Beruflich Dokumente
Kultur Dokumente
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A - 4
Torque Specifications ................................................................................................... 6A - 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing......................................................................................................................... 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6A - 24
Lubricating System .................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 27
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement...................................................................... 6A - 32
General Description....................................................................................................... 6A- 36
Removal and Installation............................................................................................... 6A- 37
Removal ...................................................................................................................... 6A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment.......................................................................................... 6A- 41
Engine Warm-Up..................................................................................................... 6A- 41
Engine Repair Kit........................................................................................................... 6A- 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6A- 43
External Parts ......................................................................................................... 6A- 43
6A – 2 ENGINE MECHANICAL
Engine model
4JA1T (L) 4JA1TC
Item
Oil pump type Gear
Oil filter type Cartridge paper element
Oil capacity lit (US/UK gal) 6.2 (1.64/1.36)
Oil cooler type Water cooled
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element Viscous paper element
Battery type/voltage ´ No. of units 80D26L ´ 1
95D31L ´ 1 (OPT)
Generator capacity V-A 12 – 60
12 – 80
Starter motor output V-Kw 12 – 2.3
Turbocharger model *IHI RHF 4H
Turbine type Mixed flow type
Compressor type Backward & rake
Engine model
4JH1TC
Item
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element (except for Euro3 spec)
Viscous paper element (for Euro3 spec)
80D26L ´ 1
Battery type/voltage ´ No. of units
95D31L ´ 1 (OPT)
75D26R ´ 2 (OPT for EC, MT)
80D26R ´ 2 (OPT for EC, AT)
12 – 60/12 – 80
Generator capacity V-A
12 – 2.3
Starter motor output V-Kw
*IHI RHF5
Turbocharger model
Mixed flow type Radial-inflow
Turbine type
Backward & rake type Radial-outflow
Compressor type
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.
6A – 8 ENGINE MECHANICAL
TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified.
N·m (kg·m/lb·ft)
Strength 8.8
Class 4.8 (4T) (7T) 9.8 (9T)
Refined Non-Refined
Bolt
Identification
Bolt
Diameter ´
Pitch (mm)
M 6 ´ 1.0 5.88 ± 1.96 7.35 ± 2.45 -
(0.60 ± 0.20/4.33 ± 1.44) (0.75 ± 0.25/5.43 ± 1.80)
M 8 ´ 1.25 12.74 ± 4.90 17.15 ± 5.39 23.52 ± 6.86
(1.30 ± 0.50/9.40 ± 3.62) (1.75 ± 0.55/12.66 ± 4.00) (2.40 ± 0.70/17.36 ± 5.06)
M 10 ´ 1.25 27.44 ± 6.86 36.75 ± 9.31 49.98 ± 12.74
(2.80 ± 0.70/20.25 ± 5.06) (3.75 ± 0.95/27.12 ± 6.87) (5.10 ± 1.30/36.89 ± 9.40)
M 12 ´ 1.25 61.25 ± 12.25 75.95 ± 15.19 94.57 ± 19.11
(6.25 ± 1.25/45.21 ± 9.04) (7.75 ± 1.55/56.06 ± 11.21) (9.65 ± 1.95/69.80 ± 14.10)
M 14 ´ 1.5 95.55 ± 19.11 116.13 ± 23.03 142.10 ± 28.42
(9.75 ±1.95/70.52 ± 14.10) (11.85 ± 2.35/85.71 ± 17.00) (14.50 ± 2.90/104.88 ± 21.00)
M 16 ´ 1.5 130.34 ± 26.46 169.54 ± 34.30 199.92 ± 40.18
(13.30 ± 2.70/96.20 ± 19.53) (17.30 ± 3.50/125.13 ± 25.32) (20.40 ± 4.10/147.55 ± 29.66)
M 18 ´ 1.5 188.16 ± 37.24 244.02 ± 49.00 287.14 ± 57.82
(19.20 ± 3.80/138.87 ± 27.49) (24.90 ± 5.00/180.10 ± 36.17) (29.30 ± 5.90/211.93 ± 42.67)
M 20 ´ 1.5 257.74 ± 51.94 337.12 ± 67.62 395.92 ± 79.38
(26.30 ± 5.30/190.23 ± 38.33) (34.40 ± 6.90/248.82 ± 49.41) (40.40 ± 8.10/292.21 ± 58.59)
M 22 ´ 1.5 332.22 ± 81.34 453.25 ± 90.65 530.18 ± 105.84
(33.90 ± 8.30/245.20 ± 60.03) (46.25 ± 9.25/334.53 ± 66.91) (54.10 ± 10.80/391.30 ± 78.12)
M 24 ´ 2.0 448.84 ± 90.16 570.36 ± 140.14 691.88 ± 138.18
(45.80 ± 9.20/331.27 ± 66.54) (58.20 ± 14.30/420.96 ± 103.43) (70.60 ± 14.10/510.65 ± 101.99)
* M 10 ´ 1.5 26.46 ± 6.86 36.26 ± 8.82 48.02 ± 11.76
(2.70 ± 0.70/19.53 ± 5.06) (3.70 ± 0.90/26.76 ± 6.50) (4.90 ± 1.20/35.44 ±8.68)
* M 12 ´ 1.5 56.84 ± 11.76 70.56 ± 13.72 89.18 ± 17.64
