or rear side.
52.915 - 52.930 52.9
Pin
(2.0833 - 2.0839) (2.083)
1 2 3 4 5
RTW56ASH017201
Legend
1. No.1
2. No.2
3. No.3
4. No.4
5. No.5
NOTE:
Be careful about difference in the shape of the bearings
when installing them.
69.927-
1 or 69.932
1
- (2.7530-
2.7532)
73.975- 69.922-
73.982 2 or 69.927
3
(2.9124- -- (2.7528-
2.9127) 2.7530)
2
69.917-
3 or 69.922
1 --- (2.7526-
2.7528)
2
Bearing Selection Table (#3)
mm (in)
Crankshaft
RTW56ASH017301 Crankshaft Journal Crankshaft
Bearing Housing
Bearing
Legend Grade Grade
Diameter Diameter Size Code
1. Lot No Mark Mark
2. Size Code
69.927-
1 or 69.932
Bearing Selection Table (#1, #2, #4, #5) - (2.7530-
mm (in) 2.7532)
2
Crankshaft 73.992- 69.922-
Crankshaft Journal Crankshaft
Bearing Housing 74.000 2 or 69.927
Bearing 1
Grade Grade (2.9131- -- (2.7528-
Diameter Diameter Size Code 2.9134) 2.7530)
Mark Mark
69.927- 69.917-
1 or 69.932 3 or 69.922
3
- (2.7530- --- (2.7526-
2.7532) 2.7528)
4 69.927-
73.992- 69.922-
74.000 2 or 69.927 1 or 69.932
1 0
(2.9131- -- (2.7528- - (2.7530-
2.9134) 2.7530) 2.7532)
69.917- 73.983- 69.922-

3 or 69.922 73.991 2 or 69.927
5 2 1
--- (2.7526- (2.9127- -- (2.7528-
2.7528) 2.9130) 2.7530)
69.927- 69.917-
1 or 69.932 3 or 69.922
2 2
- (2.7530- --- (2.7526-
2.7532) 2.7528)
73.983- 69.922-
73.991 2 or 69.927
2 3
(2.9127- -- (2.7528-
2.9130) 2.7530)
69.917-
3 or 69.922
4
--- (2.7526-
2.7528)
69.927- 2. Install the crankshaft assembly.Apply an ample

1 or 69.932 coat of engine oil to the crankshaft journals and the
9 crankshaft bearing surfaces before installing the
- (2.7530-
2.7532) crankshaft.
73.975- 69.922-
73.982 2 or 69.927
3
(2.9124- -- (2.7528-
2.9127) 2.7530)
0
69.917-
3 or 69.922
--- (2.7526-
2.7528)
Installation
1. Install the crankshaft upper bearing.
• The crankshaft upper bearings have an oil hole
and an oil groove. The lower bearings do not.
• Carefully wipe any foreign material from the
upper bearing.
LNW61ASH006101
• Locate the position mark applied at
disassembly if the removed upper bearings are 3. Install the thrust bearing.
to be reused. • Apply an ample coat of engine oil to the thrust
bearings before installation. Install the thrust
NOTE:
bearings to the crankshaft center journal.
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces. • The thrust bearing oil grooves must be facing
the sliding faces.
4. Install the lower crankshaft bearing.

• Before the crankshaft bearing installation,
select the appropriate bearings in accordance
with the description in CRANK BEARING
SELECTION of INSPECTION AND REPAIR.
5. Install the bearing cap.
• Install the bearing caps with the bearing cap 8. Install the crankshaft gear.
head arrow mark facing the front of the engine.
The bearing cap numbers must be facing up.
1 2 3 4 5
RTW56ASH017001
9. Install the gear case assembly.

LNW21BSH038601
• Tighten the crankshaft bearing cap bolts to the 10. Install the oil pump.
specified torque a little at time in the sequence Refer to "Oil Pump".
shown in the illustration.
11. Install the timing gear train.
Refer to "Timing Gear train".
Crankshaft Bearing Cap Torque N⋅m (kg⋅m / lb ft) 12. Install the water pump.
Refer to "Water Pump" in the Cooling System
166 (16.9 / 122)
Section.
13. Install the front cover.
Check to see the crankshaft turns smoothly by
rotating it manually.
14. Install the crankshaft rear oil seal.
NOTE: Refer to "Crankshaft Rear Oil Seal".
Confirm that the crankshaft turns smoothly. 15. Install the fuel supply pump and common rail.
Refer to "Fuel Supply Pump and Common Rail".
17. Install the camshaft assembly.
1 5 9 18. Install the cylinder head cover.
8 4
19. Mount the engine assembly on the chassis.
Refer to "Engine Assembly".
3 2 6
7 10
LNW21BSH038701
6. Install pistons and connecting rods.

Refer to "Pistons and Connecting Rods".
7. Install the crank case.
Refer to "Crank Case and Oil Pan".
N·m(kg·m/lb ft)
166(16.9/122)
12N·m(1.2kg·m/104 lb in)
RTW56AMF001301
Cylinder Block
Components
RTW76ASF000101
Legend
1. Cylinder Block
Removal 13. Remove the oil pump.

Refer to "Engine Assembly". 14. Remove pistons and connecting rods.
Refer to "Cylinder Head Cover". 15. Remove the crankshaft.
Refer to "Crankshaft"
3. Remove the camshaft assembly.
Refer to "Camshaft Assembly". 16. Remove the piston cooling pipe.
5. Remove the fuel supply pump and fuel rail
assembly.
Refer to "Fuel Supply Pump” and “Fuel Rail
Assembly" in FUEL SYSTEM section.
6. Remove the oil filter assembly and oil cooler.
Refer to "Oil Filter Assembly and Oil Cooler".
7. Remove the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal".
8. Remove the crankshaft rear oil seal.
9. Remove the oil pan.
Refer to "Oil Pan".
10. Remove the water pump.
RTW76ASH001101
Section.
11. Remove the front cover.
Refer to "Front Cover". Inspection
12. Remove the timing gear train.
1. Carefully remove water stains or other foreign
Refer to "Timing Gear Train".
matters on the surface of the cylinder block.
• Be careful not to damage the cylinder block. Standard 95.421 - 95.450 (3.7567 - 3.7579)
2. Carefully remove the liquid gasket on the Limit 95.48 (3.7590)
crankcase mounting surface.
3. Clean up the cylinder block. 6. Cylinder Reboring.
4. Visually inspect the cylinder block. • Select oversize pistons to fit the largest cylinder
• Conduct color check and hydraulic (or bore (previously measured).
pneumatic) test and if you find a crack or other • At a point 11 mm (0.43 in) above the lower
damage, replace the cylinder block. edge of the piston skirt, measure the piston
diameter at a right angle to the piston pin.
Calculate the additional cylinder boring required
for each cylinder.
RTW76ASH000801
5. Cylinder block wear measurement.

• Use a cylinder indicator to measure the cylinder
RTW56ASH023101
bore at measuring point (1) in the thrust (2-2)
and axial (3-3) directions of the crankshaft. Legend
• Measuring Point (1): 20 mm (0.79 in). 1. 11 mm (0.43 in)
If the measured value exceeds the specified
limit, the cylinder block must be replaced or • Formula
rebored. Boring inside diameter = D + C - H ± E
D = Piston outside diameter
(Measured Oversize Piston)
C = Piston and cylinder bore clearance
0.082 - 0.100 mm (0.0032 - 0.0039 in)
H = Honing allowance
0.03 mm (0.0012 in) or less
E = Boring machine error
1
Piston size mm (in)

2
Standard 95.340 - 95.389 (3.7535 - 3.7555)
3
3 Oversize(0.25) 95.590 - 95.639 (3.7634 - 3.7653)
2 Oversize(0.50) 95.840 - 95.889 (3.7732 - 3.7752)
Oversize(0.75) 96.090 - 96.139 (3.7831 - 3.7850)
• Bore and hone the cylinders individually as

LNW21BSH039801
required.
• Once again, measure each cylinder bore.
Cylinder block bore diameter mm (in)

Each cylinder bore remainder mm (in)
0.02 (0.0008) or less. Installation

1. Install the piston cooling pipe.
7. Cylinder block upper face warpage. • Align the dowel pin of the piston cooling pipe
• Use a straight edge (1) and a thickness gauge with the pin hole on the cylinder block and
(2) to measure the four sides and the two tighten with the relief valve.
diagonals of the cylinder body upper face.
Tightening torque:
• If the measured values exceeds the limit, the
cylinder body must be replaced. Relief valve 30 N⋅m (3.1 kg⋅m / 22 lb ft)
bolts M8 25 N⋅m (2.5 kg⋅m / 18 lb ft)
Cylinder block upper face warpage mm (in) bolts M6 8 N⋅m (0.8 kg⋅m / 69 lb in)
Standard 0.05 or less (0.002 or less)
NOTE:
Limit 0.20 (0.079) Be careful not to deform or damage the piston cooling
pipe nozzle.
LNW61ASH006501
RTW76ASH001101
2. Install the crankshaft.

Cylinder body height (H) (Reference) mm (in) Refer to "Crankshaft".
Standard 262.945 - 263.055 (10.352 - 10.356) 3. Install pistons and connecting rods.
4. Install the oil pump.
5. Install the timing gear train.
Refer to "Timing Gear Train".
6. Install the front cover.
7. Install the water pump.
Section.
H 8. Install the oil pan.Refer to "Oil Pan".
9. Install the crankshaft rear oil seal.
10. Install the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal".
11. Install the oil filter assembly and oil cooler.
Refer to "Oil Filter Assembly and Oil Cooler".
LNW71BSH000301
12. Install the fuel supply pump and fuel rail assembly. 14. Install the camshaft assembly.
Refer to "Fuel Supply Pump” and “Fuel Rail Refer to "Camshaft Assembly".
Assembly" in FUEL SYSTEM section. 15. Install the cylinder head cover.
13. Install the cylinder head. Refer to "Cylinder Head Cover".
Refer to "Cylinder Head". 16. Mount the engine assembly on the chassis.
Refer to "Engine Assembly”.
30 (3.1/22) 25 (2.5/18)
8 (0.8/69lb in)
LNW71BSF000301
Lubrication System
Service Precautions • Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
• During each disassembly, remove the old gasket
coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely
and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid
is insufficient.
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton • Always, the start and end of the application should
and apply the specified new fluid gasket at each be overlapped.
location.
Explanations on functions and operation
The lubrication system uses the filter element
combined with a full flow bypass, water-cooled oil
cooler, and oil jet for piston cooling.
Lubricating system diagram
4. Oil Press. Warning

SW Lamp
Oil Gallery
Oil Filter & Cooler Assembly
5. Regulating Crankshaft Turbo-

Valve Bearing charger
Oil Filter 3. Relief
Valve
Idler Gear Camshaft Vacuum
Shaft Bearing Pump
Oil Cooler Piston Connecting

Cooling Jet Rod Bearing
2. Relief Timing Chain
Valve Oil Jet
Timing Gear
1. Relief Oil Pump

Valve
Rocker Arm
Oil
Strainer
Oil Pan
LNW76ALF000201
Legend
1. Oil Pump Relief Valve Operating Pressure: 490 - 2. Oil Cooler Relief Valve Opening Pressure: 176 -
686 kPa (5.0 - 7.0 kg/cm2 / 71 - 100 psi) 216 kPa (1.8 - 2.2 kg/cm2 / 26 - 31 psi)
3. Oil Filter Relief Valve Opening Pressure: 80 - 5. Regulating Valve: 176 - 216 kPa (1.8 - 2.2 kg/
120 kPa (0.8 - 1.2 kg/cm2 / 11 - 17 psi) cm2 / 26 - 31 psi)
4. Oil Pressure Switch Operating Pressure: 29.4 -
49.0 kPa (0.3 - 0.5 kg/cm2 / 4.3 - 7.1 psi)
Functional Check Engine oil

Oil pressure check Ensure the car is on level ground. Before starting the
engine or when 30 minutes or more have elapsed after
1. Check whether the engine oil is contaminated with
stopping the engine, check the engine oil volume using
dirt, light oil, or water. If contaminated with dirt,
the level gauge. The volume is appropriate if the engine
light oil, or water (after examining the cause and
oil is between the upper and lower limits of the level
taking the appropriate measures for light oil or
gauge. Replenish the engine oil, if level is below the
water contamination), replace the oil.
lower limit. Also, check for contamination of the engine
2. Check the engine oil level. The oil level should be oil.
between the two holes of the level gauge. If the oil
level is insufficient, replenish it.
3. Remove the oil pressure switch on the nipple.
4. Install the oil pressure gauge on the nipple.
5. Warm the engine.
6. Measure the oil pressure, to check whether it is
more than 400 kPa (4 kg/cm2 / 58 psi) at 3600
rpm.
7. Stop the engine. ADD FULL
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
1 2
10. Start the engine and check for oil leakage.
RTW56ASH015701
Legend
1. Lower Limit
2. Upper Limit
Engine oil leakage

• In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.
Oil Filter Element

Components
1
2
3
6
4
5 7
8
9
10
LNW71HSF000101
Legend
1. Oil Cooler 6. Center Bolt
2. Oil Filter Element 7. O-ring
3. Gasket 8. O-ring
4. Plate 9. Drain Plug
5. Spring 10. Oil Filter Case
Removal
1. Place a tray under the oil filter.
2. Remove the drain plug, and oil in the filter is
drained.
3. Remove the center bolt, and remove the element
in the case.
NOTE:
Do not reuse the two O-rings and the gasket.
Installation
1. Install the oil filter element.
• Apply grease(Besco L2, L3 or equivalent) or
engine oil to the O-rings and the gasket.
• Tighten the bolt and the drain plug using the
specified torque.
Tightening torque:
Center bolt 44 N⋅m (4.5 kg⋅m / 33 lb ft)
Drain plug 24 N⋅m (2.4 kg⋅m / 17 lb ft)
44(4.5/33)
25(2.5/18)
LNW76ASF000101
Oil Filter Assembly and Oil Cooler

Components
LNW71HMF000101
Legend
1. Oil Filter Assembly and Oil Cooler 3. Water Intake Pipe
2. Water By Pass Pipe
Removal 3. Remove the water by pass pipe (1).

