2011MY

2011MY

WORKSHOP MANUAL ENGINE (4JB1 model)

WORKSHOP MANUAL

ENGINE
(4JB1 model)

No.LG4JB-WE-1111
LG4JB-WE-1111_Maegaki 2011.7.25 11:40 AM ページ 1

This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A GENERAL INFORMATION
0B MAINTENANCE AND LUBRICATION
1 HEATING AND AIR CONDITIONING 00 SERVICE INFORMATION
1A HEATING AND VENTILATION
2 FRAME AND CAB 00 SERVICE INFORMATION
2 CAB AND FRAME
3 STEERING, SUSPENSION, WHEELS 00 SERVICE INFORMATION
AND TIRES 3A FRONT END ALIGNMENT
3B1 POWER STEERING
3B2 MANUAL STEERING
3B3 STEERING LINKAGE
3B4 STEERING COLUMN
3C FRONT SUSPENSION
3D REAR SUSPENSION
3E WHEELS AND TIRES
4 PROPELLER SHAFT AND AXLE 00 SERVICE INFORMATION
4A PROPELLER SHAFT
4B REAR AXLE
4C FRONT AXLE
5 BRAKES 00 SERVICE INFORMATION
5A HYDRAULIC BRAKES
5C PARKING BRAKES
5E EXHAUST BRAKE
6 ENGINE 00 SERVICE INFORMATION
6A GENERAL ENGINE MECHANICAL
6A1 4JB1/4JB1-TC-ENGINE
6B ENGINE COOLING
6C ENGINE FUEL
6D ENGINE ELECTRICAL
6E EXHAUST GAS RECIRCULATION (EGR) SYSTEM
6F ENGINE EXHAUST
6G TURBOCHARGER
7 MANUAL TRANSMISSION AND CLUTCH 00 SERVICE INFORMATION
7B MANUAL TRANSMISSION
7C CLUTCH
8 CAB AND CHASSIS ELECTRICAL 8 CAB AND CHASSIS ELECTRICAL
(LEFT HAND DRIVE MODEL)
8 CAB AND CHASSIS ELECTRICAL 8 CAB AND CHASSIS ELECTRICAL
(RIGHT HAND DRIVE MODEL)
9 SEAT BELT, SRS AIRBAG 9A SEAT BELT
LG4JB-WE-1111_Maegaki 2011.7.25 11:40 AM ページ 2
LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-1

ENGINE
SECTION 00
SERVICE INFORMATION
Contents
TROUBLE SHOOTING ......................................... 00-2
Hard Starting ..................................................... 00-2
Unstable Idling................................................... 00-5
Insufficient Power .............................................. 00-6
Excessive Fuel Consumption ............................ 00-7
Excessive Oil Consumption............................... 00-7
Overheating ....................................................... 00-7
White Exhaust Smoke ....................................... 00-8
Dark Exhaust Smoke......................................... 00-8
Oil Pressure Does Not Rise............................... 00-8
Abnormal Engine Noise..................................... 00-9
Engine Cooling Trouble ................................... 00-10
Engine Electrical Part Trouble ......................... 00-11
Turbocharger ................................................... 00-16
Lubrication Chart ............................................. 00-23
MAIN DATA AND SPECIFICATIONS ................. 00-24
Main Data and Specifications .......................... 00-24
Engine Cooling ................................................ 00-26
Starting System ............................................... 00-26
Charging system.............................................. 00-27
SERVICE STANDARD........................................ 00-28
Engine Mechanical .......................................... 00-28
SERVICING ........................................................ 00-31
Model Identification.......................................... 00-31
Air Cleaner....................................................... 00-31
Lubricating System .......................................... 00-32
Fuel System..................................................... 00-32
Cooling System ............................................... 00-34
Engine Control................................................. 00-37
Compression Pressure Measure-ment............ 00-42
Quick-On Start II System................................. 00-43
FIXING TORQUE................................................ 00-44
Cylinder Head Cover, Cylinder Head, Rocker
Arm Shaft......................................................... 00-44
Crankshaft, Bearing Cap, Connecting Rod
Cap, Crankshaft Damper Pulley, Flywheel,
Oil Pan............................................................. 00-45
Timing Pulley Housing, Timing Pulley, Timing
Gear, Camshaft Oil Seal Retainer ................... 00-46
Cooling System and Lubrication System......... 00-47
Intake Manifold, Exhaust Manifold, Exhaust
Pipe ................................................................. 00-48
Engine Electricals ............................................ 00-50
Engine Fuel ..................................................... 00-51
Engine Mounting Bracket ................................ 00-52
SPECIAL TOOLS................................................ 00-53
LG4JB-WE-1111.book 2 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-2 SERVICE INFORMATION

TROUBLE SHOOTING
Hard Starting
1. Starter Inoperative

Checkpoint Possible cause Correction

Battery Loose battery cable terminal poor connec- Clean and/or retighten the battery cable
tions due to rusting terminal
Battery discharged or weak Recharge or replace the battery
Fan belt loose or broken Adjust or replace the fan belt
Fusible link Fusible link shorted Replace the fusible link
Starter switch Defective starter switch or starter relay Replace the starter switch or the starter
relay
Starter motor Defective magnetic switch or starter relay Repair or replace the magnetic switch
Defective starter motor Repair or replace the starter motor

2. Starter Motor Operates But Engine Does Not Turn Over

Checkpoint Possible cause Correction

Battery Loose battery cable terminal Clean and/or retighten the battery cable
terminal
Poor connections due to rusting Recharge or replace the battery
Battery discharged or weak Recharge or replace the battery
Fan belt loose or broken Adjust or replace the fan belt
Starter Defective pinion gear Replace the pinion gear
Defective magnetic switch Repair or replace the magnetic switch
Brush wear, Weak brush spring Replace the brush and/or the brush spring
Engine Piston, crank bearing seizure, or other Repair or replace the related parts
damage
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SERVICE INFORMATION 00-3

3. Engine Turns Over But Does Not Start

Checkpoint Possible cause Correction

Engine stop mecha- Defective fuel cut solenoid valve Replace the fuel cut solenoid valve
nism
Fuel is not Being Delivered to the Injection Pump
Fuel Fuel tank is empty Fill the fuel tank
Fuel piping Clogged or damaged fuel lines. Loose fuel Repair or replace the fuel lines
line connection Retighten the fuel line connection
Fuel filter Fuel filter overflow valve does not close Repair or replace the fuel filter overflow
valve
Clogged fuel filter element Replace the fuel filter element or the filter
cartridge
Fuel system Air in the fuel system Bleed the air from the fuel system
Fuel feed pump Defective feed pump Repair or replace the feed pump
Fuel is Being Delivered to the Injection Pump
Fuel Use of the wrong fuel Use the correct fuel
Water particles in the fuel Change the fuel
Fuel system Air in the injection pump Bleed the air from the fuel system
Injection nozzle Injection nozzle sticking
Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Improper spray condition
Injection pump Defective fuel injection nozzle resulting in Replace the delivery valve
the fuel drippage after fuel injection
Defective injection pump control rack oper- Repair or replace the injection pump con-
ation trol rack
Injection pump plunger worn or stuck Replace the injection pump plunger
assembly
Injection pump drive shaft seizure or other Replace the injection drive shaft
damage
Injection pump governor spring seizure Replace the injection pump governor
spring

4. Quick-On Start System

Preparation
1. Disconnect the thermo switch connector.
2. Determine whether or not the glow plugs are receiving power.
a. Make sure that the starter switch is “OFF”.
b. Connect a voltmeter between one of the glow plugs and the cylinder wall.
c. Move the starter switch to the “ON” position.
The voltmeter needle will show the souse voltage (12V) if the glow plugs are receiving power.
If the voltmeter needle does not move, the glow plugs are not receiving power.
3. Perform the troubleshooting procedure.
LG4JB-WE-1111.book 4 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-4 SERVICE INFORMATION

Checkpoint Possible cause Correction

Glow Plugs are Receiving Power
Glow plug indicator Defective indicator light bulb Replace the indicator light bulb
light does not turn on
Quick-on start timer Defective quick-on start timer Replace the quick-on start timer
Glow plug indicator Defective quick-on start timer Replace the quick-on start timer
light turns on the 0.3
seconds
Glow plug indicator Return the starter switch to the “ON” posi- Replace the quick-on start timer
light turns on for 3.5 tion from the “START” position after the
seconds engine starts if the glow plug relay remains
on less than 14 seconds, the quick-on start
timer is defective
Move the starter switch from the “OFF” Replace the quick-on start timer
position to the “ON” position if the glow
plug relay remains on less than 14 sec-
onds, the quick-on start timer is defective
Thermo switch Defective thermo switch Replace the thermo switch
Glow plug continuity No glow plug continuity Replace the glow plugs
Glow Plugs are not Receiving Power
Glow plug indicator Broken indicator light fuse Replace the fuse
light does not turn on
Quick-on start timer Defective quick-on start timer Replace the quick-on start timer
Glow plug indicator Defective glow plug relay Replace the glow plug relay
light turns on for 3.5 The glow plug relay does not turn on after
seconds the starter switch is moved from the “OFF”
position to the “ON” position
Defective quick-on start timer Replace the quick-on start timer
Defective glow plug relay wiring harness Repair or replace the wiring harness
Defective fusible link or wiring harness Replace the fusible link or the wiring har-
The glow plug relay turns on when the ness
starter switch is moved from the “OFF”
position to the “ON” position
LG4JB-WE-1111.book 5 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-5

Unstable Idling

Checkpoint Possible cause Correction

Idling system Idling improperly adjusted Adjust the idling
Fast idling speed Defective fast idling speed control device Repair or replace the fast idling speed
control device
Accelerator control Accelerator control system improperly Adjust the accelerator control system
system adjusted
Fuel system Fuel system leakage or blockage Repair or replace the fuel system
Air in the fuel system Bleed the air from the fuel system
Water particles in the fuel system Change the fuel
Fuel filter Clogged fuel filter element Replace the fuel filter element or the fuel
filter cartridge
Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump
Injection nozzle Injection nozzle sticking Replace the injection nozzle
Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Improper spray condition
Injection pump Defective delivery valve resulting in fuel Replace the delivery valve
drippage after fuel injection
Injection timing improperly adjusted Adjust the injection timing
Insufficient injection volume Adjust the injection volume
Defective idle spring Replace the idle spring
Defective governor lever operation Repair or replace the governor lever
Regulator valve improperly adjustment Adjust or replace the regulator valve
Broken plunger spring Replace the plunger spring
Worn plunger Replace the plunger assembly
Worn cam disc Replace the cam disc
Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Compression pressure Blown out cylinder head gasket. Worn cyl- Replace the related parts
inder liner.
Piston ring sticking
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00-6 SERVICE INFORMATION

Insufficient Power

Checkpoint Possible cause Correction

Air cleaner Clogged air cleaner element Clean or replace the air cleaner element
Fuel Water particle in the fuel Replace fuel
Fuel filter Clogged fuel filter element Replace the fuel filter element or the fuel
filter cartridge
Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump
Injection nozzle Injection nozzle sticking Replace the injection nozzle
Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Improper spray condition
Fuel injection pipes Fuel injection pipes damaged or Replace the fuel injection pipes
obstructed
Injection pump Defective regulating valve Repair or replace the regulating valve
Defective delivery valve Replace the delivery valve
Defective timer Repair or replace the timer
Worn cam disc Replace the cam disc
Improper control lever operation Adjust or replace the control lever
Defective injection timing Adjust the injection timing
Repair or replace the injection pump timer
Weak governor spring Replace the governor spring
Worn plunger Replace the plunger assembly
Compression pressure Blown out cylinder head gasket. Worn cyl- Replace the related parts
inder liner.
Piston ring sticking
Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Valve spring Valve spring weak or broken Replace the valve spring
Exhaust system Exhaust pipe clogged Clean the exhaust pipe
Full load adjusting Open and improperly set adjusting screw Adjust and reseal the adjusting screw
screw seal seal
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SERVICE INFORMATION 00-7

Excessive Fuel Consumption

Checkpoint Possible cause Correction

Fuel system Fuel leakage Repair or replace the fuel system related
parts
Air cleaner Clogged air cleaner element Clean or replace the air cleaner element
Idling speed Poorly adjusted idling speed Adjust the idling speed
Injection nozzle Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Improper spray condition
Fuel injection timing Fuel injection timing improperly Adjust the fuel injection timing
Injection pump Defective Delivery valve resulting is fuel Replace the delivery valve
drippage after fuel injection
Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Compression pressure Blown out cylinder head gasket. Worn cyl- Replace the related parts
inder liner.
Piston ring sticking
Valve spring Valve spring weak or broken Replace the valve spring

Excessive Oil Consumption

Checkpoint Possible cause Correction

Engine oil Engine oil unsuitable Replace the engine oil
Too much engine oil Correct the engine oil level
Oil seal and gasket Oil leakage from the oil seal and/or the Replace the oil seal and/or the gasket
gasket
Air breather Clogged air breather Clean the air breather
Intake and exhaust Worn valve stems and valve guides Replace the intake and exhaust valves
valve and the valve guides

Overheating

Checkpoint Possible cause Correction

Cooling water Insufficient cooling water Replenish the cooling water
Fan clutch Oil leakage from the fan clutch Replace the fan clutch
Fan belt Fan belt loose or cracked causing slippage Replace the fan belt
Radiator Defective radiator cap or clogged radiator Replace the radiator cap or clean the radi-
core ator core
Water pump Defective water pump Repair or replace the water pump
Cylinder head and cyl- Defective sealing cap resulting in water Replace the sealing cap
inder body sealing cap leakage
Thermostat Defective thermostat Replace the thermostat
Cooling system Cooling system clogged by foreign mate- Clean the foreign material from the cooling
rial system
Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing
LG4JB-WE-1111.book 8 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-8 SERVICE INFORMATION

White Exhaust Smoke

Checkpoint Possible cause Correction

Cooling water Insufficient cooling water Replace the cooling water
Fuel Water particles in the fuel Replace the fuel
Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing
Compression pressure Blown out cylinder head gasket. Worn cyl- Replace the related parts
inder liner.
Piston ring sticking
Inlet and exhaust valve Defective valve seals. Replace the valve seals, the valves, and
Valves seals Worn valves stems and valve guides the valve guides

Dark Exhaust Smoke

Checkpoint Possible cause Correction

Air cleaner Clogged air cleaner element Clean or replace the air cleaner element
Injection nozzle Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Improper spray condition
Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing
Injection pump Defective delivery valve resulting in fuel Replace the delivery valve
drippage after fuel injection
Excessive injection volume Adjust the injection volume

Oil Pressure Does Not Rise

Checkpoint Possible cause Correction

Engine oil Improper viscosity engine oil. Replace the engine oil
Insufficient engine oil Correct the engine oil volume
Oil pressure gauge or Defective oil pressure gauge or unit Repair or replace the oil pressure gauge or
unit unit
Oil pressure indicator Defective indicator light Replace the indicator light
light
Oil filter Clogged oil filter element Replace the oil filter element or the oil filter
cartridge
Relief valve and by- Relief valve sticking and/or weak by-pass Replace the relief valve and/or the by-pass
pass valve valve spring valve spring
Oil pump Clogged oil pump strainer Clean the oil pump strainer
Worn oil pump related parts Replace the oil pump related parts
Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing
Camshaft Worn camshaft and camshaft bearing Replace the camshaft and the camshaft
bearing
Crankshaft and bear- Worn crankshaft and bearings Replace the crankshaft and/or the bear-
ings ings
LG4JB-WE-1111.book 9 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-9

Abnormal Engine Noise
1. Engine Knocking
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

Checkpoint Possible cause Correction

Fuel Fuel unsuitable Replace the fuel
Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing
Injection nozzle Improper injection nozzle starting pressure Adjust or replace the injection nozzle
and spray condition
Compression pressure Blown out head gasket Replace the head gasket or the piston ring
Broken piston ring

2. Gas Leakage Noise

Checkpoint Possible cause Correction

Exhaust pipes Loosely connected exhaust pipes. Broken Tighten the exhaust pipe connections
exhaust pipes Replace the exhaust pipes
Injection nozzles and/ Loose injection nozzles and/or glow plugs Replace the washers
or glow plugs Tighten the injection nozzles and/or the
glow plugs
Exhaust manifold Loosely connected exhaust manifold and/ Tighten the exhaust manifold connections
or glow plugs
Cylinder head gasket Damaged cylinder head gasket Replace the cylinder head gasket

3. Continuous Noise

Checkpoint Possible cause Correction

Fan belt Loose fan belt Readjust the fan belt tension
Cooling fan Loose cooling fan Retighten the cooling fan
Water pump bearing Worn or damaged water pump bearing Replace the water pump bearing
Generator or vacuum Defective generator or vacuum pump Repair or replace the generator or the vac-
pump Defective generator or vacuum pump uum pump
Valve clearance Clearance improperly adjust Adjust the valve clearances

4. Slapping Noise

Checkpoint Possible cause Correction

Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Rocker arm Damaged rocker arm Replace the rocker arm
Flywheel Loose flywheel bolts Retighten the flywheel bolts
Crankshaft and thrust Worn or damaged crankshaft and/or thrust Replace the crankshaft and/or the thrust
bearings bearings bearings
Crankshaft and con- Worn or damaged crankshaft and/or con- Replace the crankshaft and/or the con-
necting rod bearings necting rod bearings necting rod bearings
Connecting rod bush- Worn or damaged connecting rod bushing Replace the connecting rod bushing and/
ing and piston pin and piston pin or the piston pin
Piston and cylinder Worn or damaged piston and cylinder Replace the piston and the cylinder liner.
liner liner.
LG4JB-WE-1111.book 10 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-10 SERVICE INFORMATION

Engine Cooling Trouble

Checkpoint Possible cause Correction

Engine overheating Low coolant level Replenish
Thermo unit faulty Replace
Faulty thermostat Replace
Faulty coolant unit Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of improper Replenish or change oil
engine oil Replenish
Damaged cylinder head gasket Replace
Clogged exhaust system Clean exhaust system or replace faulty
parts
Loose fan belt Adjust
Excessive fuel injected Adjust
Improper injection timing Adjust
Engine overcooling Faulty thermostat Replace
Too long engine warm- Faulty thermostat Replace
up time Thermo unit faulty Replace
LG4JB-WE-1111.book 11 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-11

Engine Electrical Part Trouble

N6A3628E
LG4JB-WE-1111.book 12 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-12 SERVICE INFORMATION

N6A3629E
LG4JB-WE-1111.book 13 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-13

N6A3630E
LG4JB-WE-1111.book 14 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-14 SERVICE INFORMATION

N6A0631E
LG4JB-WE-1111.book 15 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-15

N6A3632E
LG4JB-WE-1111.book 16 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-16 SERVICE INFORMATION

Turbocharger
Engine Has Less Than Normal Power

N6A3633E
LG4JB-WE-1111.book 17 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-17

N6A3634E
LG4JB-WE-1111.book 18 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-18 SERVICE INFORMATION

Blue or Black Smoke

N6A3635E
LG4JB-WE-1111.book 19 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-19

Excessive Oil Consumption

N6A3636E
LG4JB-WE-1111.book 20 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-20 SERVICE INFORMATION

Excessive Turbocharger Noise

N6A3637E
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SERVICE INFORMATION 00-21

N6A3638E
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00-22 SERVICE INFORMATION

Excessive Rotating Part Wear

N6A3639E
LG4JB-WE-1111.book 23 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-23

Lubrication Chart
4JB1, 4JB1-TC, Oil Filter & Oil Cooler

N6A3001E

Operating Pressure
Oil filter relief valve (1): 559 — 618 kPa (5.7 — 6.3 kg/cm2/81 — 90 psi)
Oil cooler safety valve (2): 314 — 373 kPa (3.2 — 3.8 kg/cm2/46 — 54 psi)
Oil filter safety valve (3): 78 — 118 kPa (0.8 — 1.2 kg/cm2/11 — 19 psi)
Oil pressure switch (4): 29.4 — 49.0 kPa (0.3 — 0.5 kg/cm2/4.3 — 7.1 psi)
The 4J Series engine lubricating system is a full flow type.
Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter (re-
placeable type oil filters have on oil cooler). It is then delivered to the vital parts of the engine from the cylinder body
oil gallery.
LG4JB-WE-1111.book 24 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-24 SERVICE INFORMATION

MAIN DATA AND SPECIFICATIONS

Main Data and Specifications

Engine model
4JB1 / 4JB1-TC
Engine type Four-cycle, overhead valve, water injection
Combustion chamber type Direct injection
Cylinder liner type Dry type, chrome plate, stainless steel tube
Timing train system Gear drive
No. of cylinders — Bore × stroke mm (in) 4 — 93 × 102 (3.66 × 4.02)
No. of piston rings Compression rings: 2 / Oil ring: 1
Total piston displacement cm3 (in3) 2,771 (169.0)
Compression ratio (to 1) 18.2 (4JB1)
18.1 (4JB1-TC)
Compression pressure kPa (kg/cm2/psi) 3,038 (31/441)
Engine weight (Dry) kg (lb) Approximately
229 (505) (4JB1)
256 (564) (4JB1-TC)
Fuel injection order 1—3—4—2

Item Fuel injection timing deg BTDC 12 (4JB1)

BTDC 4 (4JB1-TC)
Specified fuel type SAE No. 2 diesel fuel
Idling speed r/min 750 — 790
Valve clearance (AT cold) Intake: mm (in) 0.40 (0.016)
Exhaust: mm (in) 0.40 (0.016)
Valve clearance (AT hot) Intake: mm (in) 0.45 (0.018)
Exhaust: mm (in) 0.45 (0.018)
Intake valves Open at (BTDC) 24.5
deg
Close at (BTDC) 55.5
deg
Exhaust valves Open at (BTDC) 54
deg
Close at (BTDC) 26
deg
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SERVICE INFORMATION 00-25

Engine model
4JB1 / 4JB1-TC
Lubrication system
Lubrication method Pressurized circulation
Specified engine oil (API grade) CC (4JB1)
CD (4JB1-TC)
Oil pump type Gear
Oil filter type Disposable cartridge (Spin-on) Paper element
Oil capacity (Including oil filter) lit (US/UK gal) 6.6 — 7.1 (1.74 — 1.87/2.62 — 2.82)
Oil cooler type Water cooled
Fuel system
Injection pump type Bosch distributor
Item
Governor type Mechanical (Partially variable speed)
Injection nozzle type Hole
Injection nozzle opening pres- kPa (kg/cm2/psi) 18,142 (185/2,631) (4JB1)
sure 1st: 19,500 (199/2,830)
2nd: 26,500 (270/3,840) (4JB1-TC)
Main fuel filter type Cartridge paper element and water separator
Air cleaner type Dry paper element
Generator capacity V — A (W) 12 — 50 (600) and 12 — 60 (720)
Starter motor output V — kW 12 — 2.0
Turbocharger IHI RHF4 (4JB1-TC)
LG4JB-WE-1111.book 26 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-26 SERVICE INFORMATION

Engine Cooling

Cooling system Coolant forced circulation

Radiator (2 tube in row) Tube type Corrugated
Heat radiation capacity kcal/h 71400
Heat radiation area m2 (ft2) 11.78 (126.8)
Front area m2 (ft2) 0.216 (2.325)
Dry weight N (kg/lb) 105 (10.7/23.6)
Radiator cap
Valve opening pressure kPa (kg/cm2/psi) 88.2 — 116. 7 (0.899 — 1.199/12.78 — 17.05)
Coolant capacity lit (lmp.qt./US qt.) 3.1 (2.73/3.28)
Coolant pump
Pulley type Centrifugal impeller type
Pulley ratio 1.2
Thermostat type Wax pellet with jiggle valve.
Valve opening °C (°F) 82 (180)
Valve full open °C (°F) 95 (203)
Coolant total capacity lit (lmp.qt./US qt.) 10 (8.80/10.57)

Starting System

Manufacturer DENSO
Engine model 4JB1 / 4JB1-TC
Rating
Voltage V 12
Output kW 2.0
Time Sec. 30
Number of tooth of pinion 9
Rotating direction (as viewed from pinion) Clockwise
Weight (approx.) kg 4.6
No-load characteristics
Voltage / current V/A 11.5/100 or less
Speed r/min 3700 or more
Load characteristics
Voltage / current V/A 7.5/500 or less
Torque N⋅m (kg⋅m/lb⋅ft) 13.7 (1.4/10.1)
Speed r/min 1200 or more
Locking characteristics
Voltage / current V/A 2.4/800 or less
Torque N⋅m (kg⋅m/lb⋅ft) 18 (1.8/13 or more)
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SERVICE INFORMATION 00-27

Charging system

Manufacturer HITACHI LR150-449F HITACHI LR160-447F

Rated voltage V 12 12
Rated out put A 50 60
Rotating direction (As viewed from pulley) Clockwise Clockwise
Pulley effective diameter mm (in) 80 (3.15) 82 (3.23)
Weight (with pump) kg (lb) 5.8 (13.27) 6.1 (13.45)
LG4JB-WE-1111.book 28 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-28 SERVICE INFORMATION

SERVICE STANDARD
Engine Mechanical

mm (in)
Service standard Service limit
Parts Item Remarks
4JB1 / 4JB1-TC 4JB1 / 4JB1-TC
Cylinder Cylinder head deck, and Cannot be
Head exhaust manifold mating sur- 0.05 (0.002) or less 0.2 (0.0079) Reground
face for flatness
Cylinder head height 92.0 (3.622) 91.55 (3.6043)
Cylinder Head Lower Face
0.05 (0.002) or less 0.20 (0.008)
Warpage.
Manifold Warpage. 0.05 (0.002) or less 0.20 (0.008)
Hot plug sinking — 0.02 (0.0008)
Hot plug exert pressure 4,500 — 5,500 kg
—
(9922.5 — 12127.5 lbs)
Valve Free height 48.0 (1.891) 47.10 (1.856)
Spring
Squareness — 1.7 (0.067)
Spring tension N (kg/lb) At installed
296 (30.2/66.4) 257.9 (26.3/57.9) height 38.9
(1.531)
Valve Diameter Valve IN 7.946 — 7.961
7.880 (0.3102)
and Stem (0.3128 — 0.3134)
Valve
EX 7.921 — 7.936
Guide 7.850 (0.3090)
(0.3118 — 0.3124)
Valve and valve IN 0.039 — 0.069
0.200 (0.0079)
guide clearance (0.0015 — 0.0027)
EX 0.064 — 0.096
0.250 (0.0098)
(0.0025 — 0.0038)
Valve guide upper end height
(Measured from the Cylinder 13.0 (0.512) —
head upper face)
Valve guide margin 1.1 (0.0433) 1.6 (0.0630)
Valve thickness IN 1.79 (0.0705) 1.5 (0.06)
EX 1.83 (0.0720) 1.5 (0.06)
Valve seat contact surface
45°
angle
Valve seat contact IN 1.7 (0.0669) 2.2 (0.0866)
width
EX 2.0 (0.0787) 2.5 (0.0984)
Push rod Curvature — 0.4 (0.0157) or less
LG4JB-WE-1111.book 29 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-29

mm (in)
Service standard Service limit
Parts Item Remarks
4JB1 / 4JB1-TC 4JB1 / 4JB1-TC
Cam- End play 0.08 (0.0031) 0.2 (0.0079)
shaft
Cam lobe height 42.02 (1.6543) 41.65 (1.6397)
Journal diameter 49.945 — 49.975
49.60 (1.9527)
(1.9663 — 1.9675)
Runout 0.02 (0.0008) or less 0.10 (0.0039)
Camshaft bearing inside diame- 50.000 — 50.030
50.08(1.9716)
ter (1.9685 — 1.9697)
Camshaft oil clearance 0.025 — 0.085
0.12 (0.0047)
(0.0098 — 0.00334)
Tappet Outside diameter 12.97 — 12.99
12.95 (0.5098)
(0.5106 — 0.5114)
Oil clearance (Between tappet
0.03 (0.0118) 0.10 (0.0039)
and cylinder body)
Rocker Rocker shaft outside diameter 18.98 — 19.00
18.90 (0.7440)
arm (0.7472 — 0.7480)
Assem-
Rocker arm inside diameter 19.036 — 19.060
bly 19.10 (0.7520)
(0.7494 — 0.7504)
Oil clearance (Between rocker 0.06 — 0.08
0.10 (0.004)
arm and rocker shaft) (0.00235 — 0.00315)
Rocker shaft runout — 0.2 (0.0079) or less
Oil pump Oil clearance Body and gear 0.14 (0.0055) 0.15 (0.0059)
Body cover and gear 0.06 (0.0024) 0.15 (0.0059)
Crank- Thrust clearance 0.10 (0.0039) 0.30 (0.018)
shaft
Main bearing clearance
0.035 — 0.080
(Between main bearing and 0.11 (0.0043)
(0.0014 — 0.0032)
Crankshaft)
Crankshaft runout 0.05 (0.00197) or less 0.08 (0.0031)
Main journal diameter 69.917 — 69.932
69.91 (2.7524)
(2.7526 — 2.7532)
Crankshaft pin diameter 52.915 — 52.930
52.90 (2.0827)
(2.0833 — 2.0839)
Crankshaft Journal and Crank
0.05 (0.002) or less 0.08 (0.003)
Pin uneven wear
Crank Pin and Bearing Clear- 0.029 — 0.066
0.100 (0.0039)
ance. (0.0011 — 0.0026)
LG4JB-WE-1111.book 30 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-30 SERVICE INFORMATION

mm (in)
Service standard Service limit
Parts Item Remarks
4JB1 / 4JB1-TC 4JB1 / 4JB1-TC
Piston, Piston diameter 92.985 — 93.024
—
Piston (3.6600 — 3.6623)
pin, Pis-
Piston Clearance (Between pis- 0.025 — 0.045
ton ring —
ton and Cylinder liner) (0.0010 — 0.0018)
and Con-
necting Piston ring gap 1st 0.20 — 0.40
1.5 (0.0591)
rod (0.0079 — 0.0157)
2nd 0.20 — 0.40
1.5 (0.0591)
(0.0079 — 0.00157)
Oil 0.10 — 0.30
1.5 (0.0591)
(0.0039 — 0.0118)
Piston ring clear- 1st 0.090 — 0.125
ance (0.0035 — 0.0049)
2nd 0.050 — 0.075
0.15 (0.0059)
(0.0020 — 0.0030)
Oil 0.03 — 0.07
0.15 (0.0059)
(0.0012 — 0.0028)
Piston pin diameter 30.995 — 31.000
30.970 (1.2190)
(1.2202 — 1.2204)
Fitting interference (Between 0.008 — 0.020
0.05 (0.0020)
connecting rod and piston pin) (0.0003 — 0.0008)
Fitting interference (Between 0.002 — 0.015
0.04 (0.0016)
piston and piston pin) (0.0001 — 0.0006)
Piston, Connecting rod Bend 0.08 (0.0031) or less 0.20 (0.0079) Per 100 (3.94)
Piston alignment
Twist 0.05 (0.0020) or less 0.15 (0.0059) Per 100 (3.94)
pin, Pis-
ton ring Piston pin and Connecting Rod 0.008 — 0.020
0.050 (0.0020)
and Con- Bushing Clearance (0.0003 — 0.0008)
necting Connecting rod thrust clearance 0.230 (0.0091) 0.35 (0.0138)
rod
Oil clearance (Between crank 0.029 — 0.066
0.100 (0.0039)
pin and Connecting rod) (0.0011 — 0.0026)
Cylinder Warpage (Upper surface of the
— 0.20 (0.0079)
Block cylinder block)
Cylinder bore diameter 95.011 — 95.040
(3.7406 — 3.7417)
Cylinder liner projection 0.0 — 0.1
(0.00 — 0.0039)
Cylinder liner inside diameter 93.020 — 93.060
(3.6622 — 3.6638)
Cylinder liner outside diameter 95.011 — 95.050
(3.7405 — 3.7421)
LG4JB-WE-1111.book 31 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-31

SERVICING
Servicing refers to general maintenance procedures to
be performed by qualified service personnel.

Model Identification
Engine Serial Number
The engine number is stamped on the front left hand
side of the cylinder body.

N6A0009E

Caution:
Do not bang the element against another object in an at-
tempt to clean it. Damage to the element will result.

Carbon and Dust Fouled Element

N6A3002E 1. Prepare a cleaning solution of Isuzu Genuine Ele-
ment Cleaner (Donaldson D1400) diluted with wa-
Air Cleaner ter.
Dry Type Paper Element 2. Submerge the element in the solution for twenty
Element cleaning procedures will vary according to the minutes.
condition of the element.

Dust Fouled Element

Rotate the element with your hand while applying com-
pressed air to the inside of the element. This will blow
the dust free.

Compressed air pressure kPa (kg/cm2/psi)

392 — 490 (4 — 5/57 — 71)

N6A0010E

3. Remove the element from the solution and rinse it

well with running water.
Water pressure must not exceed 274 kPa (2.8 kg/
cm2/40 psi)
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00-32 SERVICE INFORMATION

5. Use the filter wrench to turn in the filter an addition-
al 1 and 1/4 turns.
Oil Filter Wrench:
5-8840-0200-0 (89mm/3.5in)
5-8840 0202-0 (106mm/4.2in)
5-8840-2209-0 (100.6mm/4.0in)

N6A0011E

4. Dry the element in a well ventilated area.

An electric fan will hasten drying.

N6A3007E

6. Check the engine oil level and replenish to the

specified level if required.

Replenishment Engine Oil lit (Imp qt/US qt)

0.7 (0.62/0.74)

N6A0012E

Notice:
Do not use compressed air or an open flame to dry the
element quickly. Damage to the element will result. It will
usually take two or three days for the element to dry
completely. Therefore, it is a good idea to have a spare
on hand to use in the interim.

Lubricating System
Main Oil Filter (Cartridge Type Paper Element) N6A3008E

Replacement Procedure
7. Start the engine and check for oil leakage from the
1. Loosen the used oil filter by turning it counterclock- main oil filter.
wise with the filter wrench.
2. Clean the oil filter fitting face. Fuel System
This will allow the new oil filter to seat properly.
Fuel Filter Replacement Procedure
3. Apply a light coat of engine oil to the O-ring.
1. Loosen the used fuel filter by turning it counter-
4. Turn in the new oil filter until the filter O-ring is fitted
clockwise with the filter wrench.
against the sealing face.
Oil Filter Wrench: 5-8840-0253-0 (J-22700)
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SERVICE INFORMATION 00-33

N6A3009E N6A3011E

2. Clean the filter cover fitting faces. 4. Turn in the fuel filter an additional 2/3 of a turn with
This will allow the new fuel filter to seat properly. a filter wrench.
Fuel Filter Wrench: 5-8840-0253-0 (J-22700)
5. Loosen the bleeder plug on the injection pump
overflow valve.

N6A3010E

3. Turn in the fuel filter until the sealing face comes in

contact. N6A3012E

6. Operate the priming pump until fuel begins to flow

from the fuel filter.
7. Retighten the bleeder plug.
8. Operate the priming pump several times and check
for fuel leakage.
Notice:
The use of an ISUZU genuine fuel filter is strongly rec-
ommended.

Fuel Filter Water Draining Procedure

The indicator light will come on when the water level in
the water separator exceeds the specified level.
Drain the water and foreign material from the water sep-
arator with the following procedure.
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00-34 SERVICE INFORMATION

Air Bleeding
1. Loosen the bleeding plug on the injection pump
overflow valve.
2. Operate the priming pump until fuel mixed with
foam flows from the bleeding plug.
3. Tighten the bleeding plug.
4. Operate the priming pump several times and check
for fuel leakage.

N6A3013E

1. Find a safe place to park the vehicle.

2. Open the engine hood and place a container (Ap-
proximately 0.2 liter capacity) at the end of the vinyl
hose beneath the drain plug on the separator.
3. Loosen the drain plug by turning it counterclock-
wise (Approximately 5 turns) and operate the prim-
ing pump up and down about 10 times until water
is drained approximately 0.1 liter. N6A3012E

Cooling System
Engine coolant level detection
• Inspect the coolant level in the reserve tank. If the
level is within its maximum (upper limit) and mini-
mum (lower limit), (the amount is appropriate. In
addition, open the radiator cap and check if the
coolant is filled up to the radiator filler. Coolant lev-
el should be checked only after the engine has
cooled down). Note that if there is insufficient cool-
ant, remove the reserve tank cap and pour in a
mixture of tap water and engine coolant at the ap-
propriate proportion and fill the tank to the MAX
line.

Reference Value
Replacement
N6A3012E Every 2 years
Period
4. After draining, securely tighten the drain plug by
turning it clockwise and operate the priming pump
manually up and down several times.
5. After starting the engine, check to see that there is
no fuel leak from the drain plug. Also check to see
that the fuel filter water indicator light has turned
off.
If water separator requires frequent draining, have
the fuel tank drained for removal of water at your
Isuzu Dealer.
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SERVICE INFORMATION 00-35

• Never use the coolant which contains borate or sil-
icate. The engine, radiator or heater core may cor-
rode, causing a water leakage.
2. Measurements of engine coolant concentration
Hydrometry
• Use an antifreeze hydrometer to measure the
specific gravity and coolant temperature. If you
remove the cap when the engine is hot, be
careful because the coolant will burst out.
• Use a container that is deeper than the length
of the hydrometer.

1
N6A3390E

Legend
1. Reserve tank 2

Coolant concentration inspection

1. Engine coolant concentration
• The concentration of the engine coolant affects its
freezing temperature. Therefore, the concentration
should be set to the lowest temperature.
• Use genuine Isuzu engine coolant.
LNW46BSH001001
• If the mixing ratio of the engine coolant is higher
than 60%, it overheats easily. If it is less than 30%,
it will not be sufficient to prevent corrosion. Legend
1. Density gauge
• When diluting the coolant, use the distilled or
deionized water. 2. Radiator
• When it is used at the temperature of -30°C (-22° • The temperature of the coolant should be with-
F) or below, make the concentration to 55%. in 0°C - 50°C (32°F - 122°F) for measurement.
Coolant • After measuring the temperature and relative
Region where used density, find the concentration from the table
Concentration
below.
General regions, regions where the
lowest temperature is -12°C (10.4°F) 30%
or above 1.100
Cold regions, regions where the 1.090
lowest temperature is -30°C (-22°F) 50% 1.080
or above 50%
1.070
SPECIFIC GRAVITY

Regions where the lowest

temperature is -30°C (-22°F) or 55%
1.060
below 1.050 30%
1.040
Caution: 1.030
• For the coolant, make sure to use the products 1.020
specified (recommended) by Isuzu. 1.010
• If the coolant specified (recommended) by Isuzu is 1.000
not used, the engine, radiator or heater core may
be damaged. 0 10 20 30 40 50 60 70
TEMPERATURE
MFW91CSH001001
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00-36 SERVICE INFORMATION

Coolant Scope Method
• Measure the concentration using a coolant scope.