(5.80 ± 1.20/41.95 ± 8.68) (7.20 ± 1.40/52.08 ± 10.13) (9.10 ± 1.80/65.82 ± 13.02)
* M 14 ´ 2.0 89.18 ± 17.64 109.76 ± 21.56 133.28 ± 26.46
(9.10 ± 1.80/65.82 ± 13.02) (11.20 ± 2.20/81.01 ± 15.91) (13.60 ± 2.70/98.37 ± 19.53)
* M 16 ´ 2.0 124.46 ± 24.50 161.70 ± 32.34 191.10 ± 38.22
(12.70 ± 2.50/91.86 ± 18.08) (16.50 ± 3.30/119.34 ± 23.87) (19.50 ± 3.90/141.04 ± 28.21)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
FLARE NUTS N·m (kg·m/lb·ft)
4.76 (0.187) 15.2 ± 2.45(1.55 ±0.25/11.2 ± 1.8) 10.00 (0.394) 53.95 ± 4.90(5.50 ± 0.5 /39.7 ± 3.6)
6.35 (0.250) 26.48 ± 2.94(2.70 ± 0.30/19.5 ± 2.1) 12.00 (0.472) 88.29 ± 9.80(9.00 ± 1.0/65.0 ± 7.2)
8.00 (0.315) 44.14 ± 4.90(4.50 ± 0.50/32.5 ± 3.6) 15.00 (0.591) 105.45 ± 12.26(10.75 ± 1.25/77.7 ± 9.0)
ENGINE MECHANICAL 6A – 9
RTW46AXF000501
6A – 10 ENGINE MECHANICAL
Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley,
Flywheel, and Oil Pan
N·m (kg·m/lb·ft)
RTW36AXF000101
ENGINE MECHANICAL 6A – 11
RTW46AXF000601
6A – 12 ENGINE MECHANICAL
RTW46AXF000701
ENGINE MECHANICAL 6A – 13
RTW36AXF000201
6A – 14 ENGINE MECHANICAL
RTW46AXF000801
ENGINE MECHANICAL 6A – 15
RTW46AXF000901
6A – 16 ENGINE MECHANICAL
RTW46AXF001001
ENGINE MECHANICAL 6A – 17
Engine Electricals
N·m (kg·m/lb·ft)
RTW36AXF000501
6A – 18 ENGINE MECHANICAL
RTW46AXF001101
ENGINE MECHANICAL 6A – 19
RTW46AXF001201
6A – 20 ENGINE MECHANICAL
RTW46AXF001301
ENGINE MECHANICAL 6A – 21
022R300001
6A – 22 ENGINE MECHANICAL
Note:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacturer’s instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of
greater than 0.25 mm (0.01 in). Poor adhesion will result.
ENGINE MECHANICAL 6A – 23
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.
RTW36ASH000401
AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Drain the engine oil.
2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0200-0
6A-6
4. Clean the oil cooler fitting face. This will allow the new
oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn in the filter an additional
2/3 turns.
8. Check the engine oil level and replenish to the
specified level if required.
RTW36ASH000101
ENGINE MECHANICAL 6A – 25
6A-7
RTW46ASH000501
041RY00009
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.
041RY00011
Air Bleeding
1. Operate the priming pump until strong resistance is
felt.
2. Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3. Once more wait, and operate the priming pump until
strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait until
Except EURO III model the glow indicator lamp turns off.
RTW46ASH002901
5. Turn the ignition switch to the "START" position and
For EURO III model crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.
RTW46ASH000501
ENGINE MECHANICAL 6A – 27
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the “MAX” line.
111R300001
2
Testing Pressure kPa(kg/cm /psi)
150 (1.5/21)
030LX003
2
Negative Valve (Reference) kPa(kg/cm /psi)
1.9 – 4.9 (0.02 – 0.05/0.28 – 0.71)
ENGINE MECHANICAL 6A – 29
014RY00014
014RY00015
014RY00017
6A – 32 ENGINE MECHANICAL
COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80 °C (158 – 176 °F).
2. Remove the following parts.
· Leak off pipe
· Injection nozzle holder bracket
· Injection nozzle holder
F06XL056 3. Install the following parts.
· Set the adapter and compression gauge (SST) to
the No.1 cylinder injection nozzle hole.
· Injection nozzle holder bracket
4. Turn the engine over with the starter motor and take
the compression gauge reading.
2
Compression Pressure MPa (kg/cm /psi) at 200 rpm
Standard Limit
3.0 (31.0/441) 2.1 (21.7/309)
GENERAL DESCRIPTION
RTW46AMF000401
The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design
provides superior fuel economy over a wide range of driving conditions.
Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when
the engine is cold.
Chrome plated dry type cylinder liners provide the highest durability.
The laminated steel sheet cylinder head gasket is very durable and, to increase the head gasket reliability.
The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be
reground.
The 4JA1T(L) engine is equipped with the BOSCH VE-Type distributor injection pump.
The 4JH1TC and 4JA1TC engine is equipped with the BOSCH VP44-Type distributor injection pump.
The engine is turbocharger equipped.
ENGINE MECHANICAL 6A – 37
Removal
1. Battery
1) Disconnect the battery cable and the grounding cable
from the battery terminals.
2) Remove the battery clamp. Take care not to
accidentally short the battery with the wrench or some
other tool.