1. Remove the turbocharger.
Refer to “Turbocharger”.
2. Remove the exhaust manifold.
Refer to “Exhaust Manifold”.
RTW56ASH008401
4. Remove the water intake pipe (1). Disassembly
1. Remove the element mounting nuts(1).
2
3
1
RTW56ASH012601
Legend RTW56ASH012901
1. Water Intake Pipe
2. Remove the element (1).
2. Bracket
3. Bracket 3. Remove the gasket (2).
4. Bolt
5. Remove the oil cooler and oil filter.
RTW56ASH013001
LNW71HSH000101 Reassembly
1. Install the gasket on the element.
2. Install the element.
3. Tighten the element fixing nuts using the specified
torque.
Installation
1. Install the oil filter and cooler.
• Install the O-ring on the oil filter and cooler,
apply grease.
• Apply the liquid gasket and mount within 5 • Tighten the bolts to the specified torque in the
minutes. Apply liquid gasket (ThreeBond TB- order shown in the illustration.
1207C or equivalent) to the flange surface
groove (cylinder block). Bead diameter must
be between 2 and 3 mm (0.008 and 0.012 in).
Refer to the illustration for the offset position
(no more than 1 mm (0.004 in)).
10
4 5 6 7 8 9 1 11
1
3
12
2
22 22 20 17 16 15 14 13
19 18
LNW76ASH002001
2
2. Install the water intake pipe.
• After applying soapy water to O-ring, set it on
LNW76ASH001801 water intake pipe and insert into the oil
Legend cooler.Tighten the bolts to the specified torque.
1. Liquid Gasket Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)
2. O-ring
3. Install the water by pass pipe.
• Align the oil filter and cooler holes with the • After applying soapy water to O-ring, set it on
cylinder block studs. Install the oil cooler to the by pass pipe and insert into the cylinder
cylinder clock. head.Tighten the bolts to the specified torque.
4. Install the bracket of generator.
1 1 1 1 1 1 4 2 5. Install the adjustment bracket of generator.
1 Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb ft)
2 6. Install the generator.
4 Refer to Installation procedure for generator in this
2 2 1 1 1 1 5 manual.
7. Install the exhaust manifold.
Refer to Installation procedure for turbocharger
3 and exhaust manifold in this manual.
LNW76ASH001901
Legend
1. Bolt 35 mm X 11
2. Bolt 70 mm X 4
3. Bolt 90 mm X 2
4. Nut X 2
Crank Case and Oil Pan

Components
LNW76ALF000501
Legend
1. Flywheel Housing 4. Crank Case
2. Cylinder Block 5. Oil Pan
3. Oil Strainer
Removal
Refer to “Engine Assembly“.
2. Remove the oil level gauge guide tube.
3. Remove the heater pipe and hose.
4. Remove the oil pan. 9. Remove the retainer.
LNW76ASH001301 RTW76ASH002001
5. Remove the flywheel. Legend

Refer to “Flywheel”. 1. Retainer
6. Remove the flywheel housing. 2. Bolt
10. Remove the crank case.
1
3
1
2
LNW71BSH001601
Legend RTW56ASH021901
1. Bolt
2. Bolt Legend
3. Nut 1. O-ring
2. Crank Case
Refer to “Cylinder Head”. NOTE:
8. Remove the timing gear case. Take care not to damage an O-ring.
Refer to “Timing Gear Case”.
Disassembly
1. Remove the oil strainer.
2
1
4
2
1
RTW56ASH015301
Legend
RTW66ASH009201 1. 2.0 - 3.0 mm (0.079 - 0.118 in)
2. 4.0 - 5.0 mm (0.157 - 0.179 in)
Legend
2. Oil Strainer
2. Install the oil pan.
3. Bolt
Apply the liquid gasket (ThreeBond TB-1207B or
4. Crank Case
equivalent)and mount within 5 minutes.
Reassembly
Install the oil strainer.
• Install the packing on the strainer.
Installation
1. Install the crank case.
• Apply the liquid gasket (ThreeBond TB-1207C 1 2
or equivalent) and mount within 5 minutes.
RTW56ASH015201
Legend
1. 2.0 mm (0.079 in)
2. 3.0 mm (0.118 in)
3. Install the retainer.

• Apply the liquid gasket (ThreeBond TB-1207C
or equivalent) and mount within 5 minutes.
4. Install the heater pipe and hose.
RTW56ASH017701
LNW76ASH001301
Legend
1. 2 - 2.5 mm (0.079 - 0.098 in) 5. Install the timing gear case.
2. 2 - 2.5 mm (0.079 - 0.098 in) Refer to “Timing Gear Case”.
7. Install the Flywheel housing.
Tightening torque:
Bolt (1) : 106 N⋅m (10.8 kg⋅m / 78 lb ft)
Bolt (2) : 82 N⋅m (8.4 kg⋅m / 61 lb ft)
1
Bolt (1) : 51 N⋅m (5.2 kg⋅m / 38 lb ft)
2
1
3
RTW76ASH002001
Legend
1. Retainer
2. Bolt
2
LNW71BSH001601
8. Install the flywheel.

Refer to “Flywheel”.
9. Install the oil level gage guide tube.
• Apply the engine oil to the O-ring.
Refer to “Engine Assembly“.
106(10.8/78)
51(5.2/38)
25(2.5/18)
25(2.5/18)
82(8.4/61)
25(2.5/18)
22(2.2/16)
44(4.5/33)
LNW76ALF000901
Oil Pump
Components
2
1
RTW66AMF000701
Legend
1. Bolt 2. Oil Pump Assembly
Removal
3. Remove the fan guide bracket. 8. Remove the noise cover (1).
2
1
3 1
LNW76ASH000701 RTW56CSH001401
Legend 9. Remove the crank pulley.

1. Fan Guide Bracket (RH)
2. Fan Guide Bracket (LH) NOTE:
3. Bolt Do not reuse the crank pulley bolt and washer.
4. Remove the fan and fan clutch. 10. Remove the cover of the gear case cover(1).
• Loosen the fan clutch nuts.
• Remove the fan together with the fan clutch.
Take care not to damage the radiator core.
5. Remove the fan drive belt and pulley.
• Loosen the tension adjust bolt on the generator 1
and A/C.
• Remove the fan drive belt with the fan pulley.
6. Disconnect the power steering pump.
7. Remove the vacuum pump.
• Remove the vacuum pipe bracket and vacuum
pipe.
• Remove the oil pipe (feed side and return side)
of vacuum pump.
LNW76ASH003201
11. Remove the gear case cover. 4. Install the spring pin.
2 3 4
12. Remove the oil pump. Legend

1. Spring Pin
2. Spring Seat
3. Spring
1 4. Valve
Inspection
NOTE:
Think to match direction of ditch of gear when
assembling it.
1. Measure the clearance between the driven gear/

drive gear shaft and the bush.
• Measure the outside diameter of the driven
gear shaft using a micrometer.
RTW56ASH020001 Outside diameter of the driven gear shaft/ mm (in)

Legend drive gear shaft
1. Oil Pump Standard 15.989 - 16.000 (0.62949 - 0.62992)
Limit 15.900 (0.62598)
Disassembly
1. Remove the spring pin.
2. Remove the spring seat.
3. Remove the spring.
4. Remove the valve.
Reassembly
1. Install the valve.
2. Install the spring.
3. Install the spring seat.
• Measure the width size the driven gear/drive
gear.
RTW56ASH025601
• Measure the inside diameter of the bushes of

RTW56ASH025501
the cylinder block using the dial gauge.
• If the clearance between the driven gear shaft/ • Measure the Depth size of the gear case
drive gear shaft and bush exceeds the limit, housing surface and the oil pump housing gear
replace the oil pump assembly. case side.
Clearance between the driven gear shaft/ mm (in) Depth size the gear case housing surface mm (in)
drive gear shaft and bush Standard 14.500 - 14.527 (0.5709 - 0.5719)
Standard 0.04 - 0.07 (0.0016 - 0.0028)
Limit 0.20 (0.0079)
RTW56ASH014801
RTW56ASH014701
Clearance between the gear side surface mm (in)
2. Measure the clearance between the gear side and the gear side surface of the oil pump
surface and the gear side surface of the oil pump housing
housing.
Standard 0.065 - 0.109 (0.0026 - 0.0043)
Limit 0.20 (0.0079)
Installation • Tighten the bolts to the specified torque.
1. Install the oil pump. Tightening torque: 8 N⋅m (0.8 kg⋅m / 69 lb in)
• Apply engine oil to the oil pump attachment
gearbox.
RTW56ASH012101
3. Install the cover of the gear case cover.

4. Install the crank pulley.
RTW56ASH020001
Legend 5. Install the noise cover.
1. Oil Pump
• Installed pump gear should be smooth to rotate. Tightening torque: 10 N⋅m (1.0 kg⋅m / 87 lb in)
2. Install the gear case cover. 6. Install the vacuum pump.
• Apply the liquid gasket (Threebond TB-1207B • Tighten the nuts to the specified torque.
or equivalent) mount within 5 minutes.
1 • Install the oil pipe (feed side and return side) of
vacuum pump.
• Install the vacuum pipe bracket and vacuum
pipe.
7. Install the power steering pump.
• Tighten the nuts to the specified torque.
8. Install the fan drive belt and pulley.
• Install the fan drive belt with the fan pulley.
9. Install the fan and fan clutch.
10. Adjust the drive belt of generator and A/C
compressor.
RTW56ASH020101 • Apply tension to the fan drive belt by moving
Legend the generator.
1. Apply The Liquid Gasket in Area
• Install the gasket in the slot of the gear case

cover.
• Apply a force of 98 N (10 kg / 22 lb) to the drive
belt mid portion to check the drive belt
deflection.
Generator drive belt deflection mm (in)

New belt 5 - 6 (0.20 - 0.24)
Reuse belt 7 - 8 (0.28 - 0.32)
A/C compressor drive belt deflection mm (in)

New belt 6 - 7 (0.24 - 0.28)
Reuse belt 8 - 9 (0.32 - 0.35)

Oil Pressure SW
Components
3
2
1
LNW76AMF000601
Legend
1. Oil Pressure SW 3. Nipple; Oil Pressure Warning SW
2. Gasket
Removal
1. Remove the oil pressure SW.
2. Remove the nipple; oil pressure warning SW and
gasket.
Installation
1. Install the nipple; oil pressure warning SW and
gasket.
2. Install the oil pressure SW.
Inspection
Check the continuity between the switch terminal and
the body grounding in a no-load condition.If there is no
connectivity, replace with normal parts.
LNW21HSH003301
Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and
confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the
circuit between the meter and the oil pressure
switch, and repair the disconnected locations.
LNW21HSH003401
Air Cleaner Element

Removal
1. Remove the air cleaner cover fixing bolt.
2. Remove the air cleaner element assembly.
Cleaning
Dry type 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/cm2 /psi)

690 (7 / 100)
LNW46ASH003201
Installation
1. Install the air cleaner element assembly.
2. Install the air cleaner cover.
MEMO
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ENGINE COOLING (4JJ1) 6B-1
ENGINE
ENGINE COOLING
(4JJ1)
TABLE OF CONTENTS
Main Data and Specifications . . . . . . . . . . . . . . . . 6B-2
Main Data and Specifications. . . . . . . . . . . . . . . 6B-2
General Description . . . . . . . . . . . . . . . . . . . . . . 6B-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7
Draining and Refilling Cooling System . . . . . . . . . 6B-8
Draining and Refilling Cooling System. . . . . . . . 6B-8
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9
Removal and Installation . . . . . . . . . . . . . . . . . . 6B-9
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-11
Removal and Installation . . . . . . . . . . . . . . . . . 6B-11
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Removal and Installation . . . . . . . . . . . . . . . . . 6B-13
Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15
Radiator Core. . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15
Flushing the Radiator . . . . . . . . . . . . . . . . . . . . 6B-15
Cooling System Leakage Check . . . . . . . . . . . 6B-15
Engine coolant change . . . . . . . . . . . . . . . . . . 6B-17
Fan Clutch with Cooling Fan . . . . . . . . . . . . . . . . 6B-18
Inspection and Repair . . . . . . . . . . . . . . . . . . . 6B-18
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19
6B-2 ENGINE COOLING (4JJ1)
Main Data and Specifications

Main Data and Specifications
Description
Item
M/T Smoother
Cooling system Engine coolant forced circulation
Water pump type Centrifugal impeller type
Pump to crankshaft speed ratio (To 1) 1.25
Delivery volume lit (US/UK gal)/min 240 (63.1/53.3)
Pump speed at 5600 rpm
Water temperature at 30°C (86°F)
Pump bearing type Double row shaft
Thermostat type Wax pellet with jiggle valve

Valve initial opening temperature °C (°F) 85 (185)
Valve full opening temperature °C (°F) 100 (212)
Valve lift at fully open position mm (in) 10 (0.39)
Radiator Tube type corrugated
Heat radiation capacity kW 91.2
Heat radiation area m2 (ft2) 10.9 (117.3)
Radiator front area m2 (ft2) 0.242 (2.6)
Radiator dry weight N (kg/lb) 125.5 (12.8 / 28.2) 128.5 (13.1 / 28.9)
Radiator cap valve opening pressure kPa (psi) 93.3 – 122.7 (13.5 – 17.8)
Engine coolant capacity lit (U.S pint) 6.7 (7.1)
Engine coolant total capacity lit (U.S pint) 10 (10.6)
General Description
Coolant Flow
Turbocharger
EGR
Cooler
Cylinder head
Thermostat
Reservoir
Tank
Radiator Oil cooler
Cooling fan
Water
pump
Cylinder block
Car heater
RTW76BLF000301
The engine cooling system consists of the radiator, the

water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for
smooth engine operation, the coolant is circulated by
the water pump and thermostat through the bypass
pipe and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value,
the thermostat will begin to open and a gradually
increasing amount of coolant will circulate through the
radiator.
The thermostat will be fully open when the coolant
temperature reaches specified value. All of the coolant
is now circulating through the radiator for effective
engine cooling.
Water Pump
RTW56BSF000101
A centrifugal type water pump forcefully circulates the

coolant through the cooling system.
The water pump is not disassembled type.
Thermostat
RTW56BSF000201
A wax pellet type thermostat is used.