Engine Coolant Change Procedure

1. Check that the engine is cool.
2. Open the radiator cap.
3. Loosen the air removal plug (2) of the water outlet
pipe.
4. Pour coolant up to the filler neck.
5. After filling, press the radiator upper hose two or
three times. Then, if the level has dropped because
the air in the hose has been removed, add the
equivalent amount of coolant.
6. Pour coolant up to the "MAX" line of the reserve
tank.
7. Tighten the air removal plug of the water outlet
pipe. N6A3016E
8. Close the radiator cap and start the engine. Let the
engine idle for two to three minutes then stop it. Radiator Cap Inspection
Open the radiator cap again and pour in more cool- The radiator filler cap is designed to maintain coolant
ant if the level has dropped. pressure in the cooling system at 1.05 kg/cm2 (15 psi /
103 kPa). Check the radiator filler cap with a radiator fill-
WARNING:
Warning: er cap tester. The radiator filler cap must be replaced if
Do not loosen or remove the radiator cap when the
it fails to hold the specified pressure during the test pro-
coolant is hot. Steam and boiling water can burst
cedure.
out from the radiator possibly causing burns or heat
Radiator Filler Cap Pressure
related injuries. When opening the radiator cap,
place a thick cloth over the cap when the coolant is Pressure Valve kPa (kg/cm2/psi)
cooled, and turn it gradually to release the pressure
before opening it. 88 — 118 (0.9 — 1.2/12.8 — 17.1)
9. After securely tightening the radiator cap, warm up
the engine at approximately 2,000 r/min. Negative Valve (Reference) kPa (kg/cm2/psi)
10. When verified that the thermostat has opened after
1.0 — 13.9 (0.01 — 0.04/0.14 — 0.57)
the water temperature gauge indicator has passed
the center, idle the engine for about five more min-
utes, then stop the engine and let the vehicle
stand.
11. After the engine has adequately cooled, check the
level again at the filler neck and add more if neces-
sary. If the coolant is excessively low, check the
coolant path and reserve tank hose for leaks.
12. Pour coolant up to the "MAX" line of the reserve
tank again.

Cooling System Inspection

Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for leak-
age.
The testing pressure must not exceed the specified
pressure.

Testing Pressure kPa (Kg/cm2/psi)

N6A3017E
147 (1.5/21)
Thermostat Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
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SERVICE INFORMATION 00-37

Stir the water constantly by suitable wood bar (1) to
avoid direct heat being applied use wood plate (2) Belt Deflection mm (in)
to the thermostat. 8 — 12 (0.32 — 0.47)
3. Check the thermostat initial opening temperature.

Thermostat Initial Opening °C (°F)

Temperature
2 3
82 (180)
1
4. Check the thermostat full opening temperature. 4

Thermostat Full Opening °C (°F) 5

Temperature
95 (203)

Valve Lift at Fully Open mm (in)

Position
10 (0.39)
7
6

LNWB1BSH023401

Legend
1. AC generator
2. AC generator & fan pulley drive belt
3. Fan pulley
4. P/S oil pump drive belt (with P/S oil pump type
only)
5. P/S oil pump pulley
6. Idle pulley
7. Crank pulley

Engine Control
Idling Speed Inspection
N6A3018E 1. Set the vehicle parking brake and choke the drive
wheels.
Drive Belt Adjustment 2. Place the transmission in neutral.
Depress the drive belt mid portion with a 98 N (10 kg / 3. Start the engine and allow it to warm up.
22 lb) force.
4. Disconnect the engine control cable from the con-
Drive Belt Deflection mm (in) trol lever.
5. Set a tachometer to the engine.
8 — 12 (0.32 — 0.47)
6. Check the engine idling speed.
Check the drive belt for cracking and other damage. If the engine idling speed is outside the specified
range, it must be adjusted.
AC Generator & Fan Pulley Drive Belt
Fan belt tension is adjusted by moving the generator. Engine Idling Speed rpm
Depress the drive belt mid portion with a 98 N (10 kg / 4JB1 / 4JB1-TC 750 — 790
22 lb) force.
P/S oil pump drive belt is adjusted by moving the idle Idling Speed Adjustment
pulley. 1. Loosen the idling set bolt lock nut on the injection
Depress the drive belt mid portion with a 98 N (10 kg / pump idling set bolt.
22 lb) force.
2. Adjust the idling speed to the specified range by
turning the idling set bolt.
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00-38 SERVICE INFORMATION

3. Lock the idling set bolt with the idling set bolt lock 3. Check to see if the accelerator pedal play is in the
nut. range of 5 to 10mm above the pedal pad.
4. Check that the idling control cable is tight (free of 4. Press down on the accelerator pedal fully and
slack). check to see if the engine rotates at its maximum
If required, remove the slack from the cable. speed with each of the linkage in the smooth oper-
ation.
5. In the operating range of accelerator pedal and the
injection pump lever returns to their respective
original positions without fail.
RHD
1. Hold the accelerator pedal pad securely by hand,
and give it a full stroke.
2. Adjust the stopper bolt so that the clearance be-
tween the pad stopper bolt and the rear side of the
pad becomes the specified length.

mm (in)
0 — 2 (0 — 0.079)

N6A3779E

Accelerator Control Cable Adjustment

1. Loosen the accelerator cable clamp bolt.
2. Check that the idling control knob on the instru-
ment panel is in the engine idling position.
3. Hold the accelerator lever in the fully closed posi-
tion and stretch the control cable in the direction in-
dicated by the arrow to remove any slack.

Accelerator Pedal Adjustment

LHD
1. Loosen the lock nut.
2. Adjust bolt height from floor.
N6A3025E

Adjust Bolt Height (A) mm (in)

3. Check to see if the accelerator pedal play is in the
18 — 28 (0.71 — 1.1) range of 5 to 10mm above the pedal pad.
4. Press down on the accelerator pedal fully and
check to see if the engine rotates at its maximum
speed with each of the linkage in the smooth oper-
ation.
5. In the operating range of accelerator pedal and the
injection pump lever returns to their respective
original positions without fail.

Valve Clearance Adjustment

1. Bring the piston in either the No. 1 cylinder or the
No. 4 cylinder to TDC on the compression stroke
by turning the crankshaft until the crankshaft
damper pulley TDC line is aligned with the timing
pointer.

N6A3024E
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SERVICE INFORMATION 00-39

N6A3026E N6A3028E

2. Check the rocker arm shaft bracket nuts for loose- Adjust the No. 1 or the No. 4 cylinder valve clear-
ness. ance while their respective cylinders are at TDC on
Tighten any loose rocker arm shaft bracket nuts the compression stroke.
before adjusting the valve clearance.
Valve Clearance (At Cold) mm (in)
Tighten:
• Rocker arm shaft bracket nut to 54 N⋅m (5.5 kg⋅m / 40 0.4 (0.016)
lb⋅ft)
4. Loosen each valve clearance adjusting screw as
shown in the illustration.
• No.1 Cylinder T.D.C. (Compression stroke)

N6A3027E

3. Check for play in the No. 1 intake and exhaust

valve push rods. N6A3029E
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the 5. Insert a feeler gauge of the appropriate thickness
compression stroke. between the rocker arm and the valve stem end.
If the No. 1 cylinder intake and exhaust valve push 6. Turn the valve clearance adjusting screw until a
rods are depressed, the No. 4 piston is at TDC on slight drag can be felt on the feeler gauge.
the compression stroke. 7. Tighten the lock nut securely.
8. Rotate the crankshaft 360°.
9. Realign the crankshaft damper pulley TDC
notched line with the timing pointer.
10. Adjust the clearance for the remaining valves as
shown in the illustration.
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00-40 SERVICE INFORMATION

• No.4 Cylinder T.D.C. (Compression stroke)

N6A3032E

N6A3030E
Notice:
Injection Timing Adjustment Check for play in the No. 1 intake and exhaust valve
1. Check that the notched line on the injection pump push rods.
flange is aligned with the front plate or the timing If the No. 1 cylinder intake and exhaust valve push rods
gear case notched line. have play, the No. 1 piston is at TDC on the compres-
sion stroke.
3. Disconnect the injection pipe from the injection
pump.
4. Remove one bolt from the distributor head.
5. Turn the lever portion of Wax CSD attached to the
injection pump to create a gap with the moving part
of Wax CSD, and fix the lever by inserting the ob-
ject of 11mm (0.43in.) in between.

N6A3031E

2. Bring the piston in the No. (1) cylinder to TDC 1 on

the compression stroke by turning the crankshaft
until the crankshaft pulley TDC line is aligned with
the timing mark (2).
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SERVICE INFORMATION 00-41

N6A3034E

10. Turn the crankshaft clockwise and read the gauge

Legend indication when the crankshaft pulley timing mark
1. Wax CSD is aligned with the pointer.
2. Injection pump
3. Adjust bolt 4JB1 BTDC 14°
4. Object 4JB1-TC BTDC 4°
5. 11mm (0.43 in)
6. φ10mm (0.39 in)
7. Wax CSD Moving parts Standard Reading mm (in)
0.5 (0.02)
6. Install the static timing gauge (1).
The probe of the gauge should be depressed in-
ward approximately 2 mm (0.079 in).
Static Timing Gauge: 5-8840-0145-0 (J-28827) (1)
• Use adapter for the 4JB1-TC.
Timing Gauge Adapter: 5-8840-2834-0 (2)

N6A3035E

If the injection timing is outside the specified range,

continue with the following steps.
11. Loosen the injection pump fixing nuts and bracket
bolts.
12. Adjust the injection pump setting angle.
7. Rotate the crankshaft to bring the piston in the No.
When large than When smaller than
1 cylinder to a point 30 — 40° BTDC.
standard value standard value
8. Set the timing gauge needle to zero.
9. Move the crankshaft pulley slightly in both direc- Gear drive A B
tions to check that the gauge indication is stable.
LG4JB-WE-1111.book 42 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-42 SERVICE INFORMATION

A: Move the injection pump toward the engine.
B: Move the injection pump away from the engine.
Tighten the pump fixing nut, adjust bolt and pump
distributor head plug to the specified torque.

Tighten:
• Pump fixing bolt to 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
• Adjust bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Injection pump distributor head plug to 17 N⋅m (1.7
kg⋅m / 12 lb⋅ft)

N6A3037E

4. Turn the engine over with the starter motor and

take the compression gauge reading.

Compression Pressure at 200 rpm kPa (kg/cm2/psi)

Standard Limit
3,038 (31/441) 2,157 (22/313)

N6A3036E

Legend
A. To advance
B. To retard

Caution:
When installing the distributor head/plug, be sure to use
new copper washer.

Compression Pressure Measure-ment

1. Start the engine and allow it to idle until the coolant
temperature reaches 70 — 80°C (158 — 176°F).
2. Remove the following parts.
• Glow plugs
N6A3038E
• Fuel cut solenoid connector
• QOS (Quick-On Start System) fusible link wire at 5. Repeat the procedure (Steps 3 and 4) for the re-
the connector. maining cylinders.
3. Set the adapter and compression gauge to the No. If the measured value is less than the specified lim-
1 cylinder glow plug hole. it, refer to “Troubleshooting” in this Manual.
Compression Gauge
(with Adapter): 5-8840-2008-0 (J-29762)
Adapter: 5-8531-7001-0
LG4JB-WE-1111.book 43 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-43

Quick-On Start II System
Quick-On Start System Inspection Procedure
1. Disconnect the thermo-sensor connection on the
thermostat outlet pipe.

N6A3039E

2. Turn the starter switch to the “ON” position.

If the Quick-On Start II System is operating proper-
ly, the glow relay will make a clicking sound within
15 seconds after the starter switch is turned on.
3. Measure the glow plug terminal voltage with a cir-
cuit tester immediately after turning the starter
switch to the “ON” position.

Glow Plug Terminal Voltage V

Approx. 11

N6A3040E
LG4JB-WE-1111.book 44 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-44 SERVICE INFORMATION

FIXING TORQUE
Cylinder Head Cover, Cylinder Head, Rocker Arm Shaft

N6A3042E
LG4JB-WE-1111.book 45 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-45

Crankshaft, Bearing Cap, Connecting Rod Cap, Crankshaft Damper Pulley, Flywheel, Oil
Pan

LNWB1BLF006601
LG4JB-WE-1111.book 46 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-46 SERVICE INFORMATION

Timing Pulley Housing, Timing Pulley, Timing Gear, Camshaft Oil Seal Retainer

N6A3044E
LG4JB-WE-1111.book 47 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-47

Cooling System and Lubrication System

N6A3045E
LG4JB-WE-1111.book 48 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-48 SERVICE INFORMATION

Intake Manifold, Exhaust Manifold, Exhaust Pipe

N6A3046E
LG4JB-WE-1111.book 49 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-49

N6A3047E
LG4JB-WE-1111.book 50 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-50 SERVICE INFORMATION

Engine Electricals

N6A3048E
LG4JB-WE-1111.book 51 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-51

Engine Fuel

4JB1

4JB1-TC

LNWB1BLF006701
LG4JB-WE-1111.book 52 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-52 SERVICE INFORMATION

Engine Mounting Bracket

N6A3051E
LG4JB-WE-1111.book 53 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-53

SPECIAL TOOLS
Tool Number /
Tool Number / Illustration
Illustration Description / Remarks
Description / Remarks

5-8840-0200-0 / Oil Filter 5-8840-2093-0 / Tacho

Wrench (89.0 mm/3.5 in) Meter

5884020930
5884002000

5-8840-0202-0 / Oil Filter 9-8523-1212-0 / Valve

Wrench (106.0 mm/4.2 Guide Replacer
in)

9852312120
5884002020

5-8840-2209-0 / Oil Filter 5-8840-0199-0 / Rubber

Wrench (100.6 mm/4.0 Hardness Tester
in)

5884001990
5884022090

9-8523-1423-0 (J-29760) 5-8840-2675-0 / Com-

/ Valve Spring Compres- pression gauge
sor

5884026750
9852314230

5-8531-7001-0 / Gauge
5-8840-2033-0 / Oil Seal
Adapter
Installer

5853170010
5884020330

5-8840-9018-0 / Piston 5-8531-7002-0 / Gauge

Ring Compressor Adapter

5853170020
5884090180
LG4JB-WE-1111.book 54 ページ ２０１１年７月２７日　水曜日　午後６時１４分

00-54 SERVICE INFORMATION

Tool Number / Tool Number /

Illustration Illustration
Description / Remarks Description / Remarks

5-8840-0145-0 / Measur- 5-8840-2360-0 / Rear Oil

ing Device Seal Remover

5884001450 5884023600

5-8840-0266-0 / Angle 5-8840-2359-0 / Rear Oil

Gauge Seal Installer

5884002660 5884023590

5-8840-9016-0 / Injec- 5-8840-2040-0 / Cylin-

tion Nozzle Tester der Liner Installer

5884090160 5884020400

5-8840-2034-0 / Nozzle 5-8840-2039-0 / Cylin-

Holder Remover der Liner Remover

5884020340 5884020390

5-8840-2038-0 / Cam- 5-8840-2000-0 / Pilot

shaft Bearing Replacer Bearing Remover

5884020380 5884020000

Base 5-86739-149-0 /
5-8840-0019-0 / Sliding
Lever 5-86739-150-0 /
Hammer
Scissor gear setting tool

5867391490 5884000190

5-8840-0253-0 / (J-
5-8522-0024-0 / Pilot
22700) Fuel Filter
Bearing Installer
Wrench

5884002530 5852200240
LG4JB-WE-1111.book 55 ページ ２０１１年７月２７日　水曜日　午後６時１４分

SERVICE INFORMATION 00-55

Tool Number /
Illustration
Description / Remarks

5-8840-2834-0 / Static
Timing Gauge Adapter
Set
LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

MEMO
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LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-1

ENGINE
SECTION 6A
GENERAL ENGINE MECHANICAL
Contents
CYLINDER HEAD ................................................. 6A-2
Component ........................................................ 6A-2
Disassembly ...................................................... 6A-2
Clean ................................................................. 6A-3
Inspection and Repair........................................ 6A-3
Reassembly....................................................... 6A-4
VALVE SPRING, VALVE GUIDE OIL SEAL,
VALVE GUIDE, PUSH ROD ................................. 6A-7
Component ........................................................ 6A-7
Disassembly ...................................................... 6A-7
Inspection and Repair........................................ 6A-8
Reassembly..................................................... 6A-12
CAMSHAFT, TAPPET ........................................ 6A-14
Component ...................................................... 6A-14
Disassembly .................................................... 6A-14
Inspection and Repair...................................... 6A-15
Reassembly..................................................... 6A-17
ROCKER ARM ASSEMBLY ............................... 6A-21
Component ...................................................... 6A-21
Disassembly .................................................... 6A-21
Inspection and Repair...................................... 6A-21
Reassembly..................................................... 6A-23
OIL PUMP ........................................................... 6A-24
Component ...................................................... 6A-24
Removal .......................................................... 6A-24
Installation ....................................................... 6A-25
CRANKSHAFT.................................................... 6A-26
Component ...................................................... 6A-26
Disassembly .................................................... 6A-26
Inspection and Repair...................................... 6A-27
Reassembly..................................................... 6A-30
PISTON AND CONNECTING ROD .................... 6A-37
Component ...................................................... 6A-37
Disassembly .................................................... 6A-37
Inspection and Repair...................................... 6A-38
Reassembly..................................................... 6A-42
CYLINDER BLOCK............................................. 6A-45
Component ...................................................... 6A-45
Disassembly .................................................... 6A-45
Inspection and Repair...................................... 6A-46
Reassembly..................................................... 6A-49
LG4JB-WE-1111.book 2 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-2 GENERAL ENGINE MECHANICAL

CYLINDER HEAD
Component

5
1

LNWB6AMF000601

Legend
1. Thermostat housing assembly 4. Rocker arm shaft and rocker arm
2. Injection nozzle holder 5. Push rod
3. Glow plug and plug connector 6. Cylinder head

Notice:
• During disassembly, be sure that the valve train
components are kept together and identified so
that they can be re-installed in their original loca-
tions.
• Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
make a compression test and note the results.

Disassembly
1. Thermostat Housing Assembly
2. Injection Nozzle Holder
1) Remove the nozzle holder bracket nuts.

N6A3437E
LG4JB-WE-1111.book 3 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-3

2) Use the nozzle holder remover and the sliding Carefully remove all varnish, soot and carbon to
hammer to remove the nozzle holder together the bare metal. Do not use a motorized wire brush
with the holder bracket. on any gasket sealing surface.
Nozzle Holder Remover: 5-8840-2034-0
Sliding Hammer: 5-8840-0019-0 Inspection and Repair
Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
• Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause;
– Improper installation
– Loose or warped cylinder head
– Insufficient torque on head bolts
– Warped case surface
1. Cylinder head bolts for damaged threads or
stretching and damaged heads caused by improp-
er use of tools.
Caution:
Suspected bolts must be replaced.
2. Cylinder head for cracks, especially between valve
N6A3054E
seats and in the exhaust ports.
3. Glow Plug and Glow Plug Connector 3. Cylinder head deck for corrosion, sand particles in
4. Rocker Arm Shaft and Rocker Arm head and porosity.
5. Push Rod Caution:
6. Cylinder Head Do not attempt to weld the cylinder head. Replace it.
• Loosen the cylinder head bolts a little at a time 4. Cylinder head deck, intake and exhaust manifold
in the numerical order shown in the illustration. mating surfaces for flatness.
These surfaces may be re-conditioned by milling
(except cylinder head lower face). If the surfaces
are “out of flat” by more than specification, the sur-
face should be ground to within specifications. If
more than limit of specification, it should be re-
placed.

N6A3055E

Notice:
Failure to loosen the cylinder head bolts a little at a time
in numerical order will adversely effect the cylinder head
lower surface.
N6A3056E
Clean
• Cylinder head bolts Notice:
• Cylinder head The cylinder head lower face cannot be reground.
LG4JB-WE-1111.book 4 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-4 GENERAL ENGINE MECHANICAL

mm (in)
Standard Limit
Standard Limit
0.05 (0.002) or
Cylinder Head 0.20 (0.0079)
less
Lower Face
Cylinder Head
92 (3.622) 91.55 (3.6043)
Height

5. Water jacket sealing plugs seating surfaces.

6. Use a straight edge and a feeler gauge to measure
the manifold cylinder head lifting face warpage.
Regrind the exhaust manifold cylinder head lifting
surfaces if the measured values are between the
specified limit and the standard.
If the measured values exceed the specified limit,
the manifold must be replaced. N6A3086E

Exhaust Manifold Warpage mm (in)

Notice:
Standard Limit Do not apply an excessive amount of pressure with the
0.05 (0.002) or less 0.20 (0.0079) bench press. Damage to the valve seat will result.
Measure the height of the valve guide upper end from
the upper face of the cylinder head.

Valve Guide Upper End Height (H) (Reference)

mm (in)
13 (0.51)

N6A3057E

Reassembly
Cylinder Head
1. Valve Seat Insert Installation
1) Carefully place the attachment (1) (having a
smaller outside diameter than the valve seat in- N6A3067E

sert) on the valve seat insert (2).

Notice:
Notice:
If the valve guide has been removed, both the valve and
The smooth side of the attachment must contact the
the valve guide must be replaced as a set.
valve seat insert.
3) Spring lower seat
2) Use the bench press (3) to gradually apply
pressure to the attachment and press the valve 4) Valve stem oil seal
seat insert into place. • Install a new oil controller in the valve.
• Guide using special tool
Oil seal installer: 5-8840-2003-0
LG4JB-WE-1111.book 5 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-5

• Set the split collar by tapping lightly around
the head of the collar with a rubber hammer.
Valve spring compressor: 9-8523-1423-0 (J-
29760)

N6A3068E

5) Valve
• Apply engine oil to the outside of the valve
stem before installing it. N6A3070E
6) Valve Spring
• Attach the valve spring to the upper spring 2. Push Rod
seat. 3. Rocker Arm Shaft and Rocker Arm

Caution: Tighten:
• The painted area of the valve spring should be fac- • Rocker arm shaft fixing bolts to 54 N⋅m (5.5 kg⋅m/40
ing downward. lb⋅ft)
• Apply compressed air to cylinder from the 4. Glow Plug and Glow Plug Connector
glow plug hole to hold the valve in place. Tighten:
• Install split collar by special tool. Glow plugs to 23 N⋅m (2.3 kg⋅m/17 lb⋅ft)
Valve spring compressor: 9-8523-1423-0 (J-
5. Injection Nozzle Holder (4JB1/4JB1-TC only)
29760)
1) Install the injection nozzle gasket (1) and the O-
ring (2) to the injection nozzle holder (3).
Be sure that the O-ring fits snugly in the injec-
tion nozzle groove.
2) Apply engine oil to the cylinder head nozzle
holder hole.
3) Install the nozzle holder together with the noz-
zle holder bracket (4) to the cylinder head.
Tighten:
37 N⋅m (3.8 kg⋅m/27 lb⋅ft)

N6A3069E

7) Split Collar
• Use a spring compressor to push the valve
spring into position.
• Install the spring seat split collar.
LG4JB-WE-1111.book 6 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-6 GENERAL ENGINE MECHANICAL

LNWB6ASH002701

6. Thermostat Housing Assembly

Tighten:
Thermostat housing assembly fixing bolt to 19 N⋅m (1.9
kg⋅m/14 lb⋅ft)
LG4JB-WE-1111.book 7 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-7

VALVE SPRING, VALVE GUIDE OIL SEAL, VALVE GUIDE, PUSH ROD
Component

N6A3074E

Legend
1. Rock arm assembly 4. Valve
2. Split collar 5. Valve guide oil seal
3. Valve spring 6. Valve guide

Disassembly
1. Rocker Arm Assembly
2. Split Collar
Using special Tool, compress valve spring
Valve spring compressor: 9-8523-1423-0 (J-
29760)

N6A3075E

3. Valve Spring
4. Valve
LG4JB-WE-1111.book 8 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-8 GENERAL ENGINE MECHANICAL

5. Valve Guide Oil Seal
6. Valve Guide
Valve Guide Replacer: 9-8523-1212-0

Inspection and Repair

Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.

Valve spring
Caution:
Visually inspect the valve springs and replace them if
damage or abnormal wear is evident.
1. Free height
• Measure the free height of the springs. The
springs must be replaced if the height is below
the specified limit. N6A3077E

Free Height mm (in) 3. Spring tension

Standard Limit • Use spring tester to compress the springs to
the installed height. Measure the compressed
48.0 (1.891) 47.100 (1.8560) spring tension.
Replace the springs if the measured tension is
below the specified limit.

Tension N (kg/lb)
Standard Limit
At installed height
38.9 mm (1.5 in) 296.2 (30.2/ 257.9 (26.3/
66.6) 57.9)

N6A3076E

2. Squareness
• Measure the valve spring squareness with a
steel square.
• Replace the valve springs if the measured val-
ue exceeds the specified limit.

Limit mm (in) N6A3078E

1.7 (0.067) Valve Guide

Caution:
Taking care not to damage the valve seat contact sur-
face, when removing carbon adhering to the valve head.
Carefully inspect the valve stem for scratching or abnor-
mal wear. If these conditions are present, the valve and
the valve guide must be replaced as a set.
LG4JB-WE-1111.book 9 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-9

1. Valve Guide Clearance Valve Guide Replacement
• Measure the valve stem diameter with a mi- 1. Using special tool, drive out the valve guide from
crometer. the combustion chamber side.
If the valve stem diameter is less than the spec- Valve guide replacer: 9-8523-1212-0
ified limit, the valve and the valve guide must be
replaced as a set.

mm (in)
Standard Limit
7.946 — 7.961
7.880
Inlet (0.3128 —
(0.310.2)
Diameter of 0.3134)
Valve stem 7.921 — 7.936
7.850
Exhaust (0.3118 —
(0.3091)
0.3124)

• Measure the inside diameter of the valve guide

with a micrometer.
• Subtract the measured outer diameter of the
valve stem from the measured inner diameter
of the valve guide. If the valve exceeds of the
N6A3080E
valve guide.
If the valve exceeds the specified limit, the 2. Apply engine oil to the outside of the valve guide.
valve and the valve guide must be replaced as Using special tool, drive in a new valve guide from
a set. cylinder head upper face side, and check the valve
guide height.
Valve Guide Clearance mm (in)
Valve guide replacer: 9-8523-1212-0
Standard Limit
0.039 — 0.069 Height mm (in)
0.200
Inlet clearance (0.0015 — 13 (0.51)
(0.0079)
0.0027)
0.064 — 0.096
0.250
Exhaust clearance (0.0025 —
(0.0098)
0.0038)

N6A3067E

Notice:
If the valve guide has been removed, both the valve and
N6A3079E the valve guide must be replaced as a set.
LG4JB-WE-1111.book 10 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-10 GENERAL ENGINE MECHANICAL

Valve Thickness Valve Depression
1. Measure the valve thickness 1. Install the valve (1) to the cylinder head (2).
2. If the measured value is less than the specified lim- 2. Use a depth gauge or a straight edge with steel
it the valve and the valve guide must be replaced rule to measure the valve depression from the cyl-
as a set. inder head lower surface.
If the measured value exceeds the specified limit,
Valve Thickness mm (in) the valve seat insert must be replaced.
Standard Limit
Valve Depression mm (in)
4JB1 Inlet 1.79 (0.0705)
1.5 (0.06) Standard Limit
4JB1-TC Exhaust 1.83 (0.0720)
4JB1 Inlet 0.73 (0.029) 1.28 (0.050)
4JB1-TC Exhaust 0.70 (0.028) 1.20 (0.047)

N6A0129E

Contact Surface Angle on Valve Seat on Valve N6A3083E

1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace Valve Contact Width
valve guide and valve seat as a set. 1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact sur-
Standard Degrees faces.
45° 2. Measure the valve contact width.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.

Contact Width mm (in)

Standard Limit
Inlet 1.7 (0.0670) 2.2 (0.0866)
Exhaust 2.0 (0.0788) 2.5 (0.0984)

N6A0132E
LG4JB-WE-1111.book 11 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-11

2. Use a bench press (3) to gradually apply pressure
to the attachment and press the valve seat insert
into place.

N6A3084E

Valve Seat Insert Replacement

Valve Seat Insert Removal N6A3086E
1. Arc weld the tire inside circumference (1) of the
valve seat insert (2). Notice:
2. Allow the valve seat insert to cool for a few min- Do not apply an excessive amount of pressure with the
utes. bench press. Damage to the valve seat insert will result.
This will invite contraction and make removal of the
valve seat insert easier. Valve Seat Insert Correction
3. Use a screwdriver (3) to pry the valve seat insert 1. Remove the carbon from the valve seat insert sur-
free. face.
Take care not to damage the cylinder head (4). 2. Use a valve cutter (15°, 45°, and 75° blades) to
4. Carefully remove carbon and other foreign material minimize scratches and other rough areas, this will
from the cylinder head insert bore. 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
unblemished area of the valve seat surface.

Valve Seat Angle degree

45°

N6A3085E

Valve Seat Insert Installation

1. Carefully place the attachment (1) (having a small-
er outside diameter than the valve seat insert) on
the valve seat insert (2).
Notice:
N6A3087E
The smooth side of the attachment must contact the
valve seat insert.
LG4JB-WE-1111.book 12 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-12 GENERAL ENGINE MECHANICAL

Notice: Push Rod Curvature Limit mm (in)

Use an adjustable valve cutter pilot.
0.4 (0.0157) or less
Do not allow the valve cutter pilot to wobble inside the
valve guide.
3. Apply abrasive compound to the valve seat insert
surface.

N6A3090E

3. Visually inspect both ends of the push rod for ex-

N6A3088E cessive wear and damage. The push rod must be
replaced if these conditions are discovered during
4. Insert the valve into the valve guide. inspection.
5. Turn the valve while tapping it to fit the valve seat
insert.
Reassembly
1. Valve Guide
• Apply engine oil to the outside of the valve
guide.
Using special tool, drive in a new valve guide
from the rocker arm shaft side.
Valve guide replacer: 9-8523-1212-0
2. Valve Guide Oil Seal
• Using special tool, drive in a new oil seal
Oil special tool, drive in a new oil seal
Oil seal installer: 5-8840-2033-0

N6A3089E

6. Check that the valve contract width is correct.

7. Check that the valve seat insert surface is in con-
tact with the entire circumference of the valve.

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.
N6A3068E
If the measure value exceeds the specified limit,
the push rod must be replaced.
LG4JB-WE-1111.book 13 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-13

3. Valve
• Apply engine oil to the outside of the valve
stem.
4. Valve Spring
• Attach the valve seat to the upper spring seat.
The painted area of the valve spring should be
facing downward.

N6A3091E

N6A3069E

5. Split Collar
• Use a spring compressor to push the valve
spring into position.
• Install the spring seat split collar.
• Set the split collar by tapping lightly around the
head of the collar with a rubber hammer.
Valve spring compressor: 9-8523-1423-0 (J-29760)

N6A3070E

6. Rocker Arm Assembly

Tighten:
54 N⋅m (5.5 kg⋅m/40 lb⋅ft)
LG4JB-WE-1111.book 14 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-14 GENERAL ENGINE MECHANICAL

CAMSHAFT, TAPPET
Component

N6A3092E

Legend
1. Cylinder head assembly 6. Camshaft timing gear
2. Flywheel 7. Camshaft thrust plate
3. Cylinder block rear plate 8. Camshaft
4. Oil pan assembly 9. Tappet
5. Oil pump assembly

Disassembly
1. Cylinder Head Assembly
2. Flywheel
3. Cylinder Block Rear Plate
4. Oil Pan Assembly
5. Oil Pump Assembly
6. Camshaft Timing Gear
• Remove the camshaft timing gear bolt from the
camshaft.
Notice:
Hold the camshaft stationary to prevent the camshaft
from turning.
• Use the universal puller (1) to pull out the cam-
shaft timing gear (2).
• Universal Puller: 5-8521-0002-0
Remove the thrust plate (3). N6A3093E
LG4JB-WE-1111.book 15 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-15

7. Camshaft Thrust Plate • Use a micrometer to measure each camshaft
8. Camshaft journal diameter in two directions (1) and (2). If
9. Tappet the measured value is less than the specified
limit, the camshaft must be replaced.

Journal Diameter mm (in)

Standard Limit
49.945 — 49.975 (1.9663 —
49.60 (1.9528)
1.9675)

N6A3094E

Inspection and Repair

Make the necessary adjustment, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
1. Measure the Camshaft Thrust Clearance
N6A3096E
• Use a dial indicator to measure the camshaft
end play. 3. Cam Height
This must be done before removing the cam- • Measure the cam height H with a micrometer. If
shaft gear. the measured value is less than the specified
If the camshaft end play exceeds the specified limit, the camshaft must be replaced.
limit, the thrust plate must be replaced.
Cam Height mm (in)
Camshaft End Play mm (in)
Standard Limit
Standard Limit
42.02 (1.6543) 41.65 (1.6398)
0.08 (0.0031) 0.2 (0.0079)

N6A3097E
N6A3095E
4. Camshaft Run-Out
2. Camshaft Journal Diameter
LG4JB-WE-1111.book 16 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-16 GENERAL ENGINE MECHANICAL

• Mount the camshaft on V-blocks.
• Measure the run-out with a dial indicator.
If the measured value exceeds the specified
limit, the camshaft must be replaced.

Run-Out mm (in)
Standard Limit
0.02 (0.008) or less 0.10 (0.0039)

N6A3099E

Camshaft Bearing Replacement

Camshaft Bearing Removal
1. Remove the cylinder body plug plate.
2. Use the bearing replacer to remove the camshaft
bearing.
Bearing Replacer: 5-8840-2038-0

N6A3098E

5. Camshaft and Camshaft Bearing Clearance

• Use an inside dial indicator to measure the
camshaft bearing inside diameter.

Camshaft Bearing Inside Diameter mm (in)

Standard Limit
50.00 — 50.03 (1.9685 — 1.9696) 50.08 (1.9716)

Camshaft Bearing Clearance mm (in)

Standard Limit
0.025 — 0.085 (0.0010 — 0.0033) 0.12 (0.005)

• If the clearance between the camshaft bearing N6A3100E

inside diameter and the journal exceeds the
specified limit, the camshaft bearing must be Camshaft Bearing Installation
replaced. 1. Align the bearing oil holes with the cylinder body oil
holes.
2. Use the replacer to install the camshaft bearing.
Bearing Replacer: 5-8840-2038-0
LG4JB-WE-1111.book 17 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-17

1. Measure the tappet outside diameter with a mi-
crometer. If the measured value is less than the
specified limit, the tappet must be replaced.

Tappet Outside Diameter mm (in)

Standard Limit
12.97 — 12.99 (0.510 — 0.511) 12.95 (0.509)

N6A3101E

Tappet
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.

N6A3103E

2. Measure the inside diameter tappet on the cylinder

block and calculate the clearance.
If the clearance exceeds the limit, replace tappet
or/and cylinder block.

Tappet and Cylinder Body Clearance mm (in)

Standard Limit
0.03 (0.001) 0.10 (0.004)

N6A3102E

Legend
1. Normal contact
2. Cracking
3. Pitting
4. Irregular contact
5. Irregular contact

Notice:
The tappet surfaces are spherical. Do not attempt to
grind them with an oil stone or similar tool in an effort to
N6A3104E
repair the tappet. If the tappet is damaged, it must be re-
placed. Reassembly
Tappet Outside Diameter 1. Tappet
LG4JB-WE-1111.book 18 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-18 GENERAL ENGINE MECHANICAL

1) Apply a coat of engine oil to the tappet (1) and
the cylinder body tappet insert holes (2).

N6A3109E

4. Camshaft Timing Gear

N6A3105E
1) Install the camshaft timing gear to the cam-
2) Locate the position mark applies at disassem- shaft.
bly (if the tappet is to be reused). The timing gear mark (“Y — Y”) must be facing
outward.
Notice:
2) Tighten the timing gear to the specified torque
The tappet must be installed before the camshaft.
Tighten:
2. Camshaft
Timing Gear Bolt to 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
1) Apply a coat of engine oil to the camshaft and
the camshaft bearings.
2) Install the camshaft to the cylinder body.
Take care not damage the camshaft bearings.

N6A3111E

5. Oil Pump Assembly

6. Oil Pan Assembly
N6A3106E Above works refer to “OIL PUMP” Section in this
manual.
3. Camshaft Thrust Plate
Install the thrust plate to the cylinder body and 7. Cylinder Block Rear Plate
tighten the thrust plate bolts to specified torque. • Tighten cylinder block rear plate fixing bolts to
the specified torque.
Tighten:
Thrust Plate Bolt to 18 N⋅m (1.8 kg⋅m/13 lb⋅ft) Tighten:
Rear Plate Bolt to 82 N⋅m (8.4 kg⋅m/61 lb⋅ft)
8. Flywheel
• Apply engine oil to fixing bolts.
LG4JB-WE-1111.book 19 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-19

• Tighten the flywheel bolts to the specified • Use the bench press (3) to gradually apply
torque in two steps using the Angular Tighten- pressure to the attachment and press the
ing Method. valve seat insert into place.
Follow the numerical order shown in the illus-
tration.
Tighten:
• Flywheel Bolt to
1st Step (Snug torque): 59 N⋅m (6.0 kg⋅m/43 lb⋅ft)
2nd Step (Final torque): 60° — 90°

5 1
3
8 7
4
2 6 N6A3086E

Notice:
Do not apply an excessive amount of pressure with the
bench press. Damage to the valve seat insert will result.
Measure the height of the valve guide upper
LNWB1BSH023201 end from the upper face of the cylinder head.