3) Remove the battery.
4) Disconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
P1010011
2. Engine Hood
Apply setting marks to the engine hood and the engine
hood hinges before removing the engine hood. This will
facilitate reinstallation of the engine hood to its original
position.
P1010002
F06R300006
P1010025
F06R300007
ENGINE MECHANICAL 6A – 39
18. Radiator
1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.
P1010009
19. Fan
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC)
from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box
from engine room.
3) Remove the two air ducts from inter cooler
(4JA1TC/4JH1TC).
P1010034
140R300001
RTW46ASH000501
022R300002
F06R300008
Installation
To reassemble, follow the removal steps in the reverse
order.
ENGINE MECHANICAL 6A – 41
Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
6. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.
9.5 (2.5/2.1)
Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system.
Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.
6A – 42 ENGINE MECHANICAL
RTW36ALF000601
Removal Steps
1. Cylinder head gasket 11. Vacuum pump gasket
2. Head cover gasket 12. Water pump O-ring
3. Head cover cap nut gasket 13. Water outlet pipe gasket
4. Drain cock gasket 14. Intake pipe gasket
5. Crankshaft rear oil seal 15. Thermostat housing gasket
6. Gear case gasket 16. Intake manifold gasket
7. Oil pan drain plug gasket 17. Exhaust manifold gasket
8. Oil pan gasket 18. Nozzle holder O-ring
9. Oil filter gasket 19. Nozzle holder gasket
10. Joint bolt gasket 20. Crankshaft front oil seal
NOTE
Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of
these parts will result in oil, water, and gas leakage.
ENGINE MECHANICAL 6A – 43
ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS
RTW36AMF000401
Removal Steps
1. Clutch Assembly or Flex Plate 15. Oil Pressure Warning Switch
2. Intake Pipe and Throttle Body 16. Fuel Leak Off Pipe
3-1. EGR Pipe 17. Oil Cooler Water Pipe
3-2. EGR cooler (EURO III model only) 18. Cooling Fan Pulley
4. EGR Valve 19. Heat Protector
5. Oil Level Gauge 20. Catalytic Converter
6. Fuel Filter Assembly (Except EURO III) 21. Turbocharger
7. Fuel Filter Bracket (Except EURO III) 22. Compressor Bracket
8. Fuel Injection Pipe with Clip 23. Vacuum Pump Oil Return Hose
9. Power Steering Oil Pump Bracket 24. Generator and Adjusting Plate
10. Intake Manifold 25. Water Inlet Pipe
11. Engine Mounting Bracket and Foot 26. Generator Bracket
12. Injection Pump Cover 27. Oil Cooler with Oil Filter
13. Injection Pump 28. Exhaust Manifold
14. Starter Motor
6A – 44 ENGINE MECHANICAL
Removal
1. Clutch Assembly or Flex Plate
Remove the clutch assembly or the flex plate.
RTW46ASH000801
4JA1TC/4JH1TC
RTW36ASH000201
025R100008
4JH1TC
RTW36ASH000301
4. EGR Valve
4JA1*L
1) Remove four nuts and remove the EGR valve
assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the
EGR valve assembly.
RTW46ASH001001
4JA1*TC
RTW46ASH000901
RTW36ASH000701
027R100007
21. Turbocharger
1) Disconnect the water hose between thermostat
housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe
and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
037RY00001
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.
1
DISASSEMBLY
INTERNAL PARTS
MAJOR COMPONENTS
011R300001
Disassembly Steps-1
1. Water bypass hose 5. Rocker arm shaft and rocker
2. Thermostat housing with thermo arm
switch 6. Push rod
3. Cylinder head cover 7. Cylinder head
4. Injection nozzle and bracket 8. Cylinder head gasket
6A – 48 ENGINE MECHANICAL
RTW46ALF000101
Disassembly Steps-2
9. Crankshaft damper pulley
10. Timing gear case cove
11. Water pump
12. Idle gear "B" and shaft
13. Idle gear "A"
14. Idle gear shaft
15. Crankshaft timing gear
16. Injection pump
ENGINE MECHANICAL 6A – 49
014R300005
Disassembly Steps-3
17. Flywheel 27. Piston and connecting rod with
18. Crank case upper bearing
19. Oil pump with oil pipe 28. Crankshaft bearing cap with
20. Camshaft timing gear lower bearing
21. Camshaft thrust plate 29. Crankshaft thrust bearing
22. Camshaft 30. Crankshaft
23. Timing gear case 31. Crankshaft upper bearing
24. Cylinder body rear plate 32. Tappet
25. Piston cooling oil jet 33. Crankshaft rear oil seal
26. Connecting rod bearing cap with 34. Cylinder body
lower bearing
6A – 50 ENGINE MECHANICAL
Disassembly
1. Water Bypass Hose
2. Thermostat Housing with Thermo Switch
3. Cylinder Head Cover
4. Injection Nozzle and Bracket
1. Remove the injection nozzle bracket bolts.
011R100002
011RY00005
6. Push Rod
011RY00006
7. Cylinder Head
Loosen the cylinder head bolts in numerical order a little at
a time.
Note:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely affect the cylinder
head lower surface.
020L200006
020L200020
NOTE:
Refer to the following items for details on the backlash
and end play measurement procedures.
