WORKSHOP MANUAL N SERIES 4BC2 .4BE1 4BD1 .4BD1T DIESEL ENGINE SECTION 6 ISUZU MOTORS LIMITEDTHIS MANUAL INCLUDES FOLLOWING SECTIONS ‘SECTION 6A 6B 6D 6E oF CONTENTS Fi Engine Electr Exhaust SystemNOTICE Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recom- mended that you carefully read and thoroughly understand the information contained in Section - 0A under the headings “GENERAL REPAIR INSTRUCTIONS" and “HOW TO USE THIS. MANUAL.” All material contained in this Manual is based on the latest pro- duct information available at the time of publication. All rights are reserved to make changes at any time without prior notice. This Manual is applicable to 1985 model year and later vehi- cles.TROUBLESHOOTING 6—1 SECTION 6 TROUBLESHOOTING TABLE OF CONTENTS Hard Starting Starter Motor Inoperative . Starter Motor Operates But Engine Does Not Turn Over . Engine Turns Over But Does Not Start No Preheating .. Unstable Idling . . Insufficient Power . 6-13 Excessive Fuel Consumption . 617 Excessive Oil Consumption . 6—19 Overheating .. 6-20 White Exhaust Smoke . 6-22 Dark Exhaust Smoke . 6-23 Oil Pressure Does Not Rise 6—24 Abnormal Engine Noise Engine Knocking Gas Leakage Noise .. 6-27 6—28 Continuous Noise . Slapping Noise6—2 TROUBLESHOOTING TROUBLESHOOTING Refer to the following troubleshooting charts to quickly pinpoint and repair engine problems. 1. This Section is divided into ten Sub-Sections. Refer to the Table of Contents. 2. Each troubleshooting chart has three headings arranged from left to right. Example: 3. INSUFFICIENT POWER Checkpoint Trouble Cause Countermeasure a et (tt L_______] | Lf : |__| pata tone cum vettine — | UL es | SO S= Fuel pump NS Defective fuel pump Replace the fuel pump L 3. Easily checked areas are presented at the beginning of the troubleshooting chart. Procedures beco- me more complex as the chart progresses, 4. It is suggested that you work from the beginning of the troubleshooting chart. Do not start from the middle. 5. It is possible that a seemingly apparent engine problem is not related to the engine. For example, the engine may appear to have insufficient power. This could be caused by dragging brakes or a slipping clutch instead of an engine malfunction. Refer to the other troubleshooting charts if required. 6. Optional equipment and variations are included in the troubleshooting charts. If the vehicle you are servicing is not equipped with a particular option or variation, noted in the “Checkpoint” frame, disregard the frame and move on to the next one.Checkpoint 1. Trouble Cause HARD STARTING 1) STARTER MOTOR INOPERATIVE TROUBLESHOOTING 6—3 Countermeasure Neutral switch (If so equipped) ns) Defective neutral switch Replace the neutral switch Ei exer LSE see ae wt [| Soccer tem oo NG | gattery discharged or weak | Recharge or replace the battery ui} Fan belt loose or broken. Adjust or replace the fan belt 3 ] Fusible fink | NG_| Fusible link shorted — Replace the fusible link OK : - curren | AE Das ter |_| at L__ L J ns Defective starter motor —| Repair or replace the starter motor6—4 TROUBLESHOOTING 2) STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER Checkpoint Trouble Cause Countermeasure | a NG_| Loose battery cable terminals Clean end/or retighten the bat- u Poor connections due to rusting tery cable terminals | NG) Battery discharged or weak Recharge or replace the battery Bs Fan belt loose or broken ‘Adjust or replace the fan belt ok ‘Starter motor bg Defective pinion gear Replace the pinion gear lepair or replace the magnetic | NS | Detective magnetic switch |__|. Repsir or replace the magnet [7 switen NG | Brush wear Replace the brush and/or the Weak brush spring brush spring ox roo NG_| Piston, crank bearing seizure, Repair or replace the related ‘or other damage parts |TROUBLESHOOTING 6—5 3) ENGINE TURNS OVER BUT DOES NOT START Checkpoint Trouble Cause Countermeasure ug _| Detective enginge stop mechanism Replace the engine stop Engine stop mechanism Control wire improperly adjusted mechanism (incline pump) | Adjust the control wire 1 NG_| Defective fuel cut solenoid valve Replace the fuel cut solenoid (VE pump) valve J FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP. Fuel Li Fuel tank is empty, Fill the fuel tank ox 1 . Rep or replace te ful ines Fuel ining | wa | loased or damaged fel ine Retghon te fe ine somectons ox Ng _| Fetter overtow valve does Rapa or replace the ful iter a not close ‘overflow valve na nt replace the fel iter element or (Clogged fuel filter eleme the fuel filter cartridge ox Na Fuel yer Ain the fel yt Bled the irom he ful estom Continued on the next page6—6 TROUBLESHOOTING Checkpoint Eorontearene pensteneae x | Trouble Cause Countermeasure Fuel feed pump NG. Fuel feed pump strainer is ‘logged (Indine pump only) | —| clean the fuel feed pump strainer Defective feed pump Repair or replace the feed pump FUEL IS BEING DELIVERED TO THE INJECTION PUMP Fuel ne Use of the wrong fuel Use the correct fuel Le Water particles in the fuel Change the fuel cs 6 Fue sso dicate jection pum Bid rom te ful ter Ee Continued on the next pageTROUBLESHOOTING 6—7 Checkpoint Continued from the previous page ok Trouble Cause Countermeasure Injection nozzle [6 | tear ootw |_| Injection nozzle injection starting | Improper spray condition ‘Adjust or replace the injection nozzle ox ] | ug. | Defective fuel injection nozzle Injection pump [NG _| resulting in fue drinpage after |——1 Replace the delivery valve fuel injection NG_| Detective injection pump control Repair oF replace the injection rack operation pur control rack NG_| Injection pump plunger worn or Replace the injection pump stuck plunger assembly oK ] NG _ Injection pump drive shat seizure Replace the injection pump drive Injection pump (VE pump) eee ee ee NG_| Injection pump governor spring Replace the injection pump | ‘governor spring6—8 TROUBLESHOOTING 4) NO PREHEATING ‘Checkpoint Trouble Cause Countermeasure Fusible link mee) Melted Replace Glow relay i Defective Replace: l Glow plug a} Loose terminal Tighten ns) Defective Replace j ‘Thermoswitch ne ‘Short circuit Repair a Defective Replace Timer unit NG Poorly grounded Repair l as) Defective ReplaceTROUBLESHOOTING 6—9 2. UNSTABLE IDLING Checkpoint Trouble Cause Countermeasure NG Idling system Idling improperly adjusted Adjust the idling oK ‘comrol device NG_| Defective fast idling speed Repair or replace the fast idling se ec control device speed control device ok NG_| Accelerator control system ‘Adjust the accelerator control \ccelerator control system | aac cae improperly adjusted system ok | NG. Fuel system Fuel system leakage or blockage |-——_Repair or replace the fuel system NS ‘Air in the fuel system |_| Bleed the air from the fuel system NS_| Water particles in the fuel system Change the fuel | 0k Le Replace the fuel filter element or | Fuel fter Clogged fuel fiter element fins soe nig Sorina Continued on the next page6—10 TROUBLESHOOTING Checkpoint Continued from the previous page ok Trouble Cause Countermeasure Fuel feed pump Repair or replace the fuel feed Defective fuel feed pump pump ox Injection nozzle id Injection nozzle sticking Replace the injection nozzle n_| Ileton na nection staring Adj replete injection rose improper spray condton ox Injection pump ng | Defective delivery valve resulting NS in fuel drippage after fuel injection Replace the delivery valve NG_| Injection timing improperly adjusted ‘Adjust the injection timing Continued on the next page ne Insufficient injection volume Adjust the injection volume ne Defective idle spring re Replace the idle spring aTROUBLESHOOTING 6—11 Checkpoint Trouble Cause Countermeasure Continued from the previous page ox. Injection pump NG | Detective governor lever operation oe eee NG_| Regulator valve improperly Adjust or replace the regulator adjusted (VE pump only) valve NG. Broken plunger spring Replace the plunger spring ug Worn plunger Replace the plunger assembly | NG. NG Worn camshaft (Inline pump only) Replace the camshaft NG Worn roller tappet In-line pump only) Replace the roller tappet Continued on the next page Worn cam disc (VE pump only) Replace the cam disc6~12 TROUBLESHOOTING Checkpoint Trouble Cause Countermeasure Continued from the previous page ok NG | Valve clearance improperly Valve clearance aera ‘Adjust the valve clearance oK Blown out cylinder head gasket ng | Wer evlinder tiner Compression pressure Piston ring sticking or broken Improper seating between the vvalve and the valve seat Replace the related partsTROUBLESHOOTING 6—13 3. INSUFFICIENT POWER Checkpoint Trouble Cause Countermeasure Air cleaner ne Clogged air cleaner element OUT sloment ox Fuel a ‘Water particies in the fuel Replace the fuel ox As Replace te fuser elemento fue titer Clogged fue iter lament ele te ul it ox ] ruelted pump NS] betetive ul fed pump Reps or epion fns ] ox | Injection nozzle - Injection nozzle sticking Replace the injection nozzle tg | triesin nonte nection carina | | gue reac he econ pressure to fom nous Improper spray condition ox Fuel injection pipes me) one Pipes dameged or Replace the fuel injection pipes Continued on the next page6—14 TROUBLESHOOTING Checkpoint Trouble Cause Countermeasure Continued om the previous page ox NG) Detective regulating ave epi or replace the eau Ijeton pum ME pump ony va ree he esuaing —— ne Defective delivery valve Replace the delivery valve ne Defective timer Repair or replace the timer No Worn com disk (VE pump ont) Replace the cam dk NS | improper consol ever operation Adit or replace the conto na Adj he tion ting Detective injection timing epaoreloce the ction pump ter xe Continued on the next page Weak governor spring Replace the governor springTROUBLESHOOTING 6—15 Checkpoint Trouble Cause Countermeasure Continued from the previous page oK Injection pump Ne Worn plungs Replace the plunger assembly ne | + Worn camshaft (In-line pump only) Replace the camshaft NG_| Worn roller tappet (In-tine pump only) Replace the roller tappet, NS _| Worn cam disc (VE pump only) Replace the cam disc ok Turbocharger NG_| Booster compensator pipe broken| Replace the booster compen- or cracked sator pipe Continued on the next page Exhaust gas leakage from the NG | exhaust system jr oF replace the related Air leakage from the intake system | parts NG | Detective power echo gate Repair or replace the power echo gate6—16 TROUBLESHOOTING Checkpoint Trouble Cause Countermeasure Continued from the previous page ok NG. Turbocharger Defective turbocharger assembly Replace the turbocharger assembly ok ‘Blown out cylinder head gasket ug | Worn eytinder liner Compression pressure LNS_! piston ring sticking or broken Replace the related parts. Improper seating between the valve and the valve seat ok NG_| Valve clearance improperly Valve clearance lea Recess ‘Adjust the valve clearance ok ] Le Vaive spring [SS Valve spring weak or broken Replace the valve spring | Ll ok j NG. Exhaust system Exhaust pipe clogged Clean the exhaust pipe ok Full load adjusting screw seal |NG_| Open ond improper oct Aatust end reseal the adjustingTROUBLESHOOTING 6—17 4. EXCESSIVE FUEL CONSUMPTION Checkpoint Trouble Cause Countermeasure ais we sete Repair or replace the tel sytem fuel item Fue eaage Rens op ox ne Clean or replace the ar dearer sir dear Clogged cleaner element Seen ox Ne ling speed Footy ase ting seed As te ing speed ox jection noe injection staring senace weinecton jection note NG | esau to low [| ute repiace he es Inpro spray condition ox ] Fuel injection timing is ue iniecsion Senna ltoesoresty Adjust the fuel injection timing oases ox sug | Detective deliver valve esi ection pump ings userpage ar fs Replace te devery vane ox | socchrcer NG | Airealage tom ne rbochrgey__| Resi ne wrbacergrinake ean intake side side Continued on the next page6—18 TROUBLESHOOTING Checkpoint Trouble Cause Countermeasure Continued from the previous page OK NG Turbocharger Defective turbocharger assembly Replace the turbocharger assembly | OK ] /alve clearance [Ne | reer just the valve clearance Valve el I eared Adjust the valve cl ok Blown out cylinder head gasket Worn cylinder finer Compression pressure Piston ring sticking or broken Replace the related parts Improper seating between the vaive and the vaive seat ok NG Valve spring Valve spring weak or broken Replace the valve springTROUBLESHOOTING 6—19 5. EXCESSIVE OIL CONSUMPTION Checkpoint Trouble Cause Countermeasure NG_| Engine oil unsuitable Engine oil Too much engine oil Correct the engine oil volume ok [ | | seol and ge NG | i fatage fom theo sea Replace te il sesl and/or the | eon coe and/or the gasket gasket ox 7 Air brsther Ctogged air breather Clean the sr restr ox NG. Replace the intake and exhaust Intake and exhaust valves ‘Worn valve stems and valve guides! acer care ane eae6—20 TROUBLESHOOTING 6. OVERHEATING Checkpoint Trouble Cause Countermeasure NG i Coolant Insufficient coolant Replenish the coolant J oK. NG. Fan coupling (if so equipped) Oil leakage from the fan coupling Replace the fan coupling ok an NG_| Fen bett loose or cracked causing ee [7 sippage ox Raditor NG | Defective raciator cap or clogged poo ‘adiator cap or clean 0K ‘Water pump: Le) Defective water pump Repair or replace the water pump ok Cylinder head and cylinder body |_NG_| Defective seating cap resulting in sealing cap water leakage Replace the sealing cap OK Thermostat ne Detective thermostat Replace the thermostat Continued on the next pageTROUBLESHOOTING 6—21 Checkpoint Trouble Cause Countermeasure Continued from the previous page ox | NG_| Cooling system clogged by Clean the foreign material from eae foreign material the cooling system T oK NG_| Fuel injection timing improperly adjusted Fuel injection timing ‘Adjust the fuel injection timing622 TROUBLESHOOTING WHITE EXHAUST SMOKE Checkpoint Trouble Cause Countermeasure Fuel es Water particles in the fuel Replace the fuel ox | Fuel injection timing [-NS_| Delayed fuel injection timing ‘Adjust the fuel injection timing ox ‘Blown out cylinder head gasket ~ ng Womyinder ner Compresion pressure Piston ig sticking or broken Aepace the related parts Improper seating between ne | ave ond the valve sot ox a Turbocharger Dafecve wrbocharger || Replace the turbocharger ox | Z iit and exhaust valves ng | Delestvevabe seas Replace he valve sas, the Valve seis py wer Valves, and he vane guidesTROUBLESHOOTING 6—23 8. DARK EXHAUST SMOKE Checkpoint Trouble Cause Countermeasure Air cleaner NG | Clogged air cleaner element aan ned 0K te Cf 1g | Ineeton nis jection starting Adjust of replace the injection Injection nozzle ressure too low pecae Improper spray condition oK NG_| Fuel injection timing improperly ust the fuel injection tin Fuel injection timing ole Adjust the fuel injection timing oK ig | Detective delivery vaive resulting Injection pump in fuel drippage after fuel Replace the delivery valve injection NG Excessive injection volume ‘Adjust the injection volume6—24 TROUBLESHOOTING 9. OIL PRESSURE DOES NOT RISE Checkpoint Trouble Cause Countermeasure aes NG_| Improper viscosity engine oil Replace the engine oil 3 Insufficient engine oil Correct the engine oil volume ok Cane Na_| Defeat ol pressure gauge or Repair Frente the i pret Oil pressure indicator light, rd ae Defective indicator light Replace the indicator light ok NG Replace the oil filter element or Oil fiter Clogged oil filter element ae one ok i NG_| Reliet valve sticking end/or week Replace the relief vaive and/or Reliet valve and by-pass valve ae by-pass valve spring the by-pass valve spring OK NG. Oil pump Clogged oil pump strainer, | —4 Clean the oil pump strainer ; l | r NG. Replace the oil pump related Worn oil pump related parts mera ok NG. Rocker arm shaft [NS Worn rocker arm bushing Replace the rocker arm bushing Continued on the next pageTROUBLESHOOTING 6—25 Checkpoi Trouble Cause Countermeasure Continued from the previous page ox | NG_| Worn camshaft and camshaft Replace the camshaft and the Camshett bearing camshaft bearings ok NG Replace the crankshaft and/or Crankshaft and bearings Worn crankshaft and bearings the b 1986-26 TROUBLESHOOTING 10. ABNORMAL ENGINE NOISE 1) ENGINE KNOCKING Checkpoint Trouble Cause Countermeasure ‘Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure, Fuel ne Fuel unsuitable Replace the fuel OK Fuel injccion ining LN Fuel insti ing imeroperty Act the fel jection ting 7 | Injection nozzle NG. ee el ‘or replace the injection E oy Comprnson ammo |-NC| Rovnuttenmees |_| nes end otto he 2) GAS LEAKAGE NOISE NG | Loosely connected exhaust pipes Tighten the exhaust pipe eats oleae) Broken exhaust pipes Pannestions Replace the exhaust pipes ox Injection nozse ane/or glow —|_NG | Loose injection noses andor re Plugs slow plugs and/or the glow plugs Continued on the next pageTROUBLESHOOTING 6—27 Checkpoint Trouble Cause Countermeasure Continued from the previous page ok | it NG_| Loosely connected exhaust mani- Tighten the exhaust manifold Exhaust manifold fold and/or glow plugs connections ok | NG Cylinder head gasket Damaged cylinder head gasket Replace the cylinder head gasket 3) CONTINUOUS NOISE Fan belt a Loose fan belt 1 _ Readjust the fan belt tension ox cooing fn Loose cooing fn Retghen te cooing fen J ox Wer pump bering LNG}. Wor or damaged wat ump Replace the water pune bering ox NNG_| efectve aerator or vasum Repti or repace the aterntor Atemator or vacuum pup es Rapat or rnlace te ox Vahe clarance NG. Vat clearance improper Adjust the valve clearance6-28 TROUBLESHOOTING 4) SLAPPING NOISE Checkpoint Trouble Cause Countermeasure Vat slarance NG | be clans imeropey Adjot he vavecerace ox! Rocker arm bd Damaged rocker arm / Replace the rocker arm: ox 6 Fee Loose yl bot Aetihten te ye! bots ok} —] ‘on vempeunge [.NG-| Wore damaged rankhat Replace th rankshat andor | icsananiat efi tinued Dearne and/or thrust bearings the thrust bearings ox cranata and comecing od [NG | Wom or damaged crankshaft Replace he crankhat andor beatae sro vabeninas | —] Wecomecing ed eine | ox consesing od musing and |_NG | Wom or damaged conning od| | Rule the conesing od onan Deating sn pater in Desh enalorthe torn ox [_g_| Wom or dsmaged piston ci Replace the piston and the cylir Piston and cylinder liner cylinder liner Foreign material in the cylinder der linerENGINE MECHANICAL 6A—1 SECTION 6A ENGINE MECHANICAL TABLE OF CONTENTS PAGE Main Data and Specifications Torque Specifications .. Standard Bolts Special Parts Fixing Nuts and Bolts Recommended Liquid Gasket Recommended Thread Locking Agent General Description . Removal and Installation Engine Repair Kit .. Engine Overhaul Disassembly .. Inspection and Repair .. Reassembly Turbocharger (4BD1T) Main Data and Specifications ... General Description 6A-115 6A-115 6A-116 6A-117 6A-122 .- 6A-127 .- 6A—127 6A-128 6A-130 s+ 6A—138 .. 6A—143 Removal and Installation (Garrett) .. Removal and Installation (IHI RHB-6) Lubricating System .. Main Data and Specifications ... General Description6A—2 ENGINE MECHANICAL MAIN DATA AND SPECIFICATIONS Engine Model Item 4Bc2 4BE1 Engine type Combustion chamber type Cylinder liner type Timing drive system No. of cylinders — Bore X stroke mm(in) No. of piston rings Total piston displacement om?tin®) Compression ratio (to 1) Compression pressure kg/em?