Radiator
The radiator is a tube type with corrugated fins. In order Mix ratio
to raise the boiling point of the coolant, the radiator is Freezing Liter (qts) Concentration
fitted with a cap in which the valve is operated at 93.3 – temperature of engine
122.7 kPa (0.95 – 1.25 kg / cm2 / 13.5 – 17.8 psi) guideline Engine Tap coolant
pressure. (No oil cooler provided for M/T) coolant water
-18°C (-0.4°F) 3.5 (3.7) 6.5 (6.9) 35%
-25°C (-13°F) 4.2 (4.4) 5.8 (6.1) 42%
-35°C (-31°F) 5.0 (5.3) 5.0 (5.3) 50%
-40°C (-40°F) 5.3 (5.6) 4.7 (5.0) 53%
2. Engine coolant density measurement

Methods for measuring specific gravity
• Measure the specific gravity and the
temperature of the cooling water using an anti-
freeze specific gravity meter and thermometer.
Take precautionary measures as the boiled

cooling water may gush out at high
temperatures if the cap is removed.
LNW76BSH002801 • Use a deep container to suit the height of the

specific gravity meter.
Engine Coolant
1. About the engine coolant concentration
• Take the concentration corresponding to the
minimum temperature because the freezing
temperature varies according to the 1
concentration of the engine coolant.
• Use only genuine Isuzu engine coolant.
• Use engine coolant with a mix ratio in the range
2
of 30 to 60% because over heating is likely to
occur if the ratio is greater than 60% and
corrosion prevention is inadequate if the ratio is
less than 30%.
ANTIFREEZE CONCENTRATION (%)

0 10 20 30 40 50
LNW46BSH001001
FREEZING TEMPERATURE (°C)
Legend
-10 1. Anti-Freeze Specific Gravity Meter
2. Radiator
-20
• Fix the temperature of the cooling water being
-30 measured in the range of 0 to 50 °C (32 to
122 °F).
-40
-50
LNW46BSH001301
• Measure the temperature and specific gravity
and determine the concentration from the table
given below.
1100
1090 60%
1080 50%
1070
SPECIFIC GRAVITY
1060 40%
1050 30%
1040
1030 20%
1020 10%
1010
1000
0 10 20 30 40 50 60 70
TEMPERATURE (°C)
LNW46BMH000101
Coolant scooping method
• Measure the concentration using the coolant
scoop.
Diagnosis
Diagnosis

Engine overheating Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature Repair or replace
sensor
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of Replenish or change oil
improper engine oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position Repair or replace
sensor circuit
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Engine slow to warm–up Faulty thermostat Replace
Thermo unit faulty Replace
Draining and Refilling Cooling System

Draining and Refilling Cooling System • Press the radiator upper hose(1) 2 to 3 times as
shown in the illustration. If the coolant level is
Before draining the cooling system, inspect the system
down caused by the air was bled, poor the coolant
and perform any necessary service to ensure that it is
again.
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
"MIN" and "MAX" lines of reserve tank when the engine
is cold. If low, check for leakage and add EC up to the 2
"MAX" line. 1
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole,
and the EC should also be free from oil.Replace the EC
if excessively dirty.
1. Completely drain the cooling system by opening
the drain plug at the bottom of the radiator.
2. Remove the radiator cap.
WARNING:
To avoid the danger of being burned, do not remove the
cap while the engine and radiator are still hot. Scalding
fluid and steam can be blown out under pressure.
3. Disconnect all hoses from the EC reserve tank. LNW76BSH002901
Scrub and clean the inside of the reserve tank with • Pour the coolant up to the "MAX" line in the
soap and water. Flush it well with clean water, reserve tank.
then drain it. Install the reserve tank and hoses.
• Tighten the air bleeding bolt firmly.
4. Refill the cooling system with the EC.
• Close the radiator cap and the reserve tank cap
and start the engine. Stop the engine after running
Procedure for filling with coolant (in case of full
for about 2 to 3 minutes at the idling rpm. Open the
change)
radiator cap again and replenish if the water level
• Confirm that the engine has cooled. is low.
• Open the radiator cap and the reserve tank cap.
WARNING:
• Unscrew the air bleeding bolt(2).
Do not loosen or remove the radiator cap when the
• Pour the coolant up to the filler neck. temperature of the cooling water is high. Steam or
boiling water will gush out and you may be burnt. To
open the radiator cap, cover the cap with a thick cloth
when the cooling water is cool, release the pressure by
slowly turning the cap, and then remove the cap.
• After tightening the radiator cap, warm up the

engine by running it at about 2000 rpm.
• When the pointer of the thermometer crosses the
median and the thermostat has activated, run at
idling rpm for another 5 minutes, then stop the
engine and leave it as-is.
• After the engine has cooled down sufficiently,
check the water level in the filler neck part and
replenish if necessary. If the level is extremely low,
check for leaks in the cooling water conduit system
and reserve tank hose.
Water Pump
Removal and Installation b. Remove the fan drive belt with the fan pulley.
Read this Section carefully before performing any
removal and installation procedure. This Section gives
you important points as well as the order of operation.
Be sure that you understand everything in this Section
before you begin.
Removal
2. Radiator Upper Hose
a. Partially drain the engine coolant.
b. Remove the radiator upper hose.
3. Water Outlet Pipe
a. Disconnect the turbocharger-cooling pipe from
the outlet pipe.
b. Loosen the fixing bolt and remove the water
outlet bolt. RTW56ASH025401
4. Fan guide bracket
7. Water Pump
2
a. Remove the water pump bolts and nuts.
1 b. Remove the water pump.
LNW76ASH000701
Legend
1. Fan Guide Bracket RH
RTW56BSH000201
2. Fan Guide Bracket LH
3. Bolt
Inspection and Repair
5. Fan and Fan Clutch The water pump is not disassembled type.Make
a. Loosen the fan clutch nuts. necessary parts replacement if extreme wear or
b. Remove the fan together with the fan clutch. damage is found during inspection. Should any of the
Take care not to damage the radiator core. following problems occur, the entire water pump
assembly must be replaced.
6. Fan Drive Belt and Pulley
• Cracks in the water pump body.
a. Loosen the tension adjust bolt on the generator.
• Coolant leakage from the sealed unit.
• Excessive radial play or abnormal noise in the fan
center when rotated by hand.
• Excessive thrust play in the fan center (Standard
play: less than 0.2 mm (0.0078 in)).
• Cracks or corrosion in the impeller. d. Apply a force of 98 N (10 kg/22 lb) to the drive
belt mid-portion to check the drive belt
Installation deflection.
1. Water Pump
Fan Drive Belt Deflection mm (in)
New belt 5 - 6 (0.20 – 0.24)
Reuse belt 7 - 8 (0.28 – 0.32)
3. Fan guide bracket

4. Water Outlet Pipe.
a. Install the water outlet pipe to the thermostat
housing.
b. Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque:
25 N⋅m (2.5 kg⋅m /18 lb ft)
c. Connect the turbocharger-cooling pipe to outlet
pipe.
5. Radiator Upper Hose.
RTW56BSH000201
a. Connect the radiator upper hose to the water
a. Install the water pump with a new gasket. outlet pipe.
b. Tighten bolts and nuts to specified torque. b. The knob of clamp shall be directed to
horizontal.
Water Pump Bolt/Nut Torque:
c. Replenish the engine coolant.
25 N⋅m (2.5 kg⋅m /18 lb ft)
2. Fan Drive Belt and Pulley and Fan and Fan Clutch.
RTW56ASH025401
a. Install the fan drive belt and fan pulley and fan
and fan clutch.
b. Tighten the nuts to specified torque.
Fan Clutch Nut Torque: 8 N⋅m (0.8 kg⋅m /69 lb in)
c. Apply tension to the fan drive belt by moving
the generator.
Thermostat
Removal and Installation 2. Heat the water.Stir the water constantly to avoid
direct heat being applied to the thermostat.
removal and installation procedure. This Section gives 3. Check the thermostat initial opening temperature.
before you begin. Thermostat Initial Opening Temperature: °C (°F)
85 (185)
Removal
1. Remove the engine cover. 4. Check the thermostat full opening temperature.
2. Radiator Upper Hose
a. Partially drain the engine coolant. Thermostat Full Opening Temperature: °C (°F)
b. Remove the radiator upper hose. 100 (212)
c. Remove the engine harness clip.
3. Water Outlet Pipe
a. Disconnect the turbocharger-cooling pipe from Valve Lift At Fully Open Position: mm (in)
outlet pipe.
10 (0.39)
b. Loosen the fixing bolt and remove the water
outlet bolt.
4. Thermostat
Remove the thermostat from the thermostat
housing.
Take care not to damage the thermostat.
1 2
2 3
LNW61BSH003501
Legend
1. Agitating Rod
2. Thermometer
LNW71CSH000401 3. Wooden Piece
Legend
1. Jiggle Valve
2. Thermostat

replacements if excessive wear or damage is
Operating Test of Thermostat

1. Completely submerge the thermostat in water.
Installation
1. Thermostat
Install the thermostat.
Mount the jiggle valve with the valve facing engine
front.
LNW71CSH000401
Legend
1. Jiggle Valve
2. Thermostat
2. Water Outlet Pipe.

a. Install the water outlet pipe with a new gasket to
the thermostat housing.
b. Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque:
25 N⋅m (2.5 kg⋅m /18 lb ft)
c. Connect the turbocharger-cooling pipe to outlet
pipe.
d. Install the engine harness clip.
3. Radiator Upper Hose.
a. Connect the radiator upper hose to the water
outlet pipe.
b. The knob of the clamp should be directed to the
horizontal side.
c. Replenish the engine coolant.
Radiator
Removal and Installation
Radiator and Associated Parts
3 4
1
LNW76BLF001901
Legend
1. Reserve Tank Hose 4. Fan Guide
2. Radiator Upper Hose 5. Radiator Lower Hose
3. Radiator & Intercooler
Removal
1. Disconnect battery ground cable.
2. Loosen the drain plug to drain the engine coolant.
• After draining the coolant, tighten the drain
plug.
LNW46BSH000401 LNW76ASH000501
Legend 6. Remove the radiator upper hose on the radiator

1. Radiator Drain Plug side.
7. Remove the radiator lower hose on the radiator
3. Remove the air intake pipe with the hoses. side.
• Disconnect the hose from the intercooler side. 8. Remove the coolant reserve tank hose from the
• Remove the air intake pipe with the hoses from radiator side.
the turbocharger side. 9. Remove the fan guide bracket.
pipe. 2
1
LNW76ASH000701
Legend
LNW76ASH000301
1. Fan Guide Bracket RH
4. Disconnect the ECM harness connector. 2. Fan Guide Bracket LH
5. Remove the air intake pipe with the hoses. 3. Bolt
10. Remove the inter cooler.
sensor.
pipe.
11. Take care to avoid damage to the radiator core
from the fan blade, and remove the brackets on
the right and left sides of the radiator.
Simultaneously remove the radiator.
LNW21BSH000201
Radiator Core
LNW76BSH003001
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
Inspection and Repair straightened. Pay close attention to the base of the
Make the necessary adjustments, repairs, and part fin when it is being straightened.
replacements if excessive wear or damage is 2. Remove all dust, bugs and other foreign material.
Flushing the Radiator

Radiator Cap Thoroughly wash the inside of the radiator and the
Measure the valve opening pressure of the engine coolant passages with cold water and mild
pressurizing valve with a radiator filler cap detergent. Remove all signs of scale and rust.
tester.Replace the cap if the valve opening pressure is
outside the standard range.
Cooling System Leakage Check
Valve opening pressure:
Use a radiator cap tester to force air into the radiator
93.3 – 122.7 kPa (0.95 – 1.25 kg / cm2 / 13.5 – 17.8 through the filler neck at the specified pressure of 196
psi) kPa (2.0 kg / cm2 / 28.5 psi) with a cap tester:
Cap tester: 5-8840-0277-0
• Leakage from the radiator.
Adapter: 5-8840-2603-0
Check the condition of the vacuum valve in the center • Leakage from the coolant pump.
of the valve seat side of the cap. If considerable rust • Leakage from the water hoses.
or dirt is found, or if the valve seat cannot be moved by • Check the rubber hoses for swelling.
hand, clean or replace the cap.
Valve opening vacuum:
1.96 – 4.91 kPa (0.02 – 0.05 kg / cm2 / 0.28 – 0.71 psi)
6. Mount the radiator upper hose.
7. Pour engine coolant up to filler neck of radiator,
and up to MAX mark of reserve tank. Important
operation (in case of 100% engine coolant change)
procedure for filling with engine coolant.
• Confirm that the engine has cooled.
• Open the radiator cap and the reserve tank
cap.
• Unscrew the air bleeding bolt(2).
• Pour the coolant up to the filler neck.
• Press the radiator upper hose(1) 2 to 3 times as
shown in the illustration. If the coolant level is
down caused by the air was bled, poor the
coolant again.
LNW21BSH000301 2
1
Installation
1. Ensure that no damage occurs to the radiator core
because of the fan brade.Mount the brackets on
the left and right sides of the radiator on the frame
according to the figure.
Tightening Torque: 26 N⋅m (2.6 kg⋅m /19 lb ft)
1
6 LNW76BSH002901
• Pour the cooling water up to the "MAX" line in

the reserve tank.
2
• Tighten the air bleeding bolt firmly.
5
• Close the radiator cap and the reserve tank cap
and start the engine. Stop the engine after
4 running for about 2 to 3 minutes at the idling
3 rpm. Open the radiator cap again and replenish
if the water level is low.
LNW46BSH000101
WARNING:
Do not loosen or remove the radiator cap when the
Legend temperature of the cooling water is high. Steam or
1. Flange nut boiling water will gush out and you may be burnt. To
2. Rubber open the radiator cap, cover the cap with a thick cloth
3. Stud Bolt when the cooling water is cool, release the pressure by
4. Bracket slowly turning the cap, and then remove the cap.
5. Bracket on the Radiator Side
6. Washer • After tightening the radiator cap, warm up the
engine by running it at about 2000 rpm.
2. Install the intercooler.
• When the pointer of the thermometer crosses
3. Install the fan guide bracket. the median and the thermostat has activated,
4. Mount the reserve tank hose of the coolant on the run at idling rpm for another 5 minutes, then
radiator. stop the engine and leave it as-is.
5. Mount the radiator lower hose.
• After the engine has cooled down sufficiently,
check the water level in the filler neck part and
replenish if necessary. If the level is extremely
low, check for leaks in the cooling water conduit
system and reserve tank hose.
2 3
LNW76BSH000101
Legend
1. Reserve Tank
2. MAX Line (Upper Limit)
3. MIN Line (Lower Limit)
Engine coolant change

Refer to change procedure for Draining and Refilling
Cooling System in this section.
Fan Clutch with Cooling Fan

Inspection and Repair 2. Inspection (in unit)
Warm up the bimetal of the fan clutch by using the
Make necessary correction or parts replacement if
heat gun until the temperature gets to about
wear, damage or any other abnormal condition are
85°C(185°F) when measured with the thermistor.
found through inspection.
Then confirm that the fan clutch can be turned with
Visually inspect for damage, leak (silicon grease) or
considerable effort (clutch torque).
other abnormal conditions.
If the fan clutch rotates more readily at this time,
1. Inspection (on-vehicle) this indicates that the silicone grease is leaking
a. Turn the fan clutch by hand when in a low internally.
temperature condition before starting the Replace the fan clutch with a new one.
engine, and confirm that it can be turned
readily.
b. Start the engine to warm it up until the
temperature at the fan clutch portion gets to
around 85°C(185°F). Then stop the engine
Heat gun
and confirm that the fan clutch can be turned
with considerable effort (clutch torque) when
turned by hand.
If the fan clutch rotates more readily, however,
this indicates that the silicone grease is leaking
internally.
Thermistor
Replace the fan clutch with a new one.
LNW61BSH003701
3. Clearance between fan and fan guide