9. Cylinder Head Assembly Valve Guide Upper End Height (H) (Reference)
1) Hot plug mm (in)
• Set the nock ball in the positioning groove on
13 (0.51)
the cylinder head side according to the order
of the cylinders, and hit it lightly with a plastic
hammer.
Notice:
After being pressed into the cylinder head, the hot plugs
were provided with surface grinding.
Accordingly, their dimensions are different individually
among them, and take care not confuse the order of the
cylinders.
When replacing the hot plug with new one:
When assembling a new hot plug, set the knock ball in
the positioning groove on the cylinder side and hit it
lightly with a plastic hammer until the hot plug is set in
stably.
With patch attached to the hot plug to prevent it from be-
ing damaged, press it in with a force of 4.5 ~ 5.5 ton ap-
plied.
2) Valve Seat Insert Installation
N6A3067E
• Carefully place the attachment (1) (having a
smaller outside diameter than the valve seat
insert) on the valve seat insert (2). Notice:
If the valve guide has been removed, both the valve and
Notice: the valve guide must be replaced as a set.
The smooth side of the attachment must contact the
valve seat insert.
LG4JB-WE-1111.book 20 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-20 GENERAL ENGINE MECHANICAL

3) Spring Lower Seat
4) Valve Stem Oil Seal
5) Valve
6) Valve Spring
7) Split Collar
Above works refer to “VALVE” Section in this
manual.
LG4JB-WE-1111.book 21 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-21

ROCKER ARM ASSEMBLY

Component

N6A3113E

Legend
1. Rocker arm shaft assembly 5. Rocker arm
2. Rocker arm shaft snap ring 6. Rocker arm shaft spring
3. Rocker arm 7. Rocker arm shaft
4. Rocker arm shaft bracket

Disassembly Replace the rocker shaft if the diameter exceeds the

specified limit.
1. Rocker Arm Shaft Assembly
2. Rocker Arm Shaft Snap Ring mm (in)
3. Rocker Arm
Standard Limit
4. Rocker Arm Shaft Bracket
18.98 — 19.00 (0.7472
5. Rocker Arm 18.9 (0.744)
— 0.7480)
6. Rocker Arm Shaft Spring
7. Rocker Arm Shaft

Inspection and Repair

Make the necessary adjustment, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.

Use a micrometer to measure the rocker shaft outside

diameter at the point where the rocker arm moves on the
rocker shaft.
LG4JB-WE-1111.book 22 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-22 GENERAL ENGINE MECHANICAL

3. Check that the rocker arm oil port is free is obstruc-
tions.
If necessary, use compressed air to clean the rock-
er arm oil port.

N6A3114E

Oil Clearance
1. Use either a vernier caliper or a dial indicator to
measure the rocker arm inside diameter. N6A3116E

Rocker Arm Inside Diameter mm (in) Rocker Arm Correction

Standard Limit Inspection the rocker arm valve stem contact surface for
step wear (1) and scoring (2).
19.036 — 19.060 (0.7494 —
19.100 (0.7519) If the contact surfaces have light step wear or scoring,
0.7503)
they may be honed with an oil stone.
2. Measure the rocker arm shaft outside diameter. If the step wear or scoring is severe, the rocker arm
If the measured value exceeds the specified limit, must be replaced.
replace either the rocker arm or the rocker arm
shaft.

Rocker Arm and Rocker Shaft Clearance

mm (in)
Standard Limit
0.06 — 0.08 (0.0024 —
0.10 (0.0039)
0.0031)

N6A3117E

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
N6A3115E the specified limit, the rocker arm shaft must be re-
placed.
LG4JB-WE-1111.book 23 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-23

7. Rocker Arm Shaft Assembly
Rocker Arm Shaft Run-Out mm (in)
• Install the rocker arm shaft assembly in cylinder
Limit head.
4JB1 / 4JB1-TC 0.2 (0.008) • Tighten the rocker arm shaft fixing bolts to the
specified torque.

N6A3118E N6A3091E

Reassembly
1. Rocker Arm Shaft
• Apply a light coat of engine oil to the rocker arm
shafts.
• Position the rocker arm shaft with the large oil
hole (φ4) facing the front of the engine.
• Install the rocker shaft together with the rocker
arm, the rocker arm shaft bracket, and the
spring.

N6A3119E

2. Rocker Arm Shaft Spring

3. Rocker Arm
4. Rocker Arm Shaft Bracket
5. Rocker Arm
6. Rocker Arm Shaft Snap Ring
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6A-24 GENERAL ENGINE MECHANICAL

OIL PUMP
Component

N6A3120E

Legend
1. Vacuum pump oil hose 3. Oil pan assembly
2. Stiffener & space rubber 4. Oil pump assembly

Removal
1. Vacuum Pump Oil Hose
• Remove the oil hose (1) from oil pan.

N6A3121E
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GENERAL ENGINE MECHANICAL 6A-25

2. Stiffener & Space Rubber
• Remove the stiffener from of the oil pan left &
right side.
• Take out space rubber.
3. Oil Pan Assembly
4. Oil Pump Assembly

Installation
1. Oil Pump Assembly
• Apply molybdenum mixed engine oil to drive
gear of camshaft and driven gear of oil pump.
• Tighten the oil pump fixing bolt to the specified
torque.
Tighten:
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
2. Oil Pan Assembly N6A3126E

• Apply the recommended liquid gasket or its

• Be absolutely sure that the lipped portion is fit-
equivalent to the No. 5 bearing cap arches, the
ted snugly into the groove.
grooves, the cylinder block and the timing gear
case fitting face at the positions shown in the il- • Install the oil pan to the cylinder body.
lustration. • Tighten the oil pan bolts to the specified torque.
Tighten:
Oil Pan Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
3. Stiffener & Space Rubber
• Install the space rubber.
• Install the stiffener tighten to the specified
torque.
Tighten:
• Engine Body Side to 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
• Clutch Housing Side to 78 N⋅m (8.0 kg⋅m/58 lb⋅ft)
4. Vacuum Pump Oil Hose
• Install the oil hose to oil pan.

N6A3125E

• Fit the gasket rear lipped portion into the No. 5

groove.
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6A-26 GENERAL ENGINE MECHANICAL

CRANKSHAFT
Component

4
10
13

15 12

14

11
5

LNWB6ALF000701

Legend
1. Cylinder head assembly and gasket 9. Cylinder block rear plate
2. Oil pan assembly 10. Crankshaft rear oil seal
3. Timing gear 11. Main bearing cap
4. Timing gear housing 12. Crankshaft
5. Oil pump assembly 13. Upper bearing
6. Piston cooling oil pipe 14. Lower bearing
7. Piston and connecting rod 15. Thrust bearing
8. Flywheel

Disassembly 5. Oil Pump Assembly

1. Cylinder Head Assembly and Gasket 6. Piston Cooling Oil Pipe
2. Oil Pan Assembly 7. Piston and Connecting Rod
3. Timing Gear 8. Flywheel
4. Timing Gear Housing 9. Cylinder Block Rear Plate
LG4JB-WE-1111.book 27 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-27

10. Crankshaft Rear Oil Seal
• With the oil seal pushed in deep, install the spe-
cial tool as shown in the illustration to remove
the oil seal.
Remover: Rear Oil Seal 5-8840-2360-0

N6A3130E

2. Main bearing clearance

1) Remove the main bearing caps in the se-
quence shown in the illustration.
Arrange the removed main bearing caps in the
N6A3129E
cylinder number order.

Notice:
Take care not to damage sealing surface of rear plate
and crankshaft when removing oil seal.
11. Main Bearing Cap
12. Crankshaft
13. Upper Bearing
14. Lower Bearing
15. Thrust Bearing

Inspection and Repair

Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
1. Crankshaft
Thrust clearance
Set the dial indicator as shown in the illustration N6A3131E
and measure the crankshaft thrust clearance.
If the thrust clearance exceeds the specified stan- 2) Remove the crankshaft. Remove the main
dard, replace the thrust bearing as a set. bearings.
3) Clean the upper and lower bearings as well as
Thrust clearance mm (in) the crankshaft main journal.
Standard 4) Check the bearings for damage or excessive
wear.
0.040 — 0.201 (0.0016 — 0.0079)
The bearings must be replace as a set if dam-
age or excessive wear is discovered during in-
spection.
5) Set the upper bearings and the thrust washers
to their original positions. Carefully install the
crankshaft.
6) Set the lower bearings to the bearing cap origi-
nal position.
LG4JB-WE-1111.book 28 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-28 GENERAL ENGINE MECHANICAL

7) Apply plastigage to the crankshaft journal unit
as shown in the illustration.

N6A3133E

3. Run-out
N6A3132E
1) Carefully set the crankshaft on the V-blocks.
8) Install the main bearing caps. Apply engine oil Slowly rotate the crankshaft and measure the
to the bolt threads and the seats. Tighten the runout.
bolts to the specified torque. If the crankshaft runout exceeds the specified
limit, the crankshaft must be replaced.
Tighten:
167 N⋅m (17 kg⋅m/123 lb⋅ft) Run-Out mm (in)
Notice: Standard Limit
Do not allow the crankshaft to rotate. 0.05 (0.0020) or less 0.08 (0.0031)
9) Remove the main bearing caps.
10) Measure the plastigage width and determine
the oil clearance. If the oil clearance exceeds
the specified standard, replace the main bear-
ings as a set and/or replace the crankshaft.
11) Clean the plastigage from the bearings and the
crankshaft.
12) Remove the crankshaft and the bearings.

Oil Clearance mm (in)

Standard
4JB1
0.030 — 0.054 (0.0012 — 0.0021)
4JB1-TC

N6A3134E

Measure the diameter and the uneven wear of

main journal and crank pin.
If the crankshaft wear exceeds the specified
limit, crankshaft must be replaced.
Use a micrometer to measure the journal and
pin outer diameters to calculate difference of
the maximum and minimum. Measure in 4 sec-
tions on the journal and on the pin.
LG4JB-WE-1111.book 29 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-29

mm (in) Notice:
To increase crankshaft strength, Tufftride Method (Soft
Standard Limit nitriding) has been applied. Because of this, it is not pos-
Main journal 69.917 — 69.932 sible to regrind the crankshaft surfaces.
69.91 (2.7524)
diameter (2.7526 — 2.7532) 1. Use an organic cleaner to thoroughly clean the
Crank pin 52.915 — 52.930 crankshaft. There must be no traces of oil the sur-
52.90 (2.0843)
diameter (2.0833 — 2.0839) faces to be inspected.
2. Prepare a 5 — 10% solution of ammonium cupric
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 horizon-
tal to prevent the solution from running.

Notice:
Do not allow the solution to come in contact with the oil
ports and their surrounding area.
Testing
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 copper), the crankshaft must
be replaced.
2. Steam clean the crankshaft surface immediately
N6A3135E
after completing the test.
Crankshaft Inspection Notice:
Inspect the surface of the crankshaft journals and crank The ammonium cupric chloride solution is highly corro-
pins for excessive wear and damage. sive. Because of this, it is imperative that the surfaces
Inspect the oil seal fitting surfaces for excessive wear being tested be cleaned immediately after completing
and damage. the test.
Inspect the oil ports for obstructions.
Crankshaft Tufftriding Inspection Crankshaft Bearing Selection
The portion to be tested must be held horizontally so as When installing new crankshaft bearings or replacing
not let the test solution flow (1). old bearings, refer to the selection table.
Test liquid should not be applied to the area around the
oil port (2).
Approximately 10 mm (0.39 in) (3)
The sliding surface of the pin or journal (4).

N6A3137E

N6A3136E
LG4JB-WE-1111.book 30 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-30 GENERAL ENGINE MECHANICAL

Play close attention to the distinction during the installa-
tion procedure.

LNWB1BSH023501

Notice: N6A3139E
Although all upper journal bearings (cylinder body side)
have oil grooves and holes, all lower bearings (bearing
cap side) have no groove and hole.

mm (in)
Crankshaft Bearing Housing Crankshaft Journal Crankshaft Bearing
Grade Mark Diameter Grade Mark Diameter Size Code
69.927 — 69.932
1 or -
(2.7530 — 2.7532)
4
73.992 — 74.000 69.922 — 69.927
1 2 or - -
(2.9131 — 2.9134) (2.7528 — 2.7530)
69.917 — 69.922
3 or - - - 5
(2.7526 — 2.7528)
69.927 — 69.932
1 or - 2
(2.7530 — 2.7532)
73.983 — 73.992 69.922 — 69.927
2 2 or - - 3
(2.9127 — 2.9131) (2.7528 — 2.7530)
69.917 — 69.922
3 or - - - 4
(2.7526 — 2.7528)
69.927 — 69.932
1 or - 1
(2.7530 — 2.7532)
73.975 — 73.983 69.922 — 69.927
3 2 or - -
(2.9124 — 2.9127) (2.7528 — 2.7530)
2
69.917 — 69.922
3 or - - -
(2.7526 — 2.7528)

Reassembly
1. Crankshaft
• Install the main bearings to the cylinder body
and the main bearing caps.
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GENERAL ENGINE MECHANICAL 6A-31

N6A3140E N6A3142E

• Be sure that they are positioned correctly.

Notice:
• Apply new engine oil to the upper and lower Be sure that the bearing cap fitting surface is completely
main bearing faces. free of oil before applying the liquid gasket.
• Carefully mount the crankshaft. Do not allow the liquid gasket to obstruct the cylinder
• Apply engine oil to the thrust washer. thread holes and bearings.
• Assemble the thrust washer to the No.3 bear- • Install the bearing caps with the bearing cap
ing journal. The oil grooves must face the head arrow mark facing the front of the engine.
crankshaft.

N6A3143E
N6A3141E
• Apply engine oil to the crankshaft bearing cap
2. Main Bearing Cap bolts.
• Apply the recommended liquid gasket or its • Tighten the crankshaft bearing cap bolts to the
equivalent to the No. 5 crankshaft bearing cap specified torque a little at a time in the se-
(1) as shown in the illustration. quence shown in the illustration.
• Install the arch gasket (2) to the No. 5 bearing Tighten:
cap. 167 N⋅m (17 kg⋅m/123 lb⋅ft)
Use your fingers to push the arch gasket into
the bearing cap groove.
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6A-32 GENERAL ENGINE MECHANICAL

N6A3144E N6A3145E

4. Cylinder Block Rear Plate

Notice:
Align the rear plate with the cylinder body knock
Check to see that the crankshaft turns smoothly by ro-
pins.
tating it manually.
Tighten the rear plate to the specified torque
3. Crankshaft Rear Oil Seal
Use the oil seal installer to install the oil seal to the Tighten:
cylinder body. 82 N⋅m (8.4 kg⋅m/61 lb⋅ft)
Installer: Rear Oil Seal 5-8840-2359-0 5. Flywheel
Notice: 1) Thoroughly clean the remove the oil from the
Wipe off rust and scraps clean from the press-in portion threads of crankshaft.
of the oil seal. 2) Mount the flywheel on the crankshaft and then
Take note of the press-in direction of the oil seal. install the washer.
1) Install the adapter of the special tool to the rear 3) Apply a coat of engine oil to the threads of the
end of the crankshaft with two bolts. flywheel bolts.
2) Install the oil seal to the outer circumference of 4) Align the flywheel with the crankshaft dowel
the adapter. pin.
3) Insert the slave into the adapter portion, and 5) Tighten the flywheel bolts to the specified
tighten it in with the bolt (M12 × 1.75L=70) until torque in two steps using the Angular Tighten-
the adapter section hits the slave. ing Method.
Follow the numerical order shown in the illus-
4) Remove the adapter and the slave.
tration.
5) After installing the oil seal, check the measure-
ment of the oil seal. Tighten:
• Flywheel Bolt to
Standard mm (in) 1st Step: 59 N⋅m (6.0 kg⋅m/43 lb⋅ft)
12.2 — 12.8 (0.48 — 0.50) 2nd Step: 60° — 90°
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GENERAL ENGINE MECHANICAL 6A-33

5 1
3
8 7
4
2 6

LNWB1BSH023201 N6A3160E

6. Piston and Connecting Rod 11. Crankshaft Timing Gear

7. Piston Cooling Oil Pipe 1) Install the camshaft timing gear to the cam-
8. Oil Pump Assembly shaft.
Above works refer to “PISTON AND CONNECT- The timing gear mark (“Y — Y”) must be facing
ING ROD” outward.
Section in this manual. 2) Tighten the timing gear to the specified torque.
9. Timing Gear Housing Tighten:
1) Install the timing gear housing to the cylinder 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
body.
2) Tighten the timing gear housing bolt together
with the timing gear housing gasket to the spec-
ified torque.
Tighten:
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
3) Cut away the gasket protruding above the fit-
ting surface (as shown in the illustration).
10. Crank Shaft Gear
1) Install the crankshaft gear.
2) Use the crankshaft gear installer (1) to install
the crankshaft gear (2).
The crankshaft gear timing mark (“X — X”)
must be facing outward.
Crankshaft Gear Installer: 9-8522-0020-0

N6A3111E

12. Idle Gear

1) Apply engine oil to the idle gear and the idler
gear shaft.
The idler shaft oil hole must be facing up.
2) Position the idler gear setting marks “X” and “Y”
so that they are facing the front of the engine.
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6A-34 GENERAL ENGINE MECHANICAL

Tighten:
76 N⋅m (7.7 kg⋅m/56 lb⋅ft)

N6A3161E

3) Align the idler gear “X” setting mark with the

crankshaft timing gear (1) “X — X” setting mark. N6A3163E
4) Align the idler gear “Y” setting mark with the
camshaft timing gear (1) “Y — Y” setting mark. 14. Injection Pump
5) Install the thrust collar and bolts to the cylinder 1) Install the O-ring (1) to the injection pump
body through the shaft. flange (2).
The thrust collar oil hole must be facing up, and 2) Install the injection pump to the timing gear
the thrust collar chamfered must be outward. case.
6) Tighten the idler gear bolt to the specified Align the idler gear “B” (3) “V — V” mark.
torque.
Tighten:
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

N6A3164E

Gear
N6A3162E Crank gear A|Idle gear “A” X—X
13. Idler Gear “B” and Shaft Idle gear “A” — Cam gear Y—Y
1) Apply engine oil to the idler gear and the idler Idle gear “A” — Idle gear “B” Z—Z
gear shaft.
Idle gear “B” — Injection pump V—V
2) Align the idler gear “B” (3) “Z” setting mark with
the idler gear “A” (4) “Z — Z” setting mark. 3) Temporarily tighten the six injection pump bolts
3) Tighten the idler gear bolt to the specified (5).
torque.
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GENERAL ENGINE MECHANICAL 6A-35

The injection pump bolts will be finally tight-
ened after the injection pump rear bracket
bolts.

N6A3168E

16. Timing Gear Case Cover

N6A3166E
1) Align the gear case with the timing gear case
knock pin and then install the timing gear case
4) Install the injection pump rear bracket (6) and cover.
the rear bracket bolts (7) to the cylinder body. 2) Tighten the gear case cover bolts to the speci-
5) Install the rear bracket bolts (8) to the injection fied torque.
pump bracket (9). Tighten:
Do not tighten the bolts. 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
The rear bracket bolts (7) and (8) will be finally
tightened to the specified torque.

Tighten:
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

N6A3169E

17. Crankshaft Pulley

Tighten the crankshaft damper pulley bolt to the
specified torque.
N6A3167E
Notice:
15. Timing Gear Oil Pipe Hold the flywheel ring gear stationary to prevent the
1) Install the oil pipe to the timing gear case and crankshaft from turning when tightening the damper pul-
idler gear “A”. ley.
2) Tighten the oil pipe eye bolt (1) and bolt (2) to
the specified torque. Tighten:
296 N⋅m (30 kg⋅m/217 lb⋅ft)
Tighten:
13 N⋅m (1.3 kg⋅m/9 lb⋅ft)
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6A-36 GENERAL ENGINE MECHANICAL

N6A3170E

18. Cooling Fan Assembly

1) Mount fan pulley, distance piece, and cooling
fan assembly (in this order) on the water pump,
and tighten to the specified torque.
Tighten:
8 N⋅m (0.8 kg⋅m/69 lb⋅in)
19. AC Generator, Power Steering Pump Drive Belt
1) Install AC Generator, Power Steering pump
drive belt and adjust belt tension.
2) Depress the drive belt mid-portion with a 98 N
(10 kg/22 lb) force.

Drive Belt Deflection mm (in)

8 (0.31) — 12 (0.47)

3) Tighten the idler lock nut to the specified

torque.
Tighten:
27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
20. Fan Shroud
1) Install the fan shroud and reservoir tank hose.
2) Pour coolant
3) Start the engine and check coolant leakage.
21. Oil Pan Assembly
Above works refer to “OIL PUMP” Section in this
manual.
22. Cylinder Head Assembly and Gasket
• Piston Head Projection Measurement Point
• Cylinder Head Assembly
• Push Rod
• Rocker Arm Shaft Assembly
Valve clearance adjustment.
Above works refer to “CYLINDER BLOCK” Section
in this manual.
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GENERAL ENGINE MECHANICAL 6A-37

PISTON AND CONNECTING ROD

Component

LNWB1BMF003901

Legend
1. Cylinder head assembly 7. Piston ring
2. Oil pan assembly 8. Piston pin snap ring
3. Oil pump assembly 9. Piston pin
4. Piston cooling oil pipe 10. Piston
5. Connecting rod cap 11. Connecting rod
6. Piston and connecting rod

Disassembly
1. Cylinder Head Assembly
2. Oil Pan Assembly
3. Oil Pump Assembly
4. Piston Cooling Oil Pipe
5. Connecting Rod Cap
6. Piston and Connecting Rod
• Remove carbon deposits from the upper por-
tion of the cylinder wall with a scraper before re-
moving the piston and connecting rod.
7. Piston Ring
Remove the piston rings with a piston ring expand-
er.
Arrange the removed piston rings in the cylinder
number order.
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6A-38 GENERAL ENGINE MECHANICAL

Visually check each piston for cracking, scoring, and
other signs of excessive wear.
If any of the above conditions are present, the piston
must be replaced.
Piston Diameter
1. Measure the piston outside diameter with mi-
crometer at the piston grading position.

Piston Grading Position mm (in)

4JB1 / 4JB1-TC 73 (2.874)

N6A3172E

8. Piston Pin Snap Ring

• Use a pair of pliers to remove the piston pin
snap rings.

N6A3174E

4JB1 / 4JB1-TC
mm (in)
Size Mark Outside Diameter
A 92.971 — 92.985 (3.6603 — 3.6608)
B 92.981 — 92.995 (3.6607 — 3.6612)
C 92.991 — 93.005 (3.6611 — 3.6616)

N6A3173E
D 93.001 — 93.015 (3.6615 — 3.6620)

9. Piston Pin
Notice:
Keep the parts removed from each cylinder separate.
All parts must be reinstalled in their original positions.
10. Piston
11. Connecting Rod

Inspection and Repair

Piston and Piston Ring
Pistons
Carefully clean away all the carbon adhering to the pis-
ton head and the piston ring grooves.
Notice:
Never use a wire brush to clean the pistons. Damage
will result.
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GENERAL ENGINE MECHANICAL 6A-39

Notice:
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.
Piston Rings
Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement
• Insert the piston ring into the bore.
• Push the ring by the piston, at a right angle to
the wall, into the point ring at which the cylinder
bore diameter is the smallest.

N6A3175E

Legend
1. G-mark
2. Front mark

The grading position for piston outside diameter is rep-

resented by the ‘G’ as shown in Figure.
Measure the cylinder bore inside diameter (refer to “in-
spection of the cylinder Block” in this Section).
If the piston clearance does not conform to the specified
valve, the piston and/or cylinder liners must be replaced.

Piston Clearance mm (in)

0.036 — 0.059
4JB1 / 4JB1-TC N6A3177E
(0.0014 — 0.0023)
• The top mark of the piston ring are shown in the
Selection Method of Piston Grade for Service Parts. illustration.
If you find piston grade A from size mark or piston out-
side diameter measurement result, you will select AX for Notice:
service piston grade. There is no up or down side with the compression ring
The stamped piston grade on the head of piston for ser- 1st.
vice parts.

Service piston grade

Piston Size Mark Service Parts Grade
A AX
B AX
C CX
D CX

Service piston diameter

mm (in)
Piston Grade 4JB1 / 4JB1-TC
1
AX 92.976 — 92.995 (3.6605 — 3.6612)
CX 92.991 — 93.011 (3.6611 — 3.6619) LNW21BSH034901
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6A-40 GENERAL ENGINE MECHANICAL

Legend Piston pin outside diameter mm (in)

1. N mark (2nd ring)
Standard Limit
30.995 — 31.000
mm (in) 4JB1 30.970 (1.2190)
(1.2202 — 1.2204)
Standard Limit 33.995 — 34.000
4JB1-TC 33.970 (1.3374)
0.27 — 0.56 (1.3384 — 1.3386)
1st
Compression (0.0106 — 0.0220)
ring 0.27 — 0.56 1.5
2nd
(0.0106 — 0.0220) (0.059)
0.17 — 0.46
Oil ring
(0.0067 — 0.0181)

2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. If
the piston ring groove/piston ring clearance ex-
ceeds the specified limit, the piston must be re-
placed.

4JB1 / 4JB1-TC mm (in)

Standard Limit
0.090 — 0.125
1st
Compression (0.0035 — 0.0049)
ring 0.050 — 0.085 0.15
2nd N6A3180E
(0.0020 — 0.0033) (0.0059)
0.03 — 0.07 2. Measure the inside diameter of the connecting rod
Oil ring small end. If the clearance between the small end
(0.0012 — 0.0028)
and pin does not conform to the specified value,
the connecting rod or bushing and pin must be re-
placed.

mm (in)
Standard Limit
0.008 — 0.020
Clearance 0.05 (0.0020)
(0.0003 — 0.0008)

N6A3179E

Piston Pin
Visually inspect the piston pin for cracks, flaws, and oth-
er damage and replace if necessary.
1. Use a micrometer to measure the piston pin out-
side diameter in both directions at three different
positions.
If the measurement exceed the specified limit the
N6A3181E
piston pin must be replaced.
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GENERAL ENGINE MECHANICAL 6A-41

3. Insert the piston pin into the piston and rotate it. If
the pin rotates smoothly with no backlash, the
clearance is normal. If there is backlash or rough-
ness, measure the clearance. If the clearance ex-
ceeds the specified limit, the piston and the piston
pin must be replaced.

mm (in)
Standard Limit
0.002 — 0.015
Clearance 0.04 (0.0016)
(0.00008 — 0.00059)

Connecting Rods
1. Check the connecting rod alignment with a con-
necting rod aligner.
If either the bend or the twist exceeds the specified
limit, the connecting rod must be replaced.
N6A3184E

mm (in)
3. Measure the oil clearance between the connecting
Standard rod and the crankshaft by:
Bend per 100 (3.94) 0.05 (0.0020) or less 1) Remove the connecting rod nuts and the rod
caps.
Twist per 100 (3.94) 0.05 (0.0020) or less Arrange the removed connecting rod caps in
the cylinder number order.
2) Clean the connecting rod bearings and the
crankshaft pins.
3) Carefully check the connecting rod bearings.
If even one bearing is found to be damaged or
badly worn, the entire bearing assembly must
be replaced as a set. Reinstall the connecting
rod bearings in their original positions.
Apply plastigage to the crank pin.

N6A3183E

2. Measure the connecting rod thrust clearance.

Use a feeler gauge to measure the thrust clear-
ance at the big end of the connecting rod.
If the clearance exceeds the specified limit, the
connecting rod must be replaced.

Thrust Clearance mm (in)

Standard N6A3185E

0.175 — 0.290 (0.0069 — 0.0114) 4) Put the plastigage, and reinstall the rod caps to
their original positions.
5) Tighten the cap nuts in 2 steps, using angular
tightening method as shown in the following
specifications. (4JB1-TC)
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6A-42 GENERAL ENGINE MECHANICAL

Tighten:
• 4JB1-TC to
1st Step: 29.4 N⋅m (3 kg⋅m/22 lb⋅ft)
2nd Step: 45° — 60°
• 4JB1 to 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)

Notice:
Do not allow the crankshaft to rotate.
6) Remove the rod caps.
7) Measure the width of the plastigage and deter-
mine the oil clearance. If the oil clearance ex-
ceeds the limit, replace the rod bearings as a
set.
8) Remove the plastigage from the bearings and
the crankshaft pins.

Crankshaft Journal and Bearing Clearance N6A3187E

mm (in)
Standard Legend
1. Front mark
0.033 — 0.075 (0.0013 — 0.0030)
2. ISUZU mark

5. Piston Ring
• Install the piston rings with the piston ring ex-
pander.
The compression ring must be set with the N
mark facing up.
• Discrimination mark is painted as shown in the
illustration.
Notice:
There is no up or down side with the compression ring
1st.

N6A3186E

Reassembly
1. Connecting Rod
2. Piston
3. Piston Pin
Apply a cost of engine oil to the piston pin and the
piston pin hole.
4. Piston Pin Snap Ring
Apply a thin coat of engine oil to the piston pin. 1
Try to insert the piston pin into the piston pin hole
with normal finger pressure. LNW21BSH034901

• Attach the piston to the connecting rod with the

piston front mark and the connecting rod ISU- Legend
ZU mark on the same side. 1. N mark (2nd ring)

• Install piston rings in the following sequence.

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GENERAL ENGINE MECHANICAL 6A-43

LNWB1BSH022801 LNWB1BSH022901

Legend Legend
1. Oil ring (with coil expander) 1. Oil ring
2. Compression ring 2nd 2. Coil expander
3. Compression ring 1st 3. Compression ring 2nd
4. Compression ring 1st
• 1st compression ring: N
• 2nd compression ring: N 7. Connecting Rod Cap
• After installation, apply engine oil to the en- • Tighten the cap nuts in 2 steps, using angular
tire circumference of the piston rings. tightening method as shown in the following
Check to see that all the rings rotate smooth- specifications.
ly. Tighten:
• Insert the bearings into the connecting rods 4JB1-TC to
and caps. • 1st Step: 29.4 N⋅m (3.0 kg⋅m/22 lb⋅ft)
Apply new engine oil to the bearing faces. • 2nd Step: 45° — 60°
Cap side bearings have no oil hole.
4JB1 to 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
Connecting rod side bearings oil hole should
be aligned with oil hole on the connecting After tightening the cap nuts, check to see that the
rod. crankshaft rotates smoothly.
6. Piston and Connecting Rod 8. Piston Cooling Oil Jet Pipe
• Apply engine oil to the cylinder bores, the con- • Install the piston cooling oil jet pipe to the cylin-
necting rod bearings and the crankshaft pins. der body.
• Check to see that the piston ring end gaps are • Tighten the oil jet pipe bolts and relief valve to
correctly positioned. the specified torque.
• Insert the piston/connecting rod assemblies Tighten:
into each cylinder with the piston ring compres- Oil Pipe Bolt to
sor. • M8 × 1.25: 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
• The front marks must be facing the front of the • M6 × 1.00: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
engine. Oil Pressure Regulating Valve to
Notice: • M16 × 1.5: 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
• Set the crankshaft pin to top dead center with each
cylinder, when inserting piston/connecting rod.
• When inserting piston/connecting rod if the crank
pin is set to the bottom dead center, the oil jet might
hit connecting rod and it might break.
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6A-44 GENERAL ENGINE MECHANICAL

LNW81BSH008601

Notice:
Check that there is no interference between the piston
and the oiling jet pipe by slowly rotating the crankshaft.
9. Oil Pump Assembly
10. Oil Pan Assembly
Above works refer to “OIL PUMP” Section in this
manual.
11. Cylinder Head Assembly
• Piston Head Projection Measurement Point
• Cylinder Head Assembly
• Push Rod
• Rocker Arm Shaft Assembly
Valve clearance adjustment.
Above works refer to “CYLINDER BLOCK” Section
in this manual.
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GENERAL ENGINE MECHANICAL 6A-45

CYLINDER BLOCK
Component

9
7

15

4
10

12

11
5

13

14
LNWB6ALF000801

Legend
1. Cylinder head assembly and gasket 9. Cylinder block rear plate
2. Oil pan assembly 10. Crankshaft rear oil seal
3. Timing gear 11. Main bearing cap
4. Timing gear housing 12. Crankshaft
5. Oil pump assembly 13. Camshaft
6. Piston cooling oil pipe 14. Tappet
7. Piston and connecting rod 15. Cylinder block
8. Flywheel

Disassembly 5. Oil Pump Assembly

1. Cylinder Head Assembly and Gasket 6. Piston Cooling Oil Pipe
2. Oil Pan Assembly 7. Piston and Connecting Rod
3. Timing Gear 8. Flywheel
4. Timing Gear Housing 9. Cylinder Block Rear Plate
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6A-46 GENERAL ENGINE MECHANICAL

10. Crankshaft Rear Oil Seal 4. Slowly turn the remover shaft handle counterclock-
11. Main Bearing Cap wise to pull the cylinder liner free.
12. Crankshaft Cylinder Liner Remover Ankle:
13. Camshaft 5-8840-2039-0
14. Tappet
15. Cylinder Block

Inspection and Repair

Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
1. Remove the gasket and any other material adher-
ing the upper surface of the cylinder block.
Be very careful not to allow any material to acci-
dental drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, Rear Seal retainer
and oil pan installation surface seal.
3. Wipe the cylinder block clean.

Cylinder Liner Projection Inspection

N6A3194E
1. Hold a straight edge (1) along the top edge of the
cylinder liner to be measured.
Notice:
2. Use a feeler gauge (2) to measure each cylinder
Take care not to damage the cylinder body upper during
line projection.
the cylinder liner removal procedure.
The difference in the cylinder liner projection height
between any two adjacent cylinders must not ex- 5. Use a straight edge and a feeler gauge to measure
ceed 0.03 mm (0.0012 in). the four sides and the two diagonals of the cylinder
body upper face.
Standard mm (in) If the measured values exceeds the limit, the cylin-
der body must be replaced.
0.0 — 0.1 (0.0000 — 0.0039)

N6A3195E
N6A3193E
Cylinder Liner Bore Measurement
Flatness Use a cylinder indicator to measure the cylinder liner
1. Remove the cylinder body dowel. bore at measuring point (1) in the thrust (2) — (2) and
2. Set the cylinder liner remover to the cylinder liner. axial (3) direction of the crankshaft.
Measuring Point (1) 20mm (0.79 in)
3. Check that the remover shaft ankle is firmly grip-
If the measured value exceeds the specified limit, the
ping the cylinder liner bottom edge.
cylinder liner must be replaced.
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GENERAL ENGINE MECHANICAL 6A-47

N6A3196E N6A3198E

Cylinder Body Bore Measurement

Notice:
The inside of the dry type cylinder liner is chrome plated. 1. Take measurements at measuring point (A) across
It cannot be rebored or honed. positions (1) — (1), (2) — (2), (3) — (3), and (4) —
If the inside of the cylinder liner is scored or scorched, (4).
the cylinder liner must be replaced. Measuring Point (A) 98mm (3.86 in).

Cylinder Liner Grade Selection

Measure the cylinder body inside diameter and select
the appropriate cylinder liner grade.

N6A3199E

N6A3197E

Standard Lifting Interference mm (in)

0.01 — 0.019 (0.0004 — 0.0007)

If the cylinder liner fitting interference (1) is too small, en-

gine cooling efficiency will be adversely effected.
If the cylinder liner fitting interference is too large, it will
be difficult to insert the cylinder liner into the cylinder
body.
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6A-48 GENERAL ENGINE MECHANICAL

2. Calculate the average value of the four measure-
ments to determine the correct cylinder grade.
3. Consult the following table with the resultant diam-
eter for the correct liner application.
Selection method of cylinder liner and piston grade
for service parts.
The production line stamped cylinder liner grade on the
top of cylinder body, the cylinder liner outside diameter
grade 1, 2, 3, 4.
If you find cylinder liner outside diameter grade 1 and
piston outside diameter B on the cylinder body or result
of measurement for each parts, you will select service
parts grade for cylinder liner 1, AX grade and for piston
AX grade.
The stamping grade code on the service parts are;
For cylinder liner grade stamped on the outside of cylin-
der liner.
N6A3200E For piston grade stamped on the head of piston.

4JB1 / 4JB1-TC mm (in)

Liner
Cylinder bore diameter Liner bore
outside Liner outside diameter Service liner bore measurement
average Grade
Grade
95.001 — 95.010 95.011 — 95.020 AX 93.035 (3.6628) — 93.050 (3.6634)
1
(3.7402 — 3.7406) (3.7406 — 3.7409) CX 93.051 (3.6634) — 93.066 (3.6640)
95.011 — 95.020 95.021 — 95.030 AX 93.035 (3.6628) — 93.050 (3.6634)
2
(3.7406 — 3.7409) (3.7410 — 3.7413) CX 93.051 (3.6634) — 93.066 (3.6640)
95.021 — 95.030 95.031 — 95.040 AX 93.035 (3.6628) — 93.050 (3.6634)
3
(3.7410 — 3.7413) (3.7414 — 3.7417) CX 93.051 (3.6634) — 93.066 (3.6640)
95.031 — 95.040 95.041 — 95.050 AX 93.035 (3.6628) — 93.050 (3.6634)
4
(3.7414 — 3.7417) (3.7418 — 3.7421) CX 93.051 (3.6634) — 93.066 (3.6640)

3) Insert the cylinder liner (1) into the cylinder

Notice:
body (2) from the top of the cylinder body.
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.
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in slight
decreases in cylinder liner clearances. Always measure
the cylinder liner clearance after installation to be sure
that it is correct.