(psi/kPa) Engine weight (Dry) kg(lb) Fuel injection order Fuel injection timing (BTDC) deg Specified fuel type Idling speed rpm Valve clearances (At cold): Intake mm(in) Exhaust mm(in) Intake valves Open at (BTDC) deg Close at (ABDC) deg Exhaust valves Open at (BBDC) deg Close at (ATDC) deg Fuel system Injection pump type Governor type Four-cycle, overhead valve, water cooled Direct injection Dry type, chrome plated, stainless steel tube Gear drive = 102 x 100 (4.02 x 3.98) Compression rings: 2 / Oil ring: 1 3,268 (199.3) 3,636 (221.7) 17.0 175 30 (426.2/2.943) Approximately 320 (705) 1-3-4-2 15 16 for Bosch distributor type injection pump | 17 for Bosch in-line type injection pump SAE No. 2 diesel fuel 600 700 for Bosch distributor type injection pump 600 for Bosch in-line type injection pump 0.40 (0.016) 0.40 (0.016) 28 62 70 28 4 — 105 x 105 (4.14 X 4.14) Bosch distributor type with automatic timer Bosch in-line type with automatic timer Bosch in-line type, with automatic timer Mechanical (Partially variable speed) for Bosch distributor type injection pump Mechanical (Variable speed) for Bosch in-line type injection pump RLD-K mechanical (Wariable speed)ENGINE MECHANICAL 6A—3 Engine Model Item 4BC2 4BE1 Injection nozzle type Hole type (with 4 orifices) Injection nozzle opening —_kg/em*(psi/kPa) 1988 and earlier 185 (2.631/1,814) pressure Pressure adjustment Main fuel filter type Lubricating system Lubrication method Specified engine oil (API grade) Oil pressure kg/em*(psi/kPa)/rpm Oil pump type Oil filter type Oil capacity Oil cooler type Cooling system Radiator type Coolant capacity Water pump type Thermostat type Air cleaner type Battery Alternator capacity Starter motor output Preheating system lit(US/UK gal) lit(US/UK gal) Type/voltage * No. of units V-AW) v-KW 185 (2.631/1,814) 1989 and later 220 (3.128/2,158) 1988 and earlier Screw adjusted 1989 and later Shim adjusted Disposal spin-on cartridge and remote mounted water separator Shim adjusted Full flow pressure circulation CC or CD 1.5 (21.33/147)/700 [SAE 10W-30 API CD grade engine oil at 80°C (176F)] 4.0 (66.88/392)/4,000 [SAE 10W-30 API CD grade engine oil at 120°C (280°F)] Trochoid (Rotor) Replaceable element or spin-on cartridge 60 (1.6/1.3) | 7.5 (1.98/1.65) Water cooled Corrugated fin with reserve tank 13.0 (3.43/2.86) 14.0 (3.7/3.1) Centrifugal impeller ‘Wax pellet with jiggle valve Dry paper element or oil bath '86D23R/12-60AH : 2 pes 24 - 20 (480) or 24 - 25 (600) 24-35 Quick-On-Start System or Quick-On-Start System II6A—4 ENGINE MECHANICAL MAIN DATA AND SPECIFICATIONS Engine Model Item 4BD1 4BD1T Engine type Combustion chamber type Cylinder liner type Timing drive system No. of cylinders ~ Bore x stroke mm(in) No. of piston rings Total piston displacement em’Giin’G) Compression ratio (to 1) Compression pressure kg/em*(psi/kPa) Engine weight (Ory) katlb) Fuel injection order Fuel injection timing (BTDC) deg ‘Specified fuel type Idling speed rpm Valve clearances (At cold): Intake mmi(in) Exhaust mmi(in) Intake valves Open at (BTDC) deg Close at (ABDC) deg Exhaust valves Open at (BBDC) deg Close at (ATDC) deg Fuel system Injection pump Governor type Injection nozzle type Injection nozzle opening —_kg/em*(psi/kPa) pressure Pressure adjustment Main fuel filter type Four-cycle, overhead valve, water cooled Direct injection Dry type, chrome plated, stainless steel tube Gear drive 4 — 102 X 118 (4.02 x 4.65) Compression rings: 2 / Oil control ring: 1 3,856 (235.3) 17.0 31 (441/3,038) Approximately 338 (745) 13-42 8:10 pee ee eee SAE No. 2 diesel fuel 555 — 605 0.40 (0.016) 0.40 (0.016) 1986 and 1987 and 1988 and 1989 and earlier later earlier later 8 19 28 13 a a e a 0 37 0 37 28 15 2% | 18 Bosch in-line A type, with automatic timer RLD-K, RLD-F mechanical (Variable speed) Hole type (with 4 orifices) 1986 and earlier 185 (2.631/1,814) 185 (2.631/1,814) 1987 and later 220 (3.128/2,158) 1986 and earlier Screw adjusted 1987 and later Shim adjusted Disposal spin-on cartridge and remote mounted water separator Screw adjustedENGINE MECHANICAL 6A—5 tem Engine Model 4BD1 4BDIT Lubricating system Lubrication method Specified engine oil (API grade) Oil pressure kg/om* Oil pump type Oi filter type Oil capacity Oil cooler type Cooling system Radiator type Coolant capacity Water pump type Thermostat type Air cleaner Battery Type/voltage Alternator capacity Starter motor output Preheating system Turbocharger Model Turbine type Compressor type Maximum permissible speed Wastegate opening pressure *(psi/kPa)/epm, lig(US/UK gal) lit(US/UK gal) X No, of units v-AW) v-kW rpm. mmHg(inHg) Full flow pressure circulation CE, CD or CC | CE or CD 1.5 (21.33/147)/700 [SAE 10W-30 API CD grade engine oil at 80°C (176°F)] 4.0 (56.88/392)/4,000 [SAE 10W-30 API CD grade engine oil at 120°C (280°F)] Trochoid (Rotor) | Gear Replaceable element or spin-on cartridge element 8.0 (1.98/1.65) | 88 Water cooled Corrugated fin with reserve tank 14.0 (3.7/3.1) Centrifugal impeller Wax pellet with jiggle valve Dry paper element or oll bath type 55D23R/12-60AH x 2 | 65D23R/12-65AH x 2 DELCO 31-750 x 2 24 - 20 (480), 24 - 25 (600) or 12 - 70 (840) 24-35 or 12-3.0 Quick-On-Start System or Quick-On-Start System Il 1987 and | 1988 and earlier later = THI RHB-6 [Garret Turbo| Inc. T-25 - Radial-inflow - | Radial-outflow = | 150,000 | 177,000 = 680 (27) =6A—6 ENGINE MECHANICAL TORQUE SPECIFICATION STANDARD BOLTS The torque values given in the following table should be applied whenever a particular torque is not 1 18.08/28 46-28-50) (119.38223.87/161,7023234) specified smb Ny Strength [4.8 (4T) (7) 88 9.8 (9T) Ca feted [Nanaia centicaton Bott | — Diameterx Nomen Pitch (mm) wexte Toso a7ss035 - eansiatisanss 96 (saset bor 35245) Maxtas 102050 7ss088 240.070 (oaosdeeiantsssoy (9266080117 15259) caransson3 522606) sso 1.25 200070 1021.30 (wo assbaeizraas656 (o5a5s9s0/aoa@s¥27) mra 128 e2se125 7752188 9652195 cesztenoaen 2821228) (seopert 2179521519) (esansra oraess1910 mans arses asi235 vso.290 cposeeva roaes19.1 (esves7on/tes2309 ‘ios see3 oe 40 mex ns raans270 1301350 2oanea 0 (so20ss9.na0 342646 casrsetsaeiessaiccan | arssez@ashanaaeco 0 mies vo20s280 24902500 2930-590 viasarszrasiiestess720 | ceorosdermaanozeeaon | arianeazennertasren 2018 20820 24402699 soane8%0 vnzndoamaeymasicn | qasaneasaasrrasers) | asazratess/sos80.7820 ann 22301820 46251925 54 0s1099 iasszoscouminaznseica | qaesnstnariasazsss00s) | apt. a.fa 95008-1058) waa x20 45301920 920-1490 e0s1410 tonzrscosnaosesonre | wzogssrencsisresesta0%0) | raeserb S61 882138.18 smo x15 2702070 9702050 ag0%1.20 tiasnsSenieses606) (2s 7esb 096262082) (osaasdiniaenes1.26) mais sane120 1200140 1021.80 (e g5s80/5684691 75) ts2onsr0 at 5621072) (os azera oro 00176) sna x20 9102180 z0:220 12602270 (esazaraunion 1821768 (eronesbaiian 6.2150) (oe s7etos0/i 7022646) ss x20 va7as2s0 ves0:220 19502290 (141.04 2821/191.104:98.22) An asterisk (*) indi terials such as cas by the old standard. [Q] FLare nuts icates that the bolts are used for female threaded parts that are made of soft ma- (ing. Those shown in parentheses in the strength class indicate the classification kgmiysuNiey Pipe diameter mmiin) Torque | ie siameter min) Torque 760187 1862025 (1125 18/95 22248) 7000 (0394) 550208 (997436159 95:490) 6:35 0250) 2.702030 (19522,1/264822.98) 1200 (0472) 8002 10 (65.0+7.2/88.29-9.60) 800 0315) 4502050 (925236/48.1424.90) 1500 (0591) 10.7501.25 (77749.0/105.45212.26)ENGINE MECHANICAL 6A—7 ANGULAR NUT AND BOLT TIGHTENING METHOD FA 1. Carefully wash the nuts and bolts to remove all ol and grease. Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts. A’ Sf 5 oye cavz0t 3. Tighten the nuts and bolts to the specified torque DA] * tens torque) with a torque wrench, NUT OR BOLT smug tore c2oao02 4. Draw a line @ — ® across the center of each bolt @ ® 202.008 5. Draw another line ©) — ©) on the face of each of the parts to be clamped. This line should be an extension of the line (A) — @)6A—8 ENGINE MECHANICAL species sate @ coincide ine oe _\" NS 0203-001 al a a 6. Draw another line (F) — © on the face of each of the parts to be clamped. This line will be in the direction of the specified angle @) across the cen- ter © of the nut or bolts. 7. Use a socket wrench to tighten each nut or bolt to the point where the line (8) — @) is aligned with the line © — ©. Example: Specified Angle and Tightening Rotation A 30" 1712 of turn B 60" 1/6 of turn c 90" 1/4 of turn’ D 180° 1/2 of turn E 360° One full turn ANGULAR NUT AND BOLT TIGHTENING METHOD (USING THE SPECIAL TOOL) 1. Carefully wash the nuts and bolts to remove all oil and grease. 2. Apply molybdenum disulfide grease to the threads and setting faces of the nuts and bolts. 3. Use a torque wrench to tighten the nuts and bolts to the specified torque (snug torque). 4, Attach the angle gauge to the socket wrench, ‘Angle Gauge : 5-8840-0266-0 5. Attach a magnet to some parts to hold the angle ‘gauge stationary. 6. Tighten the nuts and bolts to the specified angle, noting the angle gauge indication.ENGINE MECHANICAL 6A—9 SPECIAL PARTS FIXING NUTS AND BOLTS Cylinder Head, Head Cover, and Rocker Arm Shaft Bracket kg-m(lb.ft/N-m) [ Models for stamped cover 1.1408 (7.9:3.6/10.724.9) 2.50.5 (18.023.6/24.5:49) | Models for diecast cover 2.1405 (15.23.6/20.624.9) = 2.5202 (18.01.4/24,551.9) All 48C2/4BD1 1986 and earlier 10.0205 New bolt | (72.3:3.6/98.124.9) R 115205 feused bolt | (g3.213.6/104.524.9) All 4BE1,4801-T/1987 4801 and later ‘Ist step | 2nd step | 3rd step [_tststep_| _2n 7 (60.6/68.6)| 9 (65/88.3) | 90° + 120° 5.31.0 (98.3#7.2/51.9'9.8)6A—10 ENGINE MECHANICAL ] Exhaust Manifold, Intake Manifold, and Thermostat Housing kg-mi(lb.ft/N-m) 2.1205 (15.143,6/20.644.9) 2.1205 (15.123.6/20.6:4.9)ENGINE MECHANICAL 6A—11 a) Cylinder Body, Flywheel Housing, Oil Seal Retainer and Oil Pan kg-m(lbft/N-m) 2.60.5 (18.8:3,6/25.5°4.9) 14.054.5 (101.25709/197.35147) _ 2.60.5 (18.83.6/25.514.9) 4802, 4BD1, and 48D1T 2,020.5 (14.423.6/19.624.9)6A—12 ENGINE MECHANICAL Idler Gear, and Flywheel Crankshaft, Connecting Rod, Crankshaft Gear, kg:milb.ft/N-m) [eT 7 [073.5 + 7.2/235.4 + 9.8)/ Lubricate with engine oil" i BSE1O (38.3 +7.2/51.9 +9.8) 26205 (18.8 +3.6/25.5 +4.9) Ta0=1S (101.2 £ 10.8/137.3 $14.7) f 4426 (318.1 + 36,1/431.6 + 49,0) Ss All 48C2,4BE1/4BD1 1986 and earlier 12.0205 (86:73,6/117.74.9) 19 —|_*All 48D1-T/4BD1 1987 and later Ist step 4 (29/39.2) 2nd step 60" Ist step 2nd step 4 (29/382) 60" — 90° Lubricate with molybdenum disulfide grease to the bolt threads and setting faces. * Refer to front of this manual “TORQUE SPECIFICATION”.ENGINE MECHANICAL 6A—13 19 Gear Case Cover, Tappet Chamber Cover, kg-m(Ib.ft/N-m) 1,920.5 (13.753.6/18.64.9) 2.60.5 (18.8%3.6/25.5*4.9)6A—14 ENGINE MECHANICAL al Fuel Injection System kg-m(lbft/N-m) 3,820.9 (27.5%6.5/37.2+8.8) \ 5341.0 (38.347,2/51.99.8)ENGINE MECHANICAL 6A—15 Engine Electrical 2.520.25 (18,021.3/24.5:2.4) kg-milbft/N-m) 4BC2 only 1,840.5 (13.0%3.9/17.6#4.9) 8,621.0 (62.127,2/84,3:9.8) 5.31.0 (38.597.2/51.9:9.8)6A—16 ENGINE MECHANICAL a] Turbocharger [GARRET T-25] kg-milb.ft/N-m) 420.2 (1 2.00.4 (14.542.9/19.63.9) 2.30.2 (16,61.4/22,5%2.0) 2340.2 (16.6#1.4/22.5°2.0) [rato naoiean7e3e) | ee a eae 2.1205 (15,243.6/20.624.9)Turbocharger [IHI RHB-6] ENGINE MECHANICAL 6A—17 kg-milb.ft/N-m) 1,420.2 (10.121.4/13751.9) 0.75202 3,340.2 (28.841.4/32.3°1.9)6A—18 ENGINE MECHANICAL a] Engine Mounting Bracket kg-m(lb.ft/N-m) 4.120.6(29,724.3/40.225.9) 6.321.0(45.6¢7.2/61.79.8) 4.120.6(29.724.3/40.225.9)ENGINE MECHANICAL 6A—19 RECOMMENDED LIQUID GASKET TYPE BRAND NAME MANUFACTURER | APPLICATION PARTS (EXAMPLE) RTV* ThreeBond 12078 | ThreeBond Engine Oil Seal Retainer Silicon Base ThreeBond 1207¢ | ThreeBond Engine Oil Pan ThreeBond 1215, ‘ThreeBond Timing Gear Case ThreeBond 1216 ThreeBond Cylinder Head Cover ThreeBond 1281 ThreeBond Fuel Pump. Water Pump Water Base ThreeBond 1141E | ThreeBond Rear Axle ete Solvent ThreeBond 1104 ThreeBond BelcoBond 4 Isuzu BelcoBond 401 Isuzu BelcoBond 402 Isuzu Anaerobic LOCTITE 515 LOCTITE Engine Oil Seal Retainer LOCTITE 518 LOCTITE Water Pump Transaxle etc. +RTV: Room Temperature Vulcanizer NOTE: 1. Itis very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle. 2. 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 (0.001 in). Poor adhesion will result. 3. Be careful to use the specified amount of liquid gasket. Follow the manufacturer's instructions at all times.6A~20 ENGINE MECHANICAL Application Procedure The surfaces must be perfectly dry. amin a zie a o| +e « at, 1. Completely remove lubricant and moisture from the connecting surfaces. 2. Apply specified bead width of liquid gasket to one of the connecting surfaces. There must be no gaps in the bead. Apply liquid gasket to ‘the bolt hole interior —9os a,|« Specified bead width Example ‘Anaerobic Type : 2-3mm (0.08:0.12 inch) Others 26mm (0.08-0.24 inch) NOTE: When the application procedures are specified in this Workshop manual, follow them. RECOMMENDED THREAD LOCKING AGENT TYPE COLOR APPLICATION STEPS LOCTITE 242 Blue LOCTITE 262 Red Completely remove all lubricant and moisture from the bolts and the female threaded surfaces of the parts to be joined, The surfaces must be perfectly dry. Apply LOCTITE to the bolts. [— Apply LOCTITE to at least 1/3 of the LOCTITE 271 Red | bolt’ threaded area. Tighten the bolts to the specified torque. NoTE: After tightening, be sure to keep the bolts free from vibration and torque for at least an hour until LOCTITE hardens.ENGINE MECHANICAL 6A—21 GENERAL DESCRIPTION SL Gi SS6A—22 ENGINE MECHANICAL REMOVAL AND INSTALLATION 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. Important Operations — Removal * Carefully remove the piping, hoses, wiring harness connectors, engine control cables, and control rods from the engine. * Remove the clutch slave cylinder, the control rods, the back up light switch, and the speedometer cable from the transmission. Engine with Transmi ixed Cab Model) The engine with transmission of the fixed cab model may be lowered from the chassis as a single unit. Use an engine jack to do this. Engine and Transmission (Tilt Cab Model) The engine and transmission of the tilt cab model must be separated before the engine is hoisted from the chassis. Cab Configuration Tilt Cab Fixed Cab NKR (48C2 & 4BE1) [__ Variation ae eel ea Basic Variation 050201-026 &4BD1T) Battery 1. Disconnect the battery cable @ and the grounding cable @ from the battery terminals. Be careful not to short the battery with your span- ner or another tool at this time.ENGINE MECHANICAL 6A—23 2. Disconnect the battery cable at the starter motor and the grounding cable at the chassis frame. Coolant 1. Remove the water drain plug (at the left side of the engine) and the radiator drain plug. 2. Allow the coolant to drain completely. If long life coolant is used, drain the coolant into a clean container so that it can be reused. tor 1. Disconnect the radiator upper hose @ and the radi- ator lower hose @ from the engine side. 2. Remove the radiator with the fan shroud. Be careful not to damage the radiator core. 3. Remove the cooling fan. Engine Oil Draining Remove the oil pan drain plug to drain the engine oil, Do this while the engine is hot. Do not forget to reinstall the drain plug after draining the engine oil6A—24 ENGINE MECHANICAL 050201.039 Engine with Transmission (For Fixed Cab) 1. Jack up the vehicle and place chassis stands at the front and the rear. 2. Set an engine jack to the oil pan. 3. Operate the engine jack to slightly raise the engine with transmission. F Propeller Shaft (Single-Shaft Type) 1. Apply setting marks @ to the spline yoke @ and the propeller shaft @ before removal. This will prevent misalignment at installation. 2. Loosen the flange yoke nuts © at the parking brake drum @. 3. Disconnect the spline yoke from the parking brake drum. Do not allow the spline yoke to fall away from the propeller shaft. If the spline yoke should fall away from the propell- cr shaft, align the setting marks on the spline yoke and the propeller shaft to reassemble the two parts. Note: Correct propeller shaft balance is very important. Be sure to carefully align the setting marks at installa- tion. Rear Propeller Shaft (Dual-Shaft Type) 1. Apply setting marks @ to the spline yoke ®@ and the 2nd propeller shaft ® before removal. This will prevent misalignment at installation.ENGINE MECHANICAL 6A—25 Loosen the 1st propeller shaft flange yoke nuts @ at the parking brake drum ©. 3. Remove the center bearing retainer ® along with the 1st propeller shaft © from the parking brake drum and the 4th crossmember ®. Do not allow the spline yoke to fall away from the propeller shaft, If the spline yoke should fall away from the 2nd pro- peller shaft, align the setting marks on the spl yoke and the propeller shaft to reassemble the two parts. Note: Correct propeller shaft balance is very important. Be sure to carefully align the setting marks at instal tion. Front Exhaust Pipe (For Fixed Cab) This illustration is based on the 4BE1 engine equipped vehicle. 1. Loosen the front exhaust pipe nuts @ at the ex- haust manifold @, and the silencer ®. 2, Remove the front exhaust pipe @ from the manifold and the silencer. Parking Brake 1. Release the parking brake. 2. Insert a screwdriver © into the adjusting hole ®. Use the tip of the screwdriver to snap the adjusting screw ® upward until it reaches the stop. 3. Remove the parking brake drum ® from the main shaft flange. Refer to “Parking Brake” in Section 5. Tie Rod (For Fixed Cab) 1. Remove the tie rod end cotter pin from the tie rod end. 2. Use "the tie rod end. remover to remove the tie rod from the knuckle arm and the tie rod end. Tie Rod End Remover: 5-8840-2017-0 (Right hand end) 5-8840-2018-0 (Left hand end)6A~—26 ENGINE MECHANICAL 08641 0 Engine Mounting (For Fixed Cab) 1. Check that the engine lifting jack is securely sup- porting the engine. 2. Remove the engine rear mounting bracket nuts © from the No. 3 crossmember @. 3. Remove the engine mounting rubber nuts ® attach- ing the engine mounting cross members @. 4, Remove the engine mounting crossmember bolts © from the chassis frame ©. Note: Make sure that the connecting pipes, hoses, and cables have all been disconnected from the engine with transmission. 5. Operate the engine lifting jack to slowly raise the engine and create a space between the engine and the engine mounting crossmember. 6. Remove the engine mounting crossmember. 7. Operate the engine lifting jack to slowly lower the engine with transmission from the chassis. Be careful not to damage the brake pipe, the fuel pipe, and other parts in close proximity to the en- gine with transmission. 8. Carefully move the engine lifting jack along with the engine and transmission. WARNING: THE ENGINE WITH TRANSMISSION IS VERY HEAVY. SERIOUS INJURY TO THE MECHANIC CAN RESULT IF THE ENGINE TOPPLES FROM THE ENGINE LIFTING JACK. BE CAREFUL. 