The clearance in three places must be 3mm(0.118
in) or more.
RTW56ASH025401
LNW71CSH000501
Special Tools
5-8840-02770-0
Cap tester
5-8840-2603-0
Adapter
5884026030
MEMO
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FUEL SYSTEM (4JJ1) 6C-1
ENGINE
FUEL SYSTEM
(4JJ1)
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . .6C-2
Work procedure . . . . . . . . . . . . . . . . . . . . . . . . .6C-2
Fuel System Check . . . . . . . . . . . . . . . . . . . . . .6C-7
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . .6C-9
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . .6C-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-10
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-14
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-16
Fuel Pressure Sensor . . . . . . . . . . . . . . . . . . . . .6C-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Fuel Pressure Limiter . . . . . . . . . . . . . . . . . . . . .6C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . .6C-19
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-22
Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .6C-24
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-28
Fuel Sedimenter Switch . . . . . . . . . . . . . . . . . . .6C-34
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-34
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-36
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . .6C-37
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39
6C-2 FUEL SYSTEM (4JJ1)
Fuel System
Service Precautions • If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
Parts of the fuel system such as the internal part of the
installation.
fuel injector, and holes and clearances that form
Discard gaskets and O-rings and replace them with
passages for fuel are finished to a very high degree of
new ones.
accuracy. They are therefore highly sensitive to foreign
matter and the entry of foreign matter could cause
damage to the fuel passage. Therefore, effective Work procedure
measures should be taken to prevent the entry of
foreign matter. • The fuel opening must be quickly sealed when
If a water removal agent is used in the fuel then it will removing the fuel pipe, injection pipe, fuel injector,
absorb moisture in the light oil and may cause rust. fuel supply pump, and fuel rail.
Therefore, do not use a water removal agent in the fuel • The eyebolts and gasket must be stored in a clean
tank. parts box with a lid to prevent adhesion of foreign
When servicing the fuel system, every precaution must matter.
be taken to prevent the entry of foreign material into the • Fuel leakage could cause fires. Therefore, after
system. finishing the work, wipe off the fuel that has leaked
• Before beginning the service procedure, wash the out and make sure there is no fuel leakage after
fuel line and the surrounding area. starting the engine.
• Perform the service procedures with clean hands.
Do not wear work gloves. Explanations on functions and operation
• Immediately after removing the fuel hose and/or Fuel system diagram
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
3
1 2
4 7
11 10 9 6 8
LNW71DSF000101
Legend
1. Fuel Rail 7. Fuel Tank
2. Pressure Limiter 8. Priming Pump
3. Leak Off Pipe 9. Fuel Filter With Sedimenter
4. Fuel Injector 10. Recirculation valve
5. Fuel Return Pipe 11. Fuel Supply Pump
6. Fuel Feed Pipe
Fuel Rail Assembly
RTW76CLF000601
Legend
1. Pressure Limiter 2. Fuel Rail Pressure Sensor
Fuel Supply Pump
LNW71DLF000101
Legend
1. Fuel Temperature Sensor 4. Camshaft Key
2. Suction Control Valve 5. Camshaft Nut
3. High Pressure Pipe
Fuel Injector Fuel Filter
2
1
6 3 1
4 3
LNW76CSH000101
Legend
1. Element
2. Case
3. Drain Plug
4. Switch Connector
Functional Check
RTW76CMH000201
Air Bleeding
Legend 1. Before starting the engine
1. Terminal a. Fit a tray below the fuel filter (below the air
2. Fuel Injector ID Code bleed plug).
3. Two Dimensional Barcode b. Loosen the plug adequately and operate the
4. Parts Number priming pump more than 20 times until the fuel
5. Part for Mounting the Injection Pipe near the plug overflows.
6. O-ring c. Tighten the plug, and operate the priming pump
more than 10 times until it is filled with fuel.
d. Tighten the plug firmly and wipe the fuel in the
surrounded area. Operate the priming pump
(10 to 15 times) till it is filled with fuel and then
send fuel to the engine.
2. After starting the engine
a. Start the engine by rotating the starter without
depressing the accelerator pedal.
b. After starting, maintain the idling rotation for 5
seconds.
c. Slowly rotate the idling control knob clockwise
and maintain it for 3 minutes.
d. Fully depress the accelerator pedal and
increase the rotations to maximum.(Repeat this
operation several times)
e. Rotate the idling knob counterclockwise and
return to idling more.
NOTE: • Discharge the water.
If the air bleeding work is insufficient then it could lead • Tighten the drain plug after discharging the water.
to faults in the engine. Therefore, the procedures after
• Tighten the air bleeding plug to the specified
starting the engine should always be implemented.
torque.
Water drain Tightening torque : 7.5 N⋅m (0.7 kg⋅m/26 lb in)
A warning lamp will light up if water above the specified • Ignition switch is turned ON for 15 seconds check
volume collects in the sedimenter. In such cases, drain for fuel leakage.
out the water by performing the following operations: • Check that the warning lamp in the meter is off.
• Set a container at the tip of the plastic hose.
• Loosen the air bleeding plug and the drain plug. Trouble Shooting
Problems with starting

Problems with starting Fuel tank is empty Fill the tank.
Air has entered the fuel system. Bleed the air.
Fuel line is clogged or damaged. Repair or replace the fuel line. Re-
Connection to the fuel line is loose. tighten the connection.
Fuel filter element is clogged. Replace the cartridge.
Fault in the feed pump Replace the fuel supply pump.
Regulating valve is open. Replace
Sticking of the fuel injector Replace the fuel injector.
Defective engine control system Diagnose the engine control
system.
Hunting during idling

Hunting during idling Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel Repair or replace the fuel system.
system
Drops of water have entered the Replace the fuel.
fuel system.
Fuel filter element is clogged. Replace the fuel filter element kit.
system.
Insufficient horsepower

Insufficient horsepower Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel Repair or replace the fuel system.
system
Water mixes in the fuel system Replace the fuel.
Fuel filter element is clogged. Replace the element kit.
system.
Maximum engine speed is too low

Maximum engine speed is too low Fuel line is clogged or damaged. Repair or replace the fuel line.
system.
Engine does not stop

Engine does not stop Defective engine control system Diagnose the engine control
system.
Exhaust gas is blue or black

Exhaust gas is blue or black. Reduction in injection-valve Replace the fuel injector.
opening pressure or defective
atomizing status
Engine control system malfunction System diagnosis.
Fuel System Check • Clogged fuel filter

Description • Fuel pipe malfunction (Crushing, breakage,
clogging, disconnection, etc.)
Conforms to a fuel leak. Engine acceleration raises fuel
pressure and which increases the leak. Leak could be • Fuel tank malfunction
in the following pipes and locations. • Injector malfunction
• Between injectors and fuel rail. • Fuel supply pump malfunction
• Between fuel rail and fuel supply pump. • Pressure limiter malfunction
• Between fuel supply pump and fuel filter. An intermittent may be caused by a poor connection,
rubbed-through wire insulation or a wire broken inside
• Between fuel filter and fuel tank. the insulation. Check for poor connections or a
• Between pressure limiter and fuel tank. damaged harness.
• Between injector over flow and leak off pipe. Inspect the ECM harness and connector for improper
mating, broken locks, improperly formed or damaged
Diagnostic Aids terminals, poor terminal-to-wire connection, and
Check the following items. damaged harness.
ECU may set a DTC, if there is adequate air in fuel line.
• Air in the fuel line Schematic Reference: Engine Controls Schematics
Step Action Value(s) Yes No

Check the fuel quantity.
1 — Add fuel and go to
Was a problem found? Go to Step 2 Step 2
Check the fuel quality.
1. Discharge the fuel from fuel tank
2. Replenish the tank with specified fuel
2 —
3. Bleed the air from the fuel system
4. Start the engine
Could the engine be started? Go to Step 7 Go to Step 3
Bleed the air from fuel system. Refer to Fuel
3 System Air Bleeding in this section. —
Is the action complete? Go to Step 4 —
Step Action Value(s) Yes No

Check the main fuel filter for clogging.
Clean, repair, or replace as required.
4 Notice: Replacement of a fuel filter is —
checking to a dealer.

Check the fuel line for damage and leakage.
Clean, repair, or replace as required.
• Crushed areas
5 • Breakage —
• Cracks
• Loose connections

Check the fuel tank.
If a problem is found, clean, repair, or replace
as necessary.
• Foreign material (Clogged suction port)
• Bent or cracked suction pipe
6 • Fuel tank distortion —
• Fuel tank improper installation
• Clogged fuel cap hole
• Water

Rebleed the air from the fuel pipe. Refer to
7 Fuel System Air Bleeding in this section. —
Is the action complete? Verify repair —
Fuel Filter Assembly

Components
1
2
4 LNW76CSF000101
Legend
1. Bolt 3. Fuel Return Hose
2. Fuel Feed Hose 4. Sedimenter Harness Connector
Removal
1. Disconnect the sedimenter harness connector.
2. Remove the feed hose and the return hose from
the fuel filter and plug it so that the fuel does not
flow out.
3. Remove the bolts for mounting the fuel filter.
4. Remove the fuel filter assembly.
Installation
1. Install the fuel filter assembly.
2. Install the bolts for mounting the fuel filter.
3. Install the feed hose and the return hose.
4. Connect the sedimenter harness connector.
5. Bleed out the air.
• Refer to "Fuel System".
Fuel Filter Element

Removal 5. If foreign material is attached on the surface of the
body inner circumference, wipe it with clean cloth.
1. Remove the fuel in the element case.
a. Loosen the drain plug at the bottom of the
element case.
1
b. When the air breather of the body is loosened,
the is run out from the drain plug. 2
2. Remove the harness of the water warning switch.
3. Remove the element case from the body by 3
rotating the case in a counterclockwise direction,
using a socket (width of double socket: 29mm(a)). 4
After removing the case, confirm that the float at
the inside bottom can move up and down
smoothly. 5
If foreign materials, sludge or other dirty materials
are deposited at the bottom of the case, remove it
clearly.
4. Remove the O-ring of the body by pulling out the
element downward.
6
9
7
8
a
BLW61DMH000101
Legend
1. Cap
2. Air bleeder
3. Filter body
4. O-ring
5. Fuel filter element
6. Element case
7. O-ring
8. Drain plug
9. Wiring connector
Installation
1. Place the O-ring, packaged with the element kit,
into the groove on the outer circumference of the
body.
Careful handling of the O-ring is needed to prevent
being damaged by the threaded area of the body.
2. Apply a thin layer of fresh diesel fuel on the
gaskets, inside and outside of the element, and
then insert the gasket until it hits the end.
NOTE:
Be careful not to insert any foreign materials into the
four holes (clean side) next to the inside gasket.
5. Tighten the drain plug of the element case, and
reconnect the connector of the water warning
switch.
Tightening torque:
0.4 N⋅m (0.04 kg⋅m / 3.47 lb in)
6. After starting the engine, check each section for no
looseness.
1 2
7
4
5
MFW61DLH000101
Legend
1. Salient for socket
2. Float
3. Outside gasket
4. Inside gasket
5. Clean side hole
6. Element kit
7. O-ring grove
3. Apply a thin layer of fresh diesel fuel on the inner

circumference of the element case (or the O-ring
section at the body side). Turn the element in a
clockwise direction until it hits to the body carefully.
Biting with the O-ring must be
avoided.
No hitting of the element to the case means that
the element does not have compete insertion.
Turn the element and push it in again.
4. Tighten the element case with a torque wrench.
Fuel Injector
Components
5
3
4
2
6
LNW76CLF000201
Legend
1. Cylinder Head Cover 4. Fuel Injector
2. Fuel Injector Clamp 5. Fuel Injection Pipe
3. Fuel Injector Clamp Bolt 6. Fuel Injection Pipe Clip
The fuel system consists of many tiny holes and NOTE:

spaces that allow the movement of fuel from one place To avoid electric shock: Set the switch to the 'OFF'
to another. These holes and spaces are milled to position and disconnect the battery negative cable
extremely high precision. This is especially true of the before checking or repairing the fuel injector, wiring or/
fuel injector. and connectors.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign Removal
material into the fuel system or fuel injector during the 1. Remove the cylinder head cover.
removal and installation procedure. Refer to “Cylinder Head Cover” in ENGINE
MECHANICAL section.
2. Remove the injection pipe sleeve nut (1) from the 4. Mark each fuel injector with the number of the
injector. cylinder from which it was removed. Store the fuel
injector in a safe place. Position the fuel injector so
1 that the nozzle is protected.
NOTE:
• If a fuel injector is replaced, cross off the replaced
injector ID codes on the label with a marking pen
etc.
• If all fuel injectors are replaced, remove the fuel
injector ID code label from the engine cover.
1
2 4JJ1
51 16 1A 25 1A 24 17 17 00 14 00 52
51 19 13 OF OF OF 00 09 09 09 00 54
3 51 39 39 2C 1C 23 13 14 00 OF 00 57
51 19 19 18 00 17 00 00 00 00 00 44
4
5
LNW71DSH000101 6
3. Remove the injector.
NOTE:
Do not reuse the clip, gasket and bolt.
3
2
LNW76CSH001701
Legend
1 1. 1st Cylinder Injector ID Code
2. 2nd Cylinder Injector ID Code
3. 3rd Cylinder Injector ID Code
4. 4th Cylinder Injector ID Code
4 5. Engine Cover
6. Injector ID Code Label
RTW66CSH000101
Legend
1. Fuel Injector
2. Leak Off Pipe
3. Clip
4. Gasket
5. Washer
NOTE:
• Do not tamper with the electromagnetic portion of
the fuel injector. Reduced electromagnetic function
will result in injector failure.
Installation 4. Temporarily tighten the clamp bolts.
1. Install the new gasket and O-ring to each fuel 5. Apply a thin coat of engine oil to the outer surface
injector. of the fuel injector side sleeve nuts.
6. Install the fuel injector pipes to the position shown
3 in the illustration.
2 7. Use a spanner to carefully tighten the sleeve nuts
until the fuel injector pipes contact the fuel injector
and fuel rail.
8. Tighten the fuel injector pipe clips to the specified
1 torque.
4 1
RTW66CSH000101
Legend
1. Fuel Injector
2. Leak Off Pipe 2
3. Clip
4. Gasket
5. Washer
2. Install the fuel injector clamps. Refer to the

illustration.
• Apply Engine oil to the threads and seating
surfaces of the clamp bolts.
1
2
3
LNW76CMH000101
Legend
1. Fuel Injector
2. Pipe Clip
9. Tighten the injection pipes to the specified torque.

Tightening torque⋅
Injector Side: 30 N⋅m (3.1 kg⋅m / 22 lb ft)
Fuel rail side: 25 N⋅m (2.5 kg⋅m / 18 lb ft)
RTW56CSH000601
Legend
1. Fuel Injector
2. Fuel Injector Clamp Bolt
3. Fuel Injector Clamp
3. Install the fuel injector clamps to the cylinder head.