020RY00019
040R300009
NOTE:
Plug the injection pump delivery ports with the caps to
RTW36ASH001301
prevent the entry of foreign material.
17. Flywheel
Loosen the flywheel bolts in numerical order a little at a
time.
Use the gear stoper to stop the flywheel gear.
Gear stoper: 5-8840-0214-0
015RY00001
ENGINE MECHANICAL 6A – 53
22. Camshaft
Jiggle the camshaft with your hand as you pull it free from
the front of the engine.
052RY00001
6A – 54 ENGINE MECHANICAL
014LX056
015LX018
RTW36ASH001501
30.Crankshaft
015RY00003
015RY00005
MINOR COMPONENTS
ROCKER ARM SHAFT AND ROCKER ARM
011RY00009
Disassembly Steps
1. Rocker arm shaft snap ring 5. Rocker arm shaft spring
2. Rocker arm 6. Rocker arm shaft snap ring
3. Rocker arm shaft bracket 7. Rocker arm shaft
4. Rocker arm
Disassembly
CYLINDER HEAD
RTW46ALF001201
Disassembly Steps
1. Intake manifold 6. Intake and exhaust valve
2. Intake manifold gasket 7. Valve stem oil seal
3. Split collar 8. Valve spring lower seat
4. Valve spring upper seat 9. Cylinder head
5. Valve spring
6A – 58 ENGINE MECHANICAL
Disassembly
1. Intake Manifold
2. Intake Manifold Gasket
3. Split Collar
1. Place the cylinder head on a flat wooden surface.
2. Use the spring compressor to remove the split collars.
Do not allow the valve to fall from the cylinder head.
Spring Compressor: 9-8523-1423-0
4. Valve Spring Upper Seat
011RY00011 5. Valve Spring
011LX022
ENGINE MECHANICAL 6A – 59
RTW46ALF000301
Disassembly Steps
1. Connecting rod bearing 4. Piston pin
2. Piston ring 5. Connecting rod
3. Piston pin snap ring 6. Piston
6A – 60 ENGINE MECHANICAL
Disassembly
1. Connecting Rod Bearing
If the connecting rod bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
RTW36ASH001501
2. Piston Ring
1. Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2. Use a piston ring replacer to remove the piston rings.
Piston Ring Replacer
Do not attempt to use some other tool to remove the
piston rings. Piston ring stretching will result in
reduced piston ring tension.
015RW041
F06MV015
4. Piston Pin
5. Connecting Rod
6. Piston
Tap the piston pin out with a hammer and a brass bar.
If the pistons and piston pins are to be reinstalled, mark
their installation positions by tagging each piston and piston
pin with the cylinder number from which it was removed.
RTW36ASH001601
ENGINE MECHANICAL 6A – 61
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the
four sides and the two diagonals of the cylinder head lower
face.
2. The cylinder head lower surface warpage is more than the
limit, it should be replaced.
011RY00012
NOTE:
The cylinder head lower face cannot be reground.
011RY00013
011RY00014
Positive Crankcase Ventilation (PCV) Valve
1. Remove PCV valve assembly from cylinder head cover.
2. Inspect the diaphragm for broken.
3. Inspect the spring for broken or weaken.
4. If find any abnormal condition, replace the PCV valve
assembly.
6A – 62 ENGINE MECHANICAL
Measuring Method-II
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.
011RY00023
011LX029
011RY00024
4. Measure the height of the valve guide upper end from the
upper face of the cylinder head.
NOTE:
If the valve guide has been removed, both the valve
and the valve guide must be replaced as a set.
011RY000025
6A – 64 ENGINE MECHANICAL
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.
Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel rule to
measure the valve depression from the cylinder head lower
surface.
If the measured value exceeds the specified limit, the valve
seat insert must be replaced.
NOTE:
The smooth side of the attachment must contact the
valve seat insert.
014RY00026
2. Use a bench press (3) to gradually apply pressure to the
attachment and press the valve seat insert into place.
NOTE:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.
011LX063
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
011LX037
011LX038
ENGINE MECHANICAL 6A – 67
014RY00024
014RY00023
CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner.
Refer to "Cylinder Liner Replacement".
012RY00009
6A – 70 ENGINE MECHANICAL
NOTE:
Take care not to damage the cylinder body upper face
during the cylinder liner removal procedure.
3. Measure the cylinder body upper face warpage.
Refer to "Cylinder Body Upper Face Warpage".
ENGINE MECHANICAL 6A – 71
012RY00013 * A minus (-) value indicates that the cylinder body bore is
smaller than the liner outside diameter.
012RY00014
012R300001
012RY00022
4JH1TC mm (in)
Liner
Cylinder Body Liner Outside Liner Bore
Outside Service Liner Bore Measurement
Bore Diameter Diameter Grade
Grade
97.001-97.010 97.011-97.020 AX 95.435-95.450 (3.7573-3.7579)
1
(3.8189-3.8193) (3.8193-3.8197) CX 95.451-95.466 (3.7579-3.7585)
97.011-97.020 97.021-97.030 AX 95.435-95.450 (3.7573-3.7579)
2
(3.8193-3.8197) (3.8197-3.8200) CX 95.451-95.466 (3.7579-3.7585)
97.021-97.030 97.031-97.040 AX 95.435-95.450 (3.7573-3.7579)
3
(3.8197-3.8200) (3.8200-3.8205) CX 95.451-95.466 (3.7579-3.7585)
97.031-97.040 97.041-97.050 AX 95.435-95.450 (3.7573-3.7579)
4
(3.8200-3.8205) (3.8205-3.8209) CX 95.451-95.466 (3.7579-3.7585)
ENGINE MECHANICAL 6A – 73
NOTE:
All foreign material must be carefully removed from
012RY00017
the cylinder liner and the cylinder bore before
installation.