9. Attach lifting wires to the engine lifting hangers. 10. Use a hoist to lift the engine with transmission free of the engine lifting jack. 11. Place the engine with transmission on a clean flat surface,ENGINE MECHANICAL 6A—27 ‘Transmission (For Fixed Cab) 1. Remove the transmiss ‘engine rear plate. 2. Remove the transmission by pulling it toward the rear of the engine. n nuts and bolts from the 3. Use a hoist to lift the engine. 4, Set the engine on an engine stand. Cab Tilt (For Tilt Cab) The cab must be in the overtilt position to remove the engine. 1, Remove the headlight grille, the radiator grille, the front bumper, and the bank bars. 2. Apply setting marks to the steering lower shaft yoke © and the worm shaft ®. 3. Pull the universal joint bolt @ from the lower shaft, yoke. 4, Remove the lower shaft yoke from the worm shaft. 5. Pull the pin ® from the upper part of the tilt stop- per. 6. Carefully tlt the cab forward to the overtitt position. 7. Place a support bar between the cab and the chas- ssis at either side of the vehicle to prevent the cab from accidentally falling back on to the chassis. Notes: y 2) Position. If itis not, damage will result. ‘Transmission (For Tilt Cab) 1. Attach lifting wires to the engine lifting hangers.6A~—28 ENGINE MECHANICAL Pa ae Remove the engine rear mounting bracket nuts © from the No. 3 crossmember @. Remove the engine mounting rubber nuts @ from ‘the engine mounting crossmember ®. Operate the hoist and the transmission jack to slightly lower the engine with transmission. The front of the engine should be held the rear at this time. Remove the transmission nuts and bolts from the engine rear plate. Remove the transmission by pulling it toward the rear of the vehicle while slowly lowering the trans- mmission jack. her than Carefully pull the transmission jack and transmission from beneath the vehicle. Make sure that the connecting pipes, hoses, and cables have all been been removed from the en- gine. Operate the hoist to slowly raise the engine until it is clear of the chassis frame. Rotate the engine 90 degrees. Continue to lift the engine from the chassis. Carefully move the hoist and engine. Set the engine on an engine stand.| s0202-029 ENGINE MECHANICAL 6A—29 Important Operations — Installation Follow the removal procedure in reverse order to per- form the installation procedure. Pay careful attention to the important points during the installation procedure. Engine with Transmission (For Fixed Cab) 1. Remove the engine assembly from the engine stand. 2. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline. 3. Align the top gear shaft spline and the clutch driven plate spline. 4, Install the transmission to the engine. 5. Tighten the transmission bolts to the specified torque. Transmission Bolt Torque M10 Bolt 3.7 + 0.9 (26.8 + 65/363 + 8.8) M12 Bolt 8.1 + 0.6 (68.6 + 4.3/79.4 + 5.9) Refer to “Transmission” in Section 7. 6. Attach lifting wires to the engine lifting hangers. 7. Operate the hoist to lift the engine with transmis- sion on to the engine lifting jack. 8 Remove the engine lifting wires. 9. Carefully move the engine jack and the engine with transmission into position beneath the chassis frame, WARNING: ‘THE ENGINE WITH TRANSMISSION IS VERY HEAVY. SERIOUS INJURY TO THE MECHANIC CAN RESULT IF THE ENGINE TOPPLES FROM THE ENGINE JACK. BE CAREFUL. 10. Operate the engine lifting jack to raise the engine with transmission into the installation position.6A—30_ ENGINE MECHANICAL 50202-0258 Engine Mounting Crossmember Engine Mounting 1. Install the engine mounting cross member © to the engine mounting rubber @. Tighten the engine mounting rubber nuts @ to the specified torque. Mounting Rubber Nut Torque kgmi(lb.ft/N-m) 4.1 £06 (296 = 43/402 + 59) 3. Install the engine mounting crossmember to the chassis frame @. 4, Temporarily tighten the engine mounting cross- member bolts ®. 5. Install the engine rear mounting bracket nuts ® to the No. 3 crossmember ©. 6. Tighten the rear mounting bracket nuts to the speci- fied torque. Mounting Bracket Nut Torque kg-milb.ft/N-m) 4.1 + 0.6 (29.6 + 4.3/40.2 + 5.9) 7. Tighten the engine mounting crossmember bolts to the specified torque. Mounting Crossmember Bolt Torque __kg-milb.ft/N-m} 4.1 + 0.6 (29.6 + 4.3/40.2 + 5.9) Tie Rod (For Fixed Cab) 1. Install the two tie rod ends to the knuckle arms and the tie rod arms. 2. Tighten the tie rod end nuts to the specified torque. Tie Rod End Nut Torque kg-milb.ft/N-m) 19 £2 (137.4 + 14.5/186.2 + 19.6)ENGINE MECHANICAL 6A—31 Engine (For Tilt Cab) 1. Attach a lifting wire to the engine lifting hangers. 2. Operate the hoist to position the engine above the chassis frame. 3. Carefully lower the engine until it is just above the chassis frame. 4. Rotate the engine 90° to position it for final installa- tion. 5. Carefully set the engine to the chassis. The front of the engine should be held higher than the rear at this time. Be careful not to damage the exposed parts. 6. Lower the engine until it contacts the engine mount- \g crossmember. 7. Set the engine mounting rubbers to the engine mounting crossmember. 8. Temporarily tighten the engine mounting rubber bolts. The bolts will be finally tightened after the transmis- sion has been installed to the engine and the engine rear mounting bracket and the No. 3 crossmember connected. ‘Transmission (For Tilt Cab) 1. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline. 2. Place the transmission on the transmission jack. 3. Carefully move the transmission jack and transmis- sion into position behind the engine. 4, Operate the transmission jack to slowly raise the transmission to the level of the engine.6A—32_ ENGINE MECHANICAL 5. Align the transmission with the engine slope. Align the top gear shaft spline with the clutch driv- en plate spline. 6. Tighten the transmission bolts to the specified torque. Transmission Bolt Torque kg-milb.f/N-m) M10 Bolt 37 £09 (26.8 + 6.5/36.3 + 88) '9s0802.051 M12 Bolt 8.1 + 0.6 (68.6 + 4.3/79.4 + 5.9) Refer to “Transmission” in Section 7. 7. Operate the hoist to position the rear of the trans- mission beneath the No. 3 crossmember. 8. Install the engine rear mounting bracket to the No. 3 crossmember @. 9. Tighten the engine rear mounting bracket nuts @ to the specified torque. Mounting Bracket Nut Torque kg-milb.ft/Nm) 4.1 + 0.6 (29.6 + 4.3/40.2 + 5.9) 10. Tighten the engine mounting rubber nuts to the specified torque. Mounting Rubber Nut Torque kg:mi(lb.ft/N-m) 41 £06 (29.6 + 43/402 + 59) ye| EH ENGINE MECHANICAL 6A—33 Parking Brake Refer to “Parking Brake" Section 5. Parking Brake Adjustment Adjust the parking brake lining clearance after installing the propeller shaft. Parking Brake Lining Clearance Adjustment 1. Check that the parking brake lever is in the released position. 2. Rotate the brake drum © several times in both di- rections 3. Rotate the brake drum to align the adjusting hole with the adjusting screw ®. 4. Insert a screwdriver @ into the check hole and rot- ate the adjusting screw by pushing it upward, Continue doing this until the brake shoes begin to rag on the drum. 5. Back off the adjusting screw the specified number of notches. Adjusting Screw Notches 2 Rear Propeller Shaft (Single-Shaft Type) 1. Connect the spline yoke © with the propeller shaft ® to the parking brake drum. 2. Tighten the propeller shaft flange yoke nuts to the specified torque. Propeller Shaft Flange Yoke Nut Torque _kg-milb.ft/N-m} 6.7 + 0.7 (48.4 + 5.1/65.7 + 6.9) Rear Propeller Shaft (Dual-Shaft Type) 1. Connect the 1st propeller shaft © and the center bearing retainer ® to the parking brake drum ® and the 4th crossmember @. 2. Tighten the center bearing retainer bolts © to the specified torque. Center Bearing Retainer Bolt Torque __kg-milb.ft/N-mn) 28 £07 (20.2 5.1/275 +69)6A—34 ENGINE MECHANICAL 3. Tighten the 1st propeller shaft flange yoke nuts © to the specified torque. Flange Yoke Nut Torque kgmi(lb.ft/N-m) 6.7 + 0.7 (48.4 + 6.1/65.7 + 69) Note: The universal yoke spider pin centers (shown in the il- lustration) must be in a straight line at installation. Cab Tilt Stopper and Universal Joint Connection 1. Remove the support bar(s) from either side of the chassis frame. 2. Insert the pin © between the tilt stopper and the cab, 3. Install the universal joint bolt @ to the lower shaft yoke. Be sure that the setting marks applied at removal are aligned. 4, Tighten the universal joint bolt to the specified torque. Joint Bolt Torque kg-m(lb.ft/Nem) M8 Bolt 2.5 + 05 (18.1 + 3.6/24.5 + 4.9) M10 Bolt 1. Install the cooling fan ©. 2. Install the radiator ® with the fan shroud @. Be careful not to damage the radiator core. 3. Reconnect the radiator lower hose ® and the radi tor upper hose ©. 4, Replenish the coolant. Coolant Capacity lit(US/UK gal) ‘4BC2 4801, 4BD1T, & 4BE1 13 (3.43/2.86) 14 (3.7/3.1) 5. Carefully reconnect the piping, hoses, wiring con- nectors, control cables, and control rods.ENGINE MECHANICAL 6A—35 Engine Oil Replenishment 9 1. Remove the drain plug to completely drain the en- gine oil Do this while the engine is hot 2. Replace the drain plug. 3. Tlighten the drain plug to the specified torque. Drain Plug Torque kg-mi(lb.ft/N-m) 97 + 19 (70.2 ¢ 13.7/95.1 + 18.6) 1. Remove the filler cap. 2. Pour the specified engine oil into the crankcase through the oil filter. 3. Replace the filler cap. Crankcase and Filler Oil Capacity (Reference) Disposable Spin-On Cartridge Element _lit(US/UK gal) Engine [48C2 &48E1[ 4801 48017 63-70 | 68-75 | 76-83 giantess | (1.67 — 1.85/ | (1.80 — 1.98/ |(2.01 — 2.197 130 — 1.54) | 1150 — 1.68) | 1.67 — 1.83) 81-68 | 56-63 | 64-7. Grankease | (4.35 — 1.53/| (1.48 — 1.66/ (1.69 ~ 1.88/ uv 1.12 — 1.28) | 1.23 = 1.30) | 1.41 — 1.56) Replaceable Paper Element Engine [48C2 &4BE1 4801 4BD1T 59-66 | 64-71 Crankcase (1.56 — 1.74/ | (1.69 — 1.88/ - Sfilter [130 — 1.45) | 1.41 — 1.51) 51-58 5.6 —- 6.3 Sraptease | (1.35 — 1'59/| (1.48 — 1.66/, | — 1.12 — 1.28) | 1.23 — 1.30) 4. Start the engine and allow it to idle for a few mi- nutes. Stop the engine. Use the dipstick to check the oil level. If the oil level is below the “MIN” line, add oil through the oil filler. If the oil level is above the "MAX" line, drain off the excess oil through the drain plug.6A—36 ENGINE MECHANICAL (050201-027 Battery 1. Check the battery fluid level and the specific gravity. 2. Secure the battery with the battery clamp ©. Do not overtighten the battery clamp. 3. Connect the battery cable @ and the grounding cable ®. 4. Apply grease to the battery terminals. Engine Warm-Up After completing the required maintenance procedures, start the engine and allow it to warm up. Then check the following: 1. Engine idling speed Refer to “Servicing” for the idling speed adjustment procedure, Engine noise level Engine oil and coolant leakage Engine control cable operation Clutch engagement Indicator warning light operationENGINE MECHANICAL 6A—37 ENGINE REPAIR KIT All of the numbered parts listed below are included in the Engine Repair Kit. lustration is based on the 4BE1 Engine. Thi PENOmEReN> Cylinder head gasket Cylinder head cover gasket Drain plug gasket Gil relief O-ring Tappet chamber cover gasket Tappet chamber cover bolt gasket Oil cooler gasket Crankshaft rear oll seal Gil seal retainer gasket Timing gear case gasket Timing gear case cover gasket Gil pan drain plug gasket 13. Oil pan gasket 14. Oil pipe gasket 15. Water pump gasket 16. Water outlet pipe gasket 17. Thermostat housing gasket 18. Air inlet pipe gasket 19. Exhaust manifold gasket 20. Fuel leak off pipe gasket 21. Fuel pipe gasket 22. Crankshaft front oil seal 23. Injection pump bracket gasket 24. Nozzle holder gasket6A—38 ENGINE MECHANICAL ENGINE OVERHAUL DISASSEMBLY EXTERNAL PARTS This illustration is based on the 4BE1 engine. | 13 22 2 8 2 9 9 5 4 2 7 B a Disassembly Steps 1. Cooling fan drive belt 14, Starter motor 2. Cooling fan pulley 15. Vacuum pump oil supply hose 3. Fuel filter pipe 16. Vacuum pump oil drain hose 4, Fuel return pipe 17. Alternator with vacuum pump 5. Fuel filter and bracket 18. Oil dipstick and guide tube 6. Oil pipe 19. Injection nozzle holder 7. Oil filter and body 20. Glow plug and connector 8. Fuel leak-off pipe 21, Exhaust manifold and gasket ‘49. Fuel injection pipe with clip 22. Intake manifold and port insert (1988 10. Injection pump oil feed pipe and earlier 4BC2 and 4BE1 engines) 11. Injection pump oil return pipe 22a. Intake manifold and gasket (All 4801 12. Power steering oil pump and 1989 and later 48C2 and 4BE1 13. Throttle control link bracket engines)ENGINE MECHANICAL 6A—39 V Important Operations 9. Fuel Injection ip 1) Loosen the injection pipe sleeve nuts @ at the deliv- ery valve side. Do not apply excessive force to the injection 2) Loosen the injection pipe clips @. 3) Remove the injection pipes ©. Note: Plug the delivery holder ports to prevent the entry of foreign material.6A—40_ ENGINE MECHANICAL fe] INTERNAL PARTS. MAJOR COMPONENTS Disassembly Steps-1 > > SOx omAon= Water by-pass hose Cylinder head cover Tappet chamber cover Rocker arm shaft and rocker arm Push rod ‘Thermostat housing Cylinder head Cylinder head gasket Water pump 4.10. Crankshaft pulley nut and washer 4.11. Crankshaft damper pulley ‘4.12. Timing gear case cover 413. Idler gear 4.14. Injection pump with rear bracket (Bosch in-line type) ‘4 14a. Injection pump with rear bracket (Bosch distributor type) 15. Oil coolerENGINE MECHANICAL 6A—41 16. 16a. assembly Steps-2 Oil pan Oil pan (4BE1) Bed plate (48E1) . Flywheel Flywheel housing Oil pump drive gear and cover |. Oil pump with oil pipe . Camshaft with camshaft timing gear and thrust plate . Tappet |. Connecting rod bearing cap with lower bearing Tit 3. Piston and connecting rod with upper bearing Crankshaft rear oil seal retainer 1g gear case Crankshaft bearing cap with lower bearing Crankshaft thrust bearing 1. Crankshaft with timing gear |. Crankshaft upper bearing . Check valve (4BD1T) 3. Oiling jet (4BD1T) Relief valve 3. Cylinder bodyGA—42 ENGINE MECHANICAL Cay wy f >. tha Ae tefl (Aff Vv Important Operations 2. Cylinder Head Cover 1) Loosen the cylinder head bolts a little at a time in the numerical order shown in the illustration. 2) Disconnect the air breather between the cylinder head cover and the intake manifold. 3) Remove the cylinder head cover. 4. Rocker Arm Shaft and Rocker Arm Loosen the rocker arm shaft bracket bolts in numerical order alittle at a time. Warning: Failure to loosen the rocker arm shaft bracket bolts in numerical order a little at a time will adversely effect the rocker arm shaft. 7. Cylinder Head Use the cylinder head bolt wrench to loosen the cylin- der head bolts in numerical order a litle ata time. Cylinder Head Bolt Wrench : 1-8511-1003-0 Warning: Failure to loosen the cylinder head bolts in numerical order a little at a time will adversely effect the cylin- der head lower surface. 10. Crankshaft Pulley Nut and Washer 11. Crankshaft Damper Pulley 1) Use the flywheel holder to prevent the crankshaft from turning, Crankshaft Stopper : 5-8840-0375-0 (J-38674) 2) Use a 41 mm (1.6 in) wrench to loosen the crank- shaft front nut. 3) Use a pulley puller to remove the crankshaft dam- per pulley.Dia necator ENGINE MECHANICAL 6A—43 12. Timing Gear Case Cover 1) Remove the rubber plug ©. 2) Loosen the timing gear case through bolt @. 3) Loosen the timing gear case cover bolts. 4) Remove the timing gear case cover @. . Idler Gear Measure the backlash of each timing gear. Measure the idler gear end play. Remove the idler gear. jing Gear Backlash Measurement 1) Set a dial indicator to the timing gear to be mea- sured. Hold both the gear to be checked and the adjoining ‘gear stationary 2) Move the gear to be checked as far as possible to both the right and the left. Take the dial indicator reading, If the measured value exceeds the specified limit, the timing gear must be replaced. Timing Gear Backlash Crankshaft Gear to Idler Gear Idler Gear to Camshaft Ge ~__ Standard Limit 0.10— 0.17 {0.0039 ~ 0.0067) ee Idler Gear to Injection Purp Gear mmtin) Standard Limi 0.18 — 025 0.30 (0.0120) (0.0059 — 0.0098)6A—44 ENGINE MECHANICAL Idler Gear End Play Measurement Insert @ feeler gauge between the idler gear and the ‘thrust collar to measure the gap and determine the idler gear end play. If the measured value exceeds the specified limit, the thrust collar must be replaced. Idler Gear End Play mm(in) ‘Standard Limit 0.053 — 0.115 0.2 (0.008) (0.002 — 0.005) 14, Injection Pump with Rear Bracket (Line Type) 14a, Injection Pump with Rear Bracket (Distributor Type) 1) Remove the injection pump bolt ® from the timing gear case. 2} Remove the injection pump rear bracket bolts ® from the cylinder body. 3) Pull the injection pump free from the rear. 18. Flywheel 1) Block the crankshaft with a piece of hard wood to prevent the fiywheel from turning,ENGINE MECHANICAL 6A—45 oso201.017 2) Loosen the fiywheel bolts in numerical order a little ata time, 22. Camahafe with Camshaft Timing Geer and Thrust te 1) Remove the thrust plate bolts. 2) Pull the camshaft free along with the camshaft tim- ing gear and the thrust plate. Note: Be careful not to damage the camshaft journal, the cam, and the camshaft during the disassembly proce- dure. 23. Tappet If the camshaft tappets are to be reinstalled, mark their fitting positions by tagging each tappet with the cylinder number from which it was removed. 24. Connecting Rod Bearing Cap with Lower Bearing If the connecting rod lower bearings are to be rein- stalled, mark their fitting positions by tagging each bear- ing with the cylinder number from which it was re- moved. 25. Piston and Connecting Rod with Upper Bearing 1) Remove carbon deposits from the upper portion of the cylinder wall with a scraper before removing the piston and connecting rod.6A—46 ENGINE MECHANICAL osc301-019 2) Move the piston to the top of the cylinder and tap it with a hammer grip or similar object from the con- necting rod lower side to drive it out. If the connecting rod upper bearings are to be rein- stalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. 28. Crankshaft Bearing Cap with Lower Bearing 1) Measure the crankshaft end play at the center jour- nal of the crankshaft. Do this before removing the crankshaft bearing caps. If the measured value exceeds the specified limit, the crankshaft thrust bearing must be replaced. Crankshaft End Play mm(in} ‘Standard Limi 0.15 — 0.33 ons coTal 0.45 (0.018) 2) Loosen the crankshaft bearing cap bolts in numeri- cal order a little at a time, Hf the crankshaft bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.ENGINE MECHANICAL 6A—47 50301-029 31. Crankshaft Upper Bearing If the crankshaft upper bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. 