Cylinder Liner Installation

1. Cylinder Liner Installation Using The Special Tool.
1) Use new kerosene or diesel oil to thoroughly
clean the cylinder liners and bores.
2) Use compressed air to blow-dry the cylinder lin-
er and bore surfaces.
Cylinder Liner Installer
: 5-8840-2040-0
N6A3201E

Notice:
4) Set the cylinder liner installer (3) to the top of
All foreign material must be carefully removed from the
the cylinder liner.
cylinder liner and the cylinder bore before installation.
LG4JB-WE-1111.book 49 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-49

Position the cylinder body so that the installer
center is directly beneath the bench press shaft
center (4).
Cylinder Liner Installer
: 5-8840-2040-0

N6A3106E

4. Crankshaft
5. Main Bearing Cap
6. Crankshaft Rear Oil Seal
N6A3202E
7. Cylinder Block Rear Plate
8. Flywheel
Above works refer to “CRANKSHAFT” Section in
Notice:
this manual.
Check that the cylinder liner is set perpendicular to the
bench press and that there is no wobble. 9. Piston and Connecting Rod
1) Try to insert the piston pin into the piston pin
5) Use the bench press to apply a seating force of hole with normal finger pressure.
500 kg (1,102.5 lb/4,900 N) to the cylinder liner.
2) Clamp the connecting rod in a vise.
6) Apply a force 2,500 kg (5,512.5 lb/24,500 N) to Take care not to damage the connecting rod.
fully seat the cylinder liner.
3) Use a pair of pliers to install the piston pin snap
7) After installing the cylinder liner, measure the ring to the piston.
cylinder liner projection.
8) After installing the cylinder liner, measure the
cylinder liner projection.
Refer to “Cylinder Liner Projection Inspection”
in this Section.
Measure the cylinder liner bore inside diameter
and select the appropriate piston grade.

Reassembly
1. Cylinder Block
2. Tappet
3. Camshaft
• Apply a coat of engine oil to the tappet and the
cylinder body tappet insert holes.
• Locate the position mark applied at disassem-
bly (if the tappet is to be reused).
• Apply a coat of engine oil to the camshaft and
N6A3173E
the camshaft bearings.
• Install the camshaft to the cylinder body.
Take care not to damage the camshaft bear- Notice:
ings. When changing piston/connecting rod combinations, do
not change the piston/piston pin combination.
4) Install the piston to the connecting rod.
LG4JB-WE-1111.book 50 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-50 GENERAL ENGINE MECHANICAL

The piston head front mark (1) and the connect-
ing rod “ISUZU” casting mark (2) must be fac-
ing the same direction.

N6A3207E

7) Install the piston rings with the piston ring ex-

pander.
N6A3205E
Discrimination mark is painted as shown in the
5) Apply a coat of engine oil to the piston pin and illustration.
the piston pin hole. Notice:
Use your fingers to force the piston pin into the There is no up or down side with the compression ring
piston until it makes contact with the snap ring. 1st.

N6A3206E
LNW21BSH034901

6) Use your fingers to force the piston pin snap

ring into the piston snap ring groove. Legend
Check that the connecting rod moves smoothly 1. N mark (2nd ring)
on the piston pin.
8) Use a piston ring replacer to install the three
piston rings.
Piston Ring Replacer:
Install the piston rings in the numerical order
shown in the illustration.
LG4JB-WE-1111.book 51 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-51

Legend
1. Compression ring 1st
2. Compression ring 2nd
3. Oil ring
4. Coil expander
5. Front mark

12) Carefully wipe any oil or other foreign material

from connect rod bearing back face and the
connecting rod bearing fitting surface.
13) Apply a coat of engine oil to the upper bearing
surfaces.
Apply a coat of engine oil to the cylinder wall.

LNWB1BSH022801

Legend
1. Oil ring (with coil expander)
2. Compression ring 2nd
3. Compression ring 1st

Notice:
Install the compression rings with the stamped side fac-
ing up.
There is no up or down side with the compression ring
1st.
Insert the coil expander into the oil ring groove so that
there is no gap on either side of the coil expander before LNWB1BSH022701
installing the oil ring.
9) Apply engine oil to the piston ring surfaces. 14) Position the piston head from mark so that it is
10) Check that the piston rings rotate smoothly in facing the front of engine.
the piston ring grooves. Use the piston ring compressor to compress
the piston rings.
11) Position the piston ring gaps as shown in the il-
lustration. Piston Ring Compressor: 5-8840-9018-0 (J-
8037)
15) 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 TDC.

Notice:
• Set the crankshaft pin to top dead center with each
cylinder, when inserting piston/connecting rod.
• When inserting piston/connecting rod if the crank
pin is set to the bottom dead center, the oil jet might
hit connecting rod and it might break.

N6A3208E
LG4JB-WE-1111.book 52 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A-52 GENERAL ENGINE MECHANICAL

• 4JB1: 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)

N6A3210E

N6A3212E
16) Position the connecting rod cap front mark so
that it is facing the front of the engine.
17) Install the connecting rod caps. Notice:
Align the connecting rod cap cylinder number Check to see that the crankshaft turns smoothly by ro-
marks and the connecting rod cylinder number tating it manually.
marks. 10. Piston Cooling Oil Pipe
1) Fix the oil jet pipes with knock pins on the cylin-
der block.
2) Install the oil pipe for piston cooling in the cylin-
der block, tightening a relief valve and four joint
bolts to the specified torque.
Tighten:
• Oil pipe fixing bolts to
M8: 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
M6: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
• Relief valve fixing bolt to 29 N⋅m (3 kg⋅m/22 lb⋅ft)

N6A3211E

Legend
1. Front mark

18) Apply a coat of engine oil to the threads and

setting faces of each connecting rod bolt.
19) Tighten the connecting rod bolts to the speci-
fied torque in two steps using the Angular Tight-
ening Method.
Tighten: LNW81BSH008601
Connecting Rod Bearing Cap Bolt to
• 4JB1-TC
1st Step: 29.4 N⋅m (3.0 kg⋅m/22 lb⋅ft)
2nd Step: 45° — 60°
LG4JB-WE-1111.book 53 ページ ２０１１年７月２７日　水曜日　午後６時１４分

GENERAL ENGINE MECHANICAL 6A-53

Caution:
After installed the piston assembly. Check and see that
there is appropriate clearance between pistons and oil
jet pipes by rotating crankshaft slowly.
11. Oil Pump Assembly
Above works refer to “OIL PUMP” Section in this
manual.
12. Timing Gear Housing
13. Timing Gear
1) Crankshaft Gear
2) Crankshaft Timing Gear
3) Idle Gear
4) Idler Gear “B” and Shaft
5) Injection Pump
6) Timing Gear Oil Pipe
7) Timing Gear Case Cover N6A3214E

8) Crankshaft Damper Pulley

Piston Head Projection Measurement Point
9) Cooling Fan Assembly
2) Use a dial indicator to measure the piston pro-
10) AC Generator, Power Steering Pump Drive jection amount.
Belt
3) Refer to the illustration for the piston head pro-
11) Fan Shroud jection measuring positions.
Above works refer to “CRANKSHAFT” Section All measuring positions should be as close as
in this manual. possible to the cylinder liner.
14. Oil Pan Assembly 4) Measure the points (1) (2) (3) (4) and obtain
Above works refer to “OIL PUMP” Section in this two difference (1) — (2) and (3) — (4) on each
manual. cylinder.
15. Cylinder Head Assembly and Gasket Calculate the average value of the piston head
1) Cylinder head gasket is determined by the pis- projection on each cylinder.
ton head projection from the cylinder body up- 5) Obtain the average value in the four cylinders.
per surface, in order to improve engine 6) Determine the gasket grade required to the
performance. maximum value described above in accor-
Three types of gasket are provided by the dif- dance with the following table.
ference of thickness. Select the adequate one
out of three grades of gasket, according to the
following procedure.
Before measurement, clear off carbon from the
piston head and cylinder body surface and also
clean the place where a gasket was installed.

N6A3215E

Cylinder Head Gasket Thickness

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6A-54 GENERAL ENGINE MECHANICAL

6. Tighten the cylinder head bolts to the specific
torque in three step following the numerical and
shown in the illustration.
Tighten:
mm (in)
Cylinder Head Bolts to
• 1st Step: 49 N⋅m (5 kg⋅m/36 lb⋅ft)
1 2 3
• 2rd Step: 60° — 75°
A
0.715 - 0.813 1.60 • 3rd Step: 60° — 75°
(0.028 - 0.032) (0.0630)

0.813 - 0.859 1.65

B
(0.032 - 0.034) (0.0650)

0.859 - 0.914 1.70

C
(0.034 - 0.036) (0.0670)

LNWB1BSH023001

Legend
1. Gasket grade mark
2. Piston projection
3. Gasket thickness (Reference)

N6A3219E

Push Rod
• Apply engine oil to push rod and into the cylinder
head.
Rocker Arm Shaft Assembly
1. Loosen all adjusting screws.
2. Position the rocker arm shaft with the large oil hole
(φ4) facing the front of the engine.

N6A3216E

Notice:
The difference between the highest measured piston
head projection and the lowest measured piston head
projection must not exceed 1.0mm (0.039 in).
Cylinder Head Assembly
1. Install the dowel in cylinder block.
2. Install the cylinder head gasket with top mark up.
3. Clean up cylinder head lower surface and cylinder
body upper surface. N6A3119E
4. Install the cylinder head as softly.
3. Tighten the rocker arm shaft bracket bolts to the
5. Apply molybdenum disulfide grease to screw and
specified torque in the numerical order shown in
seat of cylinder head bolts.
the illustration.
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GENERAL ENGINE MECHANICAL 6A-55

Tighten:
Rocker Arm Shaft Bracket Bolt to 54 N⋅m (5.5 kg⋅m/40
lb⋅ft)

N6A3091E

• Valve clearance adjustment.

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MEMO
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4JB1/4JB1-TC - ENGINE 6A1-1

ENGINE
SECTION 6A1
4JB1/4JB1-TC - ENGINE
Contents
GENERAL DESCRIPTION ................................. 6A1-2 OIL PUMP ASSEMBLY .....................................6A1-40
ENGINE MOUNT (RH)........................................ 6A1-4 Component ....................................................6A1-40
Component ...................................................... 6A1-4 Removal.........................................................6A1-40
Removal .......................................................... 6A1-4 Installation......................................................6A1-41
Installation ....................................................... 6A1-5 PISTON, PISTON RING AND CONNECTING
ENGINE MOUNT (LH) ........................................ 6A1-6 ROD...................................................................6A1-43
Component ...................................................... 6A1-6 Component ....................................................6A1-43
Removal .......................................................... 6A1-6 Removal.........................................................6A1-43
Installation ....................................................... 6A1-7 Installation......................................................6A1-46
INLET MANIFOLD .............................................. 6A1-8 CAMSHAFT AND TAPPET ...............................6A1-52
Component ...................................................... 6A1-8 Component ....................................................6A1-52
Removal .......................................................... 6A1-8 Removal.........................................................6A1-52
Installation ....................................................... 6A1-9 Installation......................................................6A1-55
EXHAUST MANIFOLD...................................... 6A1-10 CRANKSHAFT FRONT OIL SEAL....................6A1-57
Component .................................................... 6A1-10 Component ....................................................6A1-57
Removal ........................................................ 6A1-10 Removal.........................................................6A1-57
Installation ..................................................... 6A1-11 Installation......................................................6A1-58
OIL COOLER (Oil Cooler Model) ...................... 6A1-12 CRANKSHAFT REAR OIL SEAL ......................6A1-59
Component .................................................... 6A1-12 Component ....................................................6A1-59
Removal ........................................................ 6A1-12 Removal.........................................................6A1-59
Inspection ...................................................... 6A1-12 Installation......................................................6A1-61
Installation ..................................................... 6A1-13 FLYWHEEL AND PILOT BEARING ..................6A1-65
OIL FILTER CARTRIDGE................................. 6A1-14 Component ....................................................6A1-65
Component .................................................... 6A1-14 Removal.........................................................6A1-65
Removal ........................................................ 6A1-14 Installation......................................................6A1-65
Installation ..................................................... 6A1-14 CRANKSHAFT AND MAIN BEARINGS ............6A1-67
CYLINDER HEAD COVER ............................... 6A1-15 Component ....................................................6A1-67
Component .................................................... 6A1-15 Removal.........................................................6A1-67
Removal ........................................................ 6A1-15 Installation......................................................6A1-70
Installation ..................................................... 6A1-15 ENGINE ASSEMBLY ........................................6A1-75
ROCKER ARM SHAFT ASSEMBLY................. 6A1-16 Component ....................................................6A1-75
Component .................................................... 6A1-16 Removal.........................................................6A1-75
Removal ........................................................ 6A1-16 Installation......................................................6A1-80
Installation ..................................................... 6A1-17
VALVESTEM OIL CONTROLLER & VALVE
SPRING ............................................................ 6A1-19
Component .................................................... 6A1-19
Removal ........................................................ 6A1-19
Installation ..................................................... 6A1-20
TIMING GEAR .................................................. 6A1-22
Component .................................................... 6A1-22
Removal ........................................................ 6A1-22
Installation ..................................................... 6A1-24
CYLINDER HEAD ASSEMBLY AND GASKET 6A1-29
Component .................................................... 6A1-29
Removal ........................................................ 6A1-29
Installation ..................................................... 6A1-32
OIL PAN ............................................................ 6A1-37
Component .................................................... 6A1-37
Removal ........................................................ 6A1-37
Installation ..................................................... 6A1-38
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6A1-2 4JB1/4JB1-TC - ENGINE

GENERAL DESCRIPTION

LNWB6ASF000301
LG4JB-WE-1111.book 3 ページ ２０１１年７月２７日　水曜日　午後６時１４分

4JB1/4JB1-TC - ENGINE 6A1-3

The 4JB1 Model engine employs a square troidal type
combustion chamber provided with a fence around it.
These designs employed allow a superior fuel economy
over a wide range of driving conditions.
For the cylinder head gasket steel sheets, laminated
steel sheets are employed.
Three grades of the gaskets according to the piston
head projection measured from the cylinder block are
employed to minimize the fluctuation of the engine com-
pression ratio.
The Angular Tightening Method is employed to tighten
the cylinder head fixing bolts, connecting rod fixing bolts
and flywheel fixing bolts.
The chrome-plated steel dry type (Chromard) cylinder
liners provide the highest durability.
Auto-thermic pistons with cast steel struts are used to
reduce thermal expansion and resulting engine noise
experienced while the engine is cold.
The tufftrided crankshaft has a long service life. Be-
cause it is tufftrided, it cannot be reground.
The crankshaft main bearings and the connecting rod
bearings are of aluminum alloy. These bearings are es-
pecially vulnerable to foreign materials such as metal
scraps. It is very important to keep the oil ports and other
related surfaces clean and free of foreign materials.
The tufftriding treatment (nitriding treatment) of the
crankshaft for the increased strength eliminates the re-
grinding of crankpins and journals.
An oiling jet device for piston cooling is provided in the
lubricating oil circuit which runs through the check valve
from the cylinder block oil gallery.
Take care not to damage the oiling jet when removing or
installing the piston and the connecting assembly.
The 4JB1 Model employs a direct injection type engine
provided with a nozzle with four holes, which makes it
possible to obtain an excellent mixing ratio of intake air
and fuel spray.
4JB1-TC engine has two springs injection nozzle sys-
tem for efficient control.
The turbocharger increase air intake efficiency, the re-
sults in increased engine power, reduced fuel consump-
tion and minimal engine noise.
Turbocharger rotating parts operate at very high speeds
and temperatures. The parts materials have been care-
fully selected and machined to extremely high precision.
The 4JB1 Model engine employs the QOS II preheating
system which features a quick-on glow to control the
glow time and the afterglow time by the thermometer.
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6A1-4 4JB1/4JB1-TC - ENGINE

ENGINE MOUNT (RH)

Component

N6A3222E

Legend
A. Rigid suspension 3. Support rubber
B. Independent suspension 4. Lock bolt
1. Fan shroud 5. AC generator fixing bolt
2. Fan belt

Removal 3. Support Rubber

Preparation • Remove two fixing nuts at the crossmember side.
• Disconnect battery ground cable.
1. Fan Shroud
• Remove reservoir tank hose and fan shroud.

N6A3224E

• Separate the generator from the engine.

• Remove the support rubber nut from engine foot
N6A3223E side.
2. Fan Belt • Remove the support rubber while raising the en-
gine.
• Remove adjust plate lock bolt.
• Loosen generator fixing bolt then remove fan belt.
LG4JB-WE-1111.book 5 ページ ２０１１年７月２７日　水曜日　午後６時１４分

4JB1/4JB1-TC - ENGINE 6A1-5

N6A3225E LNW81BSH014801

Installation
Legend
1. Support Rubber 1. AC generator & fan pulley drive belt
• Install the support rubber while raising the engine. 2. P/S oil pump drive belt (with P/S oil pump type
• Tighten the fixing nuts to the specified torque. only)
Tighten: 3. Fan Shroud
• Engine foot side to 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)
• Install the fan shroud and clip the reservoir tank
• Crossmember side to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft) hose.
2. Fan Belt
• Install the fan belt.
• Depress the fan belt mid-portion with a 98 N (10 kg/
22 lb) force and check each bolt to deflection.

mm (in)
Initial tension
AC generator & fan pulley drive belt 8—12
P/S oil pump drive belt (0.31—0.47)

• Tighten the fixing bolt to the specified torque.

Tighten:
• Adjust plate lock bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Generator fixing bolt to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
LG4JB-WE-1111.book 6 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A1-6 4JB1/4JB1-TC - ENGINE

ENGINE MOUNT (LH)

Component

N6A3227E

Legend
A. Rigid suspension 2. Fan shroud
B. Independent suspension 3. Support rubber
1. Air intake duct

Removal
Preparation
• Disconnect battery ground cable.
1. Air Intake Duct
• Remove the intake duct.
2. Fan Shroud
• Remove reservoir tank hose and fan shroud.

N6A3228E

• Remove the support rubber nut from engine foot

side.
• Remove the support rubber while raising the en-
gine.

N6A3223E

3. Support Rubber
• Remove two fixing bolts at the crossmember side.
LG4JB-WE-1111.book 7 ページ ２０１１年７月２７日　水曜日　午後６時１４分

4JB1/4JB1-TC - ENGINE 6A1-7

N6A3229E N6A3223E

Installation 3. Air Intake Duct

1. Support Rubber • Install the air intake duct.
• Install the support rubber while raising the engine. • Connect battery ground cable.
• Tighten the fixing nuts to the specified torque.
Tighten:
• Engine foot side to 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)
• Crossmember side to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

N6A3228E

2. Fan shroud
• Install the fan shroud and clip the reservoir tank
hose.
LG4JB-WE-1111.book 8 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6A1-8 4JB1/4JB1-TC - ENGINE

INLET MANIFOLD
Component

N6A3230E

Legend
1. Vacuum hose 5. Oil level gauge guide tube
2. Air intake duct 6. Oil cooler water pipe (Oil Cooler Model)
3. PCV hose 7. Inlet manifold
4. Injection pipe

Removal
Preparation
• Disconnect battery ground cable.
• Drain coolant.
1. Vacuum Hose
2. Air Intake Duct
3. PCV Hose
4. Injection Pipe
• Release injection pipe clip.
• Loosen the flare nut on the injection pump side.
• Loosen the flare nut on the injection nozzle side,
disconnect and put a side the pipe.

N6A3231E

5. Oil Level Gauge Guide Tube

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4JB1/4JB1-TC - ENGINE 6A1-9

• Remove the fixing bolt and remove level gauge 3. Oil Level Gauge Guide Tube
guide tube. • Install the guide tube and tighten the manifold with
6. Oil Cooler Water Pipe (Oil Cooler Model) guide tube.
• Remove the water pipe bracket bolt. 4. Injection Pipe
• Remove the inlet manifold fixing nut. • Connect the injection pipe and tighten flare nut to
the specified torque.
Tighten:
• Flare nut to 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
• Install the pipe clip to the original position.

N6A3232E

7. Inlet Manifold
• Remove the manifold fixing bolt and nut.

Installation N6A3781E

1. Inlet Manifold
5. PCV Hose
• Tighten the fixing bolts and nuts to the specified 6. Air Intake Duct
torque.
7. Vacuum Hose
Tighten: • Connect the battery ground cable.
• Bolt & nut to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Pour coolant.
2. Oil Cooler Water Pipe (Oil Cooler Model)
• Start the engine and check coolant leakage.
• Install the water pipe and tighten the manifold with
water pipe.
• Tighten the pipe bracket bolt of cylinder head rear
side.

N6A3233E
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6A1-10 4JB1/4JB1-TC - ENGINE

EXHAUST MANIFOLD
Component

N6A3235E

Legend
1. Vacuum hose 4. Heat protector
2. Front exhaust pipe nut 5. Exhaust manifold
3. Front exhaust pipe stay bolt

Removal
Preparation
• Disconnect battery ground cable.
1. Vacuum Hose (Exhaust Brake Model)
• Remove the vacuum actuator hose.
2. Front Exhaust Pipe Nut
• Remove the fixing nuts from exhaust manifold side.
3. Front Exhaust Pipe Stay Bolt

N6A3236E

4. Heat Protector
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4JB1/4JB1-TC - ENGINE 6A1-11

5. Exhaust Manifold
• Remove the manifold bolt and nut, then remove the
manifold and gasket.
Notice:
• Remove the EGR port cover. (4JB1-TC, without
EGR cooler type)

Installation
Notice:
• Install the EGR port cover. (4JB1-TC, without EGR
cooler type)
• Tighten the fixing nuts to the specified torque.
1. Exhaust Manifold
• Tighten the fixing nuts and bolts to the specified
torque.
Tighten:
• Manifold bolt to 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
2. Heat Protector
• Install the heat protector and tighten to the speci-
fied torque.
Tighten:
• Heat protector bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
3. Front Exhaust Pipe Stay Bolt
• Tighten the fixing bolts to the specified torque.
Tighten:
• Stay bolt to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
4. Front Exhaust Pipe Nut
• Tighten the fixing nuts to the specified torque.
Tighten:
• Without exhaust brake to 69 N⋅m (7 kg⋅m / 51 lb⋅ft)
• With exhaust brake to 69 N⋅m (7 kg⋅m / 51 lb⋅ft)
5. Vacuum Hose (Exhaust Brake Model)
• Install the two hose a vacuum actuator.
• Connect battery ground cable.
• Start the engine and check coolant leakage.
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6A1-12 4JB1/4JB1-TC - ENGINE

OIL COOLER (Oil Cooler Model)

Component

N6A3237E

Legend
1. Water hose 3. Oil cooler
2. Oil cooler fixing bolt

Removal
Relief Valve Opening Pressure kPa (kg/cm2/psi)
Preparation
Type1 559 — 618
• Disconnect battery ground cable
(5.7 — 6.3/81.0 — 89.6)
• Drain coolant
Type2 422 — 461
• Put rag to beneath side of oil cooler to prevent oil
(4.3 — 4.7/61.1 — 66.8)
leaking.
1. Water Hose
• Disconnect water inlet and outlet hose.
2. Oil Cooler Fixing Bolt
3. Oil Cooler

Inspection
Relief Valve
1. Attach an oil pressure gauge to the oil gallery near
the oil filter.
2. Start the engine to check the relief valve opening
pressure.
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4JB1/4JB1-TC - ENGINE 6A1-13

N6A3238E N6A3240E

Oil Cooler 3. Water Hose

Check for water leakage at the water passage. • Connect water hose.
1. Plug one side of the oil cooler water passage.
2. Submerge the oil cooler in water.
3. Apply compressed air (2 kg/cm2 (28.5 psi / 196.0
kPa)) to the other side of the oil cooler water pas-
sage.
If air bubbles rise to the surface, there is water
leakage.

N6A3239E

Installation
1. Oil Cooler
• Install the O-ring to oil filter body and set the oil
cooler.
2. Oil Cooler Fixing Bolt
Tighten:
• Oil cooler bolt to 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
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6A1-14 4JB1/4JB1-TC - ENGINE

OIL FILTER CARTRIDGE

Component

N6A3241E

Removal
• Place a receptacle beneath the oil filter to contain
the drained oil.
• Remove the oil filter cartridge using filter wrench.
Filter wrench: 5-8840-0200-0

N6A3242E

Installation
• Lightly oil the O-ring of oil filter cartridge.
• Turn in the new oil filter cartridge by hand until the
sealing face is fitted against the O-ring.
• Use the filter wrench to turn in the oil filter and ad-
ditional one and 1.1/8 turns.
• Start the engine and check for oil leakage from oil
filter.
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4JB1/4JB1-TC - ENGINE 6A1-15

CYLINDER HEAD COVER

Component

N6A3243E

Legend
1. PCV hose 2. Cylinder head cover

Removal • Install the cylinder head cover gasket to the cylin-

Preparation der head cover.

• Disconnect battery ground cable. • The gasket must be perfectly smooth with no loose
areas.
1. PCV Hose
• Tighten the cylinder head cover nuts to the speci-
• Disconnect the PCV hose from intake pipe side.
fied torque.
2. Cylinder Head Cover
Tighten:
• 13 N⋅m (1.3 kg⋅m / 9 lb⋅ft)
2. PCV Hose
• Connect the PCV hose to the intake pipe.
• Connect battery ground cable.

N6A3244E

Installation
1. Cylinder Head Cover
• Apply engine oil to the rocker arms and the valve
springs.
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6A1-16 4JB1/4JB1-TC - ENGINE

ROCKER ARM SHAFT ASSEMBLY

Component

N6A3245E

Legend
1. PCV hose 3. Rocker arm shaft assembly
2. Cylinder head cover

Removal
Preparation
• Disconnect battery ground cable.
1. PCV Hose
2. Cylinder Head Cover
3. Rocker Arm Shaft Assembly
• Loosen bolts and nuts of rocker shaft bracket by
turns and remove rocker shaft assembly.

N6A3246E
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4JB1/4JB1-TC - ENGINE 6A1-17

Installation Tighten:
1. Rocker Arm Shaft Assembly • Rocker arm shaft bracket nut to 54 N⋅m (5.5 kg⋅m / 40
• Install rocker arm shaft with larger oil hole φ4) to lb⋅ft)
the front of engine.

N6A3091E
N6A3119E
3) Check for play in the No.1 intake and exhaust
• Align fixing bolt with nut of rocker arm shaft and valve push rods.
tighten fixing bolts to the specified torque. If the No.1 cylinder intake and exhaust valve
push rods have play, the No.1 piston is at TDC
Tighten: on the compression stroke.
• 54 N⋅m (5.5 kg⋅m / 40 lb⋅ft)
If the No.1 cylinder intake and exhaust valve
2. Valve clearance adjustment push rods are depressed, the No.4 piston is at
1) Bring the piston in either the No.1 cylinder or TDC on the compression stroke.
the No.4 cylinder to TDC on the compression
stroke by turning the crankshaft until the crank-
shaft damper pulley TDC line is aligned with the
timing pointer.

N6A3028E

Adjust the No.1 or the No.4 cylinder valve clear-

ances while their respective cylinders are at
N6A3026E TDC on the compression stroke.

2) Check the rocker arm shaft bracket nuts for Valve Clearance (At Cold) mm (in)
looseness.
0.4 (0.016)
Tighten any loose rocker arm shaft bracket
nuts before adjusting the valve clearance.
4) Loosen each valve clearance adjusting screw
as shown in the illustration.
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6A1-18 4JB1/4JB1-TC - ENGINE

No. 1 Cylinder T.D.C (Compression stroke) 4. PCV Hose
• Connect battery ground cable.

N6A3249E

5) Insert a feeler gauge of the appropriate thick-

ness between the rocker arm and the valve
stem end.
6) Turn the valve clearance adjusting screw until
a slight drag can be felt on the feeler gauge.
7) Tighten the lock nut securely.
8) Rotate the crankshaft 360°.
9) Realign the crankshaft damper pulley TDC
notched line with the timing pointer.
10) Adjust the clearances for the remaining valves
as shown in the illustration.
No. 4 Cylinder T.D.C (Compression stroke)

N6A3250E

3. Cylinder Head Cover

• Install cylinder head cover and tighten bolts to the
specified torque.
Tighten:
• 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
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4JB1/4JB1-TC - ENGINE 6A1-19

VALVESTEM OIL CONTROLLER & VALVE SPRING

Component

N6A3251E

Legend
1. Cylinder head cover 3. Valve spring
2. Rocker arm shaft assembly 4. Valve guide oil seal

Removal
Preparation
• Disconnect battery cable.
1. Cylinder Head Cover
2. Rocker Arm Shaft Assembly
• Loosen bolts and nuts of rocker shaft bracket by
turns and removal rocker shaft assembly.
3. Valve Spring
• Apply compressed air to cylinder from the glow
plug hole hold the valve in place.
• Using special tool, compress valve spring and re-
moval split cover.
Valve spring compressor: 9-8523-1423-0 (J-
29760)

N6A3075E
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6A1-20 4JB1/4JB1-TC - ENGINE

Caution: Caution:
Put removed valve spring in the order of cylinder num- • The painted area of the valve spring should be fac-
ber. ing toward.
4. Valve Guide Oil Seal
• Remove valve guide oil seal by pliers

N6A3069E

• Apply compressed air to cylinder from the glow

N6A3253E plug hole to hold the valve in place.
• Install split collar by special tool
Caution:
Removed oil controller should not be reused. Valve spring compressor: 9-8523-1423-0 (J-
29760)
Installation 3. Rocker Arm Shaft Assembly
1. Valve Guide Oil Seal • Install rocker arm shaft with larger oil hole φ4) to
• Install new valve guide oil seal in valve. the front of engine.
• Guide using special tool.
Special tool: 5-8840-2033-0

N6A3119E

• Align fixing bolt with nut of rocker arm shaft and

N6A3068E tighten fixing bolts to the specified torque.
2. Valve Spring Tighten:
• Attach the new valve spring to the upper spring • 54 N⋅m (5.5 kg⋅m / 40 lb⋅ft)
seat. • Valve clearance adjustment
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4JB1/4JB1-TC - ENGINE 6A1-21

4. Valve clearance adjustment
Above works refer to “ROCKER ARM SHAFT AS-
SEMBLY” Section in this manual.
5. Cylinder Head Cover
• Apply engine oil to the rocker arms and the valve
spring.
• Install the cylinder head cover gasket to the cylin-
der head cover.
The gasket must be perfectly smooth with no loose
areas.
• Install cylinder head cover and tighten bolt to the
specified torque.
Tighten:
• Head cover bolt to 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)

N6A3254E

• Connected PCV hose.

• Connect battery ground cable.
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6A1-22 4JB1/4JB1-TC - ENGINE

TIMING GEAR
Component

13

11
12
14

LNWB1BLF006801

Legend
1. Fan shroud 8. Timing gear case cover
2. Power steering pump drive belt 9. Oil pipe
3. AC generator drive belt 10. Idle gear
4. Cooling fan assembly 11. Idle gear
5. Crankshaft damper pulley 12. Injection pump
6. Noise shield cover 13. Camshaft timing gear
7. Noise cover spacer 14. Crankshaft gear

Removal • Loosen power steering pump mounting bolt and

adjust bolt, and remove the drive belt.
Preparation
3. AC Generator Drive Belt
• Disconnect battery ground cable.
• Loosen AC Generator mounting bolt (under size)
• Drain coolant.
and adjust plate lock bolt, and remove the drive
1. Fan Shroud belt.
2. Power Steering Pump Drive Belt (P/S Model) 4. Cooling Fan Assembly
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4JB1/4JB1-TC - ENGINE 6A1-23

• Remove clamp nut, and remove cooling fan as-
sembly, distant pipe, and fan pulley.
5. Crankshaft Damper Pulley
6. Noise Shield Cover
7. Noise Cover Spacer
8. Timing Gear Case Cover
9. Oil Pipe
10. Idler Gear
1) Measure the camshaft timing gear backlash
and the crankshaft timing gear backlash before
removing the idler gear.
2) Measure the idler gear end play before remov-
ing the idler gear.

N6A3258E

12. Idle Gear

13. Injection Pump
1) Remove the six injection pump bracket bolts (1)
from the timing gear case.

N6A3256E

Notice:
Refer to the following items for details on the backlash
and end play measurement procedures.
11. Idler Gear “A” End Play Measurement
Insert a feeler gauge between the idler gear and
the thrust collar to measure the gap and determine
the idler gear end play.
N6A3259E
If the measured value exceeds the specified limit,
the thrust collar must be replaced. 2) Remove the injection pump rear bracket bolts
(2) from the injection pump bracket (3).
Idle Gear End Play mm (in) 3) Remove the injection pump rear bracket bolts
Standard Limit (4) and the bracket (5) from the cylinder body.
0.07 (0.0028) 0.2 (0.0079)
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6A1-24 4JB1/4JB1-TC - ENGINE

2) Remove the camshaft timing gear bolt from the
camshaft.
Notice:
Hold the camshaft stationary to prevent the camshaft
from turning.
3) Use the universal puller (1) to pull out the cam-
shaft timing gear (2).
Universal Puller: 5-8521-0002-0
4) Remove the thrust plate (3).

N6A3260E

4) Pull the injection pump along with the injection

pump timing gear free toward the rear of the en-
gine.
Notice:
Plug the injection pump delivery holder ports with the
shipping caps (or the equivalent) to prevent the entry of
foreign material.
14. Camshaft Timing Gear
N6A3093E
1) Use a dial indicator to measure the camshaft
end play. This must be done before removing 15. Crankshaft Gear
the camshaft gear.
If the camshaft end play exceeds the specified Installation
limit, the thrust plate must be replaced.
1. Crankshaft Gear
Camshaft End Play mm (in) 1) Install the crankshaft gear.
2) Use the crankshaft gear installer (1) to install
Standard Limit the crankshaft gear (2).
0.050 — 0.114 0.2 (0.008) The crankshaft gear timing mark (“X — X”)
(0.002 — 0.0044) must be facing outward.
Crankshaft Gear Installer: 9-8522-0020-0

N6A3095E
N6A3160E
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4JB1/4JB1-TC - ENGINE 6A1-25

2. Camshaft Timing Gear
1) Install the thrust plate to the cylinder body. Gear
2) Tighten the thrust plate bolts to the specified Crank gear — Idle gear “A” X—X
torque. Idle gear “A” — Cam gear Y—Y
Tighten: Idle gear “A” — Idle gear “B” Z—Z
• 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
Idle gear “B” — Injection pump V—V
3) Install the camshaft timing gear to the cam-
shaft. 3) Temporarily tighten the six injection pump bolts
The timing gear mark (“Y — Y”) must be facing (5).
outward. The injection pump bolts will be finally tight-
4) Tighten the timing gear to the specified torque. ened after the injection pump rear bracket
Tighten: bolts.
• 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)

N6A3166E

N6A3111E
4) Install the injection pump rear bracket (6) and
3. Injection Pump the rear bracket bolts (7) to the cylinder body.
1) Install the O-ring (1) to the injection pump 5) Install the rear bracket bolts (8) to the injection
flange (2). pump bracket (9).
Do not tighten the bolts.
2) Install the injection pump to the timing gear
case. The rear bracket bolts (7) and (8) will be finally
Align the idler gear “B” (3) “V — V” mark with tightened to the specified torque after tighten
the injection pump timing gear (4) “V” mark. the injection pump nuts.

N6A3167E
N6A3164E
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6A1-26 4JB1/4JB1-TC - ENGINE

6) Tighten the injection pump nuts to the specified 5) Install the thrust collar and bolts to the cylinder
torque. body through the shaft.
The thrust collar oil hole must be facing up, and
Tighten:
the thrust collar chamfered must be outward.
• 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
6) Tighten the idler gear bolt to the specified
7) Tighten the injection pump bracket bolts to the
torque.
specified torque.
Tighten:
Tighten:
• 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
5. Idler Gear
4. Idler Gear
1) Apply engine oil to the idler gear and the idler
1) Apply engine oil to the idler gear and the idler
gear shaft.
gear shaft.
The idler gear shaft oil hole must be facing up. 2) Align the idler gear “B” (3) “Z” setting mark with
the idler gear “A” (4) “Z — Z” setting mark.

N6A3161E
N6A3163E

2) Position the idler gear setting marks “X” and “Y”

so that they are facing the front of the engine. 3) Tighten the idler gear bolt to the specified
torque.
3) Align the idler gear “X” setting mark with the
crankshaft timing gear (1) “X — X” setting mark. Tighten:
4) Align the idler gear “Y” setting mark with the • 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
camshaft timing gear (2) “Y — Y” setting mark. 6. Oil Pipe
1) Install the oil pipe to the timing gear case and
idler gear “A”.
2) Tighten the oil pipe eye bolt (1) and bolt (2) to
the specified torque.
Tighten:
• Oil pipe eye bolt to 13 N⋅m (1.3 kg⋅m / 9 lb⋅ft)

N6A3270E
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4JB1/4JB1-TC - ENGINE 6A1-27

N6A3168E N6A3170E

7. Timing Gear Case Cover 11. Cooling Fan Assembly

1) Align the gear case with the timing gear case • Mount fan pulley, distance piece, and cooling fan
knock pin and then install the timing gear case assembly (in this order) on the water pump, and
cover. tighten to the specified torque.
2) Tighten the gear case cover bolts to the speci-
Tighten:
fied torque.
• 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
12. AC Generator Drive Belt
• Install AC Generator drive belt and adjust belt ten-
sion.
• Depress the drive belt mid-portion with a 98 N (10
kg / 22 lb) force.

mm (in)
Initial tension
AC generator & fan pulley drive belt 8—12
P/S oil pump drive belt (0.31—0.47)

Drive Belt Deflection mm (in)

8 (0.31) — 12 (0.47)

• Tighten the idler lock nut to the specified torque.

N6A3169E
Tighten:
8. Noise Cover Spacer • Idler lock nut to 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
9. Noise Shield Cover 13. Power Steering Pump Drive Belt (P/S Model)
10. Crankshaft Damper Pulley
• Install Power Steering pump drive belt and adjust
Tighten the crankshaft damper pulley bolt to the
belt tension.
specified torque.
• Depress the drive belt mid-portion with a 98 N (10
Notice: kg / 22 lb) force.
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper pul- mm (in)
ley. Initial tension

Tighten: AC generator & fan pulley drive belt 8—12

• Crankshaft pulley bolt to 294 N⋅m (30 kg⋅m / 217 lb⋅ft) P/S oil pump drive belt (0.31—0.47)
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6A1-28 4JB1/4JB1-TC - ENGINE

Drive Belt Deflection mm (in)

8 (0.31) — 12 (0.47)

• Tighten the idler lock nut to the specified torque.