1
2
LNW76CSH000501
Legend
1. Clamp Bolt
2. Sleeve Nut
10. Tighten the fuel injector clamp bolts to the

specified torque.
11. Tighten the engine oil level gauge guide tube.
Refer to “Cylinder Head Cover” in ENGINE
MECHANICAL section.
13. Program the Fuel Injector ID Codes
• Refer to “Programming” in ENGINE CONTROL
SYSTEM section.
SAMPLE
5F 05 00
FB 00 F7
08 F5 19
1 FF 04 49
RTW76ESH002601
Legend
1. Fuel Injector ID Code
2. Fuel Injector
30(3.1/22)
26(2.7/20)
25(2.5/18)
8(0.8kg m/69lb in)
LNW76CLF000101
Fuel Pressure Sensor

Removal Installation
1. Disconnect the fuel pressure sensor harness 1. Install the fuel pressure sensor.
connector (1).
2. Connect the fuel pressure sensor harness
connector.
1
LNW76CSH001601
2. Remove the fuel pressure sensor.
NOTE:
Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.
3 2
RTW76CSH000101
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter
Fuel Pressure Limiter

1. Remove the leak off pipe and hose (1). 1. Install the fuel pressure limiter.
NOTE: Tightening torque: 172 N⋅m (17.5 kg⋅m/127 lb ft)

Cover the areas exposed during parts removal to 2. Install the fuel leak off pipe and hose (1) using the
prevent the entry of foreign material into the fuel mounting eyebolt using the specified torque.
system. Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)
LNW76CSH000301
LNW76CSH000401
2. Remove the fuel pressure limiter.
NOTE:
system.
3 2
RTW76CSH000101
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter
Fuel Rail Assembly

Components
1
6
5
LNW76CLF000301
Legend
1. Injection Pipe (#1 to #4) 5. Fuel Rail Bracket
2. Fuel Feed Pipe Assembly 6. Space Rubber
3. Injection Pipe Clip 7. Fuel Leak Off Pipe
4. Fuel Rail
Parts of the fuel system such as the internal part of the Removal
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter • Disconnect the connector from the boost
and the entry of foreign matter could cause damage to sensor.
the fuel passage. Therefore, effective measures should • Disconnect the hose from the intercooler side.
be taken to prevent the entry of foreign matter. • Remove the air intake pipe with the hoses from
pipe.
LNW76ASH000501 LNW76CSH000701
2. Remove the noise cover left side. 6. Remove the leak off pipe and hose (1).
• Disconnect the dropping register connector and
remove the noise cover. NOTE:
3. Disconnect the fuel rail pressure sensor harness prevent the entry of foreign material into the fuel
connector (1). system.
1
LNW76CSH001601
4. Remove the engine oil level gage guide tube. LNW76CSH000401
5. Remove the fuel hose (1). 7. Remove the fuel feed pipe assembly (1) for supply
pump.
NOTE:
Cover the areas exposed during parts removal to NOTE:
prevent the entry of foreign material into the fuel Cover the areas exposed during parts removal to
system. prevent the entry of foreign material into the fuel
system.
3
2
1 1
LNW76CSH000801 LNW76CSH001201
8. Disconnect the injection pipe sleeve nut (1). Legend

1. Fuel Rail
NOTE: 2. Fuel Rail Bracket
Cover the areas exposed during parts removal to 3. Space Rubber
system.
Disassembly
1. Remove the fuel pressure limiter.
1
2. Remove the pressure sensor.
LNW76CSH000601
3 2
9. Remove the fuel rail and fuel rail bracket.
NOTE: RTW76CSH000101
• Do not grasp the pressure sensor, during the fuel Legend

rail removal procedure. 1. Fuel Rail
• Take care not to damage the connector unit of the 2. Fuel Rail Pressure Sensor
pressure sensor. 3. Fuel Pressure Limiter
Reassembly
1. Install the fuel pressure limiter.
2. Install the fuel pressure sensor. 4. Install the fuel feed pipe assembly (1) for supply
pump and tighten the bolts to the specified torque.
Installation
1. Tighten the space rubber, fuel rail bracket and fuel
rail using the specified mounting torque.
3
2
LNW76CSH000801
5. Tighten the fuel leak off pipe (1) using the

mounting eyebolt using the specified torque.
Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)
LNW76CSH001201
Legend
1. Fuel Rail
2. Fuel Rail Bracket 1
3. Space Rubber
2. Tighten the fuel pipe using the mounting sleeve nut

(1) and the specified torque.
Tightening torque: 25N⋅m (2.5 kg⋅m/18 lb ft)
LNW76CSH000401
LNW76CSH000601
3. Connect the fuel rail pressure sensor harness

connector.
6. Install the fuel hose (1). • Fit the pipe and the hose between the intake
1
marking.
LNW76CSH000701
7. Tighten the engine oil level gage guide tube and

tighten the mounting bolt to the specified torque.
Tightening torque: 25N⋅m (2.5 kg⋅m/18 lb ft)
8. Install the noise cover left side.
LNW76ASH000501
9. Install the dropping register connector.
10. Fit the air intake pipe and hose. 11. Install the boost sensor connector.
25(2.5/18)
44(4.5/33)
25(2.5/18)
LNW76CMF000101
Fuel Supply Pump

Components
1 2
4 3
11 5
10
9
8 6
7
LNW76CMF000201
Legend
1. Fuel Feed Pipe Assembly 7. Noise Cover
2. Injection Pipe Sleeve Nut 8. Timing Chain Cover Lower
3. Space Rubber A 9. Nut
4. Bracket 10. Sprocket
5. Space Rubber B 11. Fuel Supply Pump Gear
6. Fuel Supply Pump
The fuel system consists of many tiny holes and

spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to
extremely high precision. This is especially true of the
fuel injector.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injector during the
removal and installation procedure.
Removal
1. Partially drain the engine coolant. Refer to drain
procedure for engine cooling in this manual.
3. Remove the fan guide. 6. Remove the A/C compressor adjust pulley.
2
1
2 1
LNW76ASH000701 LNW76CSH001101
Legend Legend
1. Fan Guide Bracket 1. Bolt
2. Fan Guide Bracket 2. Nut
3. Bolt
7. Disconnect the A/C compressor.
4. Remove the cooling Fan. 8. Remove the A/C compressor bracket.
9. Remove the fuel rail assembly. Refer to removal
procedure for Fuel rail assembly in this manual.
Refer to removal procedure for Fuel rail assembly
in this manual.
11. Disconnect the connector of supply pump.
12. Remove the noise cover.
RTW56ASH025401
5. Remove the A/C compressor drive belt.
RTW56CSH001401
Legend
1. Noise Cover
13. Remove the timing chain cover assembly. Upper &
lower.
1
1
RTW56ASH006901
Legend
LNW76CSH001001
1. Align mark on intake camshaft and exhaust
Legend camshaft to mark of bearing cap
1. Timing Chain Cover Upper
2. Timing Chain Cover Lower. 15. Loosen the nut.
14. Align the timing marks at 3 locations as shown.
2
1
RTW56CSH001601
Legend
LNW76ASH001101
1. Nut
Legend
2. Mirror
3. TDC Mark
16. Remove the timing chain tennsioner. 19. Timing chain in moved upwards.
2
1
LNW71BSH001401 RTW56CSH003301
Legend 20. Paint the alignment mark. Between idle gear A and
1. Timing Chain Tennsioner. supply pump gear.
2. Gasket
17. Remove the timing chain tension lever pivot.

18. Remove the nut and sprocket.
RTW56CSH004101
Legend
1. Tension Lever Pivot
2. Sprocket
3. Nut
RTW56AMH000401
21. Use a gear puller to remove the fuel supply pump 23. Remove the supply pump and O-ring.
gear.
LNW76CSH000901
RTW56CSH002901
Legend
22. Remove the supply pump and supply pump 1. O-ring
bracket with spacer rubber. 2. Supply Pump
NOTE:
• Do not hold the high pressure pipe, during the Installation
supply pump removal procedure.
1. Install the O-ring to the fuel supply pump.
• Do not grasp the high pressure pipe, when moving
the supply pump from one location to another. 2. Install the fuel supply pump. Apply soapy water to
the O-rings before attaching.
NOTE:
Take care not to twist the O-ring.
3 4
3. Install the fuel supply pump bracket.
2
Temporarily tighten with the bolts and nuts (Gear
case side).
1 Temporarily tighten with the bolts (Cylinder body
side).
Fully tighten the bolts and nuts (Gear case side).
Fully tighten the bolts (Cylinder body side).
Tightening torque: 25 N⋅m (2.5 kg⋅m /18 lb ft)
LNW76CSH001301
Legend
1. Supply pump
2. Space Rubber B
3. Supply Pump Bracket
4. Space Rubber A
3 4
2 3
1
4
LNW71DSH000401 RTW56CSH005101
Legend 6. Install the timing chain to the each sprocket and

1. Fuel Supply Pump install the fuel supply pump sprocket to the pump
2. Space Rubber B shaft.
3. Fuel Supply Pump Bracket a. Align the camshaft sprocket timing mark (1)
4. Space Rubber A with the bright plate timing chain link (2).
4. Confirm that the supply pump camshaft key is b. Align the fuel supply pump sprocket timing
turned to the right and is horizontal. mark (3) with the yellow plate timing chain link
(4).
c. Install the fuel supply pump sprocket to the fuel
pump shaft by aligning the dowel pin that is
attached to the gear.
d. Hand-tighten the fuel supply pump shaft nut.
RTW56CSH004301
5. Install the fuel supply pump to the pump shaft.

a. Align the fuel pump gear timing mark (1) with
the idle gear A paint marks (2). 3
b. Ensure that the pump must be bit with 4 RTW56CSH005001
maingear(3)of the idle gear A. Depress the
Legend
pump gear when it is bitted with scissors gear
1. Timing Mark
(4) of the idle gear A.
2. Dark Plate
2. Timing Mark
2. Yellow Plate
7. Install the timing chain tension lever pivot. Hand-
tighten the pivot bolt.
Confirm that the tension lever moves smoothly.
8. Attach the hook of the timing chain tensioner.
• Hold the latch(3) depressed. Insert the
plunger(2). Attach the hook (4) to the pin (1) to
hold the plunger in place.
4 RTW56ASH020401
11. Tighten the nut (1) to the specified torque.

LNW71BSH001501
9. Install the gasket (2) and the timing chain tensioner

(1). Tighten the nut to the specified torque.
Tightening torque: 10 N⋅m (1.0 kg⋅m/ 87 lb in)
RTW56CSH001601
12. Tighten the timing chain tension lever pivot bolt to

the specified torque
2 13. Turn the crank pulley two rotations (720°CA).
1
LNW71BSH001401
10. Unlock the tensioner hook.

• Press the place of the arrow in the figure.
• The hook is opened. The plunger pushes the
tension lever.
14. Check the mark (1) on the intake camshaft and
exhaust camshaft to the mark of camshaft bearing
cap.
2
1 1
RTW76CSH001201
18. Apply liquid gasket (ThreeBond TB-1207C or

equivalent) to the timing chain cover lower (1).
RTW56ASH006901
• Attach the cover within 5 minutes of applying
15. Install the cylinder head cover. the liquid gasket.
16. Apply liquid gasket (ThreeBond TB-1207C or
equivalent) to the timing chain cover upper (1).
• Attach the cover within 5 minutes of applying
the liquid gasket.
RTW56CSH002301
1
19. Install the timing chain cover lower (1). Tighten the
bolts (2) and nuts (3) to the specified torque.
RTW56CSH002101
17. Install the timing chain cover upper (1).

Tighten the bolt to the specified torque.
• Apply Loctite #262 or equivalent to the bolt and
stud threads of cylinder head side (2).
25. Install the A/C compressor adjust pulley.
2
3
LNW76CSH001401 2 1
LNW76CSH001101
20. Install the noise cover (1). Tighten the bolts to the
specified torque. Legend
1. Bolt
2. Nut
Tighten the bolt and nut to the specified torque.

Bolt Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)
1 Nut Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)
26. Install the A/C compressor drive belt.
Refer to the drive belt tension check procedure for
Heating and air conditioning in this manual.
27. Install the cooling fan.
28. Install the fan guide.
31. Start the engine and let idle.
IMPORTANT:
RTW56CSH001401
In order for the ECM to learn the characteristics of the
fuel supply pump, let the engine idle until warn-up. If
21. Install the connector of supply pump. fuel system DTC's are stored in the meantime, clear
22. Install the fuel rail assembly. the DTC and warn-up the engine again.
• Refer to the Install procedure for Fuel rail
assembly in this manual.
23. Install the A/C compressor bracket. Tighten the
bolts to the specified torque.
24. Install the A/C compressor.
25(2.5/18)
25(2.5/18)
27(2.8/20) 25(2.5/18)
10(1.0/87lb in)
130(13.3/96)
10(1.0/87lb in)
10(1.0/87lb in)
25(2.5/18)
10(1.0/87lb in)
LNW76CLF000401
Fuel Sedimenter Switch

Inspection
1. Check that there is continuity between the switch
connector terminals when the float in the fuel
sedimenter is above the water drain line.
2. Turn on the ignition switch, remove the fuel
sedimenter connector, and connect the terminals
of the connectors on the harness side. Confirm
that the sedimenter warning lamp lights up.
If abnormalities are detected during the check, replace
the CASE – KIT (with switch) and carry out repairs in
case of defective connections between circuits or short
circuits.
2
1
4 LNW76CSH000201
Legend
1. Sensor
2. Connector on The Vehicle Side
3. Harness
4. Drain Plug
Fuel Tank
Components
1 3
2 4
LNW21DLF000301
Legend
1. Fuel gauge unit connector 4. Fuel return hose
2. Breather hose 5. Band
3. Fuel feed hose 6. Fuel tank
Removal 6. Remove the fuel feed hose.

1. Loosen the fuel filler cap. 7. Remove the fuel return hose.
2. Drain the fuel through the drain plug. • Use a stopcock to prevent fuel from spilling,
point it upwards and tie it to the frame.
3. After draining the fuel tighten the drain plug to its
specified torque. 8. Remove the band for mounting the fuel tank and
remove the tip of the band on the frame side.
Tightening torque: 20 N⋅m (2.0 kg⋅m / 14 lb ft) 9. Pull the fuel tank to the outside.
4. Remove the connector from the fuel gauge unit.
5. Remove the breather hose.
NOTE: • Put fuel into the fuel tank and tighten the fuel
If the fuel tank can not be removed, remove the bracket filler cap.
and lower the fuel tank downwards. • Connect the battery ground cable.
• After starting the engine, check the hose
connections to make sure that there are not any
fuel leaks.
6. Connect the connector to the fuel gauge unit.
LNW21DMH000501
Mounting
1. Mount the fuel tank.
NOTE:
If you removed the bracket when removing the fuel
tank, attach the bracket to the frame and tighten it to its
specified torque.
Tightening torque: 55 N⋅m (5.6 kg⋅m / 41lb ft)
Also, when placing the fuel tank on the bracket, make

sure the rubber that is attached to fuel tank contacts the
bracket.
2. Mount the band onto the fuel tank and tighten the
mounting nut to its tightening torque.
3. Mount the fuel return hose.
4. Mount the fuel feed hose.
• Put the hose onto the pipe at least 25 mm
(0.9843 in).
5. Mount the breather hose.
Fuel Gauge Unit

Components
LNW21DMF000101
Legend
1. Fuel gauge unit connector 2. Fuel gauge unit
Removal
1. Remove the wiring connector from the fuel gauge
unit.
2. Remove the mounting screw and remove the fuel
gauge unit.
NOTE:
When removing and attaching the fuel gauge unit, take
caution with respect to interference with surrounding
objects; do not deform the arm.
Also, after removing the fuel gauge unit, place a seal so
that foreign materials do not get into the tank.
Inspection 1. While moving the float from E to F, inspect the
resistance value between connector terminals 1 J-
The fuel tank unit changes its internal resistance based
28 - 2 J-28.
on the position of the float (height of liquid) and moves
the needle of the fuel meter. 2. Confirm that the low fuel light turns on when the
float is in the "E" position.
If there are any abnormalities found with the
inspection, replace with a part that works correctly.
LNW21DSH002301
a b c d
J-28
1/2 2 1
Warning lamp lighting point
LNW76DMF000101
325.2mm / 12.80in (Fuel tank capacity 63L / 13.86Imp.gal)

a
379.7mm / 14.95in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)
b

c
d
Float Position Standard resistance volume

(Ω)
F (FULL stopper) 2.5
1/2 33.0
Warning lamp lighting 87.0
point
E (EMPTY stopper) 98.3
Mounting 1. Mount the fuel gauge unit.