32. Check Valve (4BD1T) 33. Oiling Jet (4BD1T) Loosen the check valves to remove both the check valves and the oiling jets. Take care not to damage the oiling jets.6A—48 ENGINE MECHANICAL MINOR COMPONENTS: ROCKER ARM SHAFT AND ROCKER ARM Disassembly Steps ‘A 1. Rocker arm shaft snap ring 4, Rocker arm shaft spring 4 2. Rocker arm shaft bracket 5. Rocker arm shaft 3. Rocker arm V Important Operations 1. Rocker Arm Shaft Snap Ring 2. Rocker Arm Shaft Bracket 1) Use a pair of snap ring pliers to remove the snap ring. 2) Remove the rocker arm shaft bracket.ENGINE MECHANICAL 6A—49 +f] CYLINDER HEAD Disassembly Steps & 1. Split collar a 2. Valve spring upper seat 3. Valve spring (Outer) 4. Valve spring (Inner) Intake and exhaust valve Valve stem oil seal Valve spring lower seat Cylinder head @uog6A—50 ENGINE MECHANICAL V Important Operations 1. Split Collar 1) Place the cylinder head on a flat wooden surface. 2) Use the spring compressor to remove the split col- lar. Do not allow the valve to fall from the cylinder head. Spring Compressor : 9-8523-1426-0 0:0209-002 5, Intake and Exhaust Valve If the intake and exhaust valves are to be reinstalled, mark their installation positions by tagging each valve with the cylinder number from which it was removed. If the intake and exhaust valves are to be replaced, the valve guides must also be replaced, 9s0303-003ENGINE MECHANICAL 6A—51 PISTON AND CONNECTING ROD Disassembly Steps 4 1. Connecting rod bearing & 5. Piston pin & 2. Piston ring 6. Connecting rod 4 3. Piston pin snap ring & 7. Piston ‘4 4. Piston pin snap ring6A—52_ENGINE MECHANICAL Vv Important Operations 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. 2. Piston Ring 1) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2) Use a piston pin 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. iston Pin Snap Ring 4. Piston Pin Snap Ring Use a pair of snap ring pliers to remove the piston pin snap rings. 5. Piston Pin 7. Piston Tap the piston pin out with a hammer and a brass ber. If the pistons are to be reinstalled, mark their installation positions by tagging each piston with the cylinder num- ber from which it was removed.ENGINE MECHANICAL 6A—53 j+f+] CAMSHAFT, CAMSHAFT TIMING GEAR, AND THRUST PLATE Disassembly Steps 4 1. Camshaft timing gear 3. Feather key ‘& 2. Thrust plate 4. Camshaft6A—54 ENGINE MECHANICAL V Important Operations 1. Camshaft Timing Ge 2. Thrust Plate 1) Clamp the camshaft in a vise. Take care not to damage the camshaft. 2) Use the universal puller to pull out the camshaft timing gear. 3) Remove the thrust plate.ENGINE MECHANICAL 6A—55 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. 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. Regrind the cylinder head lower face if the mea- sured values are greater than the specified limit but less than the maximum grinding allowance. If the measured values exceed the maximum grind- ing allowance, the cylinder head must be replaced. Cylinder Head Lower Face Warpage—————_mmiin) ‘Standard Limit Sa ieia ing (0.002) or less | 92 (0.008) 0.3 (0.012) Cylinder Head Height (H) (Reference) mm(in) Standard i (Beas — Bee) 89.65 (3.530) Note: If the cylinder head lower face is reground, valve d pression must be checked.GA—56 ENGINE MECHANICAL Manifold Fitting Face Warpage Use a straight edge and a feeler gauge to measure the manifold cylinder head fitting face warpage Regrind the manifold cylinder head fitting faces if the measured value is greater than the specified standard but less than the specified limit. If the measured value exceeds the specified limit, the cylinder head must be replaced. Manifold Fitting Face Warpage mm(in) Standard Lim 0.05 (0.002) or less ames Exhaust Manifold Warpage Use a straight edge and a feeler gauge to measure the manifold cylinder head fitting face warpage. Regrind the manifold cylinder head fitting faces if the measured values are between the specified limit and the standard. If the measured values exceed the specified limit, the manifold must be replaced. Exhaust Manifold Warpage mmtin) Standard Limit 0.05 (0.002) or less CameS N oft © ENGINE MECHANICAL 6A—57 VALVE GUIDE Valve Stem and Valve Guide Clearance Measuring Method-| 1. With the valve stem inserted in the valve guide, set the dial indicator needle to “0”. 2. Move the valve head from side to side. Read the dial indicator. Note the total indicator reading (TIR). If the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set Valve Stem Clearance (TIR) mmtin} Standard Limit 0.039 — 0.068 020 Intake Valve | (0.0015 — 0.0027) _| (0.0080) 0.064 — 0.098 0.26 Exhaust Valve | (0.0025 — 0.0038) | (0.0088) Measuring Method-l 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. 3. Calculate the clearance between the valve guide in- side diameter and the valve stem outside diameter. If the clearance exceeds the specified limit, the valve and the valve guide must be replaced as a set. Valve Guide Replacement Valve Guide Removal Use a hammer and the valve guide remover to drive out the valve guide from the cylinder head lower face. Valve Guide Remover : 5-88402-099-06A—58 ENGINE MECHANICAL Valve Guide installa 1. Apply engine oil to the valve guide outer circumfer- ence. 2. Attach the valve guide installer to the valve g Valve Guide Installer : 5-88402-099-0 3. Use a hammer to drive the valve guide into position from the cylinder head upper face. 4, Measure the height (H) of the valve guide upper end from the cylinder head upper face. Valve Guide Upper End Height (H) mm(in) \ .050402005| | Note: If the valve guide has been removed, both the valve and the valve guide must be replaced as a set. VALVE AND VALVE SEAT INSERT 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 mmi(in) Standard Limi 8.946 — 8.961 8.88 Intake Valve (0.352 ~ 0.353) (0.350) 2.921 — 8996 2.88 Exhaust Valve | (0.351 — 0.352) (0:360) Valve Thickness and Depression 1, Measure the vaive thickness. If the measured value is less than the specified li- mit, the valve and the valve seat insert must be re- placed as a set. Intake and Exhaust Valve Thickness mmiin) { ‘Standard Limit t 1.5 (0.059) 1.0 (0.04)ENGINE MECHANICAL 6A—59 2. Install the valve © to the cylinder head ®. 3. 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 and/or the valve must be re- placed. Intake and Exhaust Valve Depression mm(in) ‘Standard Limit 0.85 (0.033) | 2.35 (0.0925) 1987 4BD1 and later | 1.15 (0.0450) | 2.65 (0.1043) Valve Contact Width 1. Check the valve contact faces for roughness and unevenness. Make smooth the valve contact surfaces. Measure the valve contact width. If the measured value exceeds the specified limit, the valve seat insert must be replaced. /e Contact Width mmi(in) Standard imit 1.5 (0.059) 2.0 (0.079)6A—60 ENGINE MECHANICAL 1050404.005, Valve Seat Insert Replacement Valve Seat Insert Removal 1. Are weld the entire ii valve seat insert @. 2. Allow the valve seat insert to cool for a few mi nutes. This will invite contraction and make removal of the valve seat insert easier. Use a screwdriver ® to pry the valve seat insert free. Take care not to damage the cylinder head @. 4, Carefully remove carbon and other foreign material from the cylinder head insert bore. side circumference © of the Valve Seat Insert Installation 1. Carefully place the attachment @ (having a smaller outside diameter than the valve seat insert) on the valve seat insert ®. Note: The smooth side of the attachment must contact the valve seat insert. 2. Use a bench press ® 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 wil result.ENGINE MECHANICAL 6A—61 s0404.007 Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert sur- face. 2. Use a valve cutter (15°, 45°, and 75° blades) to mini- mize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away un- blemished areas of the valve seat surface. Valve Seat Angle deg 45 Note: Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside the valve guide. 3. Apply abrasive compound to the valve seat insert surface. 4, Insert the valve into the valve guide. 5. Turn the valve while tapping it to fit the valve seat insert. 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve. VALVE SPRING Valve Spring Free Height Use a vernier caliper to measure the valve spring free height. If the measured value is less than the specified limit, the valve spring must be replaced. Inner Spring and Outer Spring Free Height mm(in) Standard Limit Inner 52.40 (2.065) ‘60.00 (1.970) Outer 53.65 (2.112) 180.65 (1.994)6A—62_ ENGINE MECHANICAL fo RE 50405-0029 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. Inner and Outer Spring Squareness mm(in) Limit 1.0 (0.04) Valve Spring Tension Use a spring tester to measure the valve spring tension. if the measured value is less than the specified limit, the yf valve spring must be replaced yl Valve Spring Tension kgilb/N) Set length - etlenath | Standard Limit | 109 99 | esouoso0s Inner 42.0 (1.65) | ¢24,03/106.93) | (21.83/97.10) 23.0 20.0 Outer 44.0 (1-73) | (60,72/226.63) | (44.10/196.20) ROCKER ARM SHAFT AND ROCKER ARM Rocker Arm Shaft Run-Out 1. Place the rocker arm shaft on a V-block. 2. Use a dial indicator to measure the rocker arm shaft central portion run-out. If the run-out is very slight, correct the rocker arm shaft run-out with a bench press. The rocker arm must be at cold condition. If the measured rocker arm shaft run-out exceeds ‘the specified limit, the rocker arm shaft must be re- Placed. Rocker Arm Shaft Run-Out mmi(in) Limit 0.3 (0.0012)ENGINE MECHANICAL 6A—63 Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm fitting por- tion outside diameter. If the measured value is less than the specified limit, the rocker arm shaft must be replaced. Rocker Arm Shaft Outside Diameter min) Standard 18.98 — 19.00 (0.747 ~ 0.748) cee Rocker Arm Shaft and Rocker Arm Clearance s0406-003| R= | 1. Use either a vernier caliper or a dial indicator to measure the rocker arm bushing inside diameter. Rocker Arm Bushing Inside Diameter mtn) Standard Limit 19.01 — 19.03 T (0.7489, 7497) 19.08 (0.7605) 2. Measure the rocker arm shaft outside diameter. If the measured value exceeds the specified limit, replace either the rocker arm or the rocker arm shaft. Rocker Arm and Rocker Arm Shaft Clearance __mm(in} Standard Limit 0.014 — 0.062 {0.00055 ~ 0.0024) eceeseeee 3. Check that the rocker arm oil port is free of obstruc- tions. If necessary, use compressed air to clean the rocker arm oil port. Rocker Arm Correction Inspect the rocker arm valve stem contact surfaces for step wear © and scoring @. If the contact surfaces have light step wear or scoring, they may be honed with an oil stone. If the step wear or scoring is severe, the rocker arm must be replaced.6A—64 ENGINE MECHANICAL [+>] CYLINDER BODY Cylinder Body Upper Face Warpage 1. Remove the cylinder body dowel. Refer to “Cylinder Liner Replacement.” 3. Use a straight edge @ and a feeler gauge ®@ to measure the four sides and the two diagonals of the cylinder body upper face. 4, Regrind the cylinder body upper face if the mea- sured values are greater than the specified limit but less than the maximum grinding allowance. If the measured values exceed the maximum grind- ing allowance, the cylinder body must be replaced. linder Body Upper Face Warpage mm(in) Maximum Grinding Standard Limit oo 0.05 (0.002) erless | 9-20 (0.008) 0.30 (0.012) Cylinder Body Height (H) (Reference) mm(in) |___ Standard 4802 349,93 — 360.17 (13.777 — 13.786) 4801 &4BD1T (15.115 BE 350.13 (13.778 5. Reinstall the cylinder liner. Refer to “Cylinder Body Bore Measurement.” 6. Reinstall the cylinder body dowel.ENGINE MECHANICAL 6A—65 Cylinder Liner Bore Measurement Use a cylinder indicator to measure the cylinder bore at measuring point @ in the thrust @-® and axial @-@ directions of the crankshaft. Measuring Point © 20.0 mm (0.79 in) If the measured value exceeds the specified limit, the cylinder liner must be replaced. Cylinder Liner Bore mentin) femaaree ‘Standard Limit ‘4BC2, 4BD1, 702.021 — 102.060 | 102.200 &4B01T (4.0166 — 4.0181) (4.0236) 105.021 — 105.060 | 105.200 “eet (4.1347 — 4.1362) (4.1417) Note: .050407.008 The inside of the dry type cylinder liner is chrome plat- ed. It cannot be rebored or honed. If the inside of the cylinder liner is scored or scorched, the cylinder liner must be replaced. Cylinder Liner Projection Inspection 1. Hold a straight edge ® along the top edge of the cylinder liner to be measured. 2. Use a feeler gauge ® to measure each cylinder lin- er projection. Cylinder Liner Projection mmi(in) Standard 0.03 — 0.10 (0.0012 — 0.0039) ‘The difference in the cylinder liner projection height be- tween any two adjacent cylinders must not exceed 0.03, mm (0.0012 in),6A—66 ENGINE MECHANICAL Cylinder Liner Replacement Cylinder Liner Removal 1. Set the cylinder liner remover © to the cylinder lin- er, 2. Check that the remover shaft ankle ® is firmly ripping the cylinder liner bottom edge ©. 3. Slowly turn the remover shaft handle @ clockwise to pull the cylinder liner free. Cylinder Liner Remover : 9-8523-1169-0 Ankle : (4BC2, 4BD1, & 4BD1T) 9-8523-2557-0 (4BE1) 5-8840-2108-0 Note: ‘Take care not to damage the cylinder body upper face during the cylinder liner removal procedure. Cylinder Liner Grade Selection and Standard Fitting Interference Accurately measured fitting interference and proper cylinder liner grade selection are extremely important. If the cylinder liner fitting interference is too small, engine cooling efficiency will be adversely affected. If the cylinder liner fitting interference is too large, it will be difficult to insert the cylinder liner into the cylinder body. Standard fitting 0.001 — 0.019 interference mm(in.) | (0.00004—0.00075) There are two methods by which liners can be selected. Mothod | PS The cylinder block deck has been marked during 3} production to indicate the correct ner. The liner grade (ie. 1, 2, 3, 4) is indicated in permanent ink.ENGINE MECHANICAL 6A—67 In the case of a questionable liner marking use the next method for correct liner selection. Method It 1. Measure the cylinder body bore at measuring point ® across positions D — @, @ - ®, ® — ®, and © -o Measuring Point © mm(in) 4c. 95 (3.74) _ 4801 & 4BD1T 105 (4.13) _4BEt 98 (3.86) 2. Calculate the average value of the four measurements to determine the correct cylinder liner grade. 3. Consult the following table with the resultant diameter for the correct liner application. [4BC2, 48D1, 4BD1T Engine] Cylinder Bore (Reference) Diameter Liner Liner Outside Average _mmfin) Grade ___Diameter_mmtin.) 105,001—105.010 ; 105.011—105.020 (4.1339—4.1342) (4.1343—4.1346) 105.011—105.020 a 105.021—105.030 (4.1343-4,1346) (4.1347—4.1350) 1105.021—105.030 A 105.031—105.040 (4.1347—4.1350) (4.1351-4.1354) 105.031—105.040 : 105.041—105.050 (4.1351-4.1354) (4.1355~4.1358) [4BE1 Engine] Cylinder Bore (Reference) Diameter Liner Liner Outside Average _mmiin) Grade __Diameter_mmiin.) 107.001—-107.010 Fi 107.011—107.020 (4.2126-4,2129) (4.2130-4,2133), 107.011-107.020 . 107.021—107.030 (4.2130—4.2133) (4.2134-4.2137) 107.021—107.030 107.031—107.040 (4.2134—4,2137) (4.2138—4.2141) 107.031—107.040 107.041—107.050 (4.2138-4.2141) (4.2142-4.2145)GA—68_ ENGINE MECHANICAL Cylinder Liner Installation 1. Cylinder Liner Installation Using The Special Too! 1) Use new kerosene or diesel oil to thoroughly el clean the cylinder liners and bores. 2) Use compressed air to blow-dry the cylinder lin- er and bore surfaces. Note: All foreign material must be carefully removed from er and the cylinder bore before instal 3) Insert the cylinder liner © into the cylinder body @ from the top of the cylinder body. 4) Set the cylinder liner installer © to the top of the cylinder liner. Cylinder Liner installer: (4BC2, 4BD1, & 4BD1T) 9-8523-2554-0 (4BE1) 8-8522-1070-0 5) Position the cylinder body so that the installer center @ is directly beneath the bench press shaft center ©. x = Q © | Note: YY Check that the cylinder liner is set perpendicular to ‘the bench press and that there is no wobble.ENGINE MECHANICAL 6A—69 6) Use the bench press to apply a seating force of 500 kg (1,102.5 Ib/4,900 N) to the cylinder liner. 7) Apply a force of 2,500 kg (5,512.5 Ib/24,500 N} to fully seat the cylinder liner. 8) After installing the cylinder liner, measure the cylinder liner projection. Refer to “Cylinder Liner Projection Inspection”. 2. Cylinder Liner Installation Using Dry Ice If the cylinder liner is a chrome plated dry type, It is, advisable to use dry ice during the installation procedure. Cooling the cylinder liner with dry ice will cause the cylinder liner to contract, thus making installation easier. the cylinder body immediately after it cooled. Piston Grade Selection Measure the cylinder liner bore after installing the cylin- der liner. Then select the appropriate piston grade for the installed cylinder liner. 1, Measure the cylinder liner bore. Refer to “Cylinder Liner Bore Measurement”. Measuring Point © 20 mm (0.79 in) Measuring Point ® 95 mm (3.74 in) Cylinder Liner Bore mm(in) Engine Standard Limit 4BC2,4BD1, | 102.021 — 102.060 102.200 aabit "| (4.0166 4.0181) mart 105.021 — 105.060 | 105.200 (4.1347 ~ 4.1362) (4.1417) 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.6A—70 ENGINE MECHANICAL _0s0407-008 2, Measure the piston outside diameter. Piston Measuring Point ®: (48C2, 4801, & 4BD1T) 82.0 mm (3.23 in) (481) 84.5 mm (3.33 in) Piston Grade mmi(in) Engine [Grade Piston Size ‘4BC2, 4BD1 101.955—101.974 (4.0140—4.0147) &4B01T 101.975—101.994 (4.0148-4.0155) Pay 104,955—104.974 (4.1321—4.1328) 10. 104.994 (4.1329-4.1336) Cylinder Liner and Piston Clearance mmi(in) 4BC2, 4801, _ = abi 0.057 — 0.075 (0.0022 ~ 0.0030) 4BE1 0.057 — 0.085 (0.0022 — 0.0033) Note: Cylinder liner kit clearances are preset. However, the cylinder liner installation procedure may result in TAPPET AND PUSH ROD Visually inspect the tappet camshaft contact surfaces for pitting, cracking, and other abnormal conditions. ‘The tappet must be replaced if any of these conditions are present. Refer to the illustration at the left. © Normal contact ® Cracking ©® Pitting @® Irregular contact © Irregular contact Note: The tappet surfaces are spherical. Do not attempt to grind them with an to repair the tappet. If the tappet is damaged, it must.050408.004| ENGINE MECHANICAL 6A—71 Measure the tappet outside ter. If the measured value is less than the specified li- mit, the tappet must be replaced, Tappet Outside Diameter ‘Standard 27.97 — 27.98 (1.1012 ~ 1.1016) saan Tappet and Cylinder Body Clearance Standard Limit 0.020 — 0.054 (0.0008 - 0.0020) eee mmiin) Push Rod Curvature 1. Lay the push rod on a surface plate. 2. Roll the push rod along the surface plate and mea- sure the push rod curvature with a thickness gauge. If the measured value exceeds the specified limit, the push rod must be replaced. Push Rod Curvature Limi 0.3 (0.012) mm(in) 3. Visually inspect both ends of the push rod for ex- cessive wear and damage. The push rod must be replaced if these conditions are discovered during inspection. 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 dis- covered during inspection.6A—72 ENGINE MECHANICAL 50409.002 5009-004 Camshaft Journal Use a micrometer to measure each camshaft journal di- ameter in two directions (© and @). If the measured value is less than the specified limit, the camshaft must be replaced. Camshaft Journal Diameter mm(in) Standard Limit 55.94 — 55.97 (2.0240 — 2.2035) ameter 156.60 (2.1890) Cam Height Measure the cam height (H) with a micrometer. If the measured value is less than the specified limit, the cam- shaft must be replaced, Cam Height @ mmi(in) Standard Limit 47.7 (1.878) 46.5 (1.831) 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 li the camshaft must be replaced. Camshaft Run-Out mm(in) 0.1 (0.0039) Camshaft and Camshaft Bearing Clearance Use an inside dial indicator to measure the camshaft bearing @ inside diameter. Camshaft Bearing Inside Diameter mmiin) Standard 56.00 — 56.03 (2.2064 — 2.2076) If the clearance between the camshaft bearing inside diameter and the journal exceeds the specified limit, the camshaft bearing must be replaced. Camshaft Bearing Clearance ‘Standard 0.03 — 0.09 (0.0012 — 0.0035) 0.15 (0.0059)(g Ov Align oi holes s0409-005 ENGINE MECHANICAL 6A—73 Camshaft Be: 1. Remove the cylinder body plug plate. 2. Use the bearing replacer to remove the camshaft bearing, Bearing Replacer : 9-8523-1818-0 ‘Camshaft Bearing Installation 1. Align the bearing oil holes with the cylinder body oil holes. 2. Use the bearing replacer to install the camshaft bearing, Bearing Replacer : 9-8523-1818-0 CRANKSHAFT AND BEARING Inspect the surface of the crankshaft journals and crank- pins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions. 4BD1T Engine To increase crankshaft strength, tuftriding (Nitriding Treatment) has been applied to the 4BD1T engine crank- shaft. ‘The crankshaft cannot be reground. It must be replaced if it is excessively worn or damaged. Undersize bearings are not available for the 4BD1T crankshaft.6A—74 ENGINE MECHANICAL “The portion tobe ested tei bene ereor8Y 6 yquia should Sosnorso rene cet Te alg shout sotusion Fg The area around the eitport The sting srtsco or oul J ‘Approximately ‘ene 48C2, 4BD1, and 4BE1 Engines 48C2, 48D1, and 4BE1 engine crankshafts are not tuf- trided. They can be reground if there is excessive wear or damage. Undersize bearings are available. Refer to “Crankshaft Regrinding.” Crankshaft Tuftriding Inspection (For 4BD1T Engines) 1. Use an organic cleaner to thoroughly clean the crankshaft. There must be no traces of oil on the surfaces to be inspected. 2. Prepare a 5 — 10% solution of ammonium cuprous chloride (dissolved in distilled water) 3. Use a syringe to apply the solution to the surface to be inspected Hold the surface to be inspected perfectly horizontal to prevent the solution from running. Note: Do not allow the solution to come in contact with the oil ports and their surrounding area. Judgment 1. Wait for thirty to forty seconds. If there is no discoloration after thirty or forty sec- ‘onds, the crankshaft is usable. If discoloration appears (the surface being tested will become the color of copper), the crankshaft must be replaced. 2, Steam clean the crankshaft surface immediately af- ter completing the test. Note: ‘The ammonium cuprous chloride solution is highly corrosive. Because of this, it is imperative that the surfaces being tested be cleaned immediately after completing the test.s0410-002 ENGINE MECHANICAL 6A—75 Crankshaft Run-Out (All Engines) 1. Set a dial indicator to the center of the crankshaft journal 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. Crankshaft Run-Out mm(in) Standard [ Limit 0.05 (0.020) or less 0.30 (0.012) 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. Bearing Spread mmiin) ee ‘4BC2 & 4BE1 81 (3.19) 4801 & 4BD1T 85 (3.35)GA—76_ ENGINE MECHANICAL 5010-008 Crankshaft Journal and Crankpin Diameter 1. Use a micrometer to measure the crankshaft journal diameter across points © — ® and @— @. 2. Use the micrometer to measure the crankshaft jour- nal diameter at the two points @ and @. 3. Repeat Steps 1 and 2 to measure the crankpin di ameter. If the measured values are less than the limit, the crankshaft must be reground or replaced. Crankshaft Journal Diameter mm(in) ‘Standard Limit 4BC2 & | 75.913 — 75.925 4BE1 _| (2.9887 — 2.9892) 79.913 — 79.925 78.500 (2.9724) aap | aan — 4.1467) 79.500 (3.1399) ‘appit | 79.905 — 79.925 | Refer to “Crankshaft (3.1459 — 3.1467) | Tufftriding Inspection.” Crankpin Diameter mm(in) Standard i ‘4BC2, 4BD1 | 63.932 — 63.944 84BE1 (25170-25175) | 99500 (25) Refer to “Crank- 63.924 — 63.944 ae (25167 — 2.5175) | Shaft Tufftiding Inspection. Crankshaft Journal and Crankpin Uneven Wear _mm(in) Standard [ Limit 0.001 (0.00004) (0.050 (0.002) Crankshaft Journal and Bearing Clearance For 4BD1T If the crankshaft journal and bearing clearance exceeds the specified limit, the crankshaft and/or the bearing must be replaced. For 4BC2, 4BD1, and 4BE1 If the crankshaft journal and bearing clearance exceeds the specified limit, the crankshaft must be either re- ground or replaced.ENGINE MECHANICAL 6A—77 Crankshaft Journal and Bearing Clearance min) Engine | BearingNo.| Standard Limit 0065-0116 | 0.150 48c2 3 (0.0026 — 0.0046) | (0.0059) 0.025 -0.076 | 0.110 4BE1 | 1.2485 | (oo010— 0.0030) | (0.0043) 4801 All 0,025 — 0.076 0.110 aBDiT (0.0010 ~ 0.0030) | (0.0043) Undersize Crankshaft Journal Availability mm(in) 0.25 (0.01) 0.50 (0.02) Note: ‘The 4BD1T engine crankshaft is tufftrided and cannot be reground. Undersize crankshaft journal bearings are not avail- able for the 4BD1T engine. Connecting Rod Bearing Inside Diameter 1. Install the bearing to the connecting rod big end. 2. Tighten the bearing cap to the specified torque. Connecting Rod Bearing Cap Bolt Torque kg-m(lb.fUN-mn) 48C2 (All) rae 4BD1 (1986 and earlier) Meee (86.7 = 36/1177 + 49) Connecting Rod Bearing Cap Bolt Torque kil. ft/Ne)/deg Tststep_| and step 4BD1T (All) 60 + 90 = ______ 4 (29/39.2) 4801 (1987 and later) 3. Use a dial indicator to measure the connecting rod bearing inside diameter. Crankpin and Connecting Rod Bearing Clearance If the clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit, the bearing and/or the crankshaft must be replaced or reground.6A—78 ENGINE MECHANICAL 50410-0027 FP be] al rs} Crankpin and Connecting Rod Bearing Clearance mmi(in) Engine ‘Standard imit ‘4BC2, 4BE1, 0.030 ~ 0.073 &4B01 (0.0012 ~ 0.0029) 0.100 19.030 0.081 | (0.004) leon (0.030 — 0.081 (0.004) (0.0012 — 0.0032) Undersize Connecting Rod Bearing Avail 0.25 (0.01) 0.50 (0.02) Note: ‘The 4BD1T engine crankshaft is tufftrided and cannot be reground. Undersize connecting rod bearings are not available for the 4BD1T ent Clearance Measurements (With Plastigage) Crankshaft Journal and Bearing Clearance 1. Clean the cylinder body, the journal bet surface, the bearing caps, and the bearings. 2. Install the bearings to the cylinder body. 3. Carefully place the crankshaft on the bearings. 4. Rotate the crankshaft approximately 30 degrees to seat the bearing. 5. Place the Plastigage (arrow) over the crankshaft journal across the full width of the bearing 6. Install the bearing caps with the bearing. 9 fitting 7. Tighten the bearing caps to the specified torque. Crankshaft Bearing Cap Bolt Torque _kg-milb.ft/N-m) 24 + 1.0 (173.5 + 7.2/285.4 + 9.8) Do not allow the crankshaft to turn during bearing cap installation and tightening. 8. Remove the bearing cap.ENGINE MECHANICAL 6A—79 Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container. If the measured value exceeds the limit, perform the following additional steps. 1) Use a micrometer to measure the crankshaft outside diameter. 2) Use an inside dial indicator to measure the bearing inside diameter. If the crankshaft journal and bearing clearance exceeds the limit, the crankshaft and/or the bearing must be replaced. Crankshaft Journal and Bearing Clearance mmi(in) Engine [Bearing No. Standard Limit a 0.065 — 0.116 0.150 4BC2 & (0.0026 — 0.0046) | (0.0059) 4BE1 yo gays | 0.025-0.076 0.110 ie (0.0010 — 0.0030) | (0.0043) 4801 & mi 0.025 — 0.076 0.110 aBoiT_| (0.0010 — 0.0030) | (0.0043) Undersize Crankshaft Journal Availability mm(in) 0.25 (0.01) be reground. Undersize crankshaft journal bearings are not avail- able for the 4BD1T engine. 0.50 (0.02) 1e crankshaft is tufftrided and cannot Crankpin and Connecting Rod Bearing Clearance 1. Clean the crankshaft, the connecting rod, the bear- ing cap, and the bearings. Install the bearing to the connecting rod and the bearing cap. Do not allow the crankshaft to move when installing the bearing cap. Prevent the connecting rod from moving.6A—80 ENGINE MECHANICAL fel 4. Attach the Plastigage to the crankpin. Apply engine oil to the Plastigage to keep it from falling. 5. Install the bearing cap and tighten it to the specified torque. Do not allow the connecting rod to move when in- stalling and tightening the bearing cap. Connecting Rod Bearing Cap Bolt Torque kg-milb FUN) 48C2 (All) 12405 48D1 (1986 and earlier) 2 4 heen (86.7 + 36/117.7 + 49) Connecting Rod Bearing Cap Bolt Torque kg-milb.ft/N-m)/deg ‘st step 2nd step 4BD1T (All) a 4BD1 (1987 and tater) | 4(29/99-2) | 60-90 6 Remove the bearing cap. 7. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container. If the measured value exceeds the specified limit, perform the following additional steps. 1) Use a micrometer to measure the crankpin out- side diameter. 2) Use an inside dial indicator to measure the bearing inside diameter. If the crankpin and bearing clearance exceeds the specified limit, the crankshaft and/or the bearing must be replaced. Crankpin and Connecting Rod Bearing Clearance mm(in) Engine Standard Limit 4802, 4BE1, 0.030 — 0.073 4801 | (@.0012 — 0.0029) 0.100 0,030 — 0.081 (0.004) 4601 (0.0012 — 0.0032) Undersize Connecting Rod Bearing Availability mm(in) 0.25 (0.01) (0.50 (0.02) Note: ‘The 4BD1T engine crankshaft is tufftrided and cannot be reground. Undersize connecting rod bearings are not available for the 4BD1T engine.ENGINE MECHANICAL 6A—81 Crankshaft Regrinding (48C2, 4BD1, and 4BE1 Only) To ensure crankshaft reliability, pay close attention to the following items during and after the crankshaft jour- nial and crankpin regrinding procedure. Undersize Bearing Availabilty mm(in) 0.25 (0.07) 0.50 (0.02) Crankshaft Journal and Crankpin Grinding Limit (Reference) rome] 75.287 (2.9663) aber & | Main Journal | Gthers | 75.327 (2.9679) Crankpin ‘All| 63.341 (2.4956) Main Journal | All| 79.327 (3.1231) 4801 Crankpin ‘All| 63.341 (2.4956) 1. Regrind the crankshaft journals and the crankpins. 2. Fillet the crankshaft journal and the crankpin radi- uses to a minimum of R 3.5 + 0.2 mm (0.13779 + 0.0078 in). There must be no stepping around the fillet area, 3. Finish the crankshaft journals, the crankpins, and the oil port corners to a smooth surface having a Fler radius chamfer radius of 1 mm (0.04 in). Crankshaft Journal and Crankpin Roughness 0.38 u or less Tess than 3.8 4. Check the crankshaft journal and crankpin clear ance. Refer to “Crankshaft Journal and Bearing Clearance” and “Crankpin and Bearing Clearance.” 5. Check the crankshaft run-out. Refer to “Crankshaft Run-Out.” Crankshaft Gear Replacement Crankshaft Gear Removal 1. Use the crankshaft gear remover @ to remove the Crankshaft Gear Remover : 9-8521-0141-0 2. Remove the crankshaft feather key.6A—82 ENGINE MECHANICAL —oO ae => 50410011 = al Crankshaft Gear Installation 1. Install the crankshaft gear. 2. Use a crankshaft gear installer © to install the crankshaft gear @. The crankshaft gear timing mark (‘X-X') must be facing outward. Crankshaft Gear Installer : 9-8522-0033-0 CRANKSHAFT PILOT BEARING Check the crankshaft pilot bearing for excessive wear and damage and replace it if necessary. Crankshaft Pilot Bearing Replacement Crankshaft Pilot Bearing Removal Use the pilot bearing remover and the sliding hammer to remove the crankshaft pilot bearing. Pilot Bearing Remover: 5-8840-2000-0 Sliding Hammer +: 5-8840-0019-0 (J-23907) Crankshaft Pilot Bearing Install 1. Place the crankshaft pilot bearing horizontally across the crankshaft bearing installation hole. 2. Tap around the edges of the crankshaft pilot bear- ing outer races with a brass hammer to drive the bearing into the crankshaft bearing installation hole. Note: Strike only the crankshaft pilot bearing outer races with the hammer. Do not strike the bearing inner races. Bearing damage and reduced bearing service life wil result.s0412.002 ENGINE MECHANICAL 6A—83 FLYWHEEL AND RING GEAR Flywheel 1. Inspect the flywheel friction surface for excessive wear and heat cracks. 2. Measure the flywheel thickness( t) between the fly- wheel friction surface and crankshaft setting face. If the measured value is between the standard and the specified limit, the flywheel may be reground. If the measured value exceeds the specified limit, the flywheel must be replaced. ) Flywheel Thickness ( t) mnt ‘Standard Limit 31.540.1 (1.240.004) 30.5 (1.2) Flywheel Friction Surface Roughness mm(in) Less than 0.006 (0.00024) Ring Gi Inspect the ring gear. If the ring gear teeth are broken or excessively worn, the ring gear must be replaced. Ring Gear Repl Ring Gear Removal Strike around the edges of the ring gear with a hammer and chisel to remove it. Ring Gear Installation 1. Heat the ring gear evenly with a gas burner to invite thermal expansion. Do not allow the temperature of the gas burner to exceed 200°C (390°F). 2. Install the ring gear when itis sufficiently heated The ring gear must be installed with the chamfer facing the clutch.6A—84 ENGINE MECHANICAL PISTON Piston Grade Selection and Cylinder Bore Measure- ment Refer to the Section “CYLINDER BODY", Items “Cylinder Body Measurement” and “Cylinder Liner Bore Measure- ment” for details on piston grade selection and cylinder liner bore measurement. PISTON RING Piston Ring Gap 1, Insert the piston ring horizontally (in the position it would assume if it were installed to the piston) into the cylinder liner bore. 2. Push the piston ring into the cylinder liner bore until it reaches the point © 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 mmtin) “4BC2 169 (6.65) 4801 195 (7.68) 4BE1 | 174 (6.85) Use 2 feeler gauge to measure the piston ring gap. If the measured value exceeds the specified limit, the piston ring must be replaced. Piston Ring Gap mmtin) Standard st compression ring | 0.25 — 0.45 gap (0.0089 — 0.0177) 2nd compression ring | 0.20 — 0.40 1.50 gap (0.0079 — 0.0016) | (0.0591) Oil ring gap. amaae (0.0073 — 0.0016)ENGINE MECHANICAL 6A—85 50415-0017 Piston Ring and Piston Ring Groove Clearance 1. Use a feeler gauge to measure the clearance be- tween the piston ring and the piston ring groove at several points around the piston. Piston Ring and Piston Ring Groove Clearance _mmi(in) Engine Standard tstCompres- | 4928488" | leoss — 00089 Sonfing | asor aasorr | gtoat — aoe) 2and Compres- | “8°? 451 (ooor2 — 0.0022) comes 4801 &4BDIT | GeO OPTS) oil Ring a 0,030 — 0.070 (0.0012 — 0.0028) 2. Visually inspect the piston ring grooves. If a piston ring groove is damaged or distorted, the piston must be replaced. PISTON PIN Piston Pin Diameter Use a micrometer to measure the piston pin outside di- ameter at several points. * If the measured value is less than the specified limit, the piston pin must be replaced. Piston Pin Diameter mmi(in) ‘Standard Limit 36,000 — 35.005 34.95 (1.3780 — 1.3781) (1.3760) Piston Pin and Piston Clearance Use an inside dial indicator to measure the piston pin hole (in the piston). ) Piston Pin Interference mm 4BC2 & 4BD1 (0.005 — 0.008 (0.0002 — 0.0003) 4BE1 &4BD1T | 0.005 — 0.018 (0.0002 — 0.0007)6A—86 ENGINE MECHANICAL (50416-0901 If an inside dial indicator is not available, use the follow- ing procedure to check the piston pin clearance. 1. Use a piston heater-to heat the piston to approxi- mately 80 — 100°C (176 — 212°F). 2. Push strongly against the piston pin with your thumbs. The piston pin should move smoothly with little or no resistance, 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. Connecting Rod Alignment mm(in) Per Length of 100 mm (3.94 in) Standard Limit (0.08 (0.0030) or less 0.05 (0.0020) 0.15 (0.006) or less Distortion 0.20 (0.008) Parallelism, Connecting Rod Side Face Clearance 1. _ Install the connecting rod to the crankpin. 2. Use a feeler gauge to measure the clearance be- tween the connecting rod big end side face and the crankpin side face, If the measured value exceeds the specified limit, the connecting rod must be replaced. Connecting Rod Big End and Crankpin Side Face Clearance mm(in) ‘Standard Limit 0.17 = 0.30 (0.0067 ~ 0.0120) eee® 050416-008 | IE ENGINE MECHANICAL 6A—87 Piston Pin and Connecting Rod Small End Bushing Clearance Use a caliper calibrator and a dial indicator to measure the piston pin and connecting rod small end bushing clearance. If the clearance between the piston pin and the connect- ing rod small end bushing exceeds the specified limit, replace the piston pin and/or the connecting rod bush- ing. Piston Pin and Connecting Rod Small End Bushing Clearance mm(in) Standard init 0.012 — 0.028 (0.0005 — 0.0010) oe) ing Rod Bushing Replacement Connecting Rod Bushing Removal 1. Clamp the connecting rod in a vise. 2. Use the piston pin bushing replacer to remove the connecting rod bushing. Piston Pin Bushing Replacer : 9-8523-1369-0 (v-29765) Connecting Rod Bushing Installation 1. Clamp the connecting rod in a vise. 2. Use the piston pin bushing replacer to install the connecting rod bushing. 3. Use a piston pin hole grinder © fitted with a reamer @® to ream the piston pin hole. Piston Pin Bushing Replacer : 9-8523-1369-0 (J-29765)6A~88 ENGINE MECHANICAL IDLER GEAR SHAFT AND IDLER GEAR Idler Gear Shaft Outside Diameter Use a micrometer to measure the idler gear shaft out- side diameter. Hf the measured value is less than the specified limit, the idler gear must be replaced. Idler Gear Shaft Outside Diameter mm(in) ‘Standard imit (1.7654) 1.7708) Gear Inside Diameter Use an inside dial indicator or an inside micrometer to measure the idler gear inside diameter. Idler Gear Inside Diameter mmi(in) Standard Limit 45.00 — 45.03 a7 1728) 45.100 (1.7756) If the clearance between the idler gear shaft outside di- ameter and the idler gear inside diameter exceeds the limit, the idler gear must be replaced. Idler Gear Shaft and Idler Gear Clearance mm(in) ‘Standard Limit 0.009 = 0.060 (0.00035 — 0.00240) cae TIMING GEAR CASE COVER Replace the crankshaft front oil seal if it is excessively worn or damaged.cs bel ENGINE MECHANICAL 6A—89 Crankshaft Front Oil Seal Replacement Oil Seal Removal Use a plastic hammer and a screwdriver to tap around the oil seal to free it from the gear case cover. Take care not to damage the oil seal fitting surfaces. Oil Seal Installation Use the installer to install the case oil seal to the gear case cover. il Seal Installer : 5-8840-2103-0 Crankshaft Rear Oil Seal Replacement Oil Seal Removal Use an oil seal remover to remove the oil seal from the il seal retainer. Oil Seal Installation Use an oil seal installer to install the oil seal to the oil seal retainer. Oil Seal Installer : 5-8840-2104-0 The oil seal lip must be facing the inside of the engine.6A—90 ENGINE MECHANICAL [i+] ReassemBLy INTERNAL PARTS MINOR COMPONENTS ROCKER ARM SHAFT AND ROCKER ARM Reassembly Steps ‘1. Rocker arm shaft 4, Rocker arm shaft bracket 2. Rocker arm shaft spring 5. Rocker arm shaft snap ring & 3. Rocker arm V Important Operations 1. Rocker Arm Shaft 3. Rocker Arm 1) Use compressed air to thoroughly clean the rocker arm shaft and the rocker arm oil holes. 2) Apply a coat of engine oil to the rocker arm shaft and the rocker arm bushings. 3) Install the rocker arm shaft The rocker arm shaft oil ports must be facing up.ENGINE MECHANICAL 6A~91 Reassembly Steps 1. Cylinder head ‘45. Valve spring (Inner) 2. Valve spring lower seat ‘4 6. Valve spring (Outer) 4 3. Valve stem oil seal 7. Valve spring upper seat ‘A 4. Intake and exhaust valve 8. Split collar6A—92 ENGINE MECHANICAL Vv 050501-008 50501-0085 Important Operations 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 : 185221-005-0 4, Intake and Exhaust Valve 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 (Inner) 6. Valve Spring (Outer) Install the inner and outer valve springs with their fine pitched end (painted) facing down. 8. Split Collar 1) Use the spring compressor to push the valve spring into position Spring Compressor : 9-8523-1426-0 2) Install the split collar to the valve stem. 3) Set the split collar by tapping around the head of the collar with a rubber hammer.ENGINE MECHANICAL 6A—93 Es] PISTON AND CONNECTING ROD Reassembly Steps 4 1. Piston 5. Piston pin snap ring ‘4 2. Piston pin snap ring & 6 Piston ring ‘3. Connecting rod 4 7. Connegting rod bearing ‘& 4. Piston pinGA—94 ENGINE MECHANICAL V Important Operations 1. Piston iston Pin Snap Ring 3. Connecting Rod 1) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2) Use a pair of snap ring pliers to install the piston pin snap ring to the piston, & 0 3) Install the piston to the connecting rod. The piston head front mark @ must be facing the front of the engine and the connecting rod “ISUZU” casting mark @ must be facing the rear of the en- a gine. ® Covlinder number mark |. Piston Pin Use a piston heater to heat the piston to 80 ~ 100°C (176 — 212°F). Apply a coat of engine oil to the piston pin, Use your fingers to force the piston pin into the pis- ton until it makes contact with the snap ring. Use a pair of snap ring pliers to install the other snap ring, Check that the connecting rod moves smoothly on the piston pin.0s0502-005 50502-0086 ENGINE MECHANICAL 6A—95 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 il+ lustration, © Oitring @® 2nd compression ring @ 1st compression ring Note: Install the compression rings with the stamped side facing up. Insert the expander coil into the oil ring groove so that there is no gap on either side of the expander coil be- fore installing the oil ring. 2) Apply engine oil to the piston ring surfaces. 3) Check that the piston rings rotate smoothly in the piston ring grooves. 7. Connecting Rod Bearing Carefully wipe any oil or other foreign material from the connecting rod bearing back face and the connecting rod bearing fitting surface.6A—96 ENGINE MECHANICAL E CAMSHAFT, CAMSHAFT TIMING GEAR, AND THRUST PLATE Reassembly Steps 1. Camshaft 2. Feather key 3. Thrust plate 4 4. Camshaft timing gear Important Operations 4. Camshaft Timing Gear 1) Install the thrust plate ©. 2) Apply engine oil to the bolt threads ®. 3) Install the camshaft timing gear with the timing mark stamped side facing out. Camshaft Timing Gear Bolt Torque kg-mi(lbft/N-m) 14.0 + 1.5 (101.2 + 10.8/137.3 + 14.7)ENGINE MECHANICAL 6A—97 Es] MAJOR COMPONENTS Reassembly Steps-1 A 1. Cylinder body 4.12. Connecting rod bearing cap with ‘4 2. Oiling jet (48017) lower bearing ‘4 3. Check valve (4BD1T) 4.13, Tappet A 4, Relief valve ‘414, Camshaft with timing gear ‘45. Crankshaft upper bearing 4.15. Oil pump with oil pipe 6. Crankshaft with timing gear ‘416. Oil pump drive gear and cover ‘4 7. Crankshaft thrust bearing ‘4.17. Flywheel housing ‘8. Crankshaft bearing cap with 418. Flywheel lower bearing 4.19. Bed plate (4BE1) ‘4 9. Timing gear case ‘420. Oil pan ‘410. Crankshaft rear oil seal retainer ‘4.202. Oil pan (4BE1) ‘411. Piston and connecting rod with upper bearing6A—98 ENGINE MECHANICAL eS 2a Reassembly Steps-2 421. Oil cooler 427. Water pump ‘4.22. Injection pump with rear bracket 28. Cylinder head gasket (Bosch in-line type) 429, Cylinder head ‘4.222, injection pump with rear bracket 4.30. Thermostat housing (Bosch distributor type for 4BE1 31. Push rod only) ‘432. Rocker arm shaft and rocker arm 4.23, Idler gear ‘4.33, Tappet chamber cover ‘424. Timing gear case cover ‘4 34. Cylinder head cover ‘425. Crankshaft damper pulley 35. Water by-pass hose ‘4.26, Crankshaft pulley nut and washerENGINE MECHANICAL 6A—99 V Important Operations 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. 2. Oiling Jet (4BD1T) 3. Check Valve (4BD1T) 1) Install the oiling jets together with the check valves. Take care not to damage the oiling jet nozzles. 2) Tighten the check valves and oiling jets to the speci- fied torque. Check Valve and Oiling Jet Torque kgemilb.te/N ) 24 £05 (15.2 + 3.6/20.6 + 49) 4, Relie 1) Apply engine oil to the O-ring. 2) Install the O-ring to the relief valve. 3) Tighten the relief valve to the specified torque, Relief Valve Torque kg-mi(lb.ft/N-m) 26 £ 0.3 (188 + 2.2/255 + 2.9) Valve 5. Crankshaft Upper Bearing All upper bearings have oil grooves. 1) Carefully wipe any foreign material from the upper bearing. Note: Do not apply engine oil to the bearing back faces and the cylinder body bearing fitting surfaces.GA—100 ENGINE MECHANICAL Fit correctly / ( weer 2) Locate the position mark applied at disassembly if the removed upper bearings are to be reused. 6. Crankshaft with Timing Gear Apply an ample coat of engine oil to the crankshaft jour- nals and the crankshaft bearing surfaces before install- ing the crankshaft with timing gear. 7. Crankshaft Thrust Bearing 1) Apply an ample coat of engine oil to the thrust bearings before installation. 2) Install the thrust bearings to the crankshaft center journal, The thrust bearing oil grooves must be facing the sliding faces. 8. Crankshaft Bearing Cap with Lower Bearing Lower bearing Nos. 1, 2, 4, and 5 have oil grooves. Lower bearing No. 3 does not have an oil groove. 1) Install the crankshaft bearing caps with the bearing cap head mark (arrow) facing forward. 2) Apply a coat of engine oil to the bearing cap bolts. 3) Tighten the crankshaft bearing cap bolts to the specified torque a litle at a time in the sequence shown in the illustration. Crankshaft Bearing Cap Torque kg-milb.ft/N-m) 24 £1 (173.6 + 7.2/235.2 + 98) 4) Manually rotate the crankshaft to check that it turns smoothly.ENGINE MECHANICAL 6A—101 D) 2) 3) Al; 2 3) 3) 4 5) 8) os0s04-020 Timing Gear Case Bolt Torque 10. Rear Oil Seal Retainer Bolt Torque 9. Timing Gear Case Apply liquid gasket to the timing gear case fitting surfaces. Install the timing gear case to the cylinder body. Tighten the timing gear case bolts to the speci torque. kgsmilb.ft/N-m) 2.6 + 05 (18.8 + 3.6/25.5 + 4.9) Crankshaft Rear Oil Seal Retainer Apply the recommended liquid gasket or its equiva lent to the shaded area shown in the drawing Install the crankshaft rear oil seal retainer together with the gasket. Trim away the gasket areas marked with the arrow in the illustration. kg-milb.ft/N-en) 26 +05 (188 + 3.6/255 +49) |. Piston and Connecting Rod with Upper Bearing . Connecting Rod Bearing Cap with Lower Bearing Apply a coat of engine oil to the circumference of each piston ring and piston. Position the piston ring gaps as shown in the illus- tration. © 1st compression ring @® 2nd compression ring © Oilring © Coil expander Apply a coat of molybdenum disulfide grease to the two piston skirts. This will facilitate smooth break-in when the engine is first started after reassembly. Apply a coat of engine oil to the upper bearing sur- faces. Apply a coat of engine oil to the cylinder wall, Position the piston head front mark so that it is fac- ing the front of the engine.6A—102_ ENGINE MECHANICAL 7) Use the piston ring compressor to compress the piston rings. Piston Ring Compressor : §-8840-9018-0 8) Use a hammer grip to push the piston in until the connecting rod makes contact with the crankpin At the same time, rotate the crankshaft until the crankpin is at BDC. Piston 9) Install the connecting rod bearing caps. | 10) Align the bearing cap cylinder number marks and UL the connecting rod cylinder number marks. & The cylinder number marks must be turned toward the camshaft. Cylinder number 11) Apply a coat of engine oil to the threads and setting faces of each connecting rod cap bolt. 12) Tighten the connecting rod caps to the specified torque. Connecting Rod Bearing Cap Bolt Torque _kg-milb.ft/Nim) “4BC2 & 4BE1 1986 4BD1 12.0 + 0.5 (61.5 + 3.6/83.3 + 4.9) and earlier Connecting Rod Bearing Cap Bolt Torque kg-m(lb.ft/N-m) ist Step ‘2nd Step ‘All 4BD1T = 1987 4BD1 and later 4 (29/39.2) Ce 13. Tappet 1) Apply a coat of engine oil to the tappet and the cy- linder 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.ENGINE MECHANICAL 6A—103 14. Camshaft with Timing Gear 1) Apply a coat of engine oil to the camshaft and the camshaft bearings. EEA] a nts te camsnot to he evinder body ‘Take care not to damage the camshaft bearings. 3) Tighten the thrust plate bolts to the specified torque. Operate the wrench through the camshaft gear hole. Thrust Plate Bolt Torque kg-mi(lbft/N-m) 2.6 + 0.5 (18.8 + 3.6/25.5 + 4.9) 15. Oil Pump with Oil Pipe Tighten the oil pump bolts to the specified torque. Oil Pump Bolt Torque kg-milb.f/N-m) 53 x 1.0 (08.3 = 72/519 4 98) 16. Oil Pump Drive Gear and Cover 1). Prepare a solution of 80% engine oil and 20% mo- Iybdenum disulfide. 2) Apply an ample coat of the solution or an engine oil to the teeth of the the oil pump drive gear. Note: If molybdenum disulfide is not ar oil may be used. ble, 100% engine 17. Flywheel Housing 1) Install the flywheel housing to the cylinder body. 2) Tighten the flywheel housing bolts to the specified torque. Flywheel Housing Bolt Torque 140 + 1.5 (101.2 = 10.9/137.3 = 147)6A—~104 ENGINE MECHANICAL . Flywheel Block the crankshaft with a piece of hard wood to prevent the flywheel from turning, 2). Align the flywheel with the crankshaft dowel pin. 3) Carefully wash the nuts and bolts to remove all oil and grease. 4) Apply a coat of molybdenum disulfide grease to the flywheel bolt threads and setting faces. 5) Tighten the flywheel bolts to the specified torque in two steps using the Angular Tightening Method. Follow the numerical order shown in the illustration. Flywheel Bolt Torque kgemilbt/Nm) ‘st Step (Snug Torque) _| 2nd Step (Final Torque) 4 (29/39.2) 60" = 90° 19. Bed Plate (4BE1) 20a. Oil Pan (4BE1) 1) Apply the recommended liquid gasket or its equival- ent to the shaded areas shown in the illustration. 2) Install the bed plate gasket to the cylinder body. 3) Install the bed plate to the cylinder body. 4) Tighten the bed plate bolts to the specified torque. Bed Plate Bolt Torque kg-milb.ft/Nem) 20 £05 (144 436/196 + 49) 5) Install the oil pan to the bed plate. 6) Tighten the oil pan bolts to the specified torque. Oil Pan Bolt Torque kg-milb.ft/N-m) 20 +05 (144 + 36/196 + 49) Start from the alternately. le of the oil pan and work outENGINE MECHANICAL 6A—105, 20. Oil Pan (4BC2, 4BD1, and 4BD1T) 1) Apply the recommended liquid gasket or its equiva- lent to the shaded areas shown in the illustration. 2) Install the oil pan gasket to the cylinder body. 3) _ Install the oil pan, 4) Tighten the oil pan bolts to the specified torque. Start from the middle of the oil pan and work out alternately. Oil Pan Bolt Torque kg-milb.ft/N-m) 2.0 + 05 (14.4 + 3.6/19.6 + 49) 21. Oil Cooler 1) Apply liquid gasket to the oil cooler cover. 2) Install the oil cooler gasket. 3) Install the oil cooler to the cylinder body. 4) Tighten the oil cooler bolts to the specified torque a little at a time in the sequence shown in the illustra- tion. Oil Cooler Bolt Torque kgmilb.ft/Nem) 2.6 £05 (18.8 + 3.6/25.5 + 4.9) 22. Injection Pump with Rear Bracket (Bosch In-Line Type) 22a. Injection Pump with Rear Bracket (Bosch Distrib- utor Type) 41) Install the injection pump to the timing gear case. 2) Tighten the injection pump bolt @ to the specified torque. Injection Pump Bolt Torque kgmilb.ft/Nem) 2.6 + 05 (18.8 + 3.6/25.5 + 49) 3) Tighten the injection pump rear bracket bolts ® to the specified torque. Rear Bracket Bolt Torque kg-milb.ft/N«m) 8+ 09 (188+6A—106 ENGINE MECHANICAL Injection pump gear | ‘ele gear ‘mark Camshaft 23. Idler Gear 1) Install the idler gear. 2). Set the timing marks as shown in the illustration. 3) Install the idler gear shaft. Use the thrust collar fixing bolt as a guide. The oil port must be facing the camshaft. 4) Install the thrust collar. ‘The chamfered side of the thrust collar must be fac- ing the front of the engine, 5) Tighten the idler gear bolts to the specified torque. Idler Gear Fixing Bolt Torque kg-milb.ft/N-m) 5.3 + 1.0 (88.3 + 7.2/51.9 + 98) 24, Timing Gear Case Cover 1) Apply liquid gasket to the timing gear case cover. 2) Install the cover to the timing gear case. 3) Tighten the bolts to the specified torque. ‘Timing Gear Case Cover Bolt Torque __kg-milb.ft/N-m) 2.6 + 0.5 (18.8 + 3.6/25.5 + 4.9) 1) Install the flywheel holder to prevent the crankshaft from turning, Crankshaft Stopper : 5-8840-0375-0 3) Tighten the crankshaft pulley nut to the specified torque. Wrench : 41 mm (1.6 in) Crankshaft Pulley Nut Torque kg-milb.ft/N-m) 44.0 + 5.0 (318.1 + 36.2/431.6 + 49.0) 27. Water Pump 1) Apply liquid gasket (ThreeBond 12078 or the equiv- alent) to the water pump, 2). Install the water pump. 3) Tighten the water pump bolts to the specified torque. Water Pump Bolt Torque kg-milb.f/N-m) 53+ 1.0 (38.3 + 7.2/5.9 + 9.8)ENGINE MECHANICAL 6A—107 28. Cylinder Head Gasket 1) Clean the cylinder body upper side and the cylinder head lower side. 2). Install the cylinder head gasket with the “TOP” mark facing up and toward the front of the engine. Note: Refer to “CYLINDER HEAD GASKET SELECTION” for the 4BE1 engine. CYLINDER HEAD GASKET SELECTION (4BE1) Cylinder head gasket thickness is determined by the maximum cylinder head projection from the cylinder body at top dead center. Correct cylinder gasket thickness is important. Installing the wrong thickness gasket can result in greatly reduced engine performance. There are three cylinder head gaskets available. Piston Head Projection Measurement 1) Carefully remove carbon deposits and gasket resi- due from the piston top face and the cylinder body upper surface. 2). Use a dial indicator and stand to measure the piston head projection from the cylinder body at the two measuring points © and ® shown in the illustration. 3) Calculate the average of the two measured values {individual cylinder piston head projection). 4) Repeat Steps 2 and 3 for the remaining three cylin- ders. 5) Note the cylinder having the greatest cylinder head Projection. This figure will determine the cylinder head gasket thickness. Cylinder Head Gasket Availability romiin) Gasket Grade Piston (Reference) Mark Projection Gasket . 2 Thickness 0.688 — 0.770 1.95 ® TMM | (roar - 00303 |_ 0.07 071 — 0812 2.00 ® Vl | vax3-00%9 | (0.079) 0.813 — 1.000 2.05 © Vit, | 00320-00294 | _ (0.08)6A—108 ENGINE MECHANICAL Notes: Piston head projection: must be within the range ‘shown in the table below. 1) 2) » 2) 3) 4) cyl Cylinder Head Bolt Torque \der Head Bolt Torque New Bolt Reused Bolt mmi(in) The difference in cylinder projection between the individual cylinders must be less than 0.146 mm. (0.0057 in). Cylinder Head Align the cylinder body dowels and the cylinder head dowel holes. Carefully place the cylinder head on the cylinder head gasket. Apply a coat of molybdenum disulfide grease to the cylinder head bolt threads and setting faces. 1986 4BC2 and 4BD1 Engines and Earlier Tighten the cylinder head bolts to the specified torque in three steps following the numerical order shown in the illustration. kg-milb.fUN: 10.0 + 0.5 (72.3 + 3.6/ 98.1 + 49) 11.5 + 0.5 (63.2 + 3.6/104.5 + 4.9) ) 1987 4BD1, 4BE1, and 4BD1T Engines and Later Use the angular tightening method to tighten the bolts to the specified torque in three steps. kg-milb.ft/N-m)/deg 3rd Step. 90 — 120 ‘ist Step 7 (50/68.6) 2nd Step 9 (65/88.2) . Thermostat Housing Install the thermostat housing, Tighten the thermostat housing bolts to the specifi- ed torque. ter Pump Bolt Torque 38205 (2744 kg.m(lb.fU/N: 37.2 = 49) )ENGINE MECHANICAL 6A—109 32. Rocker Arm Shaft and Rocker Arm Tighten the rocker arm shaft bracket bolts to the specifi- ed torque in the numerical order shown in the illustra- tion. Rocker Arm Shaft Bracket Bolt Torque __kg-milb.ft/N-m) 2.5 £05 (18.1 + 3.6/24.5 + 4.9) 33. Tappet Chamber Cover 1) Apply liquid gasket to the tappet chamber cover. 2) Install the tappet chamber gasket. 3) Install the tappet chamber cover. 4) Tighten the tappet chamber cover bolts to the spec- ified torque. Rocker Arm Shaft Bracket Bolt Torque _kg-m(l 26 + 0.5 (188 + 36/255 + 49) Nem) 34. Cylinder Head Cover 1) Apply engine oil to the rocker arms and the valve springs. 2) Install the cylinder head cover gasket to the cylinder head cover. The gasket must be perfectly smooth with no loose areas. 3) Tighten the cylinder head cover nuts to the specifi- ed torque. Cylinder Head Cover Bolt Torque kgsmilb.f/N-m) 2.1 £05 (16.2 + 3.6/20.6 + 4.9)6A—110 ENGINE MECHANICAL Es EXTERNAL PARTS: This illustration is based on the 4BE1 engine. Mew ou 4 we ; 4 \| \ // ® Reassembly Steps 4-1. Intake manifold and port insert 10. Throttle control link bracket (1988 and earlier 4BC2 and 4BE1 411. Power steering oil pump engines) 12. Injection pump oil return pipe A 1a, Intake manifold and gasket (4BD1 13. Injection pump oil feed pipe and 1989 and later 48C2 and 4BE1 414. ‘Fuel injection pipe with clip engines) 15. Fuel leak-off pipe ‘a 2, Exhaust manifold and gasket 416. Oil filter and body ‘4 3. Glow plug and glow plug connector 17. Oil pipe ‘4 4. Injection nozzle holder 18. Fuel filter and bracket 5. Oil dipstick and guide tube 19. Fuel return pipe 6. Vacuum pump oil drain hose 20. Fuel filter pipe 7. Vacuum pump oil supply hose 21. Cooling fan pulley 8. Alternator with vacuum pump ‘4.22. Cooling fan drive belt ‘4 9. Starter motore[ Joe (jes eS Rost 4801 $801, mopeLs Vv a ENGINE MECHANICAL 6A—111 Important Operations 1. Intake Manifold and Port Insert (1988 and Earlier 4BC2 and 4BE1 Engines) 1) Install the port inserts to the cylinder head intake ports. 2) Install the intake manifold to the cylinder head. 3) Tighten the manifold bolts to the specified torque. Intake Manifold Bolt Torque kg-milb.ft/N-m) 2.1 £05 (15.1 + 3.6/20.6 + 4.9) 1a, Intake Manifold and Gasket (4BD1 and 1989 and Later 4BC2 and 4BE1 Engines) 1) Install the gasket to the cylinder head, 2) Install the intake manifold to the cylinder head. 3) Tighten the manifold bolts to the specified torque. Intake Manifold Bolt Torque kg-milb.ft/N-m) 2.1 £05 (15.1 + 3.6/20.6 + 4.9) 2. Exhaust Manifold and Gasket 1) Install the exhaust gasket to the cylinder head. ‘The gasket “TOP” mark must be visible after instal- lation. 2) Install the exhaust manifold to the cylinder head.6A—112_ ENGINE MECHANICAL 3) Tighten the manifold bolts to the specified torque a little at a time in the numerical order shown in the illustration, Exhaust Manifold Bolt Torque kg-milb.ft/N-m) 2.1 + 0.5 (15.1 + 3.6/20.6 + 4.9) 3. Glow Plug and Glow Plug Connector 1) Install the glow plugs to the cylinder head. 2). Tighten the glow plugs to the specified torque. Glow Plug Torque kgrmi(lb.£UN-m) 2.25 £0.25 (16.3 & 18/22. & 2.5) 3) Install the glow plug connectors. 4) Tighten the glow plug connectors to the specified torque. Glow Plug Connector Torque kg-milb.ft/N-m) 0.13 + 0.20 (0.9 + 1.4/1.3 + 2.0) Note: Glow plugs in good con: If glow plug replacement is required, the glow plugs must be replaced as a set. Never replace only one glow plug. yn may be reused. 4. Injection Nozzle Holder 1). Install the injection nozzle gasket © and the dust cover @ to the injection nozzle holder ®. 2) Apply engine oil to the cylinder head nozzle holder holes. 3) Install the nozzle holder together with the nozzle holder flange @ to the cylinder head.ENGINE MECHANICAL 6A—113 4) Tighten the nozzle holder flange bolts to the specifi- ed torque. Nozzle Holder Flange Nut Torque kg-m(lb.ft/N-m) 5 x 025 (1 21.5 & 2.1) 5) Tighten the nozzle holder nut with washer © to the specified torque. Nozzle Holder Nut Torque kg-m(lb.tyN-m) 3.8 + 0.6 (26.0 + 4.3/37.2 + 5.9) 9 Starter Motor Tighten the starter motor nuts to the specified torque. Starter Motor Nut Torque kg-milb.ft/N-mn) 8.6 = 1 (62.1 + 7.2/843 298) 11. Power Steering Oil Pump 1) Apply engine oil to the timing gear case cover hole and the 2nd O-ring ®. 2) Install the power steering oil pump. 3) Tighten the oil pump bolts to the specified torque. Power Steering Pump Bolt Torque kg-milb.ft/N-m) 5.3 + 1.0 (88.3 + 7.2/51.9 + 98) 4) Install the oil pipe to the power steering pump. 5) Tighten the oil flange bolts @ to the specified torque. Oil Pipe Flange Bolt Torque kg-milb.ft/Nem) 1.8 + 05 (13.0 + 3.6/17.6 + 49)6A—114 ENGINE MECHANICAL 14, Fuel Injection Pipe with Clip 1) Temporarily tighten the injection pipe sleeve nuts © and @. 2) Set the clip @ in the prescribed position. Note: Make absolutely sure that the clip is correctly posi tioned. injection pipe breakage and fuel pulsing nois 3) Tighten the injection pipe sleeve nuts to the specifi- ed torque. Injection Pipe Sleeve Nut Torque kg-milb.f/N-m) 3.05 + 0.15 (22.1 + 1.1/30.0 + 16. Oil Fitter and Body 1) Install the oil filter and body to the cylinder body. 2) Tighten the oil filter bolts © to the specified torque. i Filter and Body Bolt Torque kg-m(lb.ft/Nim) 3+ 1.0 (88.3 + 7.2/51.9 + 9.8) . Cooling Fan Drive Belt Install the cooling fan drive belt. Apply tension to the cooling fan drive belt by mov- ing the alternator. 3) Apply a force of 10 kg 22 Ib/98 N) to the drive belt mid-portion to check the belt deflection. Cooling Fan Belt Deflection mm(in) 10 (0.4) © Crankshaft damper pulley @ Alternator pulley ® Cooling fan drive pulleyENGINE MECHANICAL 6A—115, TURBOCHARGER (4BD1T) MAIN DATA AND SPECIFICATIONS Item 1988 and earlier 1989 and later Model THI RHB-6 GARRETT 7-25 Turbine type Radialinflow Compressor type Radial-outfiow Wastegate opening pressure mmHg(ing) 680 (27) -6A—116 ENGINE MECHANICAL GENERAL DESCRIPTION The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings. These parts are supported by the bearing housing. The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing air exhaust port. The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel con- sumption, and minimal engine operating noise. The turbocharger operates at very high speeds and temperatures. Part materials have been carefully se- lected and machined to extremely high precision. Turbocharger servicing requires great care and expertise. Should servicing be required, it is recom- mended that you contact the nearest service facility specializing in turbocharger disassembly, repair, and reassembly.ENGINE MECHANICAL 6A—117 [e*] [+] REMOVAL AND INSTALLATION (GARRETT) 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. 1989 4BD1T and Later Removal Steps Heat protector a Air inlet pipe return pipe 8 Turbocharger & 7. Exhaust adapter with seal ring & 6. Water outlet pipe Oil supply pipe 4 5. Water inlet pipe a4. a3 2. 1 Water inlet pipe Water outlet pipe Exhaust adapter with seal ring Turbocharger 1. Oil supply pipe Oil return pipe Air inlet pipe Heat protector6A~—118 ENGINE MECHANICAL Vv 50300-0083 Important Operations — Removal 8. Turbocharger 1) Remove the turbocharger assembly. 2) Plug the turbocharger oil ports to prevent the entry of foreign material. Important Operations — Installation Follow the removal procedure in the reverse order to perform the installation procedure. Pay careful attention to the important points. 8. Turbocharger 7. Exhaust Adapter with Seal Ring 1) Install the turbocharger to the exhaust manifold. Use a new gasket. 2) Tighten the turbocharger nuts @ to the specified torque. Use new nuts. ‘Turbocharger Nut Torque 2.7 +05 (19.5 + 3.6/264 + 49) (lb.Ft/N-m) 3) Install the seal rings ® to the exhaust adapter ®. Note the position of the sealing gaps shown in the illustration, 4) Install the exhaust adapter with seal ring to the turbocharger. 5) Tighten the exhaust adapter nuts and bolts to the specified torque. Exhaust Adapter Bolt Torque ke 2.4 £05 (15.1 + 36/206 + 4.9) ym(lb.Ft/N-m)ENGINE MECHANICAL 6A—119 6. Water Inlet Pipe 5. Water Outlet Pipe 1) Install the water pipes to the center housing. 2) Tighten the water pipe joint bolts to the specified torque. Water Pipe Joint Bolt Torque kg-milb.ft/N-m) 2.25 + 0.25 (16.3 1.8/2.1 + 2.5) 4, Oil Supply Pipe 1) Install the oil supply pipe connector to the turbo- charger. Use a new gasket. 2) Tighten the pipe connector to the specified torque. Oil Supply Pipe Connector Torque kg-milb.ft/Nm) 2.0 + 0.4 (14.5 + 2.9/19.6 + 3.9) 3) Install the oil supply pipe. 4) Tighten the oil supply pipe joint bolts to the specifi- ed torque. Oil Supply Pipe Joint Bolt Torque kg-milb.ft/Nm) 14 £02 (10.1 + 1.4/13.7 + 2.0) 3. Oil Return Pipe 1) Install the oil pipe. 2) Tighten the oil pipe flange bolts to the specified torque. Oil Pipe Flange Bolt Torque kgmllb.f/N-m) 1.75 + 05 (12.7 + 36/17.2 + 49)6A—120 ENGINE MECHANICAL INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. Contact the nearest GARRETT SERVICE SHOP for major repairs and maintenance. Important wheel shaft end play and bearing clearance standards and limits are included below for your refer- ence. Wheel Shaft End Play Use a dial indicator to measure the wheel shaft end play. Apply a force of 1.2 kg (2.6 Ib) alternately to the com- pressor wheel end and the turbine wheel end. Wheel Shaft End Play mmtin) ‘Standard Limit 0.013 — 0.097 (0.0005 — 0.0038) Ce IDENTIFICATION OF UNIT OR EQUIPMENT ‘The Turbocharger nameplate gives the date of manufac- ture and other important information required to identify the unit when service inquiries or part orders are made.ENGINE MECHANICAL 6A—121 The turbocharger nameplate has the following informa- tion stamped on it. Refer to the illustration at the lef. © Model number ® Part number assigned by ISUZU MOTORS LIMITED Example : 8941282540 @® Serial number assigned by GARRETT TURBO IN- CORPORATED Part number assigned by GARRETT TURBO INCOR- PORATED Example : 466272 The model number © indicates the group to which the turbocharger belongs. Part numbers ® and @ indicate specific designs or con- figurations.6A—122 ENGINE MECHANICAL [eo] [e¢] REMOVAL AND INSTALLATION (HI RHB-6) 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. 1988 4BD1T and Earlier SST) SS iS Removal Steps Installation Steps 1. Heat protector 4 6. Turbocharger 2. Air inlet pipe and safety valve 4 5. Exhaust adapter assembly & 4. Oil supply pipe 3. Oil return pipe ‘& 3. Oil return pipe 4. Oil supply pipe ‘4 2. Air inlet pipe and safety valve 5. Exhaust adapter assembly 4&6 Turbocharger 1. Heat protectorENGINE MECHANICAL 6A—123 V Important Operations — Removal 6. Turbocharger 1) Remove the turbocharger assembly. 2) Plug the turbocharger oil ports to prevent the entry of foreign material 950300-003 Important Operations — Installation Follow the removal procedure in the reverse order to perform the installation procedure. Pay careful attention to the important points. 6. Turbocharger 5. Exhaust Adapter 1) Install the turbocharger to the exhaust manifold. Use a new gasket. 2) Tighten the turbocharger nuts © to the specified torque. Use new nuts and washers. Turbocharger Nut Torque kg-m(lb.fU/N-mn) 2.7 £05 (19.5 + 3.6/26.4 + 49) 3) Install the exhaust adapter to the turbocharger. 4) Hand-tighten the nuts @. 5) Install the exhaust adapter bolts @ to the exhaust manifold,6A—124 ENGINE MECHANICAL ® ‘Apoly 6) Tighten the exhaust adapter nuts and bolts to the specified torque. Exhaust Adapter Nut Torque kg-milb.ft/N-m) 3.3402 (238 + 1.4/323 + 1.9) Exhaust Adapter Bolt Torque kg-m( 1.8 £05 (13.0 + 3.6/17.6 + 4.9) Nem) 4. Oil Supply Pipe 1) Install the oil feed pipe connector to the turbocharg- er. 2) Tighten the oil feed pipe joint bolts to the specified torque. ) Oil Feed Pipe Joint Bolt Torque kg-milb.ft/ 1.4 £ 0.2 (10.1 + 14/137 + 2.0) 3. Oil Return Pipe 1) Install the oil drain pipe. 2) Tighten the oil drain pipe flange bolts to the specifi- ed torque. Oil Pipe Flange Bolt Torque kg-milb.ft/Nem) 0.75 + 0.25 (5.4 + 0.8/7.3 + 2.4) 2. Air Inlet Pipe and Safety Valve Assembly Apply ThreeBond 1207 or the equivalent to the fixing screws.ENGINE MECHANICAL 6A—125 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. Visual Check Inspect the following parts for excessive wear and da- mage. Compressor housing Turbine housing Center housing Abnormal Noise, Excessive Play, and Oil Leakage Check Perform the following checks with the engine cold. If the engine has been running, allow time for it to coo! thoroughly before beginning. 1. Remove the intake duct. 2. Rotate the turbine shaft with your hand. ‘The shaft should turn smoothly. There should be no abnormal noise. There should be no excessive play. 3. Check for oil leakage from the turbine housing. 4, Check for oil leakage from the center housing. 5. Check for oil leakage from the compressor housing flanges and the oil pipe connections. Rotor Shaft Axial PLay Use a dial indicator to measure the rotor shaft axial play. Rotor Shaft Axial Play - 0.11 (0.043)6A—126 ENGINE MECHANICAL ow ouster Rotor Shaft Radial Play 1. Invert the turbocharger so that the turbine exhaust inlet flange is facing up. 2. Use a dial indicator to measure the rotor shaft radial play Note the total indicator reading (TIR). Rotor Shaft Radial Play (TIR) mm(in) 0.19 (0.0075) Safety Valve 1. Check that the valve parts move smoothly. 2. Check for excessive wear and damage.ENGINE MECHANICAL 6A—127 LUBRICATING SYSTEM MAIN DATA AND SPECIFICATIONS tem Lubricating method Full low pressure circulation Oil pump type Trochoid Gear Delivery volume lit(US/UK gal}/min 39.5 (104/869) | 47.6 (125/105) Pump speed rpm 41,750 Delivery pressure kg/om*(psi/kPa) 4 (66.9/392) Oil temperature “cry 80 (180) | 50 (125) Engine oil SAE 30 CC or CD (For 48C2, 4BE1 and 4801) CD (For 48017) Oil pressure switch operating pressure 0.2 — 0.5 (28 ~ 7.1/19.6 — 48.0) kg/em*(psi/kPa) Oil fitter type Fullflow replaceable paper element type or disposal spin-on cartridge type Safety valve opening pressure 1 (142/98) kg/em*(psi/kPa) Oil cooler type Water cooled Oiling jet regulating valve opening 1.8 — 2.2 (25.6 ~ 31.3/176 — 216) pressure ka/em*(psi/kPa)6A—128 ENGINE MECHANICAL GENERAL DESCRIPTION LUBRICATING OIL FLOW bp Safety valve i it pressure t Cy. body oll gallery \ ‘Main On I = oi frim- fon | 48017, ‘ oS art || eel I” Sar] Sete Tit rowglent | Free Jasor-ri| fre: | [bs |[8* | PUMP er i ave] Fs | ale (99.6psi) Ghevwer font ] visassemeLy Disassembly Steps Cover a Impeller iG Shaft, bearing, and spacer a2 ‘3. Pulley center 4a 6. Oil seal and washer Seal unit 1. Water pump body gene Dust thrower 4&5. Snap ringCOOLING SYSTEM 6B—7 Vv Important Operations 2. Impeller Use the remover to remove the impeller. Remover : 1-8521-0047-0 3. Pulley Center Use a bench press to remove the pulley center. 5. Snap Ring Use a pair of snap ring pliers to remove the snap ring. 6. Shaft, Bearing, and Spacer Use a bench press to remove the shaft, bearing and spacer.6B—8 COOLING SYSTEM [i+] REAsseMBLY Reassembly Steps 1. Water pump body 6. Dust thrower a 2. Seal unit A 7. Pulley center 3. Oil seal and washer ‘A 8. Impeller & 4, Shaft, bearing, and spacer 9. Cover 5. Snap ringCOOLING SYSTEM 6B—9 V Important Operations 2. Seal Unit 1) Apply a thin coat of liquid gasket three bond 1207 or equivarent to the seal unit outer periphery. 2) Install the seal unit to the pump body. a 4. Shaft, Bearing, and Spacer 1) Apply a coat of bearing grease to the bearing and J, spacer cavity shown in the illustration. 2) Install the shaft, the bearing and the spacer assem- bly to the pump body. ‘Take care not to damage the oil seal and seal unit. 7. Pulley Center Use a bench press to install the pulley center to the shaft.6B—10 COOLING SYSTEM .970309-005 8. Impeller 1) Use a bench press to install the impeller so that the specified clearance is provided between the impell- er and the pump body. Impeller and Body Clearance mmi(in) ‘Standard 0.3 — 1.3 (0.012 ~ 0.051) 2) Use a feeler gauge and a straight edge to measure the impeller rear face depth from the pump body face. Impeller Rear Face Depth mm(in) ‘Standard (0.6 — 0.8 (0.024 — 0.031)COOLING SYSTEM 6B—11 THERMOSTAT INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection Operating Test 1. Completely submerge the thermostat in water. 2. Heat the water. Stir the water constantly to avoid direct heat being applied to the thermostat. 3. Check the thermostat initial opening temperature. Thermostat initial Opening Temperature “cre | Standard ‘Ail 4BC2 AIL4BE1 | Primary valve | 80 — 84 (176 — 189) 4801 1987 and later agort 1989 | Secondary 9 _ 87 181 — 189) valve and later 4801 1986 and earlier 80 — 84 (176 — 183) ‘4BD1T 1988 and ear F 4, Check the thermostat valve lift at 95°C (203°F). Thermostat Valve Lift at 96°C (203°F) mm(in) Thermostat Valve Lift at 95°C (2037) _mrntin)_ Standard ‘All 4BC2 and 4BE1 Primary Valve wd earlier 10 (0.39) or more 4801 1987 andearlier | secondary Valve ‘BD1T 1989 and later 8.5 (0.33) or more ‘4BD1T 1986 and earlier 4BD1T 1989 and later 10 (0.39) or more ® Thermometer ® Agitating rod ® Wooden piece6B—12 COOLING SYSTEM TROUBLESHOOTING Refer to this Section to quickly diagnose and repair engine problems. Each troubleshooting chart has three headings arranged from left to right. (1) Checkpoint (2) Trouble Cause (3) CountermeasureCOOLING SYSTEM 6B—13 OVERHEATING Checkpoint Trouble Cause Countermeasure Vehicle load bd Overloaded Reduce load oK Belts ne} Broken or slipping Replace or adjust T ok Coolant level Ld Low Replenish OK] NG Water temperature gauge Detective gauge or sending unit Replace ok . Exhaust pipes and mufflers me) Clogged Repair ox Oil level ne Low rj Replenish oK Radiator cap ns Weak or damaged H Replace Continued on the next page6B—14 COOLING SYSTEM Checkpoint Trouble Cause Countermeasure Continued from the previous page ox, NG i Radiator core and grill Clogged or dirty Clean or repair ok Thermostat bo Detective Replace ox Fan clutch (i so equipped) | NS Defective Replace ok _ Water pump Ne Defective Repair or replace ox, Water jacket ne Clogged CleanFUEL SYSTEM 6C—1 SECTION 6C FUEL SYSTEM TABLE OF CONTENTS Main Data and Spe General Description Injection Pump ... Injection Pump Data Injection Nozzle .. Disassembly ... Inspection and Repair Reassembly . Trouble shooting .6C—2 FUEL SYSTEM MAIN DATA AND SPECIFICATIONS Item Injection pump type Bosch In-line Plunger outside diameter mmtin) 9.0 (0.354) or 9.5 (0.374) Plunger lift mmiin) 8.0 (0.315) or 9.0 (0.354) Governor type RLD-K, RLD-F Mechanical (variable speed) Automatic timer type Centrifugal, flyweight Fuel feed pump type Piston Injection pump type Bosch Distributor Plunger outside diameter mm(in) 12.0 (0.472) Plunger lift mm(in) 28 (0.11) Governor type Mechanical (Partially variable speed) Automatic timing divice Oil pressure Fuel feed pump type Injection nozzle type Injection nozzle opening pressure Main fuel filter Vane with input shaft Hole type (with 4 orifices) 185 (2631/1814) or 220 (3128/2158) Disposal Spin-on Cartridge TypeFUEL SYSTEM 6C—3 GENERAL DESCRIPTION FUEL FLOW (IN-LINE TYPE INJECTION PUMP) Nozzle Water seperator =6C—4 FUEL SYSTEM FUEL FLOW (DISTRIBUTOR TYPE INJECTION PUMP)FUEL SYSTEM 6C—5 INJECTION NOZZLE 3 SI Screw Adjusted Type Shim Adjusted Type ‘A Bosch hole type injection nozzle is used. It consists of the nozzle body and the needle valve assembly. The injection nozzle assembly sprays pressurized fuel from the injection pump into the combustion cham- ber through the nozzle body injection orifice.6C—6 FUEL SYSTEM FUEL FILTER AND WATER SEPARATOR Priming pump kody asenbty boty asemy — =e aS al ae x Ly eg on far G \ A rite rie Lev sna oni peeeet —— A cartridge type fuel filter and a water separator are used along with the VE type injection pump. ‘As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches the injection pump. ‘The water separator has an internal float. When the float reaches the specified level, a warning light comes on to remind you to drain the water from the water separator. A diaphragm type priming pump is installed at the top of the water separator. It is used during the water draining and the air bleeding procedures.FUEL SYSTEM 6C—7 INJECTION PUMP INJECTION PUMP DATA (IN-LINE TYPE) INJECTION VOLUME ADJUSTMENT TEST CONDITIONS tem Condition Injection nozzle ZEXEL Part No.: 105780-0000 Bosch Type No.: DN12SD12T ZEXEL Part No.: 105780-2080 Bosch Type No.: EF8511/9 Injection nozzle opening kg/em"(psi/kPa) 175 (2,489/17,162) pressure Injection line dimensions mm(in) Inside diameter 2.0 (0.079) Outside diameter 6.0 (0.236) Length 600 (24) Fuel delivery pressure kg/cm*(psi/kPa) 1.6 (27/257) Test fuel Bosch Diesel Fuel OL61V11 ‘SAE Standard Test Diese! Fuel (SAE967D) ISO Standard Test Diesel Fuel (IS04113) Test fuel temperature “orry 40 — 45 (104 — 113) Identification numbers 48C2 101491-0268, 101491-0288, 101491-0470 401491-0262, 101491-0272 4BE1 101491-0590, 101491-0600, 101491-0670 101491-0680 4801 101401-0860, 101401-0870, 101401-0742 101401-0422, 101401-4271 4g01T 101401-0890, 101401-0880, 101401-4281 IDENTIFICATION PLATE AND NUMBER Use the data following the injection pump identification number to adjust the injection volume. ® Isuzu Part No. (Pump Assembly No.) ® ZEXEL Pump Assembly No.6C—8 FUEL SYSTEM INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-1 Identifiction Numbers: 101491-0265 ine type pump) [4BC2 Engine} Pre-stroke : No. 1 plunger 3.6 + 0.05 mm Injection order : 1 —3— 4 — 2 (interval 90° + 30") Plungers are numbered from the drive side ‘Tappet clearance : More than 0.3 mm with all plungers Injection Volume ‘Adjusting | Control rack | Pump speed Injection volume | Variance : Point | position (mm)| (p.m) | SKS | “icey1000 st.) | (36) | Fixed | Remarks 102 1100 | 1000 | 476-508 | = 25 | Rack = H_| About | 300 | 1000 | 80-110 | 2140 | Rack A Rt (10.2) 1100 | 1000 | 482— 502 = [Lever Basic 8 04 7800 | 1000 | 4948.1 = | Lever c +0.1 70 | 1000 | 382—41.4 = | Lever D +07 500 | 1000 = = | Lever 1 = too | 1000 | 625-625 | — | Lever| Control rack limit Timing Advance Specification Below Pump Speed (rpm) pelo 1600 +1800 1900 Degree for Angle of Lead (deg.) | Start ee | 25-35 | 40-50) Fish | Governor Adjustment FULL Lop apusrmenr "7" tpuinc aowustMenr ‘TIMING SETTING LEVER ANGLE STOP LEVER ANGLE ‘nme sey tntFUEL SYSTEM 6C—3 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identifiction Numbers: 101491-0283 [482 Engine] Pre-stroke : No. 1 plunger 3.6 + 0.05 mm Injection order : 1 — 3 — 4 — 2 (interval 90° + 30") Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all plungers Injection Volume ‘Adjusting| Control rack | Pump speed] oy, Injection volume Variance | 5; point | position (mm)| (ram) | SKES| “"Yceria00 st) | (36) | med] Remarks 102 1100 | 1000 | 476-508 | 2 28 | Rack = H__| About 99 300 | 1000 | 80-110 | #140 | Rack A R1 (10.2) | __1100 1000 | 48.2 — 50.2 =| Lever Basic B 0.1 1800 1000 44.9 — 48.1 = Lever c +01 700 | 1000 | 382—414 | — | Lever D +07 500 | 1000 = = [Lever 1 700 | 1000 | 625-626 | — | Lever| Control rack limit Timing Advance Specification Pump Speed (rpm) Pont 1250 1900 Below Finish Degree for Angle of Lead (deg.) | Start a ants Governor Adjustment FULL LORD ADJUSTMENT Trent “MT IDLING ADJUSTMENT ig i a LEVER ANGLE STOP LEVER ANGLE “TIMING SETTING net aoe Nee6C—10 FUEL SYSTEM INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identifiction Numbers: 101491-0470 (With Aneroid Compensator) [4BC2 Engine] Pre-stroke : No. 1 plunger 3.6 + 0.05 mm Injection order : 1 — 3 —4 — 2 (interval 90° + 30") Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all plungers Injection Volume pnt | poston teri] aml | See | Meco | VAGR® [Foes | Romans IL 10.2 1100 1000 47.6 — 50.8 +25 | Rack Basic H About 9.9 300 1000 8.0 — 11.0 #14.0 | Rack ‘a |_Ar(io2 | 1100 | 1000 | 482-602 | — |Lever) Basie 8 =01 ve00 | 1000 | aa9—4e1 | — [Lever c Fox 700) 1000 | 382-414 | — [Lever D #01 00) 1000 = = [Lever 1 = 100 | 1000 [$25 625 | — [Lever | Conv ack iit Timing Advance Specification Pump Speed (rpm) td 1250 | 1900 Degree for Angle of Lead (deg.) | Start Some Pace Governor Adjustment FuLLLonp apusrmenr """°™ eee IDLING ADJUSTMENT an i Pt : Es g i i AASPERFORMANCE LEVERANGLE ——STOPLEVER ANGLE TIMING SETTING NeowtivePrenre (mmFUEL SYSTEM 6C—11 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM Identifiction Numbers: 101491-0262 (Standard) [4BC2 Engine] Pre-stroke : No. 1 plunger 3.4 + 0.05 mm Injection order : 1— 3 — 4 — 2 (interval 90° + 30") ___Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all cylinder Injection Volume Aajgina)Convol ack [Fame se] svotes fiom ee | spayes| Fed | Romare 102 7100) 1000 | 404-526 = 25 | Rack | Basie H About 9.8 300 1000 8.0— 11.0 +14.0 | Rack A pat (102) | 1100 | 1000 | 600-620 | — | Lever| Basie 8 70. 1@00 | 1000 | 476-608 | — | Lever c 10.3 700, 1000 38.4 — 41.6 > Lever 1 [About 150100 | 1000 | @50-e1.0 | — | Lever ing Advance Specification Pump Speed (rpm) [1600 1800 1900 End Below Degree for Angle of Lead (deg.) ae 3405 | 45205 6) GOVERNOR PERFORMANCE AUTOMATIC TIMER CHARACTERISTIC es zen a — . fos i 200 2 y 2 ae ce Pump Speed (rpm) ome Control Rack Position (mm) Stop lever angle Speed lever angle6c—12 FUEL SYSTEM INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM Identifi iction Numbers: 101491-0272 (with Aneroid Compensator) [4BC2 Engine] Pre-stroke : No. 1 plunger 3.4 + 0.05 mm Injection order : 13 —4— 2 (interval 90° + 30") Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all cylinder Injection Volume ‘Adjusting] Control rack | Pump speed Injection volume ] Variance] point | position (mm)| (rpm) | S€°KeS| “icc/1000 st) | (%) | Faxed | Remarks 10.2 v100_| 1000 | 494-626 | 2 28 | Rack Basic H About 98 300 | 1000 | 80-11.0 | +140 | Rack A Ri (10.2) 1100 | 1000 | 500-520 = _| Lever Basic 8 10.1 7800 | 1000 | 476-508 =| Lever c 103 700 | 1000 | 384-416 =| Lever 1__| About 15.0 too | 1000 | 650-810 =| Lever Timing Advance Specification Pump Speed (rpm) 1600 | _ 1800 1900 End Degree for Angle of Lead (deg.) | Below | 3405 | 45208 6) GOVERNOR PERFORMANCE AUTOMATIC TIMER CHARACTERISTIC twas > | Eso: 7 «| ge & sssoe e 20s eit i z § tena} E038 2 Controt Rack Position (mm) : septa § i, 0-448 iat 2 Negative Pressure mm Hg) ANEROID COMPENSATOR PERFORMANCE ‘Speed lever angle Stop lever angleFUEL SYSTEM 6C—13 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identification Numbers: 101491-0590 [4BE1 Engine] Pre-stroke : No. 1 plunger 3.2 + 0.05 mm Injection order : 1-34 —2 (interval 90° + 30") Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all plungers, Injection Volume Adjusting | Control rack | Pump speed Injection volume | Variance | point | position (mm) | (cpm) | SKS | cc/1000 st) | (94) | Fed | Remarks 107 | 1,050 | 1000 | 565-597 | 2 35 | Rack — H | About 97 00 | 1000 | 65-95 | +100 | Rack A (10.7) 7050 | 1000 | 67.1591 = [Lever | __Basie 8 | Ri+015 | 1,750 | 1000 | (686-718 | — | Lever 1 = 100 | 1000 | (705-865) | — | Lever Timing Advance Specification Below Pump Speed (rpm) Below | 1,375 Degree for Angle of Lead (deg.) Start See Governor Adjustment FutLvoap apiusrenr eNO vouine aowusrient 1 I i i 8 é Leven anoue STOP LEVER ANGLE mma serra,6C—14 FUEL SYSTEM INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identi [4BE1 ical Engine] n Numbers: 101491-0600 (with Aner Pre-stroke : No. 1 plunger 3.2 + 0.05 mm Injection order : 1 3~ 4 2 (interval 90° + 30") Tappet clearance : More than 0.3 mm with all plungers Injection Volume Compensator) Plungers are numbered from the drive side ‘Adjusting | Control ack | Purp speed] o. ojq5] ection volume | Variance |p, 5 point | position (mm) | (rpm) | SKS | “ec/1000 st) | (%) | Fed | Remarks 10.7 1,050 | 1000 | 665-597 | +36 | Rack —_ H ‘About 9.5 300__| 1000 65-95 | 2100 | Rack A Rr (10.7) 7,050 | 1000 | 671-594 = [Lever Basic 8 Ri + 0.15 1750 | 1000 | (686— 71.8) = [Lever 1 = 100_| 1000 | (70.5— 86.5) = [Lever ing Advance Speci n Below Pump Speed (rpm) ase 1,375 1,750 Below Degree for Angle of Lead (deg.) | Start cee ace Governor Adjustment FULL LOAD ADJUSTMENT ANEROID COMPENSATOR PERFORMANCE, Asie Pere I LEVER ANGLE Seee0 ONTROL LEVER ANGLE IDLING ADJUSTMENT CONTROL RACK POSITION) — STOP LEVER ANGLE TimiNG seTTiNGFUEL SYSTEM 6C—15 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In Identification Numbers: 101491-0680 (4BE1 Engine] Pre-stroke : No. 1 plunger 3.2 + 0.05 mm Injection order : 1-3 ~ 4~ 2 (interval 90° + 30") Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all plungers ine type pump) Injection Volume AGS | CES, [PATER Stes | MRNA || Fa | Reva _ 106 1,050 tooo | 548-580 | +35 | Rack a H ‘About 95 300 | 1000 65— 95 | 2100 | Rack | A Ri (10.6) | _1,050 7000 | 554—57.4 =| Lever Basic 8 Ri + 0.15 1,750 1000 | (66.1 — 69.3) =__ [Lever i = 100 | 1000 | (70.5 ~ 86.5) = [Lever Timing Advance Specification Pump Speed (rpm) ay 1,375 41,750 Degree for Angle of Lead (deg.) | Start oe cee Governor Adjustment ute voapaowsrmenr 7” tbLiNG aDausTMENT CONTROL BACK POSITION) pur sree0 tom PUMP SPEED rm) — LEVER ANGLE ‘TimING SETTING [ATNO." plunger epg ot retion ~ pope 95 \ C)6C-16 FUEL SYSTEM INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In- e type pump) Identification Numbers: 101491-0670 (with Aneroid Compensator) [4BE1 Engine] Pre-stroke : No. 1 plunger 3.2 + 0.05 mm Injection order : 1 — 3 — 4 — 2 (interval 90° + 30") Plungers are.numbered from the drive side Tappet clearance : More than 0.3 mm with all plungers Injection Volume ‘Adjusting | Control rack | Pump speed injection volume | Variance Point | position (mm)| — (rp.m) | SKS | iec/r000 st) (%) | FNed | _—_ Remarks 106 1,050 | 1000 | 48-580 | £35 | Rack Basie HH | About 95 300 1000/| 65-95 | #100 | Rack A Ri (10.6) 7050) 1000 | 854 —57.4 = [Lever Basie B Ri + 0.15 1,750 | 1000 | (66.1 — 69.3) = [Lever I = 700 | 1000 | (705-865) — | Lever ing Advance Specification Below Pump Speed (rpm) ae 1.375 1,780 Below | Finish Degree for Angle of Lead (deg.) | Start Soe cere Governor Adjustment FuuL Loan aoiusrwen TSM 2"N= "OH rDLiN aDsUsTMENT i I 8 a ANEROID COMPENSATOR PERFORMANCE LEVER ANGLE cx posmontn) STOP LEVER ANGLE TIMING SETTINGFUEL SYSTEM 6C-17 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identifiction Numbers: 101401-0860 (with Aneroid Compensator) [4BD1 Engine] Pre-stroke : No. 1 plunger 3.6 + 0.05 mm. Injection order : 1 —3—4— 2 (interval 90° + 30") Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all plungers Injection Volume Adjusting | Control rack | Pump speed Injection volume | Variance: point | position (mm)| (rpm) _| S¥°K*S| "Yec/1000 st) | (%) | med] Remarks 11.6 950 1000, 63.9 — 67.1 + 25 Rack Basic H About 9.5 275 1000 8.1 — 10.7 ($14.0 Rack A R1 (11.6) 950 1000 64.5 — 66.5 = Lever Basic B RI 1600 1000 (72.1 — 75.3) = Lever c R1 —0.2 650 1000 (46.6 — 49.8) = Lever 1 = 150 | 1000 | 900-980 | — _| Rack | Controt rack limit Timing Advance Specification Below Pump Speed (rpm) 1100 1050 1600 Below | Finish Degree for Angle of Lead (deg.) | _ Start a oe Governor Adjustment FULL ADJUSTMENT IDLE = Control rack mit. © TOFque cam No. : “D41” Sue naEls € Ez = — 8 miner 3s any 03 & « a i £ z i Bema (soo wine Toso & otis TI Tal “ha AON aol es! E toss, scons g yee ate § Pump Speed (rpm) Pump Speed (rpm) ‘SPEED-CONTROL ‘STOP LEVER ANGLE TIMING SETTING LEVER ANGLE At No. 1 Plunger Awengio cowrensaTon Beginning of injection Paes BTC; 15° | es i eee rasa ~ ot i \ 5 Lb - ea see eee] Negev Prenure (rei)6C—18 FUEL SYSTEM INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identification Numbers: 101401-0870 [4BD1 En: Pre-stroke : No. 1 plunger 3.6 + 0.05 mm. Injection order : 13 — 4 —2 (interval 90° + 30") Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all plungers Injection Volume ‘Adjusting | Control rack | Pump speed Injection volume | Variance oint | position (mm) | (cpm) | SKS | ec/to00 st) _| 194) | Fed | Remarks 116 960 | 1000 9-671 | 225 | Rack =a H ‘About 95 275 | 1000 1=107 | 4140 | Rack “A Ri (11.6) 950 1000 | 64.5 — 66.5 =| Lever Basic B RI 1600 yo00 | (72.1 — 75.3) = [Lever _ c Ri-02 | 650 1000 | (46.6 ~ 49.8) = [Lever H = 150 | 1000 | 900-980 =| Rack | Control rack limit Timing Advance Specification Pump Speed (rpm) ee 1050] 1600 Degree for Angle of Lead (deg.) | Start Sense Governor Adjustment FULL ADJUSTMENT fT convoiackint Torque cam No. : “D41™ en = na E aah ' Brave i i i g 3 2 ota, soo meat ae F e é FB 8 phone 2A teas-10 eos ss0215 . Bee" op 800 8 ve Pump Speed (rpm) Pump Speed irpm) SPEED-CONTROL STOP LEV TIMING SETTING AUTOMATIC TIMER LEVER ANGLE ERANGLE TRIN 1 Plungers CHARACTERISTIC Beginning of injection BTD.C; 15° Approx, 95° ze < 2 ot08 1660 Pump Speed (rpm)FUEL SYSTEM 6C-19 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM Identifiction Numbers: 101401-0742 (ADR Spec.) [4BD1 Engine] Pre-stroke : No. 1 plunger 3.6 + 0.05 mm Injection order : 1 ~3—4— 2 (interval 90° + 30") Plungers are numbered from the drive side ‘Tappet clearance : More than 0.3 mm with all plungers Injection Volume Adjusting | Control rack | Pump speed Injection volume | Variance sx rh point | position (mm)| (p.m) | STOKES | ecrroo0 st) | (9%) | PMed | Remarks 11.6 950 1000 63.9 — 67.1 +25 | Rack Basic H | About 95 27% | 1000 | 81-107 | 2140 | Rack A R1 (11.6) 950 1000 64.5 — 66.5 = Lever Basic B RI 1600 1000 (72.1 — 75.3) = Lever c R1 —0.2 650 1000 (46.6 — 49.8) = Lever I = 750 1000 | 90.0 — 98.0 — | Rack | Control rack limit Timing Advance Specification Pump Speed (rpm) Below 1050 | 1600 Degree for Angle of Lead (deg.) | Start Ca a Governor Adjustment FULL ADJUSTMENT 2 Control rack mit Torque cam No. : “C38” ea F i 2 é Bae aie meat é Sy ees fea, Misoane S80" 308 Pump Speed (rpm) Pump Speed (rpm) ‘SPEED-CONTROL STOP LEVER ANGLE TIMING SETTING AUTOMATIC TIMER EVER ANGLE BN Pung SuARACrERSTC Besiming afinecton og erbe ts Be e 5 3 0 i100 7600 q Pump Speed (rpm)6C—20 FUEL SYSTEM INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM Identifiction Numbers: 101401-0422 (Standard) [4BD1 Engine} Pre-stroke : No. 1 plunger 3.6 + 0.05 mm Injection order : 1 —3— 4—2 (interval 90° + 30") Plungers are numbered from the drive side ‘Tappet clearance : More than 0.3 mm with all cylinder Injection Volume ‘Adjusting | Control rack ] Pump speed Injection volume | Variance], point | position (mm) (r.p.m.) oJ {cc/1000 st.) (%) eel pemates 112 950 | 1000 | 652-682 | + 25 | Rack Basie H About 9.5 290 1000 67— 93 +14.0 | Rack A R1 (11.2) 950 1000 65.7— 67.7 = Lever Basic 8 708 7600 | 1000 | 617-649 | — | Lever c mA 7300 | 1000 | 691-723 | — | Lever D 11.98 50 | 1000 | 480-12 | — | Lever E 11.3 500 1000 47.0— 51.0 - Lever 1 145 150 | 1000 | 950—1030 | — | Lever| (Rod limit) iming Advance Specification Pump Speed (rpm) 1360 60 | 1600 Degree for Angle of Lead (deg.) | Start 0 5_o GOVERNOR PERFORMANCE AUTOMATIC TIMER CHARACTERISTIC ora a A B80 ' : Em 3 48 7 3 3 is ae, int s & tm 3 i 8 tw 5 s £ Pump Speed (rem) B95 a5 7 a8 | TORR T ANTES “as Stop lever angle ‘Speed lever angleFUEL SYSTEM 6C—21 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identification Numbers: 101401-4271 (with Aneroid Compensator) [4BD1 Engine] Pre-stroke : No. 1 plunger 3.6 + 0.05 mm. Injection order : 1 —3— 4 —2 (interval 90° + 30") Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all plungers Injection Volume Ae on tenes [Seeks | roost | soa | Fase | Remets 108 950 | Too0 | 393-425] 325 | Feck| gage H__ | About 95 275 1000 | 81-107 | +140 | Rack A Ri (10.5) 950 | 1000 | 399-419 = [Lever a Ri 7600 1000 | (48.1 — 51.3) = | Lever c RI 02 650 | 1000 | (29-361) | — | Lever| 1 = 150 | 1000 | 90.0980 — [Lever | Control rack limit Pump Speed (rpm) Foal 1050 1580 Decree for Angle oftead (deg) | son | BHC | Frick Governor Adjustment FULLLOAD ADJUSTMENT “oneunto-0W ze ' roung aosustMeNT Bae i al PL Le a ANEROID COMPENSATOR { arurrommance cevenavcie,— STOPEOMMOL yang sere i te io commen i S Negative Pressure imma)6C—22 FUEL SYSTEM INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identifiction Numbers: 101401-0890 [4BD1T Engine} Pre-stroke : No. 1 plunger 3.6 + 0.05 mm. Injection order : 1 —3— 4 — 2 (interval 90" + 30") Plungers are numbered from the drive side ‘Tappet clearance : More than 0.3 mm with all plungers Injection Volume ‘Adjusting| Control rack | Pump speed Injection volume | Variance | -, point ~ | position (mm) | (rpm) | SKS | "(ecy1000 st) | (%) | Fed | Remarks 116 950 1000 | 705-737 | +25 | Rack — 4 About 9.6 325 1000 | 108-134 | £140 | Rack A Ri (11.6) 950 000 | 711-734 = [Lever Basic 8 $0.2 1500 7000 | 81.0- 842 = [Lever c +01 500 1000 [512-556 = [Lever D $0.2 1100 1000 | 745-777 = [Lever i = 150 1000 | 1160-1240 | — | Lever | Control rack limit Timing Advance Specification Pump Speed (rpm) 950 — 1050 1600 Degree for Angle of Lead (deg) | Start Governor Adjustment IDLING ADJUSTMENT stor conTROL enpemmocinnt LEVER ANGLE Ii SETTINGFUEL SYSTEM 6C—23 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identifiction Numbers: 101401-0880 (with Aneroid Compensator) [4BD1T Engine] Pre-stroke : No. 1 plunger 3.6 + 0.05 mm Injection order : 1 —3— 4 — 2 (interval 90° + 30") Plungers are numbered from the drive side Tappet clearance : More than 0.3 mm with all plungers Injection Volume ‘Adjusting | Control rack | Pump speed Injection volume | Variance 7 oint | position (mm) | (ep.m) | SKS | “iecy1000 st) (%4) | FMed | _—_Remarks 16 950 7000 | 705-737 | +25 | Rack —_ 4 ‘About 9.5 325 1000 | 108-134 | +140 | Rack A Ri (11.6) 950 1000 [71.1 — 734 =| Lever Basic 8 +02 1500 1000 | 81.0 — 842 = [Lever c | +01 500 i000 | 512-556 = [Lever dp | +02 1100 1000 | 74.5 — 77.7 —__| Lever if - | 160 7000 | 1160-1240 | — | Lever | Control rack limit Timing Advance Specification Pump Speed (rpm) 950 — 1050 | 1600 Finish Degree for Angle of Lead (deg) | Start | , BIS) Governor Adjustment FULL LOAD ADJUSTMENT IDLING ADJUSTMENT ANEROID COMPENSATOR 1 zit Level au “| 7 Neaotve Presure (mimi)6C—24 FUEL SYSTEM INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM (In-line type pump) Identification Numbers: 101401-4281 (with Aneroid Compensator) [4BD1T Engine] Pre-stroke : No. 1 plunger 3.6 + 0.05 mm Injection order : 1 — 3 — 4 — 2 (interval 90° + 30") Plungers are numbered from the drive side ‘Tappet clearance : More than 0.3 mm with all plungers Injection Volume Fai | oe aah [ease [ote "eager | Fowd | Ramat 116 950 1000 | 705-737 | +25 | Rack Basic A Ri (11.6) 950 1000 71.1 = 73.1 Lever B R1+0.2 1500 1000 (81.0 — 84.2) Lever c R1+01 500 1000 (51.6 — 55.6) Lever D (R1 + 0.1) 1100 1000 (74.5 — 77.7) > Lever Timing Advance Specification Pump Speed (rpm) 1000+ 50 | 1600 Degree for Angle of Lead (deg.) | Start Finish 1.5 — 2.5 Governor Adjustment FULLLOAD ADJUSTMENT — IDLING ADJUSTMENT E g fl i i 3 ? : 8 8 ANEROID COMPENSATOR PERFORMANCE LEVER ANGLE STOPCONTROL TIMING SETTING Rem oAERANGLE STOR Conate® — BRMNGSETTING an a Negative Pressure (mmHg)FUEL SYSTEM 6C—25 ANEROID COMPENSATOR ADJUSTMENT Adjust the aneroid kit Between 1.4 to 1,7 at sea level (adjust by setting screw) Setting screw6C-26 FUEL SYSTEM INJECTION PUMP DATA (DISTRIBUTOR TYPE) INJECTION VOLUME ADJUSTMENT TEST CONDITIONS Item Injection nozzle Injection nozzle opening _kg/em*(psi/kPa) Pressure Injection line dimensions mm{in) Inside diameter Outside diameter Length Fuel delivery pressure _kg/em*(psi/kPa) Test fuel Test fuel temperature “erry Identification numbers 4BE1 nssvn6 (094225 2471 asevno [104748-1010 Condition DKKC Part No.: 105780-0000 Bosch Type No.: DN12SD12T DKKC Part No.: 105780-2080 Bosch Type No.: EF8511/9A 150 (2,133/14,700) 2.0 (0.078) 6. (0.236) 840 (33.1) 0.2 (2.84/19.6) Bosch Diesel Fuel OL61V11 SAE Standard Test Diesel Fue! (SAE967D) 40 — 45 (104 — 113) 104742-1050, 104742-1062 IDENTIFICATION PLATE AND NUMBER Use the data following the injection pump identification number to adjust the injection volume.INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM Identification Numbers: 104742-1050 FUEL SYSTEM 6C—27 Test Fuel: Standard Diesel Fuel SAE J967D (or 1S04113) 1 tem | Pump speed ‘Settings ‘Charge-air pres- | Delivery difference (rpm) ‘sure (mmHg) | (ec) Timing device wavel 1600 | 28> 82mm 1.2 Supply pump pressure 1600 | 68-62 iglen 13 Fal load delivery without | 1050] 646—656 ce/10008 40 charge-air presst | Ta ale speed regulation Ey ceTdooet [20 18 Sun 100 ec000st t 16 Fulticad speed regulation | 2100 | 10a~ 164 ec/10008 70 1.7 Aneroid compensator | ecjutment | | Zest iem oat Speciicatons Soleneid ner [ON OFF 2 Timing devon a eco as0 | 140 —ve00~—~—

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