Tighten:
• 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
14. Fan shroud
• Install the fan shroud and reservoir tank hose.
• Pour coolant
• Start the engine and check coolant leakage.
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4JB1/4JB1-TC - ENGINE 6A1-29

CYLINDER HEAD ASSEMBLY AND GASKET

Component

14
1
3
7

15 2
4

17

13

5 10

16
8 9

18

11

12

LNWB1BLF006301

Legend
1. Radiator hose upper 10. Oil cooler water pipe
2. Heater hose 11. Vacuum actuator hose
3. Engine harness 12. Front exhaust pipe
4. Air intake duct 13. By-pass hose
5. Injection pipe 14. Cylinder head cover
6. Leak off pipe 15. Rocker arm shaft
7. PCV hose 16. Push rod
8. Glow plug harness 17. Cylinder head assembly
9. Oil level gauge guide tube 18. Cylinder head gasket

Removal 1. Radiator Hose Upper

Preparation • Disconnect upper radiator hose from engine side.
• Disconnect battery ground cable. 2. Heater Hose
• Drain coolant from the radiator and engine. • Disconnect heater hose from heater pipe.
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6A1-30 4JB1/4JB1-TC - ENGINE

3. Engine Harness
• Disconnect harness connectors from units on ther-
mostat housing.

N6A3287E

8. Glow Plug Harness

9. Oil Level Gauge Guide Tube
N6A3286E
• Remove the guide tube from cylinder head.

Legend
1. Thermo-sensor

4. Air Intake Duct

• Remove the clip and air intake duct.
5. Injection Pipe
• Release injection pipe clip.
• Remove flare nut injection pump side.
• Remove flare nut injection nozzle side and remove
injection pipe.
Notice:
Plug the injection nozzle holder and the delivery holder
to prevent the entry of foreign matters into them.
6. Leak Off Pipe
• Remove the leak off pipe side of leak off hose.
N6A3288E
7. PCV Hose
• Remove the PCV hose from air intake pipe. 10. Oil Cooler Water Pipe (Oil Cooler Model)
• Remove the pipe fixing bolt of cylinder head rear
side.
• Remove the oil cooler water pipe fixing nut from in-
let manifold.
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4JB1/4JB1-TC - ENGINE 6A1-31

N6A3289E N6A3292E

11. Vacuum Actuator Hose (Exhaust Brake Model) 15. Rocker Arm Shaft
• Remove the vacuum hoses from vacuum actuator. • Loosen the rocker arm shaft bracket bolts a little at
a time in the numerical order shown in the illustra-
tion.

N6A3291E

12. Front Exhaust Pipe N6A3246E

• Remove the exhaust pipe fixing bolts from exhaust
manifold. Notice:
• Remove the exhaust pipe stay bolt. Failure to loosen the rocker arm shaft bracket bolts a lit-
13. By-pass Hose tle at a time in numerical order will adversely effect the
14. Cylinder Head Cover rocker arm shaft.
16. Push Rod
17. Cylinder Head Assembly
• Loosen the cylinder head bolts a little at a time in
the numerical order shown in the illustration.
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6A1-32 4JB1/4JB1-TC - ENGINE

N6A3055E N6A3214E

2) Refer to the illustration for the piston head pro-

Notice:
jection measuring positions.
Failure to loosen the cylinder head bolts a little at a time
All measuring positions should be as close as
in numerical order will adversely effect the cylinder head
possible to the cylinder liner.
lower surface.
18. Cylinder Head gasket
• Remove the cylinder head gasket and dowel.

Installation
1. Cylinder Head Gasket
Cylinder head gasket is determined by the piston
head projection from the cylinder body upper sur-
face, in order to improve engine performance.
Three types of gasket are provided by the differ-
ence of thickness. Select the adequate one out of
three grades of gasket, according to the following
procedure.
Before measurement, clear off carbon from the pis-
ton head and cylinder body surface and also clean
the place where a gasket was installed.
Piston Head Projection Measurement Point
1) Use a dial indicator to measure the piston pro- N6A3215E

jection amount.
3) Measure the points (1), (2), (3) and (4) and ob-
tain two differences (1) — (2) and (3) — (4) on
each cylinder.
Calculate the average value of the piston head
projection on each cylinder.
4) Obtain the average value in the four cylinders.
5) Determine the gasket grade required to the
maximum value described above in accor-
dance with the following table.
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4JB1/4JB1-TC - ENGINE 6A1-33

• 2nd step: 60° — 75°
• 3rd step: 60° — 75°

mm (in)

1 2 3

0.715 - 0.813 1.60

A
(0.028 - 0.032) (0.0630)

0.813 - 0.859 1.65

B
(0.032 - 0.034) (0.0650)

0.859 - 0.914 1.70

C
(0.034 - 0.036) (0.0670)

LNWB1BSH023001

Notice: N6A3219E
The difference between the highest measured piston
head projection and the lowest measured piston head 3. Push Rod
projection must not exceed 1.0 mm (0.039 in). • Apply engine oil to push rod and in to the cylinder
head.
4. Rocker Arm shaft
1) Loosen all adjusting screws.
2) Position the rocker arm shaft with the large oil
hole (φ4) facing the front of the engine.

N6A3216E

2. Cylinder Head Assembly

1) Install the dowel in cylinder block.
2) Install the cylinder head gasket with top mark
up.
N6A3119E
3) Clean up cylinder head lower surface and cylin-
der body upper surface. 3) Tighten the rocker arm shaft bracket bolts to
4) Install the cylinder head as softly. the specified torque in the numerical order
5) Apply engine oil to screw and seat of cylinder shown in the illustration.
head bolts. Tighten:
6) Tighten the cylinder head bolts to the specified • Rocker arm shaft bracket bolt to 54 N⋅m (5.5kg⋅m / 40
torque in three steps following the numerical or- lb⋅ft)
der shown in the illustration.
Tighten:
Cylinder head bolts to
• 1st step: 49 N⋅m (5kg⋅m / 36 lb⋅ft)
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6A1-34 4JB1/4JB1-TC - ENGINE

Tighten:
• W/Exhaust brake manifold nut to 37 N⋅m (3.8 kg⋅m /
27 lb⋅ft)
• WO/Exhaust brake manifold nut to 40 N⋅m (4.1 kg⋅m
/ 30 lb⋅ft)
• Pipe stay bolts to 40 N⋅m (4.1kg⋅m / 30 lb⋅ft)

N6A3091E

• Valve clearance adjustment.

Above works refer to “ROCKER ARM SHAFT AS-
SEMBLY” Section in this manual.
5. Cylinder Head Cover
• Apply engine oil to the rocker arms and the valve
spring. N6A3294E

• Install the cylinder head cover gasket to the cylin-

8. Vacuum Actuator Hose (Exhaust Brake Model)
der head cover.
• Install the vacuum hose to the vacuum actuator.
• The gasket must be perfectly smooth with no loose
areas.
• Tighten the cylinder head cover nuts to the speci-
fied torque in the numerical order shown in the il-
lustration.
Tighten:
• Cylinder head cover to 13 N⋅m (1.3kg⋅m / 113 lb⋅in)

N6A3291E

9. Oil Cooler Water Pipe (Oil Cooler Model)

• Install the water pipe bolt and tighten bolt to the
specified torque.
Tighten:
• Water pipe nut to 19 N⋅m (1.9 kg⋅m / 1.4 lb⋅ft)
N6A3254E
• Pipe bracket bolt to 40 N⋅m (4.1kg⋅m / 30 lb⋅ft)
6. By-Pass Hose
7. Front Exhaust Pipe
• Install the pipe to manifold and tighten bolts and
nuts to the specified torque.
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4JB1/4JB1-TC - ENGINE 6A1-35

N6A3289E N6A3287E

10. Oil Level Gauge Guide Tube 13. Leak Off Pipe
• Install the guide tube bolt and tighten bolt to the • Mount using a new copper washer.
specified torque. 14. Injection Pipe
Tighten: • Install the flare nut to injection pump side.
• Guide tube bolt to 19 N⋅m (1.9 kg⋅m / 1.4 lb⋅ft) • Install the flare nut to injection nozzle side.
• Tighten the flare nut to the specified torque.
Tighten:
• Flare nut to 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)

N6A3288E

11. Glow Plug Harness

12. PCV Hose
N6A3781E

• Fit pipe clip in specified torque.

Tighten:
• Sleeve nut to 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
15. Air Intake Duct
16. Engine Harness
• Connect the thermo-sensor harness and thermo-
meter unit harness.
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6A1-36 4JB1/4JB1-TC - ENGINE

N6A3286E

Legend
1. Thermo-sensor

17. Heater Core

• Connect the heater hose them tighten the clip se-
curely.
18. Radiator Hose Upper
• Connect the radiator hose them tighten clip secure-
ly.
• Pour coolant.
• Connect the battery ground cable.
• Start the engine and check coolant leakage.
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4JB1/4JB1-TC - ENGINE 6A1-37

OIL PAN
Component

N6A3298E

Legend
A. Independent suspension (4 × 2) 2. Engine mount bolts
B. Rigid suspension (4 × 2) 3. Stiffener and space rubber
1. Vacuum pump oil hose 4. Oil pan assembly

Removal 1. Vacuum Pump Oil Hose

Preparation • Remove oil hose (1) from oil pan.
• Disconnect battery ground cable.
• Lift up car.
• Drain engine oil.
Notice:
Install drain plug with new gasket.

Tighten:
• 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
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6A1-38 4JB1/4JB1-TC - ENGINE

N6A3299E N6A3301E

2. Engine Mount Bolts 4. Oil Pan Assembly

• Remove the engine mount bolts right & left side. • Raising the engine about 50mm.
• Remove the oil pan from cylinder block.

Installation
1. Oil Pan Assembly
• Apply the recommended liquid gasket or its equiv-
alent to the No.5 bearing cap arches, the grooves,
and the timing gear case arches at the positions
shown in the illustration.

N6A3300E

3. Stiffener & Space Rubber

• Remove the exhaust pipe bracket.
• Remove the stiffener from of the oil pan left & right
side.
• Take out space rubber.

N6A3302E

• Fit the gasket rear lipped portion into the No.5

groove.
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4JB1/4JB1-TC - ENGINE 6A1-39

N6A3126E

• Be absolutely sure that the lipped portion in fitted

snugly in to the groove.
• Install the oil pan to the cylinder body.
• Tighten the oil pan bolts to the specified torque.
Tighten:
• Oil pan bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
2. Stiffener and Space Rubber
• Install the space rubber.
• Install the stiffener left side and right side tighten
bolt to the specified torque.
Tighten:
• Engine body side to 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
• Clutch housing side to 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
• Install exhaust pipe bracket.
3. Engine Mount Bolts
• Install the mount bolts and tighten to the specified
torque.
Tighten:
• Mount bolt to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
• Install the oil hose to oil pan.
4. Vacuum Pump Oil Hose
• Pour engine oil
• Connect battery ground cable.
• Start the engine and check coolant leakage.
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6A1-40 4JB1/4JB1-TC - ENGINE

OIL PUMP ASSEMBLY

Component

N6A3304E

Legend
A. Independent suspension (4 × 2) 3. Stiffener and space rubber
B. Rigid suspension (4 × 2) 4. Oil pan assembly
1. Vacuum pump oil hose 5. Oil pump assembly
2. Engine mount bolts

Removal Tighten:
Preparation • 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
• Disconnect battery ground cable. 1. Vacuum Pump Oil Hose
• Lift up car. • Remove the oil hose (1) from oil pan.
• Drain engine oil.
Notice:
Install drain plug with new washer.
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4JB1/4JB1-TC - ENGINE 6A1-41

N6A3299E N6A3301E

2. Engine Mount Bolts 4. Oil Pan Assembly

• Remove the engine mount bolts right & left side. • Raise the engine about 50mm.
• Remove the oil pan from cylinder block.
5. Oil Pump Assembly
• Remove the oil pump from cylinder block.

Installation
• Prepare a solution of 80% engine oil and 20% mo-
lybdenum disulfide.
• Apply and ample coat of the solution to the teeth of
the oil pump pinion.
1. Oil Pump Assembly
• Apply engine oil to oil pipe O-ring and insert the O-
ring in O-ring hold on cylinder block.
• Install oil pump assembly with oil pipe in cylinder
block and tighten fixing bolts to the specified
torque.
Tighten:
N6A3300E
• 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
3. Stiffener & Space Rubber • Tighten sleeve nut to the specified torque.
• Remove the exhaust pipe bracket. Tighten:
• Remove the stiffener from of the oil pan left & right • 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
side.
• Take out space rubber.
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6A1-42 4JB1/4JB1-TC - ENGINE

N6A3305E

2. Oil Pan Assembly

3. Stiffener & Space Rubber
4. Engine Mount Bolts
5. Vacuum Pump Oil Hose
Above works refer to “OIL PAN” Section in this
manual.
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4JB1/4JB1-TC - ENGINE 6A1-43

PISTON, PISTON RING AND CONNECTING ROD

Component

LNWB1BLF006101

Legend
1. Cylinder head assembly 4. Piston cooling oil pipe
2. Oil pan assembly 5. Piston and connecting rod
3. Oil pan assembly

Removal 1. Cylinder Head Assembly

Preparation 1) Radiator hose upper
• Disconnect battery ground cable 2) Heater hose
3) Engine harness
• Drain coolant
4) Air intake duct
• Drain engine oil
5) Injection pipe
Notice: 6) Leak off pipe
Install drain plug with new washer.
7) PCV hose
Tighten: 8) Glow plug harness
• 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft) 9) Oil level gauge guide tube
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6A1-44 4JB1/4JB1-TC - ENGINE

10) Oil cooler water pipe (Oil Cooler Model)
11) Vacuum actuator hose (Exhaust Brake Model)
12) Front exhaust pipe
13) By-pass hose
14) Cylinder head cover
15) Rocker arm shaft
16) Push rod
17) Cylinder head assembly
18) Cylinder head gasket
Above works refer to “CYLINDER HEAD AS-
SEMBLY AND GASKET” Section in this manu-
al.
2. Oil Pan Assembly
1) Vacuum pump oil hose
2) Engine mount bolt
3) Stiffener and spacer rubber
N6A3307E
4) Oil pan
Above works refer to “OIL PAN” Section in this 6. Piston and Connecting Rod
manual. 1) Remove carbon deposits from the upper por-
3. Oil Pump Assembly tion of the cylinder wall with a scraper before re-
4. Piston Cooling Oil Pipe moving the piston and connecting rod.
• Remove the relief valve and oil pipe.

N6A3308E

LNW81BSH008601
2) Move the piston to the top of the cylinder and
5. Connecting Rod Cap tap it with a hammer grip or similar object from
the connecting rod lower side to drive it out.
• If the connecting rod lower bearings are to be rein-
stalled, mark their fitting positions by tagging each
bearing with the cylinder number from which it was
removed.
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4JB1/4JB1-TC - ENGINE 6A1-45

N6A3309E N6A3172E

3) If the connecting rod upper bearings are to be 5) Use a pair of pliers to remove the piston pin
reinstalled, mark their fitting positions by tag- snap rings.
ging each bearing with the cylinder number
from which it was removed.

N6A3173E

LNWB1BSH023101 6) Tap the piston pin out with a hammer and a

brass bar. If the pistons and piston pins are to
4) Clamp the connecting rod in a vise. be reinstalled, mark their installation positions
Take care not to damage the connecting rod. by tagging each piston and piston pin with the
Use a piston ring replacer to remove the piston cylinder number from which it was removed.
rings.
Piston Ring Replacer
Do not attempt to use some other tool to re-
move the piston rings. Piston ring stretching will
result in reduced piston ring tension.
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6A1-46 4JB1/4JB1-TC - ENGINE

N6A3311E N6A3205E

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

the piston pin hole.
1. Piston and Connecting Rod
Use your fingers to force the piston pin into the
1) Try to insert the piston pin into the piston pin piston until it makes contact with the snap ring.
hole with normal finger pressure.
2) Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
3) Use a pair of pliers to install the piston pin snap
ring to the piston.

N6A3206E

6) Use your fingers to force the piston pin snap

ring into the piston snap ring groove.
Check that the connecting rod moves smoothly
N6A3173E on the piston pin.

Notice:
When changing piston/connecting rod combinations, do
not change the piston/piston pin combination.
4) Install the piston to the connecting rod.
The piston head front mark (1) and the connect-
ing rod “ISUZU” casting mark (2) must be fac-
ing the same direction.
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4JB1/4JB1-TC - ENGINE 6A1-47

N6A3207E LNWB1BSH022801

7) Install the piston rings with the piston ring ex-

pander. Legend
The compression ring must be set with the 1N, 1. Oil ring (with coil expander)
2N, R mark facing up. 2. Compression ring 2nd
Discrimination mark is painted as shown in the 3. Compression ring 1st
illustration.
Notice:
Notice: Install the compression rings with the stamped side fac-
There is no up or down side with the compression ring ing up.
1st.
There is no up or down side with the compression ring
1st.
Insert the coil expander into the oil ring groove so that
there is no gap on either side of the coil expander before
installing the oil ring.
9) Apply engine oil to the piston ring surfaces.
10) Check that the piston rings rotate smoothly in
the piston ring grooves.
11) Position the piston ring gaps as shown in the il-
lustration.

LNW21BSH034901

Legend
1. N mark (2nd ring)

8) Use a piston ring replacer to install the three

piston rings.
Piston Ring Replacer
Install the piston rings in the numerical order
shown in the illustration.
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6A1-48 4JB1/4JB1-TC - ENGINE

15) 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 TDC.

Notice:
• Set the crankshaft pin to top dead center with each
cylinder, when inserting piston/connecting rod.
• When inserting piston/connecting rod if the crank
pin is set to the bottom dead center, the oil jet might
hit connecting rod and it might break.

N6A3313E

Legend
1. Coil expander
2. Compression ring 1st
3. Oil ring
4. Front mark
5. Compression ring 2nd

12) Carefully wipe any oil or other foreign material

from the connecting rod bearing back face and
the connecting rod bearing fitting surface.
N6A3210E

2. Connecting Rod Cap

1) Position the bearing cap front mark (1) so that
it is facing the front of the engine.

LNWB1BSH022701

13) Apply a coat of engine oil to the upper bearing

surfaces.
Apply a coat of engine oil the cylinder wall.
N6A3211E
14) Position the piston head front mark so that it is
facing the front of the engine. 2) Install the connecting rod caps.
Use the piston ring compressor to compress Align the connecting rod cap cylinder number
the piston rings. marks and the connecting rod cylinder number
Piston Ring Compressor: 5-8840-9018-0(J- marks.
8037) 3) Apply a coat of engine oil to the threads and
setting faces of each connecting rod bolt.
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4JB1/4JB1-TC - ENGINE 6A1-49

N6A3212E LNW81BSH008601

4) Tighten the connecting rod bolts to the speci-

Notice:
fied torque in two steps using the Angular Tight-
Check that there is no interference between the piston
ening Method.
and the oil jet pipe by slowly rotating the crankshaft.
Tighten:
4. Oil Pump Assembly
• 4JB1-TC
Above works refer to “OIL PUMP” Section in this
Connecting rod bolt to manual.
1st step: 29.4 N⋅m (3.0 kg⋅m / 22 lb⋅ft) 5. Oil Pan Assembly
2nd step: 45° — 60° 1) Apply the recommended liquid gasket or its
• 4JB1 equivalent to the No.5 bearing cap arches, the
Connecting rod bolt to grooves, and the timing gear case arches at the
83 N⋅m (8.5 kg⋅m / 61 lb⋅ft) positions shown in the illustration.

Notice:
Check to see that the crankshaft turns smoothly by ro-
tating it manually.
3. Piston Cooling Oil Jet Pipe
1) Install the piston cooling oil jet pipe to the cylin-
der body.
2) Tighten the oil jet pipe bolts and relief valve to
the specified torque.
Tighten:
• Oil pipe bolt to
M8 × 1.25: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M6 × 1.00: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
• Oil pressure regulating valve to
M6 × 1.5: 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)

N6A3318E

2) Fit the gasket rear lipped portion into the No.5

groove. Be absolutely sure that the lipped por-
tion is fitted snugly into the groove.
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6A1-50 4JB1/4JB1-TC - ENGINE

N6A3126E N6A3300E

3) Install the oil pan to the cylinder body. 7) Install the vacuum pump oil hose (1) to oil pan.
• Tighten the oil pan bolts to the specified torque.
Tighten:
• Oil pan bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
4) Install the space rubber and stiffener (right &
left side) then tighten bolts to the specified
torque.
Tighten:
• Engine body side stiffener bolts to 37 N⋅m (3.8 kg⋅m /
27 lb⋅ft)
• Clutch housing side stiffener bolts to 78 N⋅m (8.0
kg⋅m / 58 lb⋅ft)

N6A3299E

6. Cylinder Head Assembly

1) Cylinder head gasket
2) Cylinder head assembly
3) Push rod
4) Rocker arm shaft
5) Valve clearance adjustment
6) Cylinder head cover
7) By-pass hoses
8) Front exhaust pipe
N6A3301E
9) Vacuum actuator hose (Exhaust Brake Model)
10) Oil cooler water pipe (Oil Cooler Model)
5) Install the exhaust pipe bracket. 11) Oil level gauge guide tube
6) Install the support rubber and tighten nuts to 12) Glow plug harness
the specified torque. 13) PCV hose
Tighten: 14) Leak off pipe
• Support rubber nut to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft) 15) Injection pipe
16) Air intake duct
17) Engine harness
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4JB1/4JB1-TC - ENGINE 6A1-51

18) Heater hose
Above works refer to “CYLINDER HEAD AS-
SEMBLY AND GASKET” Section in this manu-
al.
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6A1-52 4JB1/4JB1-TC - ENGINE

CAMSHAFT AND TAPPET

Component

LNWB1BLF006901

Legend
1. Transmission and clutch assembly 5. Oil pan
2. Engine assembly 6. Oil pump
3. Cylinder head assembly and gasket 7. Camshaft and tappets
4. Timing gear

Removal Tighten:
Preparation • Drain plug to 83 N⋅m (8.5 kg⋅m / 61 lb⋅ft)
• Disconnect battery ground cable. 1. Transmission and Clutch Assembly
• Drain coolant. 1) Transmission
• Drain engine oil. 2) Clutch
2. Engine Assembly
Notice:
Install drain plug with new washer. 1) Radiator assembly
2) Intake air duct
3) Heater hose
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4JB1/4JB1-TC - ENGINE 6A1-53

4) Engine control cable
5) Glow plug harness
6) Fuel hose
7) Oil pressure switch harness
8) Power steering pump & bracket assembly
(Power steering Model)
9) Actuator vacuum hose (Exhaust Brake Model)
10) Vacuum pump hose (Exhaust Brake Model)
11) Front exhaust pipe
12) Support rubber
13) Engine assembly
Above works refer to “ENGINE ASSEMBLY”
Section in this manual.
3. Cylinder Head Assembly and Gasket
1) Injection pipe
2) Leak off pipe
N6A3095E
3) PCV hose
4) Glow plug harness • Install the stopper bolt (1) to the timing pulley to
5) Oil level gauge guide tube prevent the pulley from turning.
6) Oil cooler water pipe (Oil Cooler Model) • Loosen the center bolt.
7) By-pass hose
8) Cylinder head cover
9) Rocker arm shaft
10) Push rod
11) Cylinder head assembly
12) Cylinder head gasket
Above works refer to “CYLINDER HEAD AS-
SEMBLY AND GASKET” Section in this manu-
al.
4. Timing Gear
1) Cooling fan assembly
2) Crankshaft damper pulley
3) Noise shield cover
4) Noise cover spacer
5) Timing gear case cover
6) Camshaft timing gear N6A3320E
Above works refer to “TIMING GEAR” Section
in this manual. • Use the timing pulley puller (2) to remove the
7) Camshaft timing pulley pulley.
• Use a dial indicator to measure the camshaft Timing Pulley Puller: 5-8840-0086-0
end play.
This must be done before removing the oil
pump.
If the camshaft end play exceeds the specified
limit, the camshaft and/or the driven gear must
be replaced.

Camshaft End Play mm (in)

Standard Limit
0.08 (0.003) 0.20 (0.008)
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6A1-54 4JB1/4JB1-TC - ENGINE

N6A3094E N6A3107E

• Remove the stopper bolt. 5. Oil Pan Assembly

• Remove the center bolt and remove the timing • Disconnect vacuum pump oil hose (1) from oil pan.
pulley (2) with pulley center (1).

N6A3299E
N6A3108E
• Remove the stiffener and space rubber from oil
• Remove the oil seal retainer (1). pan both side.
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4JB1/4JB1-TC - ENGINE 6A1-55

N6A3321E N6A3106E

• Remove the oil pan bolts and remove oil pan from • Take care not to damage the camshaft bearings.
cylinder body. • Take out the tappets from cylinder body.
6. Oil Pump Assembly
• Remove the oil pump assembly from cylinder body.

N6A3322E

N6A3305E Installation
1. Camshaft and Tappets
7. Camshaft and Tappets
• Apply a coat of engine oil to the tappet and the cyl-
• Remove the camshaft from cylinder body. inder body tappet insert holes.
• Locate the position mark applied at disassembly (if
the tappet is to be reused).
Notice:
The tappet must be installed before the camshaft.
• Apply a coat of engine oil to the camshaft and the
camshaft bearings.
• Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
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6A1-56 4JB1/4JB1-TC - ENGINE

1) Camshaft timing gear
2) Timing gear case cover
3) Noise cover spacer
4) Noise shield cover
5) Crankshaft damper pulley
6) Cooling fan assembly
Above works refer to “TIMING GEAR (Gear
Type)” Section in this manual.
5. Cylinder Head Assembly and Gasket
1) Cylinder head gasket
Piston Head Projection Measurement Point
2) Cylinder head assembly
3) Push rod
4) Rocker arm shaft
Valve Clearance Adjustment
5) Cylinder head cover
N6A3106E
6) By-pass hose
2. Oil Pump Assembly 7) Oil cooler water pipe (Oil cooler Model)
• Prepare a solution of 80% engine oil and 20% mo- 8) Oil level gauge guide tube
lybdenum disulfide. 9) Glow plug harness
• Apply and ample coat of the solution to the teeth of 10) PCV hose
the oil pump pinion. 11) Fuel leak off pipe
• Apply engine oil to oil pipe O-ring and insert the O- 12) Injection pipe
ring in O-ring hold on cylinder block. Above works refer to “CYLINDER HEAD AS-
• Install oil pump assembly with oil pipe in cylinder SEMBLY AND GASKET” Section in this manu-
block and tighten fixing bolts to the specified al.
torque. 6. Engine Assembly
Tighten: 1) Engine assembly
• Oil pump bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft) 2) Support rubber
3) Front exhaust pipe
4) Vacuum pump hose
5) Actuator vacuum hose
6) Power steering pump & bracket assembly
(With Power Steering Model)
7) Oil pressure switch harness
8) Fuel hose
9) Glow plug harness
10) Engine control cable
11) Heater hose
12) Intake air duct
13) Radiator assembly
7. Transmission and Clutch Assembly
1) Clutch
2) Transmission
Above works refer to “ENGINE ASSEMBLY”
N6A3305E
Section in this manual.
• Tighten sleeve nut to the specified torque. • Connect the battery ground cable.
• Pour coolant
Tighten:
• Oil pump bolt to 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) • Pour engine oil
3. Oil Pan Assembly • Start the engine and check coolant leakage.
Above works refer to “OIL PAN” Section in this
manual.
4. Timing Gear
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4JB1/4JB1-TC - ENGINE 6A1-57

CRANKSHAFT FRONT OIL SEAL

Component

N6A3323E

Legend
1. Fan shroud 4. Cooling fan assembly
2. Power steering pump drive belt 5. Crankshaft damper pulley
3. AC generator drive belt 6. Front oil seal

Removal • Loosen AC Generator mounting bolt (under side)

and adjust plate lock bolt, and remove the drive
Preparation
belt.
• Disconnect battery ground cable.
4. Cooling Fan Assembly
• Drain coolant.
• Remove clamp nut, and remove cooling fan as-
1. Fan Shroud sembly, distant pipe, and fan pulley.
2. Power Steering Pump Drive Belt 5. Crankshaft Damper Pulley
• Loosen power steering pump mounting bolt and
adjust bolt, and remove the drive belt.
3. AC Generator Drive Belt
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6A1-58 4JB1/4JB1-TC - ENGINE

6. Front Oil Seal
Notice:
• Use a plastic hammer and a screwdriver to top Hold the flywheel ring gear stationary to prevent the
around the oil seal to free it from the gear case cov- crankshaft from turning when tightening the damper pul-
er. ley.
Take care not to damage the oil seal fitting surfac-
es. Tighten:
• Crankshaft pulley bolt to 294 N⋅m (30 kg⋅m / 217 lb⋅ft)

N6A3324E

N6A3170E
Installation
1. Front Oil Seal 3. Cooling Fan Assembly
• Use the installer to install the front oil seal (1) to the • Mount fan pulley, distance piece, and cooling fan
gear case cover (2). assembly (in this order) on the water pump, and
Oil Seal Installer: 5-8840-2061-0 tighten to the specified torque.
Note the oil seal installation depth (3) shown in the Tighten:
illustration.
• Pulley boss bolt to 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
Depth (3) = 1 mm (0.039 in.)
4. AC Generator Drive Belt
• Install AC Generator drive belt and adjust belt ten-
sion.
• Refer to Drive Belt Adjustment in this section.
5. Power Steering Pump Drive Belt
• Install power steering pump drive belt and adjust
belt tension.
• Refer to “Drive Belt Adjustment” in this section.
6. Fan Shroud
• Install the fan shroud and reservoir tank hose.
• Pour coolant
• Start the engine and check coolant leakage.

N6A3325E

2. Crankshaft Damper Pulley

Tighten the crankshaft damper pulley bolt to the
specified torque.
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4JB1/4JB1-TC - ENGINE 6A1-59

CRANKSHAFT REAR OIL SEAL

Component

N6A3331E

Legend
1. Transmission and clutch assembly 3. Rear oil seal
2. Flywheel

Removal 2) Parking Brake Cable

Preparation • Move the joint cover.
• Disconnect battery ground cable • Disconnect the joint bolt.
1. Transmission and Clutch Assembly • Remove the clip then disconnect the cable from
• Raise vehicle and support with suitable safely. the bracket.
1) Transmission
• Reference mark (1) the flange yoke to the park-
ing brake drum.

N6A3333E

3) Wiring Connector
• Disconnect the wiring connectors from the car
N6A3332E speed sensor, the neutral switch and the back-
up light switch.
• Disconnect the propeller shaft at flange yoke.
• Put aside the propeller shaft and tie it to the frame
so that it does not interface with servicing work.
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6A1-60 4JB1/4JB1-TC - ENGINE

4) Shift Cable and Select Cable frame so that it does not interface with servicing
• Disconnect the shift cable and select cable on work.
the transmission side.

N6A3336E

N6A3334E
6) Exhaust Brake Assembly
7) Front Exhaust Pipe
Legend
1. Shift cable
2. Clip
3. Select cable
4. Snap pin
5. Snap pin

5) Clutch Slave Cylinder

• Remove the clutch pipe fixing clips and the clip
bracket (Right hand drive models only).

N6A3337E

8) Transmission Assembly
Notice:
The exhaust pipe bracket, the gear control bracket and
the clips are sometimes installed in the wrong position or
direction confusedly. To prevent incorrect installation of
these parts, put a correct installation mark on them.
• Support the transmission with mission jack.
N6A3335E Caution:
To prevent the falling of the transmission, tie it firmly to
the jack with a chain or belt.
Legend
1. Flexible hose Do not allow transmission to hang unsupported from
clutch. Damage to the clutch assembly will result.
2. Clutch pipe

• Remove the slave cylinder assembly with the

flexible hose attached, and then tie it to the
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4JB1/4JB1-TC - ENGINE 6A1-61

N6A3338E N6A3339E

• Remove the nuts of the transmission mounting • Mark the flywheel and pressure plate lug for
bracket on the crossmember side. alignment when installing.
• Engine and transmission angles may need to • Loosen the pressure plate assembly fixing
be adjusted for removal. bolts.
• Hold the rear section of the engine by the jack 2. Flywheel
or hoist. 3. Rear Oil Seal
Caution: • With the oil seal pushed in deep, install the special
When lifting the engine by the jack, use wood blocks to tool as shown in the illustration to remove the oil
prevent any possible damage to the oil pan. seal.
• Remove transmission fastening bolts. • Rear oil seal Remove: 5-8840-2360-0
• Pull out the transmission assembly rearward.
9) Mounting Bracket
• Raise vehicle and support with suitable safety
stands.
Caution:
Do not let clutch fluid remain on a painted surface, wash
it off immediately.
10) Pressure Plate Assembly
11) Driven Plate Assembly
• Use the pilot aligner to prevent the driven plate
assembly from falling free.
Pilot Aligner: 5-5825-3001-0

N6A3129E

Notice:
Take care not to damage the crankshaft or oil seal re-
tainer when removing oil seal.

Installation
1. Rear Oil Seal
• Use the oil seal installer the oil seal to the cylinder
body.
Rear oil seal Install: 5-8840-2359-0
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6A1-62 4JB1/4JB1-TC - ENGINE

Notice:
Wipe off rust and scraps clean from the press-in portion
of the oil seal.
1) Take note of the press-in direction of the oil
seal.
2) Install the adapter of the special tool to the rear
end of the crankshaft with two bolts. 1
5 3
3) Install the oil seal to the outer circumference of
the adapter. 8 7
4) Insert the sleeve into the adapter portion, and 4
2 6
tighten it in with the bolt (M12 × 1.75L = 70) until
the adapter section hits the sleeve.
5) Remove the adapter and the sleeve.
6) After installing the oil seal, check the measure-
ment of the oil seal.

Standard mm (in) LNWB1BSH023201

12.2 — 12.8 (0.48 — 0.50)

3. Transmission and Clutch Assembly
1) Driven Plate Assembly
• Apply multi-purpose with MOS2 type grease to
the driven plate hub spline.
• Use the pilot aligner to install the driven plate
assembly.
Pilot Aligner: 5-5825-3001-0

N6A3340E

2. Flywheel
• Apply engine oil to fixing bolts.
• Tighten the flywheel bolts to the specified torque in
two steps using the Angular Tightening Method.
Follow the numerical order shown in the illustra- N6A3339E
tion.
2) Pressure Plate Assembly
Tighten:
• Flywheel bolt to • Tighten pressure plate assembly fixing bolts in
numerical order.
1st step: 59 N⋅m (6.0 kg⋅m / 43 lb⋅ft)
2nd step: 60° — 90° Tighten:
• Pressure plate fixing bolt to 18 N⋅m (1.3 kg⋅m / 13
lb⋅ft)
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4JB1/4JB1-TC - ENGINE 6A1-63

Tighten:
• Clutch housing to flywheel hosing bolts to
M10: 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
M12: 91 N⋅m (9.3 kg⋅m / 67 lb⋅ft)
• Raise engine and transmission up into rear
transmission mount.
Tighten:
• Engine rear mounting nuts and bolts to
M10: 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
M12: 69 N⋅m (7.0 kg⋅m / 51 lb⋅ft)

N6A3341E

• Remove the pilot aligner.