3. Insert the cylinder liner (1) into the cylinder body (2)
from the top of the cylinder body.
NOTE:
Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.
012RY00018
NOTE:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will
result in engine failure. Always measure the cylinder
bore and select the correct piston grade.
ENGINE MECHANICAL 6A – 75
NOTE:
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in
slight decreases in cylinder liner clearances. Always
measure the cylinder liner clearance after installation
to be sure that it is correct.
NOTE:
The tappet surfaces are spherical. Do not attempt to
grind them with an oil stone or similar tool in an effort
to repair the tappet. If the tappet is damaged, it must
be replaced.
6A – 76 ENGINE MECHANICAL
012LX014
014RY00031
Limit
0.3 (0.012)
CAMSHAFT
Visually inspect the journals, the cams, the oil pump drive gear,
and the camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be replaced if
these conditions are discovered during inspection.
Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the camshaft
must be replaced.
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
If the measured value exceeds the specified limit, the
camshaft must be replaced.
014RY00035
014RY00036
ENGINE MECHANICAL 6A – 79
NOTE:
To increase crankshaft strength, tufftriding (Nitrizing
Treatment) has been applied. Because of this, it is not
possible to regrind the crankshaft surfaces.
Therefore, under size bearing are not available.
Crankshaft Run-Out
1. Set a dial indicator to the center of the crankshaft journal.
2. Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
If the measured value exceeds the specified limit, the
crankshaft must be replaced.
Bearing Spread
Use a vernier caliper to measure the bearing spread.
If the measured value is less than the specified limit, the
bearing must be replaced.
015RY00008
Crankshaft Journal and Diameter mm (in)
Standard Limit
4JA1T (L), 59.921-59.928
59.91 (2.3586)
4JA1TC (2.3591-2.3594)
69.917-69.932
4JH1TC 69.91(2.7524)
(2.7526-2.7532)
015RY00013
6A – 82 ENGINE MECHANICAL
015LX129
015LX060
NOTE:
The crankshaft journal mark No. 4 is stamped on
015RY00016
crankshaft No. 4 journal web front side or rear side.
6A – 84 ENGINE MECHANICAL
REFERENCE
4JH1TC mm (in)
Crankshaft
Crankshaft Journal Crankshaft
Bearing Housing
Bearing
Grade Grade Size Code
Diamaeter Diamaeter
Mark Mark
1 or 69.927-69.932
- (2.7530-2.7532)
73.992- 4
74.000 2 or 69.922-69.927
1
(2.9131- -- (2.7528-2.7530)
2.9134)
3 or 69.917-69.922
5
--- (2.7556-2.7528)
1 or 69.927-69.932
2
- (2.7530-2.7532)
73.983-
73.992 2 or 69.922-69.927
2 3
(2.9127- -- (2.7528-2.7530)
2.9131)
3 or 69.917-69.922
4
--- (2.7556-2.7528)
1 or 69.927-69.932
1
- (2.7530-2.7532)
73.975-
73.983 2 or 69.922-69.927
3
(2.9124- -- (2.7528-2.7530)
2.9127) 2
3 or 69.917-69.922
--- (2.7526-2.7528)
ENGINE MECHANICAL 6A – 85
015RY00018
NOTE:
015RY00010
Strike only the crankshaft pilot bearing outer race with
the hammer. Do not strike the bearing inner race.
Bearing damage and reduced bearing service life will
result.
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the ring
gear must be replaced.
6A – 86 ENGINE MECHANICAL
020LX008
020LX009
PISTON
Piston Grade Selection and Cylinder Bore
Measurement
Refer to the Section "Cylinder Body", Item "Cylinder Liner Bore
Measurement" for details on piston grade selection and
cylinder liner bore measurement.
015LX023
2. 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. It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or
Measuring Point 2 120 mm (4.7 in)
015RY00020
ENGINE MECHANICAL 6A – 87
4JH1TC
Standard Limit
1st Compression Ring 0.3-0.5
2nd Compression Ring (0.0118-0.0197) 1.5
(0.059)
0.250-0.450
Oil Ring
(0.0098-0.0177)
4JH1TC
Standard Limit
0.09-0.130
1st Compression Ring
(0.0035-0.0051)
0.05-0.090 0.15
2nd Compression Ring
(0.0020-0.0035) (0.0059)
0.03-0.070
Oil Ring
(0.0012-0.0028)
6A – 88 ENGINE MECHANICAL
015RW048
Piston Pin and Piston Pin Hole Clearance mm (in)
4JA1T (L) 0.002-0.015 (0.00008-0.0006)
4JA1TC, 4JH1TC 0.005-0.018 (0.0002-0.0007)
RTW36ASH001701
011RY00027
4JH1TC mm (in)
Gasket Thickness
Gasket Grade Mark Piston Projection
(Reference)
0.215-0.265 1.3
A
(0.0085-0.0104) (0.5118)
0.265-0.315 1.35
B
(0.0104-0.0124) (0.5315)
0.315-0.365 1.4
C
(0.0124-0.0144) (0.5512)
NOTE:
Difference of the each piston projection and must be
equal or within 0.1 mm (0.004 in).