Perform the removal process backwards for mounting. 2. Connect the wiring connector to the fuel gauge
unit.
55(5.6/41)
12(1.2/104lb in)
20(2.0/14)
LNW76DMF000201
MEMO
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ENGINE ELECTRICAL (4JJ1) 6D-1
ENGINE
ENGINE ELECTRICAL
(4JJ1)
TABLE OF CONTENTS
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .6D-2
Servicing Cautions . . . . . . . . . . . . . . . . . . . . . . .6D-2
Important Generator Components and Function 6D-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .6D-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-4
Unit Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6
Inspection and Repair . . . . . . . . . . . . . . . . . . . .6D-8
Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . .6D-8
Stator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . .6D-10
Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . 6D-11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-12
Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . .6D-12
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-14
Starting Circuit Diagram . . . . . . . . . . . . . . . . . .6D-14
Removal and Installation . . . . . . . . . . . . . . . . .6D-14
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6D-15
Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-22
Magnetic Switch . . . . . . . . . . . . . . . . . . . . . . . .6D-24
Pre-Heating System . . . . . . . . . . . . . . . . . . . . . .6D-26
Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-26
6D-2 ENGINE ELECTRICAL (4JJ1)
Charging System
Servicing Cautions • When steam cleaning or washing the engine, do
not allow steam or water to come in direct contact
• Battery polarity is important. If the battery cables
with the battery and other electrical system
are reversed, the generator diodes will be
components.
destroyed.
• Be sure to read the item on belt tension adjustment
• Do not remove the battery cables or the charging
before beginning the procedure.
circuit wiring when the engine is running.
• Confirm that the terminal wires are connected to
the proper terminals by checking the terminal Important Generator Components and
numbers (the number on the terminal wire and the Function
terminal must be the same).
• The generator uses a built-in solid-state IC voltage
• Disconnect the battery negative cable (-) before regulator. The regulator and other important
inspecting the generator. components together with their connections are
• Do not open or close the battery relay switch when shown in the illustration.
the engine is running. • The voltage regulator is installed to the rear cover
• Disconnect the battery negative cable (-) when assembly of the generator together with the brush
using external equipment (Quick-Charge) to holder and the rectifier. The generator requires no
charge the battery. additional voltage regulation.
• 9 diodes are connected to the stator coil to convert
AC to DC. The DC voltage is delivered to the
generator output terminal.
AC Generator
RTW76DMF000101
Charging System
B
S
Charge lamp
Rotor coil
Charge IG-SW
L relay
Warnning
lamp
Battery
Stator coil
B S L
F
IC Regulator QOS
P C/U SW
RTW56DMF000101
Troubleshooting • Inadequate charging

Symptoms • Excessive charging
• No charging • Unstable charging current
• Abnormal generator noise
No charging
Possible problem Countermeasure
Dead battery Replace
Open or shorted wiring Repair
Open or shorted ammeter
Loose wiring connections
One or more generator coils open or shorted Replace
Bad diode
Bad regulator
Loose regulator connections Repair
Inadequate charging
Dead battery Replace

Open or shorted wiring Repair
Loose wiring connections
Loose generator drive belt Adjust belt tension
Stator coil intermittent short Replace
Bad diode
Loose battery connections Repair
Bad regulator Replace
Loose regulator connections Repair
Excessive charging
Unstable charging current

Open wiring connection or broken wire Repair
Open or shorted stator coil Replace
Loose terminal connections Repair
Loose regulator terminal connections Repair
Abnormal operating noise

Bad bearing Replace
Loose rotor core or stator core Repair
Bad diode Replace
Open or shorted stator coil Replace
Diagnosis 3. With the engine off, turn the ignition switch to the
ON position. If the warning lamp does not light,
On-vehicle Inspection
remove the harness connector from the generator.
The charging system warning light tells the vehicle Ground the connector L terminal. The lamp should
operator of possible problems with the system. light. If it does not, the bulb is burned out. Replace
When the ignition switch is moved to the ON position, the bulb.
the light turns on. The light turns off immediately after 4. Start the engine. If the warning lamp remains on,
the engine is started. If the light turns on during engine the generator must be repaired or replaced.
operation, there is a problem with the charging system.
Perform the checks described below.
1. Check the belt (broken or loose).
2. Check the harness connectors (loose or
disconnected).
Specifications
Battery power Volts 24

Generator output Amperes 45 / 50 / 80
Rotational direction (Viewed from pulley) — Clockwise
Rated speed rpm 5000
Maximum speed 12000
Unit Servicing
Components
5
4
3 10
2
9
1
8
7
LNW76DLF000101
Legend
1. Pulley Nut 6. Through Bolts
2. Pulley 7. Rear Cover Assembly
3. Front Cover Assembly 8. Rectifier
4. Rotor Assembly 9. Ball Bearing
5. Stator Assembly 10. Ball Bearing
Disassembly
1. Remove the through bolts.
2. Insert a flat-blade screwdriver between the front
cover and the stator. Pry the parts apart.
3. Separate the front cover/rotor assembly from the 8. Remove the bearing retainer and the bearing.
rear cover/stator assembly.
LNW71DSH000201
LNW76DSH000801
9. Remove the B-terminal nut and M5 nut.
4. Place the front cover and rotor in a vise. 10. Remove the rear cover from the stator.
5. Remove the pulley nut and the pulley.
6. Remove the rotor from the front cover.
LNW71DSH000301
LNW76DSH000201
7. Remove the screw from the front cover.

11. Remove the stator assembly. Limit 30.7 (1.209)
RTW46DSH000401
12. Remove the rectifier assembly from the stator LNW76DSH000501

assembly. 3. Measure the electrical resistance between the slip
rings. If the resistance is greater than the specified
limit (open circuit), repair is required.
Rotor coil resistance at 20°C (68°F) Ω

(45 A) 10.5
(50 A) 8.2
(80 A) 10.2
LNW76DSH000601

Repair or replace any parts found to be excessively
worn or damaged during the inspection procedure.
Rotor Assembly
1. Check for dirty or rough slip ring surfaces. Remove
dirt from the surfaces with a clean rag. Use No. LNW76DSH000301
500 or No. 600 sandpaper to smooth the surfaces.
2. Measure the slip ring diameters. Replace the slip
ring if the diameter is less than the specified limit.
Slip ring diameter mm (in)

Standard 31.7 (1.248)
4. Check for conductivity between the slip rings and 2. Measure the resistance between the stator coil and
the rotor core. If there is continuity, the rotor the stator core. If the resistance is less than the
assembly must be replaced. specified value, the stator coil must be replaced.
Stator coil/core resistance: MIN 1 MΩ
LNW76DSH000401
HCW31ESH004401
Stator Coil
1. Measure the stator coil resistance. If the resistance Brushes
is less than the specified value, the stator coil must
Measure the brush height. If the height is less than the
be replaced.
specified limit, the brushes must be replaced.
Stator coil resistance at 20°C (68°F) Ω

Brush height mm (in)
45 A 0.19
Standard 25 (0.984)
50 A 0.19
Limit 6.5 (0.260)
80 A 0.07
LNW76DSH000701
Rectifier Assembly
Measure each of the diode resistances in both
1 directions (anode/cathode and cathode/anode). If any
of the diodes have the same resistance in both
directions, the rectifier must be replaced.
4
RTW46DSH001201
LNW76DMH000101
Tester Wire
E BAT
+ — + —
U,V, and WN U,V, and WN
+ —— Conductivity + —— NO conductivity
— NO conductivity —— — Conductivity ——
Negative side diode check Positive side diode check
Rectifier Assembly
(45A / 50A)
L
E
6
SWITCH 2 8
B + OUTPUT SIGNAL
7
3 5 PULSE 5~30V
LAMP 2 LAMP 1 SWITCH 3 GENERATOR
4 -
1kHz
2
1 VOLT METER V DIRECT-CURRENT
STABILIZATION POWER SUPPLY LNW76DSF000101
(80A)
L
E
S
7
SWITCH 2 9
B + 8 OUTPUT SIGNAL
4 6 PULSE 5~30V
LAMP 2 LAMP 1 SWITCH 3 GENERATOR
2 SWITCH 1 5 -
1kHz
3
1 VOLT METER V DIRECT-CURRENT
STABILIZATION POWER SUPPLY RTW46DSF000301
Test circuit
Refer to the judgment criteria shown in the Table
below.Carefully check Items 1 to 5.If all the items are
OK, the IC regulator is normal.
Circuit components
1 DC regulated power supply 0 - 30 volts variable with output of 1 ampere or more
2 Lamps (2) 24 volts, 1.8 watts
3 Switches (3) ——
4 DC voltmeter 0 to 60 volts, 0.5 grade
5 Pulse generator (Oscillator) 5 to 30 volt output at a frequency of 1KHz
Judgment criteria
Switch Switch Switch Voltmeter Lamp condition

NO. Remarks
1 2 3 reading Lamp 1 Lamp 2
On
1 ON OFF OFF ON Initial excitation check
(dim)
24V
On or
2 ON ON OFF Full excitation check
flashing
OFF
Off or Lamp 1 off or dimly lit when the voltmeter shows
3 ON ON OFF 32V
on (dim) less than 24 volts or 32 volts
On or
4 OFF ON OFF 24V Stator and brush separation check
flashing ON
5 ON ON ON 36V On Excess voltage check
Reassembly b. Tighten the pulley nut.

Follow the disassembly steps in reverse order to Tightening torque: 110 N⋅m (11.2 kg⋅m / 81lb ft)
reassemble the generator. Pay close attention to the
items below.
• Be very careful not to reverse battery polarity.
Reversed battery polarity will destroy the rectifier
diodes.
• Do not ground the generator B-terminal. Heat and
fire damage to the harness will result.
• If using a fast charge procedure, be sure to
disconnect the battery positive cable. If you do not,
the rectifier diodes will be exposed to high positive
voltage that will destroy them.
• Be very careful to reassemble the parts to their
original positions. Particular care must be taken
with insulated parts.
• Carefully clean all insulated parts so that they are
completely free of oil and/or grease.
• Be sure that B-terminal twist-type stoppers (round
RTW46DSH002101
terminal) are securely inserted before tightening
the nuts.
Final Assembly
1. Pulley and rotor assembly.
• Install the pulley and rotor assembly
a. Carefully clamp the rotor assembly in a vise.
c. The rear ball bearing is pressed into the wheel • Insert the pin from the outside of the rear cover.
eccentric groove.The bearing ring projects from Press the brushes into the holder. Complete the
the groove.During installation, rotate the assembly procedure.
bearing to the point of minimum bearing ring
projection.
Pin
Ring
Projection part
(0.65mm blow)
eccentric groove
RTW46DSH005301
3. Use a bench press to install the rear cover

assembly to the front cover assembly.
RTW46DSH004901
2. Rear cover and stator assembly.

• Use a pair of long-nose pliers to connect the
stator coil leads and the rectifier leads.
• Finish the work as quickly as possible to
prevent the rectifier from heat transferred by the
soldering.
RTW56DSH000201
4. Through bolts.
• place a guide bar through the holes in the front
cover and rear cover flange for proper
alignment.Install the through bolts.
RTW46DSH000401
Tightening torque:4N⋅m(0.4 kg⋅m / 35 lb ⋅ in)
Starter Motor
Starting Circuit Diagram 3. Install the E/G oil level gage.
4. Install the A/T oil level gage.
Type : S13-555A
5. Reconnect the battery cable at the starter motor
and the ground cable at the cylinder body.
Starter switch
6. Reconnect the battery cable and the ground cable
at the battery terminals.
B
S
Battery
RTW46DSH005501
Removal and Installation

removal and installation procedure. This Section gives
before you begin.
Important Operations - RemovalStarter Motor

1. Disconnect the battery cable and the ground cable
at the battery terminals.
2. Remove the A/T oil level gage.
3. Remove the E/G oil level gage.
4. Disconnect the magnetic switch cable at the
terminal bolts.
5. Disconnect the battery cable at the starter motor
and the ground cable at the cylinder body.
6. Remove the starter motor from the engine.
Important Operations - Installation

Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention
to the important points during the installation
procedure.
Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified
torque.
Motor Bolt Torque: N⋅m (kg⋅m / lb ft)

85 (8.7 / 63)
Components
24 V 4.0 kW
6
5
4
3
7
2
1
8
26
25
24
23
22
21
20 9
19
18
17
10
11
12
13
14
15
16
LNW76DLF000201
Legend
1. Plunger 14. Ball Bearing
2. Dust Cover 15. Armature
3. Magnetic Switch 16. Ball Bearing
4. Terminal Cover 17. Bearing Retainer
5. Gear Case 18. Pinion Shaft
6. T0rsion Spring 19. Ball Bearing
7. Dust Cover 20. Clutch
8. Shift Lever 21. Ball Bearing
9. Through Bolt 22. Return Spring
10. Rear Cover 23. Stopper
11. Brush Holder 24. Clip
12. O Ring 25. Ball Bearing
13. Yoke 26. Bearing Holder
24 V 4.5 kW
4 5
2
1 6
7
34
33
32
31
30
29
28 8
27
26 9
25
24
23
22
21
19 20
10
12
13 11
14
15
16
17
18
LNW76DLF000301
Legend
1. Plunger 18. Ball Bearing
2. Dust Cover 19. Bearing Retainer
3. Magnetic Switch 20. Clip
4. Terminal Cover 21. Pinion Stopper
5. Torsion Spring 22. Pinion
6. Shift Lever 23. Cushion Spring
7. Dust Cover 24. Sleeve Cover
8. Gear Case 25. Stopper Washer
9. Through Bolt 26. Pinion Shaft
10. Rear Cover 27. Ball Bearing
11. Drain Pipe 28. Clutch
12. Brush Holder 29. Ball Bearing
13. O Ring 30. Return Spring
14. Yoke 31. Stopper
15. O Ring 32. Clip
16. Ball Bearing 33. Ball Bearing
17. Armature 34. Bearing Holder
Important Operations Remove the torsion spring from the magnetic
1. Lead Wire switch.
Disconnect the lead wire at the magnetic switch.
RTW46DSH002801
RTW46DSH002601 3. Through Bolt

2. Magnetic Switch Assembly 4. Screw
Remove the magnetic switch bolts, then remove 5. Rear Cover
the switch from the shift lever. Remove the through bolts, then remove the rear
cover.
RTW46DSH002701
RTW46DSH002901
6. Motor Assembly 9. Armature
Remove the four brushes from the brush holders. Remove the brush holder and pull out the armature
assembly free from the yoke.
Brush
RTW46DSH003001
RTW46DSH003201
Remove the yoke along with the armature and the 10. Bearing Retainer
brush holder from the gear case.
Remove the brushes and commutator carefully so 11. Pinion Assembly
as not to allow them in contact with the adjacent 12. Dust Cover
parts. 13. Shift Lever (4.0kW only)
14. Shift Lever and Lever pin (4.5kW only)
15. Gear Case
a. Remove the bearing retainer.
b. Remove the pinion from the gear case.
RTW46DSH003101
7. Brush Holder
8. Yoke
LNW76DSH000901
c. Use a screwdriver to remove the stopper clip. 2. Check the commutator mica segments for
Then disassemble the pinion assembly. excessive wear.
3. Measure the mica segment depth.
Mica Segment Depth mm (in)

Standard 0.5 – 0.8 (0.020 – 0.030)
Limit 0.2 (0.008)
If the mica segment depth is less than the standard

but more than the limit, the commutator may be
reground.
If the mica segment depth is less than the limit, the
commutator must be replaced.
RTW46DSH003401 1 2
3

Make the necessary adjustments, repairs, and part 4
replacement if excessive wear or damage is discovered
during inspection.
Armature
1. Measure the commutator run-out. 5
Replace the commutator if the measured run-out
exceeds the specified limit.
RTW56DSH000701
Commutator Run-Out mm (in) Legend

1. Insulator
Standard 0.05 (0.002)
2. 0.5 to 0.8 mm (0.020 to 0.030 in)
Limit 0.20 (0.079) 3. Commutator Segments
4. Correct
5. Incorrect
4. Measure the commutator outside diameter.
Commutator Outside Diameter mm (in)

Standard 36.5 (1.44)
Limit 35.5 (1.40)
RTW46DSH003501
If the measured outside diameter is less than the b. Repair Step 1 at different segments of the
specified limit, the commutator must be replaced. armature core.
There should be continuity between all
segments of the commutator.
If there is not, the armature must be replaced.
HCW51ESH000901
5. Use a circuit tester to check the armature for

grounding.
RTW46DSH003701
a. Hold one probe of the circuit tester against the
commutator segment.
Yoke
b. Hold the other circuit tester probe against the
armature core. 1. Use a circuit tester to check the field winding
If the circuit tester indicates continuity, the ground.
armature is grounded. a. Hold one circuit tester probe against the field
The armature must be replaced. winding end or brush.
b. Hold the other circuit tester probe against the
bare surface of the yoke body.
There should be no continuity. If there is
continuity, the field coil is grounded. The yoke
must be replaced.
RTW46DSH003601
6. Use the circuit tester to check the armature for

continuity.
a. Hold the circuit tester probes against two
commutator segments.
RTW46DSH003801
2. Use the circuit tester to check the field winding

continuity.
a. Hold one circuit tester probe against the "M"
terminal lead wire.
b. Hold the other circuit tester probe against the 2. Use a circuit tester to check the brush holder
field winding brush. insulation.
There should be continuity.If there is no Touch one probe to the holder plate and the other
continuity, the yoke must be replaced. probe to the positive brush holder.
There should be no continuity.
RTW46DSH003901
RTW46DSH004101
Brush and Brush Holder Inspect the brushes for excessive wear.
1. Use a vernier caliper to measure the brush length If the negative brushes have excessive wear, the entire
(four brushes). brush holder assembly must be replaced.
Replace the brushes as a set if one or more of the If the positive brushes have excessive wear, the entire
brush lengths is less than the specified limit. yoke must be replaced.
Overrunning Clutch
Brush Length mm (in) 1. Inspect the overrunning clutch gear teeth for
Standard 15.5 (0.61) excessive wear and damage.
Limit 12 (0.47) Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.
RTW46DSH004001
LNW61DSH002701
Bearing b. Install the dust cover.
Inspect the bearings for excessive wear and
damage.Replace the bearings if necessary.
Dust Cover Bolt Torque: N⋅m (kg⋅m/lb in)
10.6 (1.08 / 78)
RTW46DSH004401
Reassembly RTW46DSH005701
Important Operations 4. Pinion Assembly

1. Magnetic Switch Assembly Apply a coat of grease to the reduction gear and
a. Attach the torsion spring to the hole in the install the pinion assembly to the armature shaft.
magnetic switch as illustrated.
b. Insert the shift lever into the plunger hole of the
magnetic switch.
LNW61DSH002801
5. Brush Holders
a. Install the brushes into the brush holder with
RTW46DSH005601 raising the spring end of the brush spring.
2. Gear Case Take care not to damage the commutator face.
3. Dust Cover
a. Install the magnetic switch assembly in the gear
case.
b. Install the brush holder with aligning the
peripheries of the yoke and the brush holder.
RTW46DSH002601
RTW46DSH004501 Inspection After Assembly

6. Through Bolt Use a vernier caliper to measure the pinion shaft thrust
Install the through bolts in the rear cover and play.
tighten them to the specified torque. The pinion shaft thrust play is equal to the pinion shaft
end and pinion stopper clearance.
Through Bolt Torque: N⋅m (kg⋅m/lb in)

8.1 (0.83 / 69.7) Pinion Shaft Thrust Play: mm (in)
0.3 - 1.0 (0.012 - 0.039)
0.3-1.0mm
LNW61DSH002901
7. Lead Wire LNW76DSH001001
Connect the lead wire in the magnetic switch and

tighten the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque: N⋅m (kg⋅m/lb in)

8.6 (0.88 / 74.9)
Magnetic Switch 3. Return Test
Disconnect the battery positive lead at the S
The following tests must be performed with the starter
terminal.
motor fully assembled.
The pinion should return to its home position.
The yoke lead wire must be disconnected from the "M"
terminal.
To prevent coil burning, complete each test as quickly S
as possible (within three to five seconds).
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the
solenoid switch body and the M terminal. When
current is applied to the S terminal from the battery
positive terminal, the pinion should flutter.
RTW46DSH004701
RTW46DSH004601
2. Hold-in Maintenance Test

Disconnect the lead at the M terminal. The pinion
should continue to flutter.
RTW46DSH005901
8.6 (0.88 / 6.4)
8.1 (0.83 / 6.0)
LNW76DLF000401
Pre-Heating System
replacement if excessive wear of damage is discovered
during inspection.
Visual Check
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
Glow Relay
The glow relay is located in the relay box the engine
compartment.
Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range,
the glow relay must be replaced.
LNW21KSH001401
Glow Relay Resistance: Ω

94 - 114
1
3 2
4
4 1
2 3
LNW61DSH003001
Glow Plug
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference): Ω

Approximately 0.9
EXHAUST SYSTEM (4JJ1) 6F-1
ENGINE
EXHAUST SYSTEM
(4JJ1)
TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6F-2
Explanations on functions and operation . . . . . . 6F-2
Functional check . . . . . . . . . . . . . . . . . . . . . . . . 6F-3
List of abnormal phenomena . . . . . . . . . . . . . . . 6F-3
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6F-3
Exhaust Silencer and Exhaust Pipe . . . . . . . . . . . 6F-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4
DPD Disassembly . . . . . . . . . . . . . . . . . . . . . . . 6F-5
DPD Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6F-6
DPD Reassembly. . . . . . . . . . . . . . . . . . . . . . . . 6F-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-8
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-10
Exhaust Brake System . . . . . . . . . . . . . . . . . . . . 6F-11
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-11
Explanations on functions and operation . . . . . 6F-11
Functional check . . . . . . . . . . . . . . . . . . . . . . . 6F-11
Exhaust Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13
Exhaust Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-19
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-19
Explanations on functions and operation . . . . . 6F-19
EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . 6F-20
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-21
6F-2 EXHAUST SYSTEM (4JJ1)
Exhaust System
Service Precautions Explanations on functions and operation
Offset in position of the exhaust system during The exhaust brake assembly operates the auxiliary
assembly may sometimes cause vibrations or rattling brakes by adjusting the exhaust pressure. The silencer
noise. Therefore, temporarily tighten the bolt until all has a built-in catalytic converter and the catalyst is a
the parts have been positioned, and sequentially ceramic monolith (honeycomb). This reduces the CO
tighten from the engine side to the rear pipe side. and HC in the exhaust gas. The rear exhaust pipe has
a built-in post silencer. This improves the silencing
effect.
The main parts consist of the front exhaust pipe, center
exhaust pipe, exhaust brake unit, silencer with built-in
catalyst, and rear exhaust pipe.
3
2
1
6
LNW76FLF000201
Legend
1. Front Exhaust Pipe A 5. Exhaust Silencer(EURO 3 Specification)
2. Exhaust Brake Assembly 6. Exhaust Throttle Assembly
3. Front Exhaust Pipe B 7. Exhaust Silencer
4. DPD(Diesel Particulate Defuser, EURO 4 8. Center Exhaust Pipe
Specification) 9. Rear Exhaust Pipe
Functional check • Check for dents, damage holes or cracks due to
corrosion, and abnormal noise during operation.
• During check or repairs of the exhaust system,
confirm that the clearance between the body and • If CO or HC value in the exhaust gas increases
the floor is adequate. when measuring the exhaust gas (vehicle
inspection, etc.), replace the silencer (built-in
• Adequate care should be taken to prevent damage
catalyst).
due to heating or vibrations in the body panel as it
may lead to exhaust gas entering the cabin.
• Check for loose or damaged connectors and List of abnormal phenomena
leakage of exhaust gas.
• Vibration or rattling noise from the exhaust system.
• Check for degradation, cracks or damage to the
• Clogging of the exhaust system.
clamp or rubber.
• Exhaust leakage or noise.
• If the pipe or silencer is damaged or has a dent
then repair or replace it.
Trouble Shooting
Vibration or rattling noise from the exhaust system

Vibration or rattling noise from the Loose or misaligned components Match the joints and then re-tighten.
exhaust system Or,check for damage in the hanger,
mounting brackets and clamps.
Clogging of the exhaust system

Clogging of the exhaust system The exhaust brake is in the ON Refer to the Engine Control Systems
status. in 6E section, check the electric
system and repair if there are
abnormalities.
Check if the shaft movement in the
exhaust brake throttle valve moves
is jerky and replace if there is an
abnormality.
Clogging or deformation of the Repair or replace the exhaust piping.
exhaust piping.
Exhaust leakage or noise

Exhaust leakage or noise Defect or misalignment in mounting Match the joints and then re-tighten.
Damage or burn-out of exhaust Replace the damaged parts.
piping or silencer
Defective components in the Replace the defective parts.
exhaust system (clamps, pipes,
silencer)
Internal damage to silencer Replace the silencer
Exhaust Silencer and Exhaust Pipe

Removal
1. Remove the rear exhaust pipe.
• Remove the clamp and rear exhaust pipe. 3
2 4
6
5
1
7
LNW76FSH000101
Legend
1. Differential Pressure Pipe (F)
LNW76FSH000501
2. Exhaust Temperature Sensor (R)
3. Differential Pressure Sensor
2. Remove the center exhaust pipe. 4. Differential Pressure Hose (F)
3. Remove the exhaust silencer. 5. Differential Pressure Hose (R)
4. Remove the exhaust throttle air pipe. 6. Differential Pressure Pipe (R)
7. Exhaust Temperature Sensor (F)
5. Remove the exhaust throttle assembly.
6. Remove the exhaust silencer(EURO 3
Specification). NOTE:
In the event that the differential pressure sensor
7. Remove the DPD assembly (EURO 4
assembly must be removed, pay attention to the
Specification).
following points.
• Remove the 2 connectors on the DPD exhaust
• Do not loosen the 4 screws used to tighten the
temperature sensor.
differential pressure sensor. If these screws have
• Remove the clip that secures the connectors on been loosened, replace the differential pressure
the DPD exhaust temperature sensor. sensor assembly.
• Remove the 2 DPD differential pressure hoses. • If the differential sensor assembly is dropped, it
• Remove the DPD assembly from the front pipe. cannot be reused.
2
2
LNW76FSH000201 LNW76FSH000301
Legend Legend
1. Sensor Assembly 1. Hose Clip
2. Tightening Screw 2. Sleeve Nut (Rr)
3. Clip
8. Remove the front exhaust pipe (B). 4. Sleeve Nut (Ft)
9. Remove the exhaust brake.
5. Disassemble the DPD assembly.
• Remove the air hose and the exhaust brake
assembly. • Loosen the nuts used for mounting the
oxidation catalyst section, and detach the
10. Remove the front pipe (A).
oxidation catalyst section.
• Remove the clamp and front pipe.
• Loosen the nuts used for mounting the filter and
detach the filter and rear case.
DPD Disassembly
NOTE:
1. Loosen the clip (1) from the hose connecting to the Do not submit the DPD assembly to high impact or drop
differential pressure pipe and remove the hose. the assembly.
2. Loosen the sleeve nuts (2) and (4) that secure the
differential pressure pipe.
3. Remove the clip (3) that secure the differential
pressure pipe.
4. Remove the differential pressure pipe.
4 5
3
1
2
LNW41GSH000201 LNW41GSH000601
Legend Legend
1. Oxidation Catalyst Section 1. Filter
2. Gasket 2. Filter Case
3. Filter Section
4. Gasket 3. If the differential pressure sensor assembly has
5. Rear Case been replaced, carry out the following steps (on
the vehicle).
• Without turning the engine on, turn the key from
DPD Inspection "OFF" to "ON".
• The DPD lamp is turned on, and then after 30
1. Perform an external appearance inspection on
seconds turned off.
exhaust pipe related components.
• After confirming that the DPD lamp has gone
• Damage to a body panel caused by heating or
off, turn the key to the "OFF" position and leave
vibration can lead to exhaust gas intruding into
for 15 seconds.
the cabin.
4. Check the oxidation catalyst.
• Inspect the connections for looseness,
damage, and exhaust gas leaks. • Visually inspect the catalyst for erosion,
damage, or plugging.
• Inspect the clamps and rubber for deterioration,
cracks, and damage.
• Inspect the pipe and silencer for dents and DPD Reassembly
corrosion induced cracks, and if damaged,
1. Insert gaskets in the filter section and the rear case
repair or replace the damaged part(s).
and tighten temporarily with bolts and nuts.
2. Perform an DPD related inspection.
2. Insert gaskets in the filter section and oxidation
• Visually inspect the filter for erosion, damage, catalyst and tighten temporarily with bolts and
or blocking. nuts.
• Light shines through the filter from the opposite
side. If light is transmitted and is visible, replace NOTE:
the filter section. Check the mounting location of the filter section and
rear case, and the filter section and oxidation catalyst,
NOTE: and tighten each pipe bracket in 2 places by tightening
Before DPD disassemble, be sure to use a scan tool to the bolts alternatively.
check the DPD differential pressure, status, and
inspection and servicing details. Refer to the "Engine 3. Tighten the bolts and nuts to the specified torque.
control" section for details. • Tighten all of the bolts and nuts twice.
Torque : 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
NOTE: 7. Insert the hose for the differential pressure pipe
After tightening all of the bolts and all of the nuts, until it reaches the spool and secure with a clip.
tighten them all to the same torque (tightening twice)
1
4 5
3
2
2
1 3
LNW76FSH000301
Legend
LNW41GSH000201
1. Hose Clip
Legend 2. Sleeve Nut (Rr)
1. Oxidation Catalyst Section 3. Clip
2. Gasket 4. Sleeve Nut (Ft)
3. Filter Section
4. Gasket
5. Rear Case NOTE:
If the procedures described above are not followed, the
4. Insert the protruded section of the differential sleeve nut may become loose.
pressure pipe (only Ft side) into DPF and tighten
the sleeve nut (4) by hand. Then, tighten the Air-tightness check
sleeve nut (Rr) (2) by hand. • Once the engine is warmed up, run at maximum
non-load RPM.
NOTE:
• To ensure there are no gas leakages, with the
Clean the old anti-seize compound from the sleeve nut
engine revved up, spray soapy water on the
and apply new anti-seize compound.
pressure hose (1) and sleeve nuts (2) (4)
5. Fix the pipe in place using a clip (3). connecting parts.
Torque: 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)