Notice:
In case a new pressure plate assembly is mounted, after
tightening a pressure plate at the specified torque, be
sure to remove the wiring for protection of a diaphragm
spring.
3) Mounting Bracket
Tighten:
• Mounting bracket nuts to 69 N⋅m (7.0 kg⋅m / 51 lb⋅ft)
4) Transmission Assembly N6A3343E

• Support the transmission with mission jack. 5) Front Exhaust Pipe

Caution:
Tighten:
To prevent the falling of the transmission, tie it securely
• Front exhaust pipe bolts to 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
to the jack with a chain or belt.
6) Exhaust Brake Assembly
Tighten:
• Exhaust brake bolts to 17 N⋅m (1.8 kg⋅m / 12 lb⋅ft)
7) Clutch Slave Cylinder
Tighten:
• Slave cylinder bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Perform slave cylinder adjustment before in-
stallation of the return spring.
a. Loosen the lock nut of the push rod.
b. Turn the adjust nut until it reaches the shift
fork.
c. Back off the adjust nut 1.5 turns. (shift fork
free play Approximately 2 mm / 0.1 in).
d. Tighten the lock nut.
Tighten:
• Push rod lock nut to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
N6A3338E
8) Shift Cable and Select Cable
• Shift transmission into high gear. 9) Wiring Connector
• Align transmission with engine slope. • Color of Connector
• Turn output parking brake drum to aid clutch Back-up Light Switch: Brown
spring engagement. Neutral Switch: Gray
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6A1-64 4JB1/4JB1-TC - ENGINE

10) Parking Brake Cable
11) Propeller Shaft
• Line up reference mark.
Tighten:
• Propeller shaft nuts to 66 N⋅m (6.7 kg⋅m / 48 lb⋅ft)
• Connect battery ground cable.
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4JB1/4JB1-TC - ENGINE 6A1-65

FLYWHEEL AND PILOT BEARING

Component

N6A3344E

Legend
1. Transmission and clutch assembly 3. Flywheel
2. Pilot bearing

Removal
Preparation
• Disconnect battery ground cable.
1. Transmission and Clutch Assembly
1) Transmission
2) Clutch
Above works refer to “ENGINE ASSEMBLY”
Section in this manual.
2. Pilot Bearing
• Remove pilot bearing using remover.
Pilot Bearing Puller: 5-8840-2000-0
Sliding hammer: 5-8840-0019-0

N6A3345E

3. Flywheel
• Set the flywheel stopper.
• Loosen flywheel fixing bolts then remove the fly-
wheel.

Installation
1. Flywheel
• Apply engine oil to fixing bolts.
• Tighten the flywheel bolts to the specified torque in
two steps using the Angular Tightening Method.
Follow the numerical order shown in the illustra-
tion.
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6A1-66 4JB1/4JB1-TC - ENGINE

Tighten:
• Flywheel bolt to
1st step: 59 N⋅m (6.0 kg⋅m / 43 lb⋅ft)
2nd step: 60° — 90°

5 1
3
8 7
4
2 6

LNWB1BSH023201

2. Pilot Bearing
• Install the pilot bearing using installer.
Pilot bearing Installer: 5-8522-0024-0

N6A3346E

3. Transmission and Clutch Assembly

1) Clutch
2) Transmission
Above works refer to “ENGINE ASSEMBLY”
Section in this manual.
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4JB1/4JB1-TC - ENGINE 6A1-67

CRANKSHAFT AND MAIN BEARINGS

Component

LNWB1BLF006201

Legend
1. Transmission and clutch assembly 9. Piston and connecting rod assembly
2. Engine assembly 10. Front oil seal
3. Cylinder head assembly and gasket 11. Timing gear housing
4. Timing gear (Gear drive model) 12. Timing pulley housing
5. Timing belt (Belt drive model) 13. Water pump assembly
6. Oil pan assembly 14. Flywheel and rear plate
7. Oil pump assembly 15. Rear oil seal
8. Piston cooling oil pipe 16. Crankshaft and main bearing and thrust bearing

Removal 1) Transmission
Preparation 2) Clutch
Above works refer to “ENGINE ASSEMBLY”
• Disconnect battery ground cable.
Section in this manual.
• Drain coolant from the radiator and engine.
2. Engine Assembly
1. Transmission and Clutch Assembly
1) Radiator assembly
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6A1-68 4JB1/4JB1-TC - ENGINE

2) Intake air duct
3) Heater hose
4) Engine control cable
5) Glow plug harness
6) Fuel hose
7) Oil pressure switch harness
8) Power steering pump bracket assembly (Power
Steering Model)
9) Actuator vacuum hose (Exhaust Brake Model)
10) Vacuum pump hose (Exhaust Brake Model)
11) Front exhaust pipe
12) Support rubber
13) Engine assembly
Above works refer to “ENGINE ASSEMBLY”
Section in this manual.
3. Cylinder Head Assembly and Gasket
N6A3342E
1) Injection pipe
2) Leak off pipe 5. Oil Pan Assembly
3) PCV hose 6. Oil Pump Assembly
4) Glow plug harness Above works refer to “CAMSHAFT AND TAPPET”
Section in this manual.
5) Oil level gauge guide tube
7. Piston Cooling Oil Pipe
6) Oil cooler water pipe (Oil Cooler Model)
7) By-pass hose • Remove the oil pipe from cylinder block.
8) Cylinder head cover
9) Rocker arm shaft
10) Push rod
11) Cylinder head assembly
12) Cylinder head gasket
Above works refer to “CYLINDER HEAD AS-
SEMBLY AND GASKET” Section in this manu-
al.
4. Timing Gear (Gear Drive Model)
1) Cooling fan assembly
2) Crankshaft damper pulley
3) Noise shield cover
4) Noise cover spacer
5) Timing gear case cover
6) Oil pipe
7) Idle gear LNW81BSH008601
8) Idle gear “B” and shaft
9) Injection pump 8. Piston and Connecting Rod
10) Camshaft timing gear • If the connecting rod lower bearings are to be rein-
Above works refer to “TIMING GEAR (Gear stalled, mark their fitting positions by tagging each
Type)” Section in this manual. bearing with the cylinder number from which it was
removed.
11) Crankshaft gear
• Use the crankshaft timing gear remover (1) to re-
move the crankshaft gear (2).
Crankshaft Timing Gear Remover: 5-8840-2057-0
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4JB1/4JB1-TC - ENGINE 6A1-69

N6A3307E LNWB1BSH023101

• Remove carbon deposits from the upper portion of 9. Timing Gear Housing
the cylinder wall with a scraper before removing 10. Timing Pulley Housing
the piston and connecting rod. 11. Water Pump Assembly
Move the piston to the top of the cylinder and tap it
12. Flywheel and Cylinder Body Rear Plate
with a hammer grip or similar object from the con-
necting rod lower side to drive it out. • Set the flywheel stopper.
• Loosen the flywheel fixing bolts then remove the
flywheel.
• Remove the cylinder block rear plate.
13. Rear Oil Seal (Gear and Belt Drive Model)
• With the oil seal pushed in deep, install the special
tool as shown in the illustration to remove the oil
seal.
Rear Oil Seal Remover: 5-8840-2360-0

N6A3351E

• 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.

N6A3129E

Notice:
Take care not to damage sealing surface of front plate
and crankshaft when removing oil seal.
14. Crankshaft and Main Bearing
1) Remove the main bearing caps and thrust
washer.
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6A1-70 4JB1/4JB1-TC - ENGINE

N6A3141E N6A3139E

2) Remover the crankshaft with care.

Notice:
3) Remove the crankshaft upper bearing. Do not apply engine oil to the bearing back faces and
Installation the cylinder body bearing fitting surfaces.

1. Crankshaft and Main Bearings • Be sure that they are positioned correctly.
• The crankshaft upper bearings have an oil hole • Apply new engine oil to the upper and lower main
and an oil groove. The lower bearings do not. bearing faces.
• Carefully mount the crankshaft.
• Apply engine oil to the thrust washer.
• Install thrust washer on No.3 journal.
Oil grooves in thrust washer must face the crank-
shaft.

N6A3140E

• Install main bearings in the cylinder body and main

bearing cap respectively.
• Apply new engine oil to upper and lower main bear-
ings.
N6A3141E
• Make sure that main bearing are in correct posi-
tion. • Apply the recommended liquid gasket or its equiv-
• Carefully wipe any foreign material from the upper alent to the No.5 crankshaft bearing cap cylinder
bearing. body fitting surfaces at points and shown in the il-
lustration.
• Install the main bearings to the cylinder body and
the main bearing caps.
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4JB1/4JB1-TC - ENGINE 6A1-71

Use the oil seal installer to install the oil seal to the
cylinder body.
Rear Oil Seal Installer: 5-8840-2361-0

Notice:
Wipe off rust and scraps clean from the press-in portion
of the oil seal.
Take note of the press-in direction of the oil seal.
1) Install the adapter of the special tool to the rear
end of the crankshaft with two bolts.
2) Install the oil seal to the outer circumference of
the adapter.
3) Insert the slave into the adapter portion, and
tighten it in with the bolt (M12 × 1.75L = 70) until
the adapter section hits the slave.
4) Remove the adapter and the slave.
5) After installing the oil seal, check the measure-
N6A3142E
ment of the oil seal.

Notice: Standard mm (in)

Be sure that the bearing cap fitting surface is completely 12.2 — 12.8 (0.48 — 0.50)
free of oil before applying the liquid gasket.
Do not allow the liquid gasket to obstruct the cylinder
thread holes and bearings.
• Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.
• Apply engine oil to the front of the engine.
• Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
shown in the illustration.
Tighten:
• 167 N⋅m (17.0 kg⋅m / 123 lb⋅ft)

N6A3340E

3. Flywheel and Cylinder Body Rear Plate

• Align the rear plate with the cylinder body knock
pins.
• Tighten the rear plate to the specified torque.
Tighten:
• Rear plate bolts to 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

N6A3144E

Notice:
Check to see that the crankshaft turns smoothly by ro-
tating it manually.
2. Crankshaft Rear Oil Seal
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6A1-72 4JB1/4JB1-TC - ENGINE

Tighten:
• Water pump bolts to 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

N6A3352E

• Block the crankshaft with a piece of hard wood to

prevent the flywheel form turning. N6A3353E
• Apply a coat of engine oil to the threads of the fly-
wheel bolts. 5. Timing Pulley Housing
• Align the flywheel with the crankshaft dowel pin. • Install the timing pulley housing the cylinder body.
Take care not to twist the front oil seal.
• Tighten the flywheel bolts to the specified torque in
two steps using the Angular Tightening Method. • Tighten the timing pulley housing together with the
timing pulley housing gasket to the specified
• Follow the numerical order shown in the illustra- torque.
tion.
Tighten:
Tighten: • Timing pulley housing bolt to 19 N⋅m (1.9 kg⋅m / 14
• Flywheel bolt to lb⋅ft)
1st step: 59 N⋅m (6.0 kg⋅m / 43 lb⋅ft)
2nd step: 60° — 90°

5 1
3
8 7
4
2 6

N6A3354E

LNWB1BSH023201 • Cut away the flash from the gasket.

6. Timing Gear Housing
4. Water Pump Assembly
• Install the timing gear housing the cylinder body.
• Fit the O-ring to the water pump body.
• Tighten the timing gear housing together with the
• Remove the water pump assembly and tighten timing gear housing gasket to the specified torque.
bolts to the specified torque.
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4JB1/4JB1-TC - ENGINE 6A1-73

• The crankshaft gear timing mark (“X — X”)
Tighten:
must be facing outward.
• Timing gear housing bolt to 19 N⋅m (1.9 kg⋅m / 14
Crankshaft Gear Installer: 9-8522-0020-0
lb⋅ft)
• Cut away the flash from the gasket.
7. Front Oil Seal (Belt Drive Model)
• Install oil seal using special tool.
Front Oil Seal Installer: 5-8840-2361-0
Notice:
Wipe off rust and scraps clean from the press-in portion
of the oil seal.
Take note of the press-in direction of the oil seal.
1) With the oil seal attached to the sleeve, put it in
the front end of the crankshaft.
2) With the edge of the oil seal attached securely
to the crankshaft, tighten it with the center bolt
until the sleeve hits securely against the refer-
ence plane at the front end of the crankshaft.
3) Remove the sleeve.
4) After pressing in the oil seal, check the mea- N6A3160E
surement of the oil seal.
2) Camshaft timing gear
Standard mm (in) 3) Injection pump
0.6 — 1.2 (0.024 — 0.047) 4) Idler gear “B” and shaft
5) Idle gear
6) Timing gear oil pipe
7) Timing gear case cover
8) Noise cover spacer
9) Noise shield cover
10) Crankshaft damper pulley
11) Cooling fan assembly
Above works refer to “TIMING GEAR (Gear
Type)” Section in this manual.
13. Cylinder Head Assembly and Gasket
1) Cylinder head gasket
2) Cylinder head assembly
3) Push rod
4) Rocker arm shaft assembly
Valve Clearance Adjustment
5) Cylinder head cover
N6A3148E 6) By-pass hose
7) Oil cooler water pipe (Oil Cooler Model)
8. Piston and Connecting Rod
8) Oil level gauge guide tube
9. Piston Cooling Oil Pipe
9) Glow plug harness connector
Above works refer to “PISTON” Section in this
manual. 10) PCV hose
10. Oil Pump Assembly 11) Fuel leak off pipe
11. Oil Pan Assembly 12) Injection pipe
Above works refer to “OIL PUMP AND OIL PAN” Above works refer to “CYLINDER HEAD AS-
Section in this manual. SEMBLY AND GASKET” Section in this manu-
al.
12. Timing Gear (Gear Drive Model)
14. Engine Assembly
1) Crankshaft gear
1) Support rubber
• Install the crankshaft gear.
2) Front exhaust pipe
• Use the crankshaft gear installer (1) to install
3) Vacuum pump hose
the crankshaft gear (2).
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6A1-74 4JB1/4JB1-TC - ENGINE

4) Actuator vacuum hose (Exhaust Brake Model)
5) Power steering pump & bracket assembly
(Power Steering Model)
6) Oil pressure switch harness
7) Fuel hose
8) Glow plug harness
9) Engine control cable
10) Heater hose
11) Intake air duct
12) Radiator assembly
Above works refer to “ENGINE ASSEMBLY”
Section in this manual.
15. Transmission and Clutch Assembly
1) Clutch
2) Transmission
Above works refer to “ENGINE ASSEMBLY”
Section in this manual.
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4JB1/4JB1-TC - ENGINE 6A1-75

ENGINE ASSEMBLY
Component

11
9 10

14
13

12
LNWB1BLF006401

Legend
1. Transmission and clutch assembly 9. Power steering pump & bracket assembly (Power
2. Radiator assembly steering model)
3. Intake air duct 10. Actuator vacuum hose (Exhaust brake model)
4. Heater hose 11. Vacuum pump hose
5. Engine control cable 12. Front exhaust pipe
6. Glow plug harness 13. Support rubber
7. Fuel hose 14. Engine assembly
8. Oil pressure switch harness

Removal
Preparation
• Disconnect battery ground cable.
• Drain coolant.
1. Transmission and Clutch Assembly
• Raise vehicle and support with suitable safely.
1) Propeller Shaft
• Reference mark the flange yoke to the parking
brake drum.
• Disconnect the propeller shaft at flange yoke.
• Put aside the propeller shaft and tie it to the
frame so that it does not interface with servicing
work.
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6A1-76 4JB1/4JB1-TC - ENGINE

N6A3332E N6A3334E

Legend Legend
1. Reference mark 1. Shift cable
2. Clip
2) Parking Brake Cable 3. Select cable
• Move the joint cover. 4. Snap pin
• Disconnect the joint bolt. 5. Snap pin
• Remove the clip then disconnect the cable from
5) Clutch Slave Cylinder
the bracket.
• Remove the clutch pipe fixing clips and the clip
bracket (Right hand drive models only).

N6A3333E

3) Wiring Connector N6A3335E

• Disconnect the wiring connectors from the car

speed sensor, the neutral switch and the back- Legend
up light switch. 1. Flexible hose
4) Shift Cable and Select Cable 2. Clutch pipe
• Disconnect the shift cable and select cable on
the transmission side. • Remove the slave cylinder assembly with the
flexible hose attached, and then tie it to the
frame so that it does not interface with servicing
work.
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4JB1/4JB1-TC - ENGINE 6A1-77

N6A3336E N6A3338E

6) Exhaust Brake Assembly • Remove the nuts of the transmission mounting

7) Front Exhaust Pipe bracket on the crossmember side.
• Engine and transmission angles may need to
be adjusted for removal.
• Hold the rear section of the engine by the jack
or hoist.
Caution:
When lifting the engine by the jack, use wood blocks to
prevent any possible damage to the oil pan.
• Remove transmission fastening bolts.
• Pull out the transmission assembly rearward.
9) Mounting Bracket
• Raise vehicle and support with suitable safety
stands.
Caution:
Do not let clutch fluid remain on a painted surface, wash
it off immediately.
N6A3337E 10) Pressure Plate Assembly
8) Transmission Assembly 11) Driven Plate Assembly
• Use the pilot aligner to prevent the driven plate
Notice: assembly from falling free.
The exhaust pipe bracket, the gear control bracket and Pilot Aligner: 5-5825-3001-0
the clips are sometimes installed in the wrong position or
• Mark the flywheel and pressure plate lug for
direction confusedly. To prevent incorrect installation of
alignment when installing.
these parts, put a correct installation mark on them.
• Loosen the pressure plate assembly fixing
• Support the transmission with mission jack. bolts.
Caution:
To prevent the falling of the transmission, tie it firmly to
the jack with a chain or belt.
Do not allow transmission to hang unsupported from
clutch. Damage to the clutch assembly will result.
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6A1-78 4JB1/4JB1-TC - ENGINE

N6A3339E N6A3360E

2. Radiator Assembly 6. Glow Plug Harness

1) Remove the radiator hose upper and lower. 7. Fuel Hose
2) Remove the reservoir tank hose. • Remove the fuel inlet hose and fuel return hose.
3) Remove the cushion rubbers on both sides. 8. Oil Pressure Switch Harness
4) Remove the radiator stay. 9. Power Steering Pump & Bracket Assembly (Power
Steering Model)
1) Loosen the idler pulley lock nut.
2) Loosen the adjust bolt then remove the drive
belt.
3) Remove the pipe bracket fixing bolt and clip.
4) Remove the power steering pump fixing bolts
pump to chassis frame side use the wire.

N6A3359E

3. Intake Air Duct

4. Heater Hose
5. Engine Control Cable
• Loosen the locking nut at the bracket and discon-
nect accelerator cable from injection pump control
lever. N6A3362E

Legend
1. Bracket
2. Clip
3. Lock nut

10. Actuator Vacuum Hose (Exhaust Brake Model)

• Disconnect the vacuum hose from actuator side.
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4JB1/4JB1-TC - ENGINE 6A1-79

N6A3363E N6A3294E

11. Vacuum Pump Hose (Exhaust Brake Model) 13. Support Rubber
• Disconnect the vacuum hose from vacuum tank 1) Right Hand
side and magnetic valve side. • Remove two fixing nuts at the cross member
side.
2) Left Hand
• Remove two fixing nuts at the cross member
side.

N6A3364E

12. Front Exhaust Pipe

• Remove the exhaust pipe fixing bolts from exhaust
manifold.
N6A3300E
• Remove the exhaust pipe stay bolt.
• Remover the fixing nuts from front pipe. 14. Engine Assembly
1) Lift engine carefully by using hoist.
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6A1-80 4JB1/4JB1-TC - ENGINE

• Install the exhaust pipe stay and tighten bolt nut to
the specified torque.
Tighten:
• Stay bolt nut to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

N6A3367E

2) Lift front part of engine higher than rear part of

it.
3) Take out engine assembly taking care not to
damage full pipes, brake pipes and so on. N6A3294E

Installation 4. Vacuum Pump Hose (Exhaust Brake Model)

1. Engine Assembly • Connect the vacuum hose to vacuum tank side and
• Position engine mountings by using hoist. magnetic valve side.
2. Support Rubber
• After all fixing bolts (left: two bolts, right: two bolts)
were inserted to every holes, and engine assembly
and tighten fixing bolts to the specified torque.
Tighten:
• 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

N6A3364E

5. Actuator Vacuum Hose (Exhaust Brake Model)

• Connect the vacuum hose to actuator.

N6A3300E

3. Front Exhaust Pipe

• Connect the exhaust pipe and tighten nut to the
specified torque.
Tighten:
• Exhaust pipe nut to 69 N⋅m (7.0 kg⋅m / 51 lb⋅ft)
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4JB1/4JB1-TC - ENGINE 6A1-81

• Push the middle of belts with a force of 10 kg and
check each bolt for deflection.
• Standard deflection

mm (in)
Initial tension
P/S pump drive belt 8 — 12 (0.31 — 0.47)

N6A3363E

6. Power Steering Pump & Bracket Assembly (Power

Steering Model)
• Install the power steering pump and pipe bracket
then tighten bolts to the specified torque.
Tighten:
• Pump bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Pipe bracket bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft) LNW81BSH014801
• Clip bolt to 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
Legend
1. AC generator & fan pulley drive belt
2. P/S oil pump drive belt (with P/S oil pump type
only)

7. Oil Pressure Switch Harness

• Connect the oil pressure switch harness connec-
tor.
8. Fuel Hose
• Connect the fuel feed hose and return hose then
tighten clip securely.
9. Glow Plug Harness
• Install the harness connector then tighten bolt se-
curely.
10. Engine Control Cable
1) Install the control wire to the engine control le-
N6A3362E ver.
2) Hold accelerator lever in the fully closed posi-
Legend tion and stretch the control cable in the direc-
1. Bracket tion indicated by the arrow to remove any slack.
2. Clip 3) Tighten the accelerator cable bracket bolt.
3. Lock nut

• Install Power Steering pump drive belt (1) and ad-

just belt tension.
Check drive belts for wear or damage, and replace
with new ones as necessary.
Check belts for tension, and adjust as necessary.
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6A1-82 4JB1/4JB1-TC - ENGINE

N6A3368E N6A3359E

11. Heater Hose 14. Transmission and Clutch Assembly

• Connect the heater hose then tighten clip securely. 1) Driven Plate Assembly
12. Intake Air Duct • Apply multi-purpose with MOS2 type grease to
• Connect the air duct then tighten clip securely. the driven plate hub spline.
• Use the pilot aligner to install the driven plate
assembly.
Pilot Aligner: 5-5825-3001-0

N6A3360E

13. Radiator Assembly

1) Install the cushion rubber on both sides. N6A3339E
2) Install the radiator stay
2) Pressure Plate Assembly
3) Connect the radiator hose upper and lower.
• Tighten pressure plate assembly fixing bolts in
4) Connect the reservoir tank hose.
numerical order.
Tighten:
• Pressure plate fixing bolt to 18 N⋅m (1.8 kg⋅m / 13
lb⋅ft)
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4JB1/4JB1-TC - ENGINE 6A1-83

Tighten:
• Clutch housing to flywheel hosing bolts to
M10: 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
M12: 91 N⋅m (9.3 kg⋅m / 67 lb⋅ft)
• Raise engine and transmission up into rear
transmission mount.
Tighten:
• Engine rear mounting nuts to
M10: 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
M12: 69 N⋅m (7.0 kg⋅m / 51 lb⋅ft)

N6A3341E

• Remove the pilot aligner.

Notice:
In case a new pressure plate assembly is mounted, after
tightening a pressure plate at the specified torque, be
sure to remove the wiring for protection of a diaphragm
spring.
3) Mounting Bracket
Tighten:
• Mounting bracket nuts to 69 N⋅m (7.0 kg⋅m / 51 lb⋅ft)
4) Transmission Assembly N6A3343E

• Support the transmission with mission jack. 5) Front Exhaust Pipe

Caution:
Tighten:
To prevent the falling of the transmission, tie it securely
• Front exhaust pipe bolts to 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
to the jack with a chain or belt.
6) Exhaust Brake Assembly
Tighten:
• Exhaust brake bolts to 17 N⋅m (1.8 kg⋅m / 12 lb⋅ft)
7) Clutch Slave Cylinder
Tighten:
• Slave cylinder bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Perform slave cylinder adjustment before in-
stallation of the return spring.
a. Loosen the lock nut of the push rod.
b. Turn the adjust nut until it reaches the shift
fork.
c. Back off the adjust nut 1.5 turns. (shift fork
free play Approximately 2 mm / 0.1 in).
d. Tighten the lock nut.
Tighten:
• Push rod lock nut to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
N6A3338E
8) Shift Cable and Select Cable
• Shift transmission into high gear. 9) Wiring Connector
• Align transmission with engine slope. • Color of Connector
• Turn output parking brake drum to aid clutch Back-up Light Switch: Brown
spring engagement. Neutral Switch: Gray
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6A1-84 4JB1/4JB1-TC - ENGINE

10) Parking Brake Cable
11) Propeller Shaft
• Line up reference mark.
Tighten:
• Propeller shaft nuts to 66 N⋅m (6.7 kg⋅m / 48 lb⋅ft)
• Connect battery ground cable
• Pour coolant
• Start the engine and check coolant leakage
LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE COOLING 6B-1

ENGINE
SECTION 6B
ENGINE COOLING
Contents
GENERAL DESCRIPTION ................................... 6B-2
Component ........................................................ 6B-2
WATER PUMP...................................................... 6B-6
Component ........................................................ 6B-6
Removal ............................................................ 6B-6
Inspection .......................................................... 6B-7
Installation ......................................................... 6B-7
THERMOSTAT ..................................................... 6B-9
Component ........................................................ 6B-9
Removal ............................................................ 6B-9
Inspection .......................................................... 6B-9
Installation ....................................................... 6B-10
RADIATOR.......................................................... 6B-11
Component ...................................................... 6B-11
Removal .......................................................... 6B-11
Inspection ........................................................ 6B-11
Installation ....................................................... 6B-12
DRIVE BELT ADJUSTMENT .............................. 6B-13
Component ...................................................... 6B-13
Inspection ........................................................ 6B-14
Tension Adjustment......................................... 6B-14
LG4JB-WE-1111.book 2 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6B-2 ENGINE COOLING

GENERAL DESCRIPTION
Component
Coolant Flow
4JB1

9
4

LNWB1CMF000401

Legend
1. Radiator cap 6. Thermostat
2. Reservoir tank 7. Water pump
3. Cylinder head 8. Car heater
4. Radiator 9. Oil cooler
5. Cooling fan
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ENGINE COOLING 6B-3

Coolant Flow
4JB1-TC

3
7

6
5

LNWB1CMF000501

Legend
1. Radiator cap 7. Thermostat
2. Reservoir tank 8. Water pump
3. Cylinder head 9. Car heater
4. Radiator 10. Oil cooler
5. Cooling fan 11. C.S.D
6. Turbocharger 12. Injection pump

The cooling system is a pressurized coolant forced cir-

culation type which consists of water pump, thermostat
cooling fan, radiator and other components. The circu-
lating coolant cools the lubricating oil in the oil filter and
turbocharger.

Water Pump
The coolant pump is a centrifugal impeller type and is
driven by V type drive belt.
The water pump is not disassembled type.

N6A3372E
LG4JB-WE-1111.book 4 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6B-4 ENGINE COOLING

Thermostat
The thermostat is a wax pellet type with a juggle valve
and is installed in the thermostat housing.

N6A3375E

Legend
N6A3373E 1. Radiator
2. Charge air cooler
Legend
1. Jiggle valve Engine Coolant Change Procedure
1. Check that the engine is cool.
Radiator 2. Open the radiator cap.
The radiator is a tube type with corrugated fins. In order 3. Loosen the air removal plug (2) of the water outlet
to raise the boiling point of coolant, the radiator is adjust- pipe.
ed through a valve fitted to the upper tank to a pressure 4. Pour coolant up to the filler neck.
range of 93 — 123 kPa (0.95 — 1.25 kg/cm2). The cap 5. After filling, press the radiator upper hose two or
fitted to the cylinder head thermostat housing has only a three times. Then, if the level has dropped because
water supply function. the air in the hose has been removed, add the
equivalent amount of coolant.
6. Pour coolant up to the "MAX" line of the reserve
tank.
7. Tighten the air removal plug of the water outlet
pipe.
8. Close the radiator cap and start the engine. Let the
engine idle for two to three minutes then stop it.
Open the radiator cap again and pour in more cool-
ant if the level has dropped.
WARNING:
Warning:
Do not loosen or remove the radiator cap when the
coolant is hot. Steam and boiling water can burst
out from the radiator possibly causing burns or heat
related injuries. When opening the radiator cap,
place a thick cloth over the cap when the coolant is
cooled, and turn it gradually to release the pressure
before opening it.
N6A3374E
9. After securely tightening the radiator cap, warm up
The 4JH1-TC engine is equipped with the intercooler. the engine at approximately 2,000 r/min.
10. When verified that the thermostat has opened after
the water temperature gauge indicator has passed
the center, idle the engine for about five more min-
utes, then stop the engine and let the vehicle
stand.
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ENGINE COOLING 6B-5

11. After the engine has adequately cooled, check the
level again at the filler neck and add more if neces-
sary. If the coolant is excessively low, check the
coolant path and reserve tank hose for leaks.
12. Pour coolant up to the "MAX" line of the reserve
1
tank again.

Coolant concentration inspection

1. Engine coolant concentration
2
• The concentration of the engine coolant affects its
freezing temperature. Therefore, the concentration
should be set to the lowest temperature.
• Use genuine Isuzu engine coolant.
• If the mixing ratio of the engine coolant is higher
than 60%, it overheats easily. If it is less than 30%,
it will not be sufficient to prevent corrosion.
• When diluting the coolant, use the distilled or LNW46BSH001001
deionized water.
• When it is used at the temperature of -30°C (-22°
Legend
F) or below, make the concentration to 55%.
1. Density gauge
Coolant 2. Radiator
Region where used
Concentration
• The temperature of the coolant should be with-
General regions, regions where the in 0°C - 50°C (32°F - 122°F) for measurement.
lowest temperature is -12°C (10.4°F) 30%
or above • After measuring the temperature and relative
density, find the concentration from the table
Cold regions, regions where the below.
lowest temperature is -30°C (-22°F) 50%
or above
Regions where the lowest 1.100
temperature is -30°C (-22°F) or 55% 1.090
below 1.080 50%
1.070
SPECIFIC GRAVITY

Caution: 1.060
• For the coolant, make sure to use the products
specified (recommended) by Isuzu.
1.050 30%
• If the coolant specified (recommended) by Isuzu is 1.040
not used, the engine, radiator or heater core may 1.030
be damaged. 1.020
• Never use the coolant which contains borate or sil- 1.010
icate. The engine, radiator or heater core may cor- 1.000
rode, causing a water leakage.
0 10 20 30 40 50 60 70
2. Measurements of engine coolant concentration TEMPERATURE
Hydrometry MFW91CSH001001

• Use an antifreeze hydrometer to measure the

specific gravity and coolant temperature. If you Coolant Scope Method
remove the cap when the engine is hot, be • Measure the concentration using a coolant scope.
careful because the coolant will burst out.
• Use a container that is deeper than the length
of the hydrometer.
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6B-6 ENGINE COOLING

WATER PUMP
Component

4
2

LNWB1BSF000501

Legend
1. Fan shroud 4. AC generator drive belt
2. Cooling fan assembly 5. Water pump assembly
3. P/S oil pump drive belt (with P/S oil pump type
only)

Removal
Preparation:
• Disconnect battery ground cable.
• Drain coolant.
1. Fan Shroud
• Remove the reservoir tank hose, bypass hose and
fan guide.
2. Cooling Fan Assembly
• Remove lock nut and take out cooling fan assem-
bly.
3. P/S oil pump drive belt (with P/S oil pump type
only)
• Loosen the idler pulley lock nut and loosen adjust
bolt, and remove the drive belt.

N6A3380E

4. AC Generator Drive Belt

• Loosen AC Generator mounting bolt (under side)
and adjust plate lock bolt, and remove the drive
belt.
LG4JB-WE-1111.book 7 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE COOLING 6B-7

• Install water pump assembly, and tighten to speci-
fied torque.
Tighten:
Pump Fixing Bolt to 20 N⋅m (2 kg⋅m/14 lb⋅ft)
2. AC Generator Drive Belt
3. P/S oil pump drive belt (with P/S oil pump type
only)
• Install the drive belts and adjust belt.
Check drive belts for wear or damage, and replace
with new ones as necessary. Check belts for ten-
sion, and adjust as necessary.
• Push the middle of belts with a force of 98 N (10 kg/
22 lb) and check each bolt for deflection.
• Standard deflection

mm (in)
N6A3699E
Initial tension
AC Generator drive belt 8 — 12
Legend Power Steering pump drive belt (0.31 — 0.47)
1. Lock bolt

5. Water Pump Assembly

• Remove the O-ring.

Inspection 1
Make necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump assem- 2
bly must be replaced.
• Cracks in the coolant pump body
• Coolant leakage from the seal unit
• Play or abnormal noise in the bearing
• Cracks or corrosion in the impeller

Installation
1. Water Pump Assembly
• Set O-ring in water pump body groove. LNW81BSH014801

Legend
1. AC generator & fan pulley drive belt
2. P/S oil pump drive belt (with P/S oil pump type
only)

Tighten:
• Generator Fixing Belt to 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
• Adjust Plate Fixing Belt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
• P/S Idler Pulley Lock Nut to 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
4. Cooling Fan Assembly
• Mount fan pulley and cooling fan assembly on the
water pump and tighten to the specified torque.
Tighten:
Fan Pulley Nut to 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
N6A3353E 5. Fan Shroud
LG4JB-WE-1111.book 8 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6B-8 ENGINE COOLING

• Install the fan shroud and reservoir tank hose and
bypass hose.

N6A3379E

• Connect the battery ground cable.

• Pour coolant.
• Start the engine and check coolant leakage.
LG4JB-WE-1111.book 9 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE COOLING 6B-9

THERMOSTAT
Component

N6A3385E

Legend
1. Switch harness 3. Gasket
2. Outlet pipe 4. Thermostat

Removal
Valve Opening Temperature °C(°F)
Preparation:
82 (180)
• Disconnect battery ground cable.
• Drain coolant from the radiator and engine. • Make sure that secondary valve opens fully at the
1. Switch Harness specified temperature.
2. Outlet Pipe
Valve Full Open Temperature °C(°F)
• Remove mounting bolt and remove outlet pipe to-
gether with radiator hose. 95 (203)
3. Gasket
4. Thermostat

Inspection
Submerge the thermostat assembly in the water.
Place wooden blocks on the bottom of the water con-
tainer.
Not to directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
• Make sure that primary valve begins to open at the
specified temperature.
LG4JB-WE-1111.book 10 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6B-10 ENGINE COOLING

N6A3386E

Make necessary repair and parts replacement if ex-

treme wear or damage is found during inspection.

Installation
1. Thermostat
2. Gasket
3. Outlet Pipe
• Connect outlet pipe and tighten bolts to the speci-
fied torque.
Tighten:
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
4. Switch Harness
• Install switch harness.

N6A3387E

• Install battery ground cable.

• Pour coolant.
• Start the engine and check coolant leakage.
LG4JB-WE-1111.book 11 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE COOLING 6B-11

RADIATOR
Component

N6A3388E

Legend
1. Reservoir tank hose & Bypass hose 5. Condenser
2. Radiator hose 6. Cushion rubber
3. Air intake duct 7. Radiator assembly
4. Radiator stay

Removal • Remove cushion rubbers on both sides of the bot-

tom.
Preparation:
7. Radiator Assembly
• Disconnect battery ground cable.
• Remove upward the radiator assembly with hose,
• Loosen drain plug to drain coolant.
taking care not to damage the radiator core by fan
1. Reservoir Tank Hose & Bypass Hose blade.
• Disconnect the hose from radiator.
2. Radiator Hose Inspection
• Disconnect lower hose and upper hose from the Radiator Valve
engine. • Apply air pressure from filler neck using radiator
3. Air Intake Duct cap tester and check the opening pressure of radi-
4. Radiator Stay ator valve. If the valve opening pressure is out of
the standard value range, replace with a new radi-
5. Condenser
ator valve.
• Remove the condenser from radiator and tempo-
rarily tighten the condenser to cab body front side, Radiator valve opening pressure kPa (kg/cm2 /psi)
use the wire.
93 — 123 (0.95 — 1.25/13.5 — 17.8)
6. Cushion Rubber
LG4JB-WE-1111.book 12 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6B-12 ENGINE COOLING

• Remove the radiator valve and check a negative 5. Air Intake Duct
pressure valve as the center of the valve seat side. • Connect the duct and tighten clip securely.
If the negative pressure valve does not work
6. Radiator Hose
smoothly, clean or replace the radiator valve.
• Connect inlet hose and outlet hose to the engine.
Tighten: • Connect battery ground cable.
Radiator valve to 6 N⋅m (0.6 kg⋅m/4 lb⋅ft)
• Pour coolant up to filler neck of radiator, and up to
• Conduct cooling system leakage check after rein- MAX mark of reservoir tank.
stalling the radiator valve. 7. Reservoir Tank Hose & Bypass Hose
Radiator Core
• Start engine to warm up, and check for coolant lev-
• Deformed radiator fins could reduce radiation ef- el.
fects, resulting in overheat. Straighten the fins. In
such a case, take care not to damage the fin roots.
• Remove dust and other foreign materials.
Flushing the Radiator
• Wash the inside of radiator and the coolant pas-
sage with water and neutral detergent. Remove all
scales and rust.
Checking for Coolant Leakage
• Clog up the reservoir tank hose carefully and check
the cooling system for leakage with a radiator cap
tester by applying an air pressure of 147 kPa (1.5
kg/cm2 /21 psi) from filler neck to inside the radia-
tor.

N6A3390E

Legend
1. Reservoir tank

N6A3389E

• As the radiator upper tank is provided with a valve,

the pressure fails to rise higher than the valve
opening pressure unless the hose is clogged up.