6A – 90 ENGINE MECHANICAL
CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the distortion and the
parallelism between the connecting rod big end hole and the
connecting rod small end hole.
If either the measured distortion or parallelism exceed the
specified limit, the connecting rod must be replaced.
NOTE:
Install the oil seal after assembling the timing pulley
housing. The oil seal lip section is applied with oil.
Take notice of the press-in direction of the oil seal.
ENGINE MECHANICAL 6A – 93
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENT
ROCKER ARM SHAFT AND ROCKER ARM
020RY00029
Reassembly Steps
1. Rocker arm shaft 5. Rocker arm
2. Rocker arm shaft snap ring 6. Rocker arm shaft spring
3. Rocker arm 7. Rocker arm shaft snap ring
4. Rocker arm shaft bracket
Reassembly
1. Rocker Arm Shaft
1. Position the rocker arm shaft with the large oil hole (4
) facing the front of the engine.
2. Install the rocker arm shaft together with the rocker
arm, the rocker arm shaft bracket, and the spring.
2. Rocker Arm Shaft Snap Ring
3. Rocker Arm
4. Rocker Arm Shaft Bracket
014RY00037 5. Rocker Arm
6. Rocker Arm Shaft Spring
7. Rocker Arm Shaft Snap Ring
6A – 94 ENGINE MECHANICAL
CYLINDER HEAD
RTW46ALF001301
Reassembly Steps
1. Cylinder head 6. Valve spring upper seat
2. Valve spring lower seat 7. Split collar
3. Valve stem oil seal 8. Intake manifold gasket
4. Intake and exhaust valve 9. Intake manifold
5. Valve spring
ENGINE MECHANICAL 6A – 95
Reassembly
1. Cylinder Head
2. Valve Spring Lower Seat
3. Valve Stem Oil Seal
1. Apply a coat of engine oil to the oil seal inner face.
2. Use an oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve
011RW027
1. Apply a coat of engine oil to each valve stem before
installation.
2. Install the intake and exhaust valves.
3. Turn the cylinder head up to install the valve
springs.Take care not to allow the installed valves to
fall free.
5. Valve Spring
Install the valve spring with their fine pitched end (painted)
facing down.
011LX055
7. Split Collar
1. Use the spring compressor to compress the valve
spring into position.
Spring Compressor: 9-8523-1423-0
2. Install the split collars to the valve stem.
3. Set the split collars by tapping around the head of the
collar with a rubber hammer.
014RY00039
RTW46ALF000301
Reassembly Steps
1. Piston 5. Piston pin snap ring
2. Connecting rod 6. Piston ring
3. Piston pin snap ring 7. Connecting rod bearing
4. Piston pin
ENGINE MECHANICAL 6A – 97
Reassembly
1. Piston
2. Connecting Rod
1. Clamp the connecting rod in a vise.Take care not to
damage the connecting rod.
2. Use a pair of pliers to install the piston pin snap ring to
the piston.
F06MV015
RTW36ASH001801
4. Piston Pin
1. Apply a coat of engine oil to the piston pin and the
piston pin hole.
2. Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.
RTW36ASH001901
015R100001
6A – 98 ENGINE MECHANICAL
6. Piston Ring
1. Use a piston ring replacer to install the three piston
rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring
RTW36ASH002001
NOTE:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
015R100006
ENGINE MECHANICAL 6A – 99
RTW46AMF000101
Reassembly Steps
Positive Crankcase Ventilation
1. 5. Fixing bolt
(PCV) Valve
2. Rubber space 6. Oil filler cap
3. Cylinder head insulator cover
4. Breather pipe
6A – 100 ENGINE MECHANICAL
Reassembly
1. PCV Valve
Install the PCV valve and tighten the bolts to specified
torque.
2. Rubber Spacer
010R100014
3. Cylinder Head Insulator Cover
4. Breather Hose
Apply LOCTITE 262 or equivalent to the new breather pipe.
Do not reuse the breather pipe.
5. Fixing Bolt
MAJOR COMPONENT
014R300004
Reassembly Steps-1
1. Cylinder body 10. Camshaft timing gear
Piston and connecting rod with
2. Tappet 11.
upper bearing
Connecting rod bearing cap with
3. Crankshaft upper bearing 12.
lower bearing
4. Crankshaft 13. Piston cooling oil pipe
5. Crankshaft thrust bearing 14. Oil pump with oil pipe
Crankshaft bearing cap with
6. 15. Crankshaft rear oil seal
lower bearing
7. Camshaft 16. Crank case
8. Timing gear case 17. Cylinder body rear plate
9. Camshaft thrust plate 18. Flywheel
6A – 102 ENGINE MECHANICAL
RTW46ALF000501
Reassembly Steps-2
19. Crankshaft timing gear 23. Injection pump
20. Idler gear shaft 24. Water pump
21. Idler gear "A" 25. Timing gear case cover
22. Idler gear "B" and shaft 26. Crankshaft damper pulley
ENGINE MECHANICAL 6A – 103
011R300002
Reassembly Steps-3
Thermostat housing with thermo
27. Cylinder head gasket 31.
switch
28. Cylinder head 32. Water by-pass hose
29. Push rod 33. Injection nozzle and bracket
Rocker arm shaft and rocker
30. 34. Cylinder head cover with gasket
arm
6A – 104 ENGINE MECHANICAL
Reassembly
1. Cylinder Body
Use compressed air to thoroughly clean the inside and
outside surfaces of the cylinder body, the oil holes, and the
water jackets.
015R100003
2. Tappet
1. Apply a coat of engine oil to the tappet and the
cylinder body tappet insert holes.
2. Locate the position mark applied at disassembly (if
the tappet is to be reused).
NOTE:
The tappet must be installed before the camshaft
installation.
014LX088
NOTE:
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces.
015LX125
2. Locate the position mark applied at disassembly if the
removed upper bearings are to be reused.
4. Crankshaft
Apply an ample coat of engine oil to the crankshaft journals
and the crankshaft bearing surfaces before installing the
crankshaft.
015R100004
ENGINE MECHANICAL 6A – 105
015LX115
015LX128
7. Camshaft
1. Apply a coat of engine oil to the camshaft and the
camshaft bearings.
2. Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
014RY00019
020R300003
020RY00032
RTW36ASH000901
ENGINE MECHANICAL 6A – 107
015R100006
015LX096
015R100007
6A – 108 ENGINE MECHANICAL
052LX010
Relief Valve Torque N·m(kg·m/lbft)
29 (3.0/22)
NOTE:
Check that there is no interference between the piston
and the oiling jet by slowly rotating the crankshaft.
NOTE:
051R100004 Take care not to damage the O-rings when tightening
the oil pipe bolts.
015LX112
ENGINE MECHANICAL 6A – 109
013RW011
NOTE:
Be sure that the crank case fitting surface is
completely free of oil and dust before applying the
liquid gasket.
013LV003
013R100001
6A – 110 ENGINE MECHANICAL
020R100001
18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
in the illustration.
Gear stoper: 5-8840-0214-0
020RY00034
020RY00036
Idler Gear "A" Bolt Torque N·m(kg·m/lbft)
30 (3.1/22)
020L200019
020L200007
6A – 112 ENGINE MECHANICAL
RTW31BSH000101
RTW31BSH000201
RTW31BSH000301
RTW31BSH000501
ENGINE MECHANICAL 6A – 113
8) Insert the bolts of the special tool into the rear gear
setting hole. Rotate the rear gear to mesh the teeth
of main gear and rear gear.
9) Insert a lock bolt (M6 ´ 1 L=30) into scissors gear
fixing hole to prevent the scissors gear from turning.
10) Place the main gear in a vise with copper plate so
that the front side of the main gear facing up.
11) Repeat steps 4 to 8 to install the front gear.
12) Lock the front gear, the main gear, and the rear gear
RTW31BSH000401 with lock bolt (inserted at Step 8).
6A – 114 ENGINE MECHANICAL
020RY00039
4JA1TC/4JH1TC:
4. Tighten the injection pump bolts (5) to the specified
torque.
Injection Pump Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)
NOTE:
Tighten the bracket bolt (7) first.
RTW36AMH000101
ENGINE MECHANICAL 6A – 115
4JA1T(L):
4. Tighten the injection pump bolts to the specified torque.
5. Install the injection pump bracket (4) and the bracket
bolts (5) and (6) to the cylinder body. Temporarily tighten
the bracket bolts.
6. Tighten the bracket bolts (5) to the specified torque.
7. Tighten the bracket bolts (6) to the specified torque.
NOTE:
Before the gasket installation, measure the piston
head projection and select the appropriate head
gasket.
Refer to "INSPECTION AND REPAIR", "Cylinder Head
Gasket Selection".
28. Cylinder Head
1. Align the cylinder body dowels and the cylinder head
dowel holes.
Carefully place the cylinder head on the cylinder head
gasket.
2. Apply a coat of engine oil to the cylinder head bolt
threads and setting faces.
011LX073
3rd step 60° - 75°
014LX083
031R300002
ENGINE MECHANICAL 6A – 117
RTW46ASH001201
014RY00015
INSTALLATION
EXTERNAL PARTS
RTW36AMF000701
Installation Steps
1. Exhaust Manifold 18. Engine Mounting Bracket and
2. Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. Water Inlet Pipe 20. Power Steering Oil Pump
5. Generator and Adjusting Plate Bracket
6. Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
Fuel Filter Bracket (Except
7. Compressor Bracket 22.
EURO III)
Fuel Filter Assembly (Except
8. Turbocharger 23.
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
EGR Cooler (EURO III model
12. Oil Cooler Water Pipe 26-2.
only)
Intake Pipe and Throttle Body
13. Fuel Leak Off Pipe 27.
(4JA1TC/4JH1TC only)
14. Oil Pressure Warning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover
ENGINE MECHANICAL 6A – 119
Installation
1. Exhaust Manifold
1) Install the exhaust manifold to the cylinder head with
the manifold gasket.
2) Tighten the exhaust manifold bolts and nuts to the
specified torque a little at a time.
Exhaust Manifold Bolt and Nuts
Torque N·m(kg·m/Ib ft)
027R100003
27 (2.7/20)
027R100004
RTW46ASH001301
3. Generator Bracket
Install the generator bracket to the cylinder body and
tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
40 (4.1/30)
066RY00001
6A – 120 ENGINE MECHANICAL
032R300001
066RY00002
052R300001
7. Compressor Bracket
1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
M8b1.25 19 (1.9/14)
M10b1.25 40 (4.1/30)
042RY00003
ENGINE MECHANICAL 6A – 121
8. Turbocharger
1) Install the turbocharger and the gasket.
2) Temporarily tighten the turbocharger nuts at this time.
They will be fully tightened after the installation of the
turbocharger oil pipe.
Always install new nuts and new gasket.
027R100002
036R100001
027R100005
6A – 122 ENGINE MECHANICAL
10) Install the water feed pipe with the gaskets and tighten
to the specified torque.
Water Return Pipe Torque N·m(kg·m/Ib ft)
39 (4.0/29)
11) Install the water return pipe with the gaskets and
tighten to the specified torque.
Water Return Torque N·m(kg·m/Ib ft)
39 (4.0/29)
12) Clamp the water feed pipe to the oil return pipe of the
turbocharger.
Fixing Bolt (3) Torque N·m(kg·m/Ib ft)
8 (0.8/6)
RTW46ASH001601
13) Install the hoses for the water feed and return.
9. Catalytic Converter
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque N·m(kg·m/Ib ft)
27 (2.7/20)
022R300003
4JA1TC
RTW46ASH002601
5) Install the fan drive belt and adjust the belt tension
referring SERVICING of this section
6A – 124 ENGINE MECHANICAL
431RY00013
M8 19 (1.9/14)
M6 8 (0.8/6)
ENGINE MECHANICAL 6A – 125
025R100008
RTW36ASH000301
RTW48ASH001801
RTW36ASH000201
LUBRICATION SYSTEM
LUBRICATING OIL FLOW
1. Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8kg/cm 2 (608 - 764Kpa)
2. Regulating Valve Operating Pressure: 5.7 - 6.3kg/cm 2 (558.6 - 617.4Kpa)
3. Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4kg/cm 2 (270 - 330Kpa)
4. Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2kg/cm 2 (78.4 - 117.6Kpa)
5. Oil Pressure Switch Operating Pressure: 0.3 - 0.5kg/cm 2 (29.4 - 49.0Kpa)
6. Regulating Valve: 1.8 - 2.2kg/cm 2 (176 - 216Kpa)
RTW46ALF001501
OIL PUMP
DISASSEMBLY
051R100005
Disassembly Steps
1. Oil pipe 5. Driven gear
2. Strainer 6. Relief valve assembly
3. Pump cover 7. Pinion gear
4. Driven gear with bushing 8. Oil pump body
Disassembly procedure is shown in the illustration above numerical order.
ENGINE MECHANICAL 6A – 129
REASSEMBLY
051R100006
Reassembly Steps
1. Oil pump body 5. Pinion gear
2. Drive gear 6. Strainer
3. Driven gear 7. Relief valve assembly
4. Pump cover 8. Oil pipe
Reassembly procedure is shown in the illustration above numerical order.
Pump cover fixing bolts torque: 16 N·m (1.6 kg·m/12 lb ft)
ENGINE MECHANICAL 6A – 131
050R300004
Disassembly Steps
1. Oil filter cartridge 5. Body
2. Bolt 6. Oil cooler relief valve
3. Gasket 7. Regulating valve
4. Oil cooler
Disassembly procedure is shown in the illustration above numerical order.
6A – 132 ENGINE MECHANICAL
050RY00002
ENGINE MECHANICAL 6A – 133
REASSEMBLY
050R300003
Reassembly Steps
1. Body 5. Gasket
2. Regulating valve 6. Bolt
3. Oil cooler relief valve 7. Oil filter cartridge
4. Oil cooler
Reassembly procedure is shown in the illustration above numerical order.
6A – 134 ENGINE MECHANICAL
1. Body
2. Oil Filter Safety Valve
3. Oil Cooler Safety Valve
Tighten the oil filter A and oil cooler B relief valve to the
specified torque.
Regulating Valve N·m(kg·m/lb ft)
A 64 (6.5/48)
RTW46ASH001701
4. Oil Cooler
5. Gasket
6. Bolt
Tighten bolt with gasket and oil cooler to the specified
torque.
Bolt Torque N·m(kg·m/lb ft)
40 (4.1/30)
050R300006
050RY00004
ENGINE MECHANICAL 6A – 135
INTER COOLER
REMOVAL AND INSTALLATION
RTW46ALF001001
Removal
1. Radiator Grille
· Refer to removal procedure in Sheet Metal section.
RTW36ASH000601
RTW36ASH000501
RTW46ASH002101
4. Inter Cooler
· Remove the nut and two bolts.
· Disconnect the air hose.
Installation
4. Inter Cooler
· Tighten the nut and two bolts.
1. Radiator grille
· Refer to installation procedure in Sheet Metal section.
ENGINE MECHANICAL 6A – 137
SPECIAL TOOLS
Illustration Tool Number Tool Name
5-8840-2040-0 (4JA1L/TC)
Cylinder Liner Installer
5-8840-2313-0 (4JH1TC)
5-8840-2039-0 (4JA1L/TC)
Cylinder Liner Remover
5-8840-2304-0 (4JH1TC)
ENGINE MECHANICAL 6A – 139
MEMO