6. Fully tighten the sleeve nuts.
Torque (Ft): 45 N⋅m (4.6 kg⋅m / 33 lb⋅ft)
Torque (Rr): 35 N⋅m (3.6 kg⋅m / 26 lb⋅ft)

• Attach the hose clips (4 locations) securely to
prevent gas leakage.
1 NOTE:
• Do not confuse the front/rear directions.
• Do not use hoses that are cracked.
• Do not overtighten or remove the differential sensor
assembly's tightening screws.
2 • If there is a gas leak in the coupling section, a
sensor malfunction may occur.
Ensure to check for gas leakage after starting the
3
engine.
LNW76FSH000301
Legend
1. Hose clip 8 1
2. Sleeve Nut (Rr)
3. Clip 2 2
7 7
4. Sleeve Nut (Ft)
Installation 6 3
NOTE: 5 4
• A possible cause of vibration or looseness is the

misspositioning of the exhaust system during
assembly. Therefore, do not fully tighten the bolts LNW41GSH000901
until all the components are positioned, and when
Legend
positioned, tighten the bolts starting at the engine
1. Differential Pressure Sensor
and working outwards.
2. Clip
• Do not re-use gaskets or nuts that were removed. 3. Differential Pressure Hose
4. Properly Fitted Hoses
1. Install the front exhaust pipe A.
5. Reversely Fitted Hoses
Torque : 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft) 6. Differential Pressure Hose
7. Clip
NOTE: 8. Differential Pressure Sensor
Tighten the front exhaust pipe so that it is balanced,
and make sure there are not any gas leaks.
2. Install the exhaust brake and front exhaust pipe B.

• Install the air hose.
3. Install the DPD assembly to the front pipe (EURO
4 Specification).
4. Install the DPD differential pressure hose to the
differential pressure pipe (EURO 4 Specification).
• Insert the front side of the differential pressure
hose into the port of the differential pressure
sensor that is marked "F" (white).
6. Fix the DPD temperature sensor harness with clips
(EURO 4 Specification).
7. Install the exhaust silencer to the front pipe (EURO
3 Specification).
1 2 1
8. Install the exhaust throttle assembly and extension
pipe.
F
9. Install the exhaust throttle air hose.
10. Install the center exhaust pipe.
11. Install the rear exhaust pipe.
5
4 3 • Tighten the clamp.
LNW41GSH000801
Legend
1. Nut
2. F; Front Mark
3. Rear Side Differential Pressure Hose Spigot
4. Front Side Differential Pressure Hose Spigot
5. Bracket
5. Connect the DPD temperature sensor connectors

(EURO 4 Specification).
NOTE:
Do not confuse the front/rear directions.
3
LNW76FSH000501
2 4
6
5
1
7
LNW76FSH000101
Legend
1. Differential pressure pipe (F)
2. Exhaust temperature sensor 1 (filter inlet)
3. Differential pressure sensor
4. Differential pressure hose (F)
5. Differential pressure hose (R)
6. Differential pressure pipe (R)
7. Exhaust temperature sensor 2 (catalyst inlet)
22(2.2/16)
27(2.8/20)
27(2.8/20)
67(6.8/49)
50(5.1/37)
50(5.1/37)
LNW76FLF000401
Exhaust Brake System

Service Precautions
During assembly and mounting, mount the parts
appropriately at the specified tightening torque value.
Explanations on functions and operation
LNW21GMF001401
Functional check
Operational check
• Confirm the sound of the valve touching the
stopper when the exhaust brake is operated in the
idling condition.
Exhaust Brake
Components
10
3
4
5
9
LNW76FMF000101
Legend
1. Power Chamber, Insulator, Gasket and Bearing 5. Front Exhaust Pipe B
2. Lock Nuts and Clevis Joint 6. Exhaust Brake Assembly
3. Split Pin and washer 7. Front Exhaust Pipe A
4. Exhaust Brake Valve
Removal
1. Remove the vacuum and clips.
2. Remove the nut.
3. Remove the exhaust pipe.
4. Remove the exhaust brake assembly.
Disassembly
1. Remove the split pin.
2. Remove the lock nuts.
3. Remove the clevis joint.
4. Remove the power chamber.
Reassembly
1. Mount the power chamber.
Tightening torque : 14 N⋅m (1.4kg⋅m / 122lb⋅in) Unit check
• Negative pressure in the power chamber caused
by the vacuum pump.
When a pressure of 53.3 to 93.3 kPa (400 to 700
mmHg) is applied, the exhaust brake valve should
open or close smoothly.
LNW21GSH001601
2. Mount the lock nuts.

3. After mounting the clevis joint, tighten the lock nuts
to the specified torque.
Tightening torque : 13N⋅m (1.3kg⋅m / 113lb⋅in)
LNW21GSH001401
Installation
1. Mount the exhaust brake assembly.
Tightening torque : 17N⋅m (1.7 kg⋅m / 12 lb⋅ft)
LNW21GSH002201
4. Mount the split pin.
Inspection
Check for damage or degradation in the parts
LNW46FSH000101
mentioned below.
• Exhaust brake valve
• Exhaust brake shaft
• Butterfly valve
• Bush
• Power chamber
2. Mount the exhaust pipe. 3. Mount the nuts.
Tightening torque : 67 N⋅m (6.8kg⋅m / 49lb⋅ft)
4. Mount the vacuum hose and the clips.
LNW76FSH000401
M6
41 (4.2/30)
27 (2.8/20)
67 (6.8/49)
LNW76FMF000201
Exhaust Throttle
Components
12
3
4
5
6
8
11
7
9
10
LNW76GMF000101
Legend
1. Power Chamber 7. Cover
2. Gasket 8. Extension Silencer
3. Insulator 9. Exhaust Center Pipe
4. Bearing 10. DPD (Diesel Particulate Defuser)
5. Lock Nuts and Clevis Joint 11. Exhaust Throttle Body
6. Pin and Split Pin 12. Exhaust Throttle Asembly
Removal
1. Remove the vacuum hose and clip.
2. Remove the nut.
3. Remove the rear exhaust pipe.
4. Remove the center exhaust pipe.
5. Remove the exhaust silencer.
Unit inspection
• Apply vacuum pressure to the power chamber
using a vacuum pump.
The exhaust throttle valve should open and close
smoothly when pressure of 75 - 93.3kPa {560 -
700mmHg} is applied.
LNW76FSH000601
6. Remove the exhaust throttle assembly.
Disassembly
1. Remove the split pin.
LNW21GSH001401
2. Remove the lock nut.
3. Remove the clevis joint. NOTE:
4. Remove the power chamber. Do not change the exhaust throttle's adjustment as it
may have an affect on DPD performance.
Inspection
Inspect the following parts for damage and Reassembly
deterioration, etc. 1. Install the power chamber.
• Exhaust throttle valve
Tightening torque 14 N⋅m (1.4 kg⋅m / 122 lb⋅in)
• Exhaust throttle shaft
• Butterfly valve
• Power chamber
LNW41GSH001101
2. Install the lock nut.

3. After mounting the clevis joint, tighten the lock nut
to specified tightening torque.
NOTE: 4. Install the rear exhaust pipe.
Do not adjust or remove the adjusting bolt.
Do not remove the lever.
LNW76FSH000601
2

LNW41GSH001201
5. Install the vacuum hose and clip.
Legend
1. Lever
2. Adjusting bolt
4. Install the split pin.
Installation
1. Install the exhaust throttle assembly.
Tightening torque 20N⋅m (2.0kg⋅m / 14 lb⋅in)
LNW21GSH002301
2. Install the exhaust silencer.

3. Install the exhaust center pipe.
13 (1.3/113lb in)
14 (1.4/122lb in)
27 (2.8/20)
50 (5.1/37)
LNW76GLF000101
EGR System
Service Precautions Explanations on functions and operation
Perform EGR related assembly according to the usual Re-circulate a part of the exhaust gas of the EGR
procedure of temporarily fitting and then permanently system in the intake manifold.Reduce the combustion
tightening the parts so that unnecessary stresses are temperature and inhibit NOx generation since inert
not applied on the parts. gases may be mixed up in the intake sir.
An electronic control system is used in this EGR to
balance the requirements of operability and low
emissions.A DC motor is operated using the control
current of the Engine Control Module (ECM) to control
the EGR.
Refer to the chapter on Engine Control System for
details on fault diagnosis of the EGR system.
1
3
LNW46FMF000501
Legend
1. EGR cooler 3. EGR Valve DC Motor
2. Engine Control Module (ECM)
EGR Valve and EGR Cooler

Components
1
2 3
4
LNW71FLF000101
Legend
1. EGR Valve 4. Heat Protector
2. EGR Valve Gasket 5. EGR Cooler Gasket
3. EGR Cooler 6. EGR Cooler Gasket
Removal
2. Remove the turbocharger.
Refer to “Turbocharger” in ENGINE MECHANICAL
section.
3. Remove the heat protector. b. Tighten the bolt and nuts by final tightening
order.
Final tightening order : 3→4→5→1→2→6
Tightening torque :
Bolt, Nut 1 to 5 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
Bolt 6 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)
4
1
5
3
2
LNW71FSH000101
4. Remove the EGR cooler.

• Disconnect the Water pipe rubber hose (IN ,
OUT) and remove the EGR cooler and gasket.
5. Remove the EGR valve.
LNW71FSH000201
3. Connect the water pipe rubber hose (IN,OUT).

4. Install the heat protector
Tightening torque : 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
5. Install the turbocharger.
Refer to “Turbocharger” in ENGINE MECHANICAL
section.
LNW71FSH000301
Installation
1. Install the EGR valve.
Tightening torque : 27 N⋅m (2.8kg⋅m / 20lb⋅ft)
2. Install the EGR Cooler.
a. Install the gaskets and the EGR cooler.
Temporarily tighten the bolts and the nuts.
Temporary tightening order : 1→2→3→4→5→6
52 (5.3/38)
27 (2.8/20)
27 (2.8/20) 25 (2.5/18)
27 (2.8/20)
LNW76FLF000101
ACCELERATOR CONTROL SYSYEM (4JJ1) 6H-1
ENGINE
ACCELERATOR CONTROL SYSYEM
(4JJ1)
TABLE OF CONTENTS
Accelerator Pedal Assembly . . . . . . . . . . . . . . . . .6H-2
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2
6H-2 ACCELERATOR CONTROL SYSYEM (4JJ1)
Accelerator Pedal Assembly

Components
1
2
LNW41ILF000101
Legend
1. Nut 4. Accelerator Pedal
2. Connector 5. Bolt
3. Control Link and Bracket Assembly
1. Nut to Contorol Link and Bracket Assembly 1. Install the Harness Connector
2. Bolt to Accelerator Pedal 2. Instal the Accelerator Pedal Bolt
3. Harness Connector to Accelerator Switch 3. Install the Control Link and Bracket Assembly
Connector and Accelerator Position Sensor
NOTE:
Disconnect the battery ground cable when the harness
connector is disconnected.
LG4JJ-WE-0761
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all

countries except the USA, Canada and Mexico.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
SERVICE MARKETING DEPARTMENT
Tokyo, Japan
First edition August. 2006

No. LG4JJ-WE-0761

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WORKSHOP MANUAL

Isuzu Motors Limited

Service Marketing Department

ISUZU DIESEL ENGINE (4JJ1)

Explanation of functions and operations EGR system

Fuel filter with sedimenter

2. Adjustment of valve clearance

• If the No.1 cylinder is the compression TDC,

Compression gauge: 5-8840-2675-0

Condition Possible Cause Correction

Condition Possible Cause Correction

Engine turns over but does not start

Condition Possible Cause Correction

Excessive black exhaust smoke

Condition Possible Cause Correction

Condition Possible Cause Correction

Excessive white exhaust smoke

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Abnormal engine rotation

Condition Possible Cause Correction

Abnormal battery charging

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Main Data and specifications

Item Engine model 4JJ1

Item Engine model 4JJ1

Item Engine model 4JJ1

1. Detach the negative cable from the battery.

7. Remove the air intake pipe with the hoses.

5. Remove the transmission assembly.

10. Disconnect the radiator upper hose.

Front rigid suspension model

20. Engine Mounts

4. Fit the heater hose to the heater pipe.

22. Engine Assembly

16. Fit the air intake hose (2).

20. Fit the starter.

Front rigid suspension model

The nuts on the engine foot side

2. Install the engine assembly.

Cylinder Head Cover

2. Remove the fuel injector connector (2) and the

5. Remove the nozzle seal cover from the cylinder

1. Install the nozzle seal cover. Legend

RTW56ASH020601 4. Install the blow-by hose.

8. Remove the intake manifold and gasket.

4. Install the injection pipe (No.1 to 4).

7. Remove the oil feed pipe.

Axial play on the wheel shaft

Clearance between wheel shaft and bearing LNW21BSH022401

• Use a dial gauge to measure the clearance Legend

Control rod pressure range: kPa (mmHg / psi)

Actuator operation (EURO 4 Specification)

2. Install the oil return pipe.

7. Install the AC generator.

9. Install the front exhaust pipe and gaskets.

4. Remove the EGR cooler.

6. Remove the exhaust manifold.

2. Install the exhaust manifold heat protector.