Installation
1. Radiator Assembly
• Install the radiator.
2. Cushion Rubber
• Install cushion rubbers on both sides of radiator
bottom.
• Install radiator assembly with hose, taking care not
to damage the radiator core by a fan blade.
3. Condenser
4. Radiator Stay
LG4JB-WE-1111.book 13 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE COOLING 6B-13

DRIVE BELT ADJUSTMENT

Component

10

9
4

LNW81BLF002901

Legend
1. Adjust plate 7. Belt position: AC generator & fan pulley drive belt
2. Fan pulley 8. Belt position: P/S oil pump drive belt (with P/S oil
3. P/S oil pump pulley pump type only)
4. Idle pulley 9. AC generator fixing bolt
5. Adjust bolt 10. AC generator
6. Clank pulley
LG4JB-WE-1111.book 14 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6B-14 ENGINE COOLING

Inspection Tighten:
Check drive belts for wear or damage, and replace with Lock Nut to 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
new ones as necessary. Check belts for tension, and
adjust as necessary.
• Check drive belts tension.
• Push the middle of belts with a force of 98 N (10 kg/
22 lb) and check each bolt for deflection.
• Standard deflection

mm (in)
Tension at readjustment
AC generator & fan pulley
drive belt 8 — 12 (0.31 — 0.47)
P/S pump drive belt

4JB1

LNW81BSH014801

Legend
1. AC generator & fan pulley drive belt
2. P/S oil pump drive belt (with P/S oil pump type
only)

Tension Adjustment
1. AC Generator & Fan Pulley Drive Belt
• With AC Generator mounting and lock bolts loose,
adjust belt tension with adjuster’s adjust bolt.
Tighten bolt to the specified torque.
Tighten:
• Generator Fixing Bolt to 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
• Adjust Plate Fixing Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
2. P/S Oil Pump Drive Belt (with P/S oil pump type
only)
• With idle pulley lock bolt loose, adjust P/S oil pump
drive belt tension.
Tighten lock nut to the specified torque.
LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-1

ENGINE
SECTION 6C
ENGINE FUEL
Contents
GENERAL DESCRIPTION ...................................6C-2 IDLING CONTROL CABLE ................................ 6C-54
Fuel Flow ...........................................................6C-3 Component ..................................................... 6C-54
Injection Pump...................................................6C-4 Removal.......................................................... 6C-54
Fuel Filter and Water Separator ........................6C-5 Installation....................................................... 6C-54
Injection Nozzle .................................................6C-6 Inspection........................................................ 6C-54
FUEL FILTER ASSEMBLY ...................................6C-7 AIR CLEANER ELEMENT (4JB1 Engine).......... 6C-55
Components ......................................................6C-7 Component ..................................................... 6C-55
Removal ............................................................6C-7 Removal.......................................................... 6C-55
Installation .........................................................6C-7 Inspection........................................................ 6C-55
FUEL FILTER CARTRIDGE .................................6C-8 Installation....................................................... 6C-56
Removal ............................................................6C-8 AIR CLEANER ELEMENT (4JB1-TC Engine).... 6C-57
Installation .........................................................6C-8 Component ..................................................... 6C-57
INJECTION NOZZLE ............................................6C-9 Removal.......................................................... 6C-57
Component ........................................................6C-9 Inspection........................................................ 6C-57
Removal ..........................................................6C-10 Installation....................................................... 6C-58
Disassembly (4JB1-TC Engine) ......................6C-10
Reassembly and Adjustment
(4JB1-TC Engine)............................................6C-11
Disassembly (4JB1 Engine) ............................6C-20
Inspection and Repair (4JB1 Engine)..............6C-21
Reassembly (4JB1 Engine) .............................6C-22
Injection Nozzle Adjustment (4JB1 Engine) ....6C-22
Installation .......................................................6C-22
INJECTION PUMP ASSEMBLY .........................6C-24
Component ......................................................6C-24
Removal ..........................................................6C-25
Installation .......................................................6C-26
Injection Timing Adjustment ............................6C-28
INJECTION PUMP DATA ...................................6C-32
Test Conditions................................................6C-32
Identification Plate and Number ......................6C-34
INJECTION VOLUME AND GOVERNOR
PERFORMANCE DIAGRAM ..............................6C-35
Governor Performance Diagram .....................6C-35
FUEL TANK ........................................................6C-47
Component ......................................................6C-47
Removal ..........................................................6C-48
Installation .......................................................6C-48
FUEL GAUGE UNIT............................................6C-49
Component ......................................................6C-49
Removal ..........................................................6C-49
Installation .......................................................6C-49
ACCELERATOR CONTROL CABLE ..................6C-50
Component ......................................................6C-50
Removal ..........................................................6C-50
Inspection ........................................................6C-50
Installation .......................................................6C-50
ACCELERATOR PEDAL ....................................6C-52
Component ......................................................6C-52
Removal ..........................................................6C-52
Installation .......................................................6C-52
LG4JB-WE-1111.book 2 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-2 ENGINE FUEL

GENERAL DESCRIPTION
When working on the fuel system, there are several
things to keep in mind:
• Any time the fuel system is being worked on, dis-
connect the negative battery cable except for those
tests where battery voltage is required.
• Always keep a dry chemical (Class B) fire extin-
guisher near the work area.
• Replace all pipes with the same pipe and fittings
that were removed.
Clean and inspect O-rings. Replace where re-
quired.
• Always relieve the line pressure before servicing
any fuel system components.
• Do not attempt repairs on the fuel system until you
have read the instructions and checked the pic-
tures relating to that repairs.
LG4JB-WE-1111.book 3 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-3

Fuel Flow

N6A3392E

Legend
1. CSD solenoid valve 5. Fuel filter
2. Nozzle 6. Water separator
3. Fuel cut solenoid valve 7. Fuel tank
4. VE type injection pump

The fuel system consists of the fuel tank, the water sep-
arator, the fuel filter, the injection pump, and the injec-
tion nozzle.
The fuel from the fuel tank passes through the water
separator and the fuel filter where water particles and
other foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to
the injection nozzle in the measured volume at the opti-
mum timing for efficient engine operation.
LG4JB-WE-1111.book 4 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-4 ENGINE FUEL

Injection Pump

N6A3394E

Legend
A. From fuel filter 8. Plunger spring
B. To nozzle 9. Control sleeve
1. Governor spring 10. Delivery valve
2. Control lever 11. Plunger
3. Control lever shaft 12. Fuel cut solenoid valve
4. Drive shaft 13. Tension lever
5. Feed pump gear 14. Collector lever
6. Driver disc 15. Aneroid compensator
7. Timer

A Bosch Distributor Type Injection Pump is used. A sin- An aneroid compensator is available as an option for ve-
gle reciprocating/revolving plunger delivers the fuel uni- hicles to be operated at high altitudes. It adjusts the fuel
formly to the injection nozzles, regardless of the number and air mixing ratio.
of cylinders.
The governor, the injection timer, and the feed pump are
all contained in the injection pump housing.
The injection pump is compact, light weight, and pro-
vides reliable high-speed operation.
LG4JB-WE-1111.book 5 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-5

Fuel Filter and Water Separator

N6A3395E

Legend
A. Dual type 5. Level sensor
1. Body assembly 6. Drain plug
2. Filter cartridge 7. Priming pump
3. Case 8. Body assembly
4. Float 9. Water draining level

A cartridge type fuel filter and a water separator are A diaphragm type priming pump is installed at the top of
used along with the VE type injection pump. the water separator. It is used during the water draining
As the inside of the injection pump is lubricated by the and the air bleeding procedures.
fuel which it is pumping, the fuel must be perfectly clean.
The fuel filter and the water separator remove water par-
ticles 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.
LG4JB-WE-1111.book 6 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-6 ENGINE FUEL

Injection Nozzle

N6A3397E

Legend
A. Direct injection nozzle 6. Retaining nut
B. Indirect injection nozzle 7. Nut
1. Spring 8. Gasket
2. Spring seat 9. Push rod
3. Injection nozzle 10. Spacer
4. Nozzle holder 11. Pin
5. Adjusting shim

For 4J Series diesel engines, there are two types avail- Pressurized fuel from the injection pump is sprayed by
able: Direct injection engine. Accordingly, the injection the injection nozzle into the combustion chamber
nozzles to be used are different depending on the type through the nozzle body orifices.
of the engine and the combustion chamber. 4JB1-TC Engine
The injection nozzle sprays pressurized fuel from the in- The two-spring nozzle holder has been developed to re-
jection pump into the combustion chamber through the duce NOx (Nitrogen Oxides) and particulates from direct
injection nozzle orifices. injection diesel engine exhaust.
4JB1 engines employ a hole type nozzle with four injec-
tion orifices. The nozzle is made up of the nozzle body
and the needle valve assembly.
LG4JB-WE-1111.book 7 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-7

FUEL FILTER ASSEMBLY

Components

N6A3398E

Legend
1. Fuel filler cap 3. Fuel filter assembly
2. Fuel hose

Removal
Preparation
• Disconnect battery ground cable.
1. Fuel Filler Cap
2. Fuel Hose
• Disconnect fuel hose from filter body.
Plug the hose ends to prevent fuel spillage.
3. Fuel Filter Assembly
• Remove the fixing bolts on fuel filter bracket.

Installation
1. Fuel Filter Assembly
• Install the fuel filter bracket, then tighten fixing bolt.
2. Fuel Hose
• Connect hoses to filter body.
3. Fuel Filler Cap
• Connect the battery ground cable.
• Feed fuel to the injection pump by means of the
priming, and bleed the fuel system.
LG4JB-WE-1111.book 8 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-8 ENGINE FUEL

FUEL FILTER CARTRIDGE

Removal • Operate the priming pump several times to check
for fuel leakage.
• Remove the cartridge using a filter wrench.
Filter wrench: 5-8840-0253-0 (J-22700) • Check and see the warning light is off.

Installation
• Clean the cartridge mounting surface of filter body
so that the cartridge can be securely.
Apply engine oil thinly to new cartridge O-ring.
• To facilitate bleeding, fill the new cartridge with
light oil.
• Tighten the cartridge until O-ring comes in contact
with the sealing, taking care not to spill the light oil.
• Retighten 1/3 — 2/3 using a filter wrench.
Filter wrench: 5-8840-0253-0 (J-22700)

N6A3012E

Special Tools

Tool Number /
Illustration
Description

5-8840-0253-0
(J-22700)
Filter wrench
N6A3399E
5884002530
Air Bleeding
• Operate priming pump to send the air in the fuel
system to the injection pump.
• Loosen injection pump bleeding plug, and operate
the priming pump until no bubble is made.
• Tighten the bleeding plug.
• Start the engine, and if it is not started in 10 sec-
onds or less, repeat the bleeding steps.
• Make sure of no fuel leakage, and tighten the prim-
ing pump.
Draining
• When the water in the sedimentor reaches the
specified volume, warning light is actuated.
In this case, follow the draining steps below.
• Set a vinyl hose over the drain plug.
• Loosen the drain plug.
• To drain the water, operate the priming pump sev-
eral times.
• After draining, tighten the drain plug.
LG4JB-WE-1111.book 9 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-9

INJECTION NOZZLE
Component

4JB1

4JB1-TC

LNWB1BLF006501

Legend
1. Injection pipe 3. Injection nozzle
2. Leak off pipe or hose
LG4JB-WE-1111.book 10 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-10 ENGINE FUEL

Removal
Preparation:
• Disconnect battery ground cable.
1. Injection Pipe
• Release injection pipe clip.
• Loosen the flare nut on the injection pump side.
• Loosen the flare nut on the injection nozzle side,
disconnect and put aside the pipe.
2. Leak off Pipe or Hose
3. Injection Nozzle
Injection Nozzle (Two Spring Nozzle Holder) (4JB1-
TC)
The two-spring nozzle holder has been developed to re-
duce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.

Disassembly (4JB1-TC Engine)

1. Retaining nut (1)
2. Nozzle & pin (2)
3. Spacer & pin (3)
4. Lift piece (4)
5. Spring seat (5)
6. Push rod (6)
7. Shim (Second nozzle opening pressure adjust-
ment) (7) N6A3402E
8. Second spring (8)
1) Before disassembly, remove carbon deposit
9. Collar (9)
from nozzle and nozzle holder using a wire
10. Spring seat (10) brush and wash the outside nozzle holder as-
11. First spring (11) sembly.
12. Shim (First nozzle opening pressure adjustment)
Caution:
(12)
Do not touch nozzle holes with the wire brush during
13. Nozzle holder body (13)
cleaning it.
14. Eye bolt (14)
2) Disassemble the nozzle holder assembly to nu-
15. Gasket (15)
merical order.
LG4JB-WE-1111.book 11 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-11

Reassembly and Adjustment (4JB1-TC En-
gine)
Opening Pressure Adjustment
1. Nozzle holder body
2. Shim (First opening pressure adjustment)
3. First spring
4. Spring seat
5. Collar
6. Second spring
7. Push rod
8. Shim (Second opening pressure adjustment)
9. Spring seat
10. Lift piece
11. Spacer & pin
12. Nozzle & pin
13. Retaining nut
14. Gasket
15. Eye bolt

N6A3403E

The nozzle holder is adjusted as the components are re-

assembled in the sequence above.
As adjustment of the two-spring nozzle holder is made
in hundredths of a millimeter, clean the parts thoroughly
in light oil to completely remove any dirt or foreign mat-
ter.
LG4JB-WE-1111.book 12 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-12 ENGINE FUEL

Reassembly and Adjustment Procedure

N6A3692E

First Nozzle Opening Pressure Adjustment

1. Claim the nozzle holder in a vise.

N6A3405E

N6A3404E Legend
1. Spring seat
Legend 2. First spring
1. Nozzle holder body 3. First nozzle opening pressure adjusting shim

2. Install the shim, first spring and spring seat in the 3. Install the collar, second spring, shim, spring seat
nozzle holder. and push rod in the nozzle holder.
LG4JB-WE-1111.book 13 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-13

N6A3406E N6A3408E

7. Hand-tighten the adjustment retaining nut together

Legend with the gasket to the nozzle holder.
1. Second nozzle opening pressure adjusting Retaining nut: 5-8677-7140-0
shim
Gasket: 5-8677-7139-0
2. Second spring
3. Collar
4. Push rod
5. Spring seat

4. Install the pins (3), lift piece (2) and spacer (1) in
the nozzle holder.

N6A3409E

Legend
1. Retaining nut (Special tool)
2. Gasket (Special tool)
3. Nozzle
N6A3407E
8. Tighten the adjustment retaining nut to the speci-
5. Install the pins (2) in the spacer. fied torque.
6. Install the nozzle (1) on the spacer. Tighten:
Retaining nut to 29 — 39 N⋅m (3.0 — 4.0 kg⋅m)
LG4JB-WE-1111.book 14 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-14 ENGINE FUEL

Parts No. Thickness (mm)

1-1534-9042-0 0.40
1-1534-9043-0 0.50
1-1534-9044-0 0.52
1-1534-9045-0 0.54
1-1534-9046-0 0.56
1-1534-9047-0 0.58
1-1534-9048-0 0.60
1-1534-9049-0 0.70

N6A3410E

Legend
1. Torque wrench
2. Retaining nut (Special tool)

9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester and measure the first
nozzle opening pressure.

N6A3412E

Full Needle Valve Lift Confirmation

1. Install the gasket (2) and plug (1) on the adjust-
ment retaining nut.
Gasket: 8-9722-7602-0
Plug: 5-8677-7141-0

N6A3411E

Legend
1. Nozzle holder
2. Nozzle tester

11. If the first nozzle opening pressure is not as speci-

fied, disassemble the nozzle holder and replace
the shim until the pressure is as specified.
Caution:
Use a micrometer to measure shim thickness. N6A3413E

• First nozzle opening pressure adjusting shims

LG4JB-WE-1111.book 15 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-15

2. Position the nozzle holder with the nozzle facing
down and install the dial gauge holder on the noz-
zle holder.
Dial gauge holder: 5-8677-7142-0

N6A3416E

5. Secure the dial gauge to the nozzle holder using

the nut so that the pin contacts the tip of the first
spring seat.
N6A3414E
Caution:
• Secure the dial gauge so that a stroke of 2 mm can
Legend
be measured.
1. Dial gauge holder (Special tool)
• Do not over-tighten the nut as the dial gauge shaft
3. Install the nut (1) on the dial gauge holder (2). may jam. (Confirm from the dial gauge that the
Nut: 5-8677-7143-0 shaft moves smoothly.)

N6A3415E

4. Install the pin (2) to the dial gauge (1).

Notice:
The lengths of the pin do not include the threaded por-
tions.
Pin (liter=100 mm): 5-8677-7144-0
Dial gauge: 1-8531-7015-0

N6A3417E
LG4JB-WE-1111.book 16 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-16 ENGINE FUEL

Legend
1. Dial gauge
2. Nut
3. Holder
4. Pin
5. Nozzle holder
6. First spring seat

6. Set the nozzle holder (1) to the nozzle tester (2)

and put needle to zero on the dial gauge.
7. Operate the nozzle tester (2) to bleed any air from
inside the retaining nut and to confirm that no fuel
leaks.

N6A3419E

Legend
A. Inline pressure
1. Needle valve lift
2. First nozzle opening pressure

Pre-lift Confirmation
1. With the needle valve at full lift, release the nozzle
tester handle.

N6A3411E

8. Operate the nozzle tester and increase the inline

pressure to 34.3 — 44.1 MPa (350 — 450 kg/cm2)
so that the nozzle’s needle valve moves through its
full lift.
Record full lift ‘L’. (Read dial gauge)

Notice:
The above operation is used to determine whether the
nozzle seat is worn and whether the nozzle assembly is
in good condition.

N6A3420E

Legend
1. Pressure gauge
LG4JB-WE-1111.book 17 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-17

Legend
A. Inline pressure
1. Needle valve lift
2. First nozzle opening pressure
3. Measuring point of pre-lift

Notice:
This point can be found while the pressure is decreas-
ing.
3. Confirm that pre-lift ‘liter’ is as specified.

Pre-lift mm (in)
0.04 (0.002)

N6A3421E

Legend
A. Inline pressure
1. Needle valve lift

Notice:
The inline pressure will decrease and needle valve lift
(as indicated on the dial gauge) will also decrease a lit-
tle.
2. Read the needle valve lift ‘liter’ from the dial gauge
indication (once the needle valve has descended
when the second spring has stopped operating).
Refer to the pre-lift measuring point for ‘liter’.
Pre-Lift Measuring Point:
N6A3423E
Read the dial gauge at first nozzle opening pressure
+approx 1 MPa (10 kg/cm2).
Legend
1. Push rod
2. Spring seat
3. Spacer
4. Second spring
5. Adjusting shim
6. Lift piece
7. Needle valve

4. If pre-lift is not specified, replace the pins, lift piece,

spacer and nozzle assembly with the service kit.

Service kit:
8-9720-3470-1

N6A3422E
LG4JB-WE-1111.book 18 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-18 ENGINE FUEL

N6A3424E N6A3794E

Legend Legend
1. Lift piece A. Inline pressure
2. Nozzle assembly 1. Needle
3. Pin 2. Second nozzle opening pressure
4. Spacer
5. Capsule Notice:
The inline pressure will decrease and needle valve lift
Second Nozzle Opening Pressure Confirmation (as indicated on the dial gauge) will also decrease a lit-
1. After pre-lift confirmation, operate the nozzle tester tle.
to increase inline pressure to 34.3 — 44.1 MPa
(350 — 450 kg/cm2) so that the nozzle’s needle 3. Then, read the pressure gauge indication (second
valve moves through its full lift. nozzle opening pressure) the instant that the dial
gauge indicates the specified needle valve lift (usu-
ally pre-lift liter + 0.05 mm).

N6A3411E

N6A3425E
Legend
1. Nozzle holder
Legend
2. Nozzle tester
1. When needle valve lift is L + 0.05 mm
2. Release the nozzle tester handle so that inline 2. Full needle valve lift
pressure decreases. 3. Dial gauge
LG4JB-WE-1111.book 19 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-19

Legend
1. Second nozzle opening pressure adjusting
shim
2. Second spring
3. Collar
4. Push rod
5. Spring seat

• Second nozzle opening pressure adjusting shims

Part No. Thickness (mm)

8-9711-6034-0 0.40
8-9711-6035-0 0.50
8-9711-6037-0 0.52
8-9711-6039-0 0.54
N6A3795E
8-9711-6041-0 0.56
8-9711-6043-0 0.58
Legend
1. Pressure gauge 8-9711-6044-0 0.59

Second Nozzle Opening Pressure Adjustment

If the second nozzle opening pressure is not as speci-
fied, disassemble the nozzle from the nozzle holder and
replace the shim until the pressure is as specified.
Caution:
• Because the second opening pressure changes
when the first opening pressure changes, the sec-
ond opening pressure must be adjusted when the
first opening pressure changes.
• Use a micrometer to measure shim thickness.

N6A3412E

Final Inspection
1. Remove the dial gauge (1), nut (2) and dial gauge
holder (3).

N6A3406E
LG4JB-WE-1111.book 20 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-20 ENGINE FUEL

N6A3426E N6A3411E

2. Remove the adjustment retaining nut and gasket.

Legend
3. Install the original retaining nut, confirm that the
1. Nozzle holder
pins are inserted fully into the nozzle, and then
hand-tighten the retaining nut. Then, tighten the 2. Nozzle tester
original retaining nut to the specified torque.
5. When replacing the nozzle, replace the nozzle, lift
Torque: 59 — 79 N⋅m (6.0 — 8.0 kg⋅m/43.5 — 58.2
piece, pins and spacer as a set with the nozzle ser-
lb⋅ft)
vice kit.
Caution:
Pre-lift will not be as specified if only the nozzle is re-
placed.

Disassembly (4JB1 Engine)

1. Retaining Nut (1)
2. Injection Nozzle (2)
1) Remove the nozzle assemblies from the nozzle
holders.
Tag the nozzle assemblies and the nozzle
holders to ensure that they are reinstalled in
their original positions.
The nozzle assembly and nozzle holder combi-
nations must not be interchanged.
2) Immerse the injection nozzle in a tool tray filled
with clean diesel oil to protect them from dust.
N6A3410E
3. Spacer (3)
4. Spring Seat (4)
Legend 5. Spring (5)
1. Torque wrench 6. Adjusting Shim (6)
2. Retaining nut (Special tool) 7. Nozzle Holder (7)
4. Set the nozzle holder to the nozzle tester and
check first nozzle opening pressure, spray condi-
tion, seat oil tightness and each part for oil leaks.
LG4JB-WE-1111.book 21 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-21

N6A3430E N6A3431E

Nozzle Lapping Procedure

1. Lap the nozzle needle (1) and the nozzle body (2)
by applying a compound of oxidized chrome and
animal oil (3).
Notice:
Do not apply an excessive amount of the oxidized
chrome and animal oil compound to the injection needle
valve seat area. Applying too much compound will
cause the injection nozzle needle and the injection noz-
zle body cavity to wear excessively.

N6A3431E

Inspection and Repair (4JB1 Engine)

Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
Inspection Nozzle Needle Inspection
1. Remove the needle from the nozzle body.
2. Carefully wash the nozzle needle and the nozzle
body in clean diesel fuel.
3. Check that the nozzle needle moves smoothly in-
N6A3432E
side the injection nozzle body.
If the nozzle needle does not move smoothly, it 2. Carefully wash the needle valve and the nozzle
must be repaired (See “Nozzle Lapping Proce- body in clean diesel fuel after lapping.
dure”). Nozzle Body and Needle Valve Inspection
Check the nozzle body and the needle valve for damage
and deformation.
The nozzle and body assembly must be replaced if ei-
ther of these two conditions are discovered during in-
spection.
LG4JB-WE-1111.book 22 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-22 ENGINE FUEL

kPa (kg/cm2 /psi)

18,142 (185/2630)

N6A3433E

Reassembly (4JB1 Engine)

1. Nozzle Holder
2. Adjusting Shim N6A3435E

3. Spring
If the injection nozzle does not open at the specified
4. Spring Seat pressure, install or remove the appropriate number of
5. Spacer adjusting shims to adjust it.
6. Injection Nozzle
Adjusting Shim Availability mm (in)
7. Retaining Nut
0.50 — 1.50 (0.02 —
Tighten: Range
0.06)
Retaining nut to 34 N⋅m (3.5 kg⋅m/25 lb⋅ft)
Increment 0.025 (0.001)
Total number of Shims 40

Removing or installing one shim will increase or de-

crease the nozzle opening pressure approximately
369.46 kPa (3.77 kg/cm2 /53.6 psi).
WARNING:
Warning:
TEST FLUID FROM THE INJECTION NOZZLE WILL
SPRAY OUT UNDER GREAT PRESSURE. IT CAN
EASILY PUNCTURE A PRESON’S SKIN. KEEP
YOUR HANDS AWAY FROM THE INJECTION NOZ-
ZLE TESTER AT ALL THE TIMES.

Installation
1. Injection Nozzle
1) Install the injection nozzle gasket (1) and the O-
ring (2) to the injection nozzle holder (3).
N6A3434E Be sure that the O-ring fits snugly in the injec-
tion nozzle groove.
Injection Nozzle Adjustment (4JB1 Engine) 2) Apply engine oil to the cylinder head nozzle
1. Attach the injection nozzle holder to the injection holder hole.
nozzle tester. 3) Install the nozzle holder together with the noz-
2. Apply pressure to the nozzle tester to check that zle holder bracket (4) to the cylinder head.
the injection nozzle opens at the specified pres-
sure. Tighten:
37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
LG4JB-WE-1111.book 23 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-23

LNWB6ASH002701

N6A3437E

2. Leak Off Hose

3. Injection Pipe
LG4JB-WE-1111.book 24 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-24 ENGINE FUEL

INJECTION PUMP ASSEMBLY

Component

LNWB1CLF001101

Legend
1. Cooling fan assembly 7. Air intake duct
2. Fan Shroud 8. Injection pump control cable
3. P/S oil pump drive belt (with P/S oil pump type 9. Fuel hose
only) 10. CSD water hose
4. AC generator & fan pulley drive belt 11. Injection pump harness
5. Noise shield cover 12. Injection pipe
6. Noise cover spacer 13. Injection pump assembly
LG4JB-WE-1111.book 25 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-25

Removal
Preparation:
• Disconnect battery ground cable.
• Drain coolant.
1. Cooling Fan Assembly
• Remove clamp nut, and remove cooling fan as-
sembly, distant pipe, and fan pulley.
2. Fan Shroud
3. P/S Oil Pump Drive Belt (with P/S oil pump type
only)
• Loosen power steering pump mounting bolt and
adjust bolt, and remove the drive belt.
4. AC Generator & Fan Pulley Drive Belt
• Loosen AC generator mounting bolt (under side)
and adjust plate lock bolt, and remove the drive
belt. N6A3440E

11. Injection Pump Harness

• Remove the tachometer sensor (with tachometer),
CSD solenoid, fuel cut solenoid.

N6A3439E

5. Noise Shield Cover

6. Noise Cover Spacer
7. Air Intake Duct N6A3441E

8. Injection Pump Control Cable

• Remove the control cable bracket bolt and remove Legend
the control lever side. 1. CSD solenoid
9. Fuel Hose 2. Injection pump
• Disconnect the fuel feed hose and fuel return hose. 3. Fuel cut solenoid
10. CSD (Cold Starting Device) Water Hose 4. Tachometer sensor
• Disconnect the water hose from injection pump
12. Injection Pipe
side.
• Release pipe clip.
• Remove the flare nut on the pump side.
• Remove the flare nut on the injection nozzle side,
and remove the injection pipe.
Caution:
• Be sure to plug the injection nozzle holder and de-
livery holder to prevent the entry of foreign matter.
13. Injection Pump Assembly
• Remove pump mounting nut.
LG4JB-WE-1111.book 26 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-26 ENGINE FUEL

• Loosen injection pump rear bracket adjuster lock 3) Look in through the check hole on the crank-
bolt. shaft timing gear side and check to see if the
• Remove the mounting bolt on the engine side, and “O” mark on the timing gear is in line with the
pull out the pump from the engine. pointer of the check hole.
4) In the condition above with the injection pump
gear mark “O” set to the pointer of the check
hole, install the injection pump assembly.
• Install the injection pump fixing bolts and tighten
them to the specified torque.
Tighten:
Pump Bolts to 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)

N6A3442E

Notice:
Plug the injection pump delivery holder parts with the
shipping caps (or the equivalent) to prevent the entry of
foreign materials.

Installation
N6A3444E
1. Injection Pump Assembly
1) Timing gear case a camshaft timing gear side c
injection pump timing gear side check hold cov- Legend
er. A. Camshaft gear
B. Injection pump gear

2. Injection Pipe
• Connect the pump side and nozzle side of the pipe,
and tighten securely.
• Install clip where it was.
Tighten:
Sleeve Nut to 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)

N6A3443E

2) Turn the crankshaft clockwise to see the TDC

mark of the crank pulley to the pointer, and then
bring the No. 1 cylinder to the TDC on the com-
pression stroke.
LG4JB-WE-1111.book 27 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-27

N6A3781E N6A3368E

3. Injection Pump Harness 7. Air Intake Duct

• Mount engine harness and connect it to switches. 8. Noise Cover Spacer
4. CSD Water Hose 9. Noise Shield Cover
• Connect the water hose and tighten clip securely.

N6A3447E

N6A3445E
10. AC Generator & Fan Pulley Drive Belt
5. Fuel Hose • Install AC generator drive belt and adjust belt ten-
• Connect the fuel feed hose and fuel return hose. sion.
• Connect the leak off hose. • Depress the drive belt mid-portion with a 98 N (10
kg/22 lb) force.
6. Injection Pump Control Cable
1) Install the control wire to the engine control le- Drive Belt Deflection mm (in)
ver.
8 (0.31) — 12 (0.47)
2) Hold the accelerator lever in the fully closed po-
sition and stretch the control cable in the direc-
tion indicated by the arrow to remove any slack.
3) Tighten the accelerator cable bracket bolt.
LG4JB-WE-1111.book 28 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-28 ENGINE FUEL

LNW81BSH014801 N6A3379E

Injection Timing Adjustment

Legend
1. AC generator & fan pulley drive belt 1. Check that the notched line on the injection pump
flange is aligned with the front plate or the timing
2. P/S oil pump drive belt (with P/S oil pump type
gear case notched line.
only)

• Install fixing bolt and tighten bolts to the specified

torque.
Tighten:
• Generator Fixing Bolt to 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
• Adjust Plate Fixing Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
11. P/S Oil Pump Drive Belt (with P/S oil pump type
only)
• Install P/S oil pump drive belt and adjust belt ten-
sion.
• Depress the drive belt mid-portion with a 98 N (10
kg/ 22 lb) force.

Drive Belt Deflection mm (in)

8 (0.31) — 12 (0.47)

• Tighten the idler lock nut to the specified torque. N6A3031E

Tighten: 2. Bring the piston in the No. (1) cylinder to TDC 1 on

27 N⋅m (2.8 kg⋅m/20 lb⋅ft) the compression stroke by turning the crankshaft
until the crankshaft pulley TDC line is aligned with
12. Fan Shroud
the timing mark (2).
• Install the fan shroud and reservoir tank hose.
13. Cooling Fan Assembly
• Mount fan pulley, distance piece, and cooling fan
assembly (in this order) on the water pump, and
tighten to the specified torque.
Tighten:
8 N⋅m (0.8 kg⋅m/69 lb⋅ft)
• Connect battery ground cable.
• Pour coolant.
LG4JB-WE-1111.book 29 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-29

N6A3032E

Notice: Legend
Check for play in the No. 1 intake and exhaust valve 1. Wax CSD
push rods. 2. Injection pump
If the No. 1 cylinder intake and exhaust valve push rods 3. Adjust bolt
have play, the No. 1 piston is at TDC on the compres- 4. Object
sion stroke. 5. 11mm (0.43 in)
3. Disconnect the injection pipe from the injection 6. φ10mm (0.39 in)
pump. 7. Wax CSD Moving parts
4. Remove one bolt from the distributor head.
5. Turn the lever portion of Wax CSD attached to the 6. Install the static timing gauge (1).
injection pump to create a gap with the moving part The probe of the gauge should be depressed in-
of Wax CSD, and fix the lever by inserting the ob- ward approximately 2 mm (0.079 in).
ject of 11mm (0.43in.) in between. Static Timing Gauge: 5-8840-0145-0 (J-28827) (1)
• Use adapter for the 4JB1-TC.
Timing Gauge Adapter: 5-8840-2834-0 (2)

7. Rotate the crankshaft to bring the piston in the No.

1 cylinder to a point 30 — 40° BTDC.
8. Set the timing gauge needle to zero.
9. Move the crankshaft pulley slightly in both direc-
tions to check that the gauge indication is stable.
LG4JB-WE-1111.book 30 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-30 ENGINE FUEL

A: Move the injection pump toward the engine.
B: Move the injection pump away from the engine.
Tighten the pump fixing nut, adjust bolt and pump
distributor head plug to the specified torque.

Tighten:
• Pump fixing bolt to 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
• Adjust bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Injection pump distributor head plug to 17 N⋅m (1.7
kg⋅m / 12 lb⋅ft)

N6A3034E

10. Turn the crankshaft clockwise and read the gauge

indication when the crankshaft pulley timing mark
is aligned with the pointer.

4JB1 BTDC 14°

4JB1-TC BTDC 4°

Standard Reading mm (in)

N6A3036E
0.5 (0.02)

Legend
A. To advance
B. To retard

Caution:
When installing the distributor head/plug, be sure to use
new copper washer.

Adjustment of Idling Speed

1. Pull the parking brake and lock the wheels.
2. Set the transmission gear to the neutral position.
3. Start the engine and idle it until the water tempera-
ture gets to 70 to 80°C (158 to176°F).
4. Turn back the idling control button, and remove the
control cable from the control lever (injection
pump).
N6A3035E 5. Set the engine tachometer.
6. Check the idling rotation.
If the injection timing is outside the specified range, When the idling rotation is outside the range of the
continue with the following steps. specified value, adjust it correctly.
11. Loosen the injection pump fixing nuts and bracket
bolts. Specified value (rpm) = 750 — 790
12. Adjust the injection pump setting angle.

When large than When smaller than

standard value standard value
Gear drive A B
LG4JB-WE-1111.book 31 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-31

N6A3460E

1) Loosen the lock nut of the idling set bolt.

2) Rotate the idling set bolt to set the idling rota-
tion to the specified value.
3) Tighten the lock nut to lock the set bolt.
4) Check the tension of the control cable, and re-
move any slackening as required.

N6A3368E
LG4JB-WE-1111.book 32 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-32 ENGINE FUEL

INJECTION PUMP DATA

Test Conditions

Items Conditions
Engine Type 4JB1
Injection Nozzle
Bosch Type Number 105017-1770, 1780
Injection Nozzle holder
Bosch Type Number 105048-3220, 3251
Injection Nozzle Opening Pressure
MPa (kg/cm2/psi) 13.0 (133 / 1,891)
Injection Line dimensions mm (in)
Inside Diameter 2 (0.079)
Outside Diameter 6 (0.236)
Length 450 (17.7)
Fuel delivery Pressure kPa (kg/cm2 /psi) 20 (0.2 / 2.84)
SAE Standard Test Diesel Fuel (SAE967D)
Test Fuel
ISO Standard Test Diesel Fuel (ISO4113)
Test Fuel Temperature °C(°F) 48 - 52 (118-126)
Identification Numbers 104746-6630
104746-6640
104742-1710
104742-1730
104742-1451
104742-1461
104742-1471
104742-1580
104742-1480
104742-1490
LG4JB-WE-1111.book 33 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-33

Items Conditions
Engine Type 4JB1-TC
Injection Nozzle
Bosch Type Number 105019-1260
Injection Nozzle holder
Bosch Type Number 105048-2201
2
1st Injection Nozzle MPa (kg/cm /psi) 20.0 (204 / 2900)
Opening Pressure
2nd Injection Nozzle MPa (kg/cm2/psi) 27.0 (275/ 3915)
Opening Pressure
Injection Line dimensions mm (in)
Inside Diameter 2 (0.079)
Outside Diameter 6 (0.236)
Length 450 (17.7)
Fuel delivery Pressure kPa (kg/cm2 /psi) 20 (0.2 / 2.84)
SAE Standard Test Diesel Fuel (SAE967D)
Test Fuel
ISO Standard Test Diesel Fuel (ISO4113)
Test Fuel Temperature °C(°F) 48 — 52 (118 — 126)
Identification Numbers 104746-6627
104746-5113
LG4JB-WE-1111.book 34 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-34 ENGINE FUEL

Identification Plate and Number
Use the data following the injection pump identification
number to adjust the injection volume.

N6A3464E

N6A3462E

N6A3463E
LG4JB-WE-1111.book 35 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-35

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Governor Performance Diagram
Engine ; 4JB1
Injection pump identification No. ; 04746-6630, 6640
Adjustment specification of injection volume

Average injection
Pump rotation Uneven amplitude Oil temperature
quantity Remarks
(rpm) (mm3/ST) (°C)
(mm3/ST)
500 (37.0±4.0) — 48±2
750 46.9±1.0 3.5 50±2 Standard
1150 (60.7±3.5) — 50±2
1250 (61.6±1.0) 5.0 50±2 Standard
1900 (65.6±4.0) — 50±2
2100 24.8±3.0 4.5 52±2 Standard
375 9.0±2.0 2.0 48±2 Standard
100 60 + 40 — 48±2

Injection volume adjustment

Injection volume

3
(mm /st)

Pump Speed (rpm)

LNWB1CSH002101

Adjustment specification of timer and pump case pressure

Air pressure of pump

Timer piston stroke (mm)
(kPa (kg/cm2))
Pump rotation
Remarks
(rpm) Solenoid timer Solenoid timer
ON OFF ON OFF
750 Over 0.5 — — —
1600 — 1.8±0.4 — —
618±20
1900 — 3.7±2 — Standard
(6.3±0.2)
2400 — 7.0 + 4.0-0.3 — —
LG4JB-WE-1111.book 36 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-36 ENGINE FUEL

3.7
(4.5°)
1.8
(2.2°)

750 1900 2400

1600

LNWB1CSH002201
LG4JB-WE-1111.book 37 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-37

Engine ; 4JB1
Injection pump identification No. ; 104742-1710, 1730
Adjustment specification of injection volume

Average injection
Pump rotation Uneven amplitude Oil temperature
quantity Remarks
(rpm) (mm3/ST) (°C)
(mm3/ST)
500 26.7±1.0 6.0 48±2 Standard
1000 (45.9±7.0) — 50±2 Standard
1150 (47.6±5.5) 3.5 50±2
1800 (55.5±6.5) — 50±2
2100 14.9±3.0 4.0 52±2 Standard
375 7.3±2.0 2.0 48±2
100 60 + 40 — 48±2

45.9

26.7

LNWB1CSH002301

Adjustment specification of timer and pump case pressure

Timer piston stroke At pressure of pump

Pump rotation (mm) (MPa(kg/cm2))
Remarks
(rpm) Solenoid timer Solenoid timer
ON OFF ON OFF
700 Over 0.5 — — —
1400 — (1.5±0.4) — —
0.53±0.02
1600 — 3.0±0.2 — Standard
(5.4±0.2)
1950 — 5.7+ 0.4 -0.3 — —
LG4JB-WE-1111.book 38 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-38 ENGINE FUEL

N6A3617E
LG4JB-WE-1111.book 39 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-39

Engine ; 4JB1
Injection pump identification No. ; 104742-1451, 1461, 1471, 1580
Adjustment specification of injection volume

Average injection
Pump rotation Uneven amplitude Oil temperature
quantity Remarks
(rpm) (mm3/ST) (°C)
(mm3/ST)
500 (29.7±4.5) — 48±2
1000 (46.4±3.5) — 50±2
1150 47.6±1.0 3.5 50±2 Standard
1800 (55.5 +4.0
-6.0) — 50±2
2100 14.9±3.0 4.0 52±2 Standard
375 7.3±2.0 2.0 48±2 Standard
100 (60.0 +40) — 48±2

N6A3471E

Adjustment specification of timer and pump case pressure

Timer piston stroke At of pressure pump

Pump rotation (mm) (MPa(kg/cm2))
Remarks
(rpm) Solenoid timer Solenoid timer
ON OFF ON OFF
700 Over 0.5 — — —
1400 — 1.5±0.4 — —
0.53±0.02
1600 — 3.0±0.2 — Standard
(5.4±0.2)
2100 — 5.7 +0.4-0.3 — —
LG4JB-WE-1111.book 40 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-40 ENGINE FUEL

Timer adjustment (Except 104742-1580)

N6A3617E

Timer adjustment (For 104742-1580)

4.9
(6.0)

2.4
(2.9)

1.3
(1.6)

2300

LNWB1CSH002001

Adjustment specification of aneroid compensator (For 104742-1471)

Air pressure differ-

Pump rotation Altitude Amount of reduction Rate of reduction
ence
(rpm) (m) (mm3/ST) (%)
(kPa (mmHg))
0 0 0 0
−5.9±3.3
(500) Inflation point Inflation point
1150 (−44±25)
−21.9
2000 (−5.2±1.3) (−11±3)
(−164)
LG4JB-WE-1111.book 41 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-41

N6A3470E
LG4JB-WE-1111.book 42 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-42 ENGINE FUEL

Engine ; 4JB1
Injection pump identification No. ; 104742-1480, 1490
Adjustment specification of injection volume

Average injection
Pump rotation Uneven amplitude Oil temperature
quantity Remarks
(rpm) (mm3/ST) (°C)
(mm3/ST)
500 (29.7±4.5) — 48±2
1000 (46.4±3.5) — 50±2
1150 47.6±1.0 3.5 50±2 Standard
1800 (55.5 +4.0
-6.0) — 50±2
2100 14.9±3.0 4.0 52±2 Standard
375 7.3±2.0 2.0 48±2 Standard
100 (60 +40) — 48±2

N6A3471E

Adjustment specification of timer and pump case pressure

Pump rotation At pressure of pump

Timer piston stroke (mm) Remarks
(rpm) (MPa (kg/cm2))
1400 (1.5±0.4) —
0.53±0.03
1600 3.0±0.2 Standard
(5.4±0.2)
2100 5.7 +0.4-0.3 —
LG4JB-WE-1111.book 43 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-43

N6A3619E

N6A3470E
LG4JB-WE-1111.book 44 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-44 ENGINE FUEL

Engine ; 4JB1-TC
Injection pump identification No. ; 104746-6627
Adjustment specification of injection volume

Average Uneven
Pump rotation Boost pressure Oil temperature
injection quantity amplitude Remarks
(rpm) (kPa (kg/cm2)) (°C)
(mm3/ST) (mm3/ST)
500 60.5±1.0 5.0 0 48±2 Standard
800 67.4±1.0 5.5 52.0 (0.531) 50±2 Standard
800 76.8±1.0 6.0 80.0 (0.821) 50±2 Standard
1000 (83.8±6.5) 80.0 (0.821) 50±2
1250 (91.5±6.5) 80.0 (0.821) 50±2
1700 (105.7±6.5) 80.0 (0.821) 50±2
2075 34.0±3.0 7.0 80.0 (0.821) 52±2 Standard
375 13.9±2.0 2.0 0 48±2 Standard
+40
100 60 -0 0 48±2

N6A3625E

Adjustment specification of timer and pump case pressure

Pump rotation Timer piston stroke At pressure of pump Boost Pressure

Remarks
(rpm) (mm) (KPa (kg/cm2)) (kPa (kg/cm2))
1020 Below 0.5 80.0 (0.82)
1350 1.8±0.2 471±29 (4.8±0.3) 80.0 (0.82) Standard
1500 (3.0±0.4) 80.0 (0.82)
+0.4
1800 4.5 -0.3 80.0 (0.82)
LG4JB-WE-1111.book 45 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-45

Engine ; 4JB1-TC
Injection pump identification No. ; 104746-5113
Adjustment specification of injection volume

Average Uneven
Pump rotation Boost pressure Oil temperature
injection quantity amplitude Remarks
(rpm) (kPa (kg/cm2)) (°C)
(mm3/ST) (mm3/ST)
500 57.6±1.0 5.0 0 48±2 Standard
800 63.1±1.0 5.5 52.0 (0.531) 50±2 Standard
800 68.6±1.0 6.0 80.0 (0.821) 50±2 Standard
1000 (79.7±6.5) 80.0 (0.821) 50±2
1250 (87.9±6.5) 80.0 (0.821) 50±2
1700 (98.5±6.5) 80.0 (0.821) 50±2
2075 34.0±3.0 7.0 80.0 (0.821) 52±2 Standard
375 13.9±2.0 2.0 0 48±2 Standard
+40
100 60 -0 0 48±2

N6A3908E

Adjustment specification of timer and pump case pressure

Pump rotation Timer piston stroke At pressure of pump Boost Pressure

Remarks
(rpm) (mm) (KPa (kg/cm2)) (kPa (kg/cm2))
1020 Below 0.5 80.0 (0.82)
1350 1.8±0.2 471±29 (4.8±0.3) 80.0 (0.82) Standard
1500 (3.0±0.4) 80.0 (0.82)
+0.4
1800 4.5 -0.3 80.0 (0.82)
LG4JB-WE-1111.book 46 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-46 ENGINE FUEL

N6A3626E

Potentiometer adjustment

Average injection
Pump speed Out-put voltage BoostPressure
quantity Remarks
(r/min) (V) (kPa (kg/cm2))
(mm3/st)
1080 3.56±0.03 27.5±2.0 0 Standard
375 (0.93±0.45) 13.9±2.0 0 Standard

N6A3622E
LG4JB-WE-1111.book 47 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-47

FUEL TANK
Component

1 2

3
7

LNWB1CLF001001

Legend
1. Evaporator fuel hose 5. Band
2. Fuel feed hose 6. Fuel tank
3. Fuel return hose 7. Frame
4. Fuel gauge unit connector
LG4JB-WE-1111.book 48 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-48 ENGINE FUEL

Removal • Connect battery ground cable.
Preparation:
• Disconnect battery ground cable.
• Loosen fuel filler cap.
• Drain fuel from drain plug.
• After the drain fuel, tighten the drain plug to the
specified torque.
Tighten:
Drain plug bolt to
M8: 19.6 N⋅m(2.0 kg⋅m/14.5 lb⋅ft)
M10: 29.4 N⋅m(3.0 kg⋅m/21.7 lb⋅ft)
1. Evaporator Fuel Hose
2. Fuel Feed Hose
3. Fuel Return Hose
• Plug the hose to prevent fuel from getting spilt, and
tie it to the frame with the plugged end up.
4. Fuel Gauge Unit Connector
• Remove the connector of the fuel gauge.
5. Band
• Remove the nut of the fuel tank fixing band, and
then remove the band end on the frame side.
6. Fuel Tank
• Pull out the fuel tank to the outside.
Notice:
When it is not possible to pull out the fuel tank, remove
the bracket and then draw out the fuel tank downward.

Installation
1. Fuel Tank
Notice:
When the bracket was removed to take off the fuel tank,
install the bracket to the frame and tighten it to the spec-
ified torque.

Tighten:
54 N⋅m(5.5 kg⋅m/39.8 lb⋅ft)
When mounting the fuel tank on the bracket, be sure to
place the packing section pasted on the fuel tank se-
curely on the bracket.
2. Band
• Tighten the band to the specified torque.
Tighten:
13 N⋅m(1.3 kg⋅m/113 lb⋅in)
3. Fuel Gauge Unit Connector
• Connect the fuel gauge unit connector.
4. Fuel Return Hose
5. Fuel Feed Hose
• Set the hose to the pipe more than 25 mm (0.98 in)
deep.
6. Evaporator Fuel Hose
• Fill the fuel to the fuel tank.
LG4JB-WE-1111.book 49 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-49

FUEL GAUGE UNIT

Component

N6A3473E

Legend
1. Fuel gauge unit connector 3. Evaporator fuel hose
2. Fuel gauge unit 4. Frame

Removal
Preparation:
• Disconnect battery ground cable.
1. Fuel Gauge Unit Connector
• Disconnect fuel gauge unit connector from fuel
gauge unit.
2. Fuel Gauge Unit
• Remove fuel gauge unit fixing screw and fuel
gauge unit.
Notice:
• After removing fuel gauge unit, cover fuel tank with
waste to prevent any dust entering.

Installation
1. Fuel Gauge Unit
2. Fuel Gauge Unit Connector
• Connect the wiring connector to the fuel gauge
unit.
LG4JB-WE-1111.book 50 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-50 ENGINE FUEL

ACCELERATOR CONTROL CABLE

Component

N6A3474E

Legend
1. Adjust unit 3. Accelerator control wire
2. Accelerator control wire 4. Accelerator control cable

Removal • The control cable should move smoothly.

1. Adjust Nut • The control cable should not be bent or kinked.
• Loosen the adjust nut on the cable bracket mount- • The control cable should be free of damage and
ed on the inlet manifold. corrosion.
2. Accelerator Control Wire (Injection Pump Side)
Installation
• Remove the control wire from injection pump con-
1. Accelerator Control Cable
trol lever.
• Take care that the core wire of the cable does not
3. Accelerator Control Wire (Accelerator Pedal Side)
get damaged or kinked.
• Remove the accelerator control wire from acceler-
• Pull the cable through the grommet hole from un-
ator pedal.
der the floor.
4. Accelerator Control Cable
• Set the groove of the grommet securely into the
• Remove the cable clip from intake manifold duct.
floor panel.
• Remove the cable clip from chassis frame.
• Lower the cab.
• Pull out the wire to the chassis side through the 2. Accelerator Control Wire (Accelerator pedal side)
grommet hole of the floor board, and remove the
control cable. • Connect the accelerator control wire to the acceler-
ator pedal.
Inspection • Check to see if the idling control knob is fully turned
Check the following items, and replace the control cable to the left.
if any abnormality is found.
LG4JB-WE-1111.book 51 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-51

• In the operating range of the accelerator pedal,
check to see if the accelerator pedal and the injec-
tion pump lever return without fail to their original
positions respectively.

N6A3475E

• Tilt up the cab.

3. Accelerator Control Wire (Injection pump side)
• Install the tip end of the wire to the engine control
lever.

N6A3368E

4. Lock Bolt
• With the accelerator control lever attached to the
stopper bolt, pull the cable lightly toward the front
of the axis and fasten the cable bracket with the
lock bolt.
• Check to see if the injection pump lever is at the
idle position (with the lever in touch with the stop-
per bolt).
• Connect the battery ground cable.
• Lower the cab.
• Check to see if the accelerator pedal play is in the
range of 5 — 10 mm above the pedal pad.
• Press down on the accelerator pedal fully, and
check to see if the engine rotates at the maximum
speed with the linkage in the smooth operation.
LG4JB-WE-1111.book 52 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-52 ENGINE FUEL

ACCELERATOR PEDAL
Component

N6A3477E

Legend
A. RHD 3. Idling control cable
B. LHD 4. Accelerator pedal assembly
1. Idle switch connector 5. Wire guard
2. Accelerator control cable 6. Accelerator pedal bracket

Removal • Install the cable to the lever of the accelerator ped-

al bracket.
1. Idle Switch Connector
3. Accelerator Control Cable
2. Accelerator Control Cable
• After confirming that the idling control knob is fully
• Remove control cable from accelerator pedal
turned to the left, install the accelerator control ca-
bracket.
ble.
3. Idling Control Cable
4. Idle Switch Connector
• Remove control cable from accelerator pedal
bracket.
4. Accelerator Pedal Assembly
• Remove accelerator pedal assembly from brake
pedal bracket.

Installation
1. Accelerator Pedal Assembly
• Apply the sliding section with grease, and install it
to the brake pedal bracket.
2. Idling Control Cable
LG4JB-WE-1111.book 53 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-53

RHD

N6A3475E

N6A3478E
Adjustment of the Press-Down Amount of the Accel-
erator Pedal
• After installing each cable, give a full stroke to the Legend
accelerator pedal while pushing the accelerator 1. Full stroke 0 — 2 mm
pedal pad by hand.
LHD
• Adjust the stopper bolt so that the clearance be-
tween the pedal pad stopper bolt and the back of
the pad becomes 0 — 2 mm (0 — 0.079 in), and
tighten the lock nut to the specified torque.
Tighten:
7.4 N⋅m(0.75 kg⋅m/65 lb⋅ft)
• Check to see if the accelerator pedal play is in the
range of 5 — 10 mm (0.2 — 0.4 in) above the pedal
pad.
• Press down on the accelerator pedal fully, and
check to see if the engine rotates at the maximum
speed with the linkage in the smooth operation.
• In the operating range of the accelerator pedal,
check to see if the accelerator pedal and the injec-
tion pump lever return without fail to their original
positions respectively.
N6A3479E
LG4JB-WE-1111.book 54 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-54 ENGINE FUEL

IDLING CONTROL CABLE

Component

N6A3480E

Legend
1. Idling control knob 5. Wire guide
2. Idling control cable nut 6. Accelerator pedal bracket
3. Wave washer 7. Screw
4. Idling control cable

Removal Installation
1. Idling Control Knob 1. Idling Control Cable
• Loosen the idling control knob screw and remove • Install control cable to accelerator pedal bracket.
the knob from cable. 2. Wave Washer
2. Idling Control Cable Nut 3. Idling Control Cable Nut
3. Wave Washer • Insert the idling control cable into the specified hole
4. Idling Control Cable of the instrument panel.
• Remove control cable from accelerator pedal • Install the washer to the cable, and tighten it with
bracket. the nut.
4. Idling Control Knob
Inspection
• Insert the idling control knob into the cable, and
• With the idling control knob not in use, check to see
tighten the screw.
if the injection pump lever is at the idle position
(with the lever in contact with the stopper bolt).
• With the idling control knob turned fully to the right,
check to see if the engine idles up to 1,500 rpm or
more.
LG4JB-WE-1111.book 55 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-55

AIR CLEANER ELEMENT (4JB1 Engine)

Component

LNWB1CMF000601

Legend
1. Cover wing nut 3. Filter wing nut
2. End cover 4. Air cleaner element

Removal
1. Cover Wing Nut
2. End Cover
3. Filter Wing Nut
4. Air Cleaner Element
Clean
• Wipe out the inside of the air cleaner assembly.
• Wipe off the cover.

Inspection
• Inspect the element for damage and for clogging
caused by dust.
When the element is dirty, clean the element.
Replace it if it is damaged.
LG4JB-WE-1111.book 56 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-56 ENGINE FUEL

Cleaning Method 1. Remove the element from the solution and rinse it
Dust Fouled Element well with running water.
Rotate the element with your hand while applying com- Water pressure must not exceed 274 kPa (2.8 kg/
pressed air to the inside of the element. This will blow cm2 /40 psi).
the dust free.

Compressed air pressure kPa (kg/cm2 /psi)

392 — 490 (4 — 5/57 — 71)

Caution:
Do not bang the element against another object in an at-
tempt to clean it. Damage to the element will result.

N6A0011E

2. Dry the element in a well ventilated area.

An electric fan will hasten drying.

Notice:
Do not use compressed air or an open flame to dry the
element quickly. Damage to the element will result. It will
usually take two or three days for the element to dry
N6A0009E
completely. Therefore, it is a good idea to have a spare
on hand to use in the interim.
Carbon and Dust Fouled Element
• Dissolve a mild detergent in water and soak for ap-
proximately 30 minutes. Thoroughly rinse with wa-
ter and allow to dry naturally (for 2 to 3 days).
Do not use compressed air or fire to dry.

N6A0012E

Installation
1. Air Cleaner Element
2. Filter Wing Nut
N6A0010E 3. End Cover
4. Cover Wing Nut
LG4JB-WE-1111.book 57 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE FUEL 6C-57

AIR CLEANER ELEMENT (4JB1-TC Engine)

Component

3 2 1

LNWB1CSF000201

Legend
1. Clip (3 places) 3. Element
2. Cover

Removal
1. Clip (3 places)
2. Cover
3. Element
Clean
• Wipe out the inside of the air cleaner assembly.
• Wipe off the cover.

Inspection
• Inspect the element for damage and for clogging
caused by dust.
When the element is dirty, clean the element.
Replace it if it is damaged.

N6A3482E

Cleaning Method
Dust Fouled Element
Rotate the element with your hand while applying com-
pressed air to the inside of the element. This will blow
the dust free.

Compressed air pressure kPa (kg/cm2 /psi)

392 — 490 (4 — 5/57 — 71)

Caution:
Do not bang the element against another object in an at-
tempt to clean it. Damage to the element will result.
LG4JB-WE-1111.book 58 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6C-58 ENGINE FUEL

N6A0009E N6A0011E

Carbon and Dust Fouled Element 2. Dry the element in a well ventilated area.
• Dissolve a mild detergent in water and soak for ap- An electric fan will hasten drying.
proximately 30 minutes. Thoroughly rinse with wa-
Notice:
ter and allow to dry naturally (for 2 to 3 days).
Do not use compressed air or an open flame to dry the
Do not use compressed air or fire to dry.
element quickly. Damage to the element will result. It will
usually take two or three days for the element to dry
completely. Therefore, it is a good idea to have a spare
on hand to use in the interim.

N6A0010E

1. Remove the element from the solution and rinse it

well with running water.
Water pressure must not exceed 274 kPa (2.8 kg/ N6A0012E

cm2 /40 psi).

Installation
1. Element
2. Cover
3. Clips (3 places)
LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-1

ENGINE
SECTION 6D
ENGINE ELECTRICAL
Contents
BATTERY..............................................................6D-2
General Description...........................................6D-2
Diagnosis...........................................................6D-2
Battery Charging................................................6D-3
Jump Starting ....................................................6D-4
Removal and Installation of the Battery.............6D-5
Main Data and Specifications ............................6D-5
STARTING SYSTEM ............................................6D-6
General Description...........................................6D-6
On-Vehicle Service............................................6D-8
Unit Repair.......................................................6D-10
CHARGING SYSTEM .........................................6D-18
General Description.........................................6D-18
On-Vehicle Service..........................................6D-20
Unit Repair.......................................................6D-23
QOSII PREHEATING SYSTEM ..........................6D-32
General Description.........................................6D-32
LG4JB-WE-1111.book 2 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-2 ENGINE ELECTRICAL

BATTERY
General Description
Legend
There are six battery fluid caps at the top of the battery. 1. Charge test indicator
These are covered by a paper label. 2. Upper level
The battery is completely sealed except for the six small
3. Lower level
vent holes at the side. these vent holes permit the es-
cape of small amounts of gas generated by the battery. 3. Voltage Check
This type of battery has the following advantages over
1) Put voltmeter test leads to battery terminals.
conventional batteries.
1. There is no need to add water during the entire ser- a. Voltage is 12.4V or Above - Battery condi-
vice life of the battery. tion OK.
b. Voltage is Under 12.4V - Go to procedure 2)
2. The battery protects itself against overcharging.
below.
The battery will refuse to accept an excessive
charge. 2) Determine fast charge amperage from specifi-
cation (See Main Data and Specifications in
(A conventional battery will accept an excessive
this section).
charge, resulting in gassing and loss of battery flu-
Fast charge battery for 30 minutes at amper-
id.)
age rate no higher than specified value.
3. The battery is much less vulnerable to self dis-
charge than a conventional type battery. Take voltage and amperage readings after
charge.
Diagnosis a. Voltage is Above 16V at Below 1/3 of Am-
1. Visual Inspection perage Rate — Replace battery.
Inspect the battery for obvious physical damage, b. Voltmeter is Above 16V at Above 1/3 of Am-
such as a cracked or broken case, which would perage Rate — Drop charging voltage to
permit electrolyte loss. 15V and charge for 10 — 15 hours.
Replace the battery if obvious physical damage is c. Voltage is Between 12V and 16V - Continue
discovered during inspection. charging at the same rate for an additional 3
Check for any other physical damage and correct it — 3.5 hours.
as necessary. If not, proceed to Step 2. d. Voltage is Below 12V — Replace battery.
2. Fluid Level Check 4. Load Test
The fluid level should be between the upper level 1) Connect a voltmeter and a battery load tester
line and lower level line on side of the battery. across the battery terminals.
a. Correct Fluid Level - Charge the battery. 2) Apply 300 ampere load for 15 seconds to re-
b. Below Lower Level - Replace battery. move surface charge from the battery.
Remove load.
3) Wait 15 seconds to let battery recover. Then
apply specified load from specifications (See
Main Data and Specifications in this section).
Read voltage after 15 seconds, then remove
load.
a. Voltage does not Drop Below the Minimum
Listed in Following Table - The battery is
good and should be returned to service.
b. Voltage is Less Than Minimum Listed - Re-
place battery.

N6A3487E
LG4JB-WE-1111.book 3 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-3

Battery Charging
Estimated Temperature Minimum Voltage
Observe the following safety precautions when
°F °C Limit charging the battery:
70 21 9.6 1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
60 16 9.5
battery. In this case, the battery must be replaced.
50 10 9.4 2. Pay close attention to the battery during the charg-
40 4 9.3 ing procedure.
Battery charging should be discontinued or the rate
30 -1 9.1
of charge reduced if the battery feels hot to the
20 -7 8.9 touch.
10 -12 8.7 Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
0 -18 8.5 spew electrolyte from the vent holes.
The battery temperature must be estimated by atmo- 3. In order to more easily view the hydrometer blue
sphere temperature and outside temperature (the dot or ring, it may be necessary to jiggle or tilt the
battery has been exposed to for the preceding few battery.
hours). 4. Battery temperature can have a great effect on bat-
tery charging capacity.
5. The sealed battery used on this vehicle may be ei-
ther quick-charged or slow-charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
LG4JB-WE-1111.book 4 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-4 ENGINE ELECTRICAL

Jump Starting Jump Starting Procedure
1. Set the vehicle parking brake.
Jump Starting With an Auxiliary (Booster) Bat- If the vehicle is equipped with an automatic trans-
tery mission, place the selector lever in the “PARK” po-
sition.
Caution:
Never push or tow the vehicle in an attempt to start it. If the vehicle is equipped with a manual transmis-
sion place the shift lever in the “NEUTRAL” posi-
Serious damage to the emission system as well as other
tion.
vehicle parts will result.
Turn “OFF” the ignition.
Treat both the discharged battery and the booster bat-
tery with great care when using jumper cables. Turn “OFF” all lights and any other accessory re-
quiring electrical power.
Carefully follow the jump starting procedure, being care-
ful at all times to avoid sparking. 2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is
WARNING:
Warning: completely clear, do not try to jump start.
FAILURE TO CAREFULLY FOLLOW THE JUMP 3. Attach the other end of the same cable to the pos-
STARTING PROCEDURE COULD RESULT IN THE itive terminal of the discharged battery.
FOLLOWING: Attach the end of one jumper cable to the positive
1. SERIOUS PERSONAL INJURY, PARTICULAR- terminal of the booster battery.
LY TO YOUR EYES. Do not allow the vehicles to touch each other.
2. PROPERTY DAMAGE FROM A BATTERY EX- This will cause a ground connection, effectively
PLOSION, BATTERY ACID, OR AN ELECTRI- neutralizing the charging procedure.
CAL FIRE. Be sure that the booster battery has a 12 volt rat-
3. DAMAGE TO THE ELECTRONIC COMPO- ing.
NENTS OF ONE OR BOTH VEHICLES PARTIC- 4. Attach one end of the remaining cable to the nega-
ULARLY. tive terminal of the booster battery.
NEVER EXPOSE THE BATTERY TO AN OPEN Attach the other end of the same cable to a solid
FLAME OR ELECTRICAL SPARK. GAS GENERAT- engine ground (such as the A/C compressor brack-
ED BY THE BATTERY MAY CATCH FIRE OR EX- et or the generator mounting bracket) of the vehicle
PLODE. with the discharged battery.
REMOVE ANY RINGS, WATCHES, OR OTHER JEW- This ground connection must be at least 450 mm
ELRY BEFORE WORKING AROUND THE BATTERY. (18 in) from the battery of the vehicle whose battery
PROTECT YOUR EYES BY WEARING AN AP- is being charged.
PROVED SET OF GOGGLES.
NEVER ALLOW BATTERY FLUID TO COME IN CON- WARNING:
Warning:
TACT WITH YOUR EYES OR SKIN. NEVER ATTACH THE END OF THE JUMPER CABLE
DIRECTLY TO THE NEGATIVE TERMINAL OF THE
NEVER ALLOW BATTERY FLUID TO COME IN CON-
DEAD BATTERY.
TACT WITH FABRICS OR PAINTED SURFACES.
5. Start the engine of the vehicle with the good bat-
BATTERY FLUID IS A HIGHLY CORROSIVE ACID.
tery.
SHOULD BATTERY FLUID COME IN CONTACT Make sure that all unnecessary electrical accesso-
WITH YOUR EYES, SKIN, FABRIC, OR A PAINTED ries have been turned “OFF”.
SURFACE, IMMEDIATELY AND THOROUGHLY
6. Start the engine of the vehicle with the dead bat-
RINSE THE AFFECTED AREA WITH CLEAN TAP
tery.
WATER.
7. To remove the jumper cables, follow the above di-
NEVER ALLOW METAL TOOLS OR JUMPER CA-
rections in the reverse order.
BLES TO COME IN CONTACT WITH THE POSITIVE
Be sure to first disconnect the negative cable from
BATTERY TERMINAL, OR ANY OTHER METAL SUR-
the vehicle with the discharged battery.
FACE OF THE VEHICLE. THIS WILL PROTECT
AGAINST A SHORT CIRCUIT.
ALWAYS KEEP BATTERIES OUT OF THE REACH
OF YOUNG CHILDREN.
LG4JB-WE-1111.book 5 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-5

Removal and Installation of the Battery Caution:
Removal It is important that the battery ground cable be discon-
nected first.
1. All switches should be in the “OFF” position.
Disconnecting the battery positive cable first can result
2. Disconnect the battery ground cable. (1) in a short circuit.
3. Disconnect the battery positive cable. (2)
4. Disconnect the battery cable. Installation
To install the battery, follow the removal procedure in
the reverse order, noting the following points:
1. Make sure that the rod is hooked on the body side.

N6A3488E

Main Data and Specifications

Model (JIS) 130E41R-MF 95D31R-MF

Voltage (V) 12 12
Cold-Cranking Performance (Amp) 799 622
Reserve Capacity (Min) 229 159
Load Test (Amp) 400 310
Fast Charge Maximum Amperage (Amp) 20 20
BCI Group No. — 27
Overall Dimension L×W×H (mm) 410×178×213 —
LG4JB-WE-1111.book 6 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-6 ENGINE ELECTRICAL

STARTING SYSTEM
General Description
Starting Circuit
The cranking system consists of a battery, starter, starter switch, starter relay, etc. and these main components are
connected as shown in Figure. For details of the starting circuit.

N6A3489E

Legend
1. Starter motor 7. Relay; starter
2. Hold coil 8. “50” terminal
3. Contacts 9. “30” terminal
4. Pinion clutch 10. Battery
5. Pull in coil 11. Starter switch
6. Magnetic switch

Starter
The starting system employs a magnetic type reduction starter in which the motor shaft and the pinion shaft are dif-
ferent. When the starter switch is turned on, the contacts of magnetic switch are closed, and the armature rotates.
At the same time, the plunger is attracted, and the pinion is pushed forward by the shift lever to mesh with ring gear.
Then, the ring gear runs to start the engine. When the engine starts and the starter switch is turned off, the plunger
returns, the pinion is disengaged from ring gear, and the armature stops rotation. When the engine speed is higher
than the pinion, the pinion idles, so that the armature is not driven.
LG4JB-WE-1111.book 7 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-7

Starting Circuit

N6A3490E
LG4JB-WE-1111.book 8 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-8 ENGINE ELECTRICAL

On-Vehicle Service
Component

2
3

LNWB1EMF000601

Legend
1. 50 terminal 3. Earth cable terminal
2. 30 terminal 4. Starter assembly
LG4JB-WE-1111.book 9 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-9

Removal
Preparation
• Disconnect Battery Ground Cable.
1. “50” Terminal
2. “30” Terminal
3. Earth Cable Terminal
4. Starter Assembly

N6A3492E

Installation
1. Starter Assembly
• Tighten the fixing bolt and nut to the specified
torque
Tighten:
Starter Bolts and Nuts to 81 N⋅m (8.3 Kg⋅m/60 lb⋅ft)
2. Earth Cable Terminal
• Connect the earth cable terminal.
3. “50” Terminal
• Connect the harness connector.
4. “30” Terminal
• Connect the battery cable terminal with starter
switch harness terminal, then tighten nut to the
specified torque.
Tighten:
Fixing Nut to 9 N⋅m (0.9 Kg⋅m/78 lb⋅in)
• Connect the battery cable.
LG4JB-WE-1111.book 10 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-10 ENGINE ELECTRICAL

Unit Repair
Component

N6A3493E

Legend
1. Lead wire 8. Overrunning clutch
2. Through bolt 9. Return spring
3. Yoke assembly 10. Steel ball
4. Cover yoke 11. Idle pinion
5. Brush and brush holder 12. Retainer
6. Armature 13. Roller
7. Drive side housing 14. Magnetic switch
LG4JB-WE-1111.book 11 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-11

Disassembly
1. Lead Wire
Disconnect the lead wire from the magnetic switch.

N6A3496E

5. Brush and Brush Holder

Remove (pull out) the brushes and the brush hold-
N6A3494E er from the armature with a pair of long-nose pliers.

2. Through Bolt
Remove the through bolts from the yoke.

N6A3497E

N6A3495E Legend
1. Bush
3. Yoke Assembly 2. Spring
Separate the yoke from the magnetic switch.
4. Yoke Cover 6. Armature
7. Drive Side Housing
8. Overrunning Clutch
Remove the overrunning clutch from the housing.
LG4JB-WE-1111.book 12 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-12 ENGINE ELECTRICAL

N6A3498E N6A3500E

9. Return Spring 11. Idle Pinion

Remove the return spring from magnetic switch. Remove the idle pinion from housing.

N6A3499E N6A3501E

10. Steel Ball 12. Retainer

Remove the steel ball from the overrunning clutch. Remove the retainer from housing.
LG4JB-WE-1111.book 13 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-13

N6A3502E N6A3504E

13. Roller
Legend
14. Magnetic Switch
1. Insulator
Inspection and Repair 2. Commutator segments
Make necessary correction or parts replacement if wear,
Check the commutator outer diameter.
damage or any other abnormal condition are found
through inspection. Commutator outer diameter mm (in)
Armature
Check the commutator for run-out and replace if the Standard Limit
amount of run-out exceeds the limit. 35.00 (1.378) 34.00 (1.339)

Run-out test mm (in)

Standard Limit
0.02 (0.0008) 0.05 (0.0020)

N6A3505E

Armature Short Circuit Test

Check the armature for short circuit by placing it on a
growler tester. Hold a piece of hacksaw blade against
N6A3503E the armature core while slowly rotating the armature. A
short-circuited armature will cause the blade to vibrate
Check the mica segment for wear.
and to be attracted by the core. If the hacksaw blade is
Depth of mica segment mm (in) attracted or vibrates, the armature, is short circuited,
and must be replaced.
Standard Limit
0.7 — 0.9 (0.028 — 0.035) 0.20 (0.008)
LG4JB-WE-1111.book 14 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-14 ENGINE ELECTRICAL

N6A3506E N6A3508E

Armature Ground Test Yoke

Touch one probe of a circuit tester to the commutator Field Winding Ground Test
segment and the other to the armature core. There Using circuit tester, touch one probe to the field winding
should be no continuity. If there is a continuity, the arma- end or brush and the other to the bare surface of yoke
ture is grounded. Replace the armature if it is grounded. body.
There should be no continuity. If the tester indicates a
continuity, the field coil is grounded and yoke assembly
should be replaced.

N6A3507E

Armature Continuity Test

Connect the probes of a circuit tester across the 2 seg- N6A3509E
ments. There should be continuity at any test points.
Replace if it is open-circuited. Field Winding Continuity Test
Using a circuit tester, touch one probe to the “C” terminal
lead wire and the other to the brush. There should be
continuity. Replace the yoke if it is open.
LG4JB-WE-1111.book 15 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-15

N6A3510E N6A3512E

Brush and Brush Holder Overrunning Clutch

Measure the brush length and replace if it is worn be- Inspect the teeth of pinion for wear and damage.
yond the service limit. Replace if it damaged.
Rotate the pinion in direction of rotation (clockwise).
Brush length mm (in) It should rotate smoothly. But in opposite direction, it
Standard Limit should be locked.
16 (0.63) 10 (0.39)

N6A3513E

Bearing
N6A3511E
Check the bearings for wear and damage. If the bear-
Brush Holder Insulation Test ings are noisy during operation, they should be re-
Using a circuit tester, check the brush holder insulation. placed.
Touch one probe to the holder plate and the other to the
positive brush holder. There should be no continuity.
LG4JB-WE-1111.book 16 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-16 ENGINE ELECTRICAL

Magnetic Switch
Temporarily connect the solenoid switch between the
clutch and the housing and run the following tests.
Complete each test within three to five seconds.
1. Pull-in test
Connect the battery negative terminal with the
magnetic switch body and the M terminal. When
current is applied to the 50 terminal from the bat-
tery positive terminal, the pinion should flutter.

N6A3514E

Reassembly
To install, follow the removal steps in the reverse order,
noting the following points:
• Magnetic Switch
• Idle Gear
• Clutch assembly
• Housing N6A3516E
1. Install the clutch assembly to the magnetic switch.
2. Install the idle gear and housing.
Legend
Notice: 1. M terminal
Do not fail to assemble the steel ball and the spring be- 2. 50 terminal
tween the clutch and magnetic switch.
Assemble the roller to the idle gear in advance. 2. Hold-in test
After the Pull-in test, disconnect the lead at the M
terminal. The pinion should continue to flutter.

N6A3515E

N6A3517E
Legend
1. Roller
2. Idle gear Legend
3. Steel ball 1. Disconnect
LG4JB-WE-1111.book 17 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-17

3. Return test
Connect the battery negative terminal to the 50 ter-
minal and the body. Connect the battery positive
terminal to the M terminal. The pinion will flutter.
When the lead to the 50 terminal is disconnected,
the pinion should immediately return to its station-
ary positions.

N6A3518E

4. Current value
• Make connections as shown in the illustration,
and measure the current value.
Standard = 100 A or less
Notice:
For a battery, be sure to use one fully charged.
For lead wires, use thick ones since a large amount of
current flows through them.

N6A3519E

Legend
1. 30 terminal
LG4JB-WE-1111.book 18 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-18 ENGINE ELECTRICAL

CHARGING SYSTEM
General Description
The charging system is the IC integral regulator charging system and its main components are connected as shown
in Figure.
The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator in-
stalled on the rear end cover.
The generator does not require particular maintenance such as voltage adjustment. The rectifier connected to the
stators coil has nine diodes to transform A.C. voltage into D.C. voltage. This D.C. voltage is connected to the output
terminal of generator.

N6A3521E

Legend
1. Ball bearing 8. Slip ring
2. Pulley 9. Brush
3. Front cover 10. Rear cover
4. Fan 11. Vacuum pump
5. Stator 12. Through bolt
6. Rotor 13. Ball bearing
7. IC regulator 14. Oil seal
LG4JB-WE-1111.book 19 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-19

Diagnosis
General On-Vehicle Inspection
The operating condition of charging system is indicated by the charge warning lamp. The warning lamp comes on
when the starter switch is turned on “ON” position. The charging system operates normally if the lamp goes off when
the engine starts. If the warning lamp shows abnormality or if undercharged or overcharged battery condition is sus-
pected, perform diagnosis by checking the charging system as follows:

N6A3522E

1. Check visually the belt and wiring connector.

2. With the engine in stop status, turn the starter
switch to “ON” position and observe the warning
lamp.
• If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal “L” on connector side.
• If lamp comes on:
Repair or replace the generator.
LG4JB-WE-1111.book 20 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-20 ENGINE ELECTRICAL

On-Vehicle Service
Component
Generator

4
1

8 8

9
2

3
5

LNWB1DMF000601

Legend
1. Vacuum hose 6. AC generator assembly
2. Oil hose 7. Bracket
3. AC generator drive belt 8. Clip
4. Power steering oil pipe bracket 9. Lock bolt
5. AC generator fixing bolts
LG4JB-WE-1111.book 21 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-21

Removal 5. AC Generator Fixing Bolts
Preparation 6. AC Generator Assembly
• Disconnect battery ground cable. Installation
1. Vacuum Hose (Exhaust Brake Model)
1. AC Generator Assembly
• Remove the vacuum hose to vacuum tank and
• Set the AC generator.
exhaust actuator.
2. AC Generator Fixing Bolts
2. Oil Hose
• Temporary install the AC generator fixing bolt.
• Remove the oil hose from oil pan.
3. Power Steering Oil Pipe Bracket (P/S Model)
• Remove the oil hose of vacuum pump side.
• Install the oil pipe bracket and tighten bolts to
the specified torque.
Tighten:
Pipe Bracket Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

N6A3525E

3. AC Generator & Fan Pulley Drive Belt

• Loosen the adjust plate fixing bolt.
• Remove the adjust bolt. N6A3526E

• Loosen the AC Generator fixing bolt then re-

• Install the suction pipe clip bolt and tighten bolt
move the fan belt.
to the specified torque.
4. Power Steering Oil Pipe Bracket (P/S Model)
• Remove the oil pressure pipe bracket fixing bolt Tighten:
and pipe clip bolt. Pipe Clip Bolt to 10 N⋅m (1 kg⋅m/87 lb⋅in)
• Remove the oil suction pipe clip bolt. • Install the pressure pipe and suction pipe clip
bolt, then tighten bolt to the specified torque.
Tighten:
Pipe Clip Bolt to 10 N⋅m (1 kg⋅m/87 lb⋅in)
4. AC Generator & Fan Pulley Drive Belt
• Install the AC Generator drive belt and adjust
belt tension.
• Depress the drive belt mid-portion with a 98 N
(10 kg/22 lb) force.

Drive Belt Deflection mm (in)

8 (0.31) — 12 (0.47)

N6A3526E
LG4JB-WE-1111.book 22 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-22 ENGINE ELECTRICAL

LNW81BSH014801

Legend
1. AC generator & fan pulley drive belt
2. P/S oil pump drive belt (with P/S oil pump type
only)

• Install the fixing bolt and tighten bolt to the

specified torque.
Tighten:
• Generator Fixing Bolt to 40 N⋅m (4.1/ kg⋅m/30 lb⋅ft)
• Adjust Plate Fixing Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
5. Oil Hose
• Install the oil hose (1) to vacuum pump.
• Install the oil hose (2) to oil pan.

N6A3299E

6. Vacuum Hose (Exhaust Brake Model)

• Install the vacuum hose to vacuum tank and ex-
haust actuator.
• Connect the battery ground cable.
LG4JB-WE-1111.book 23 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-23

Unit Repair
Component
12V-50A

N6A3527E

Legend
1. Vacuum pump 8. Terminal bolt and nut
2. Lead wire 9. Rear cover
3. Through bolts 10. Stator
4. Rotor and front cover assembly 11. Diode
5. Stator and rear cover assembly 12. IC regulator assembly
6. Rotor 13. Brush holder
7. Rear bearing
LG4JB-WE-1111.book 24 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-24 ENGINE ELECTRICAL

Disassembly
Notice:
1. Vacuum Pump Take care not to damage the stator coil with the screw-
• Drain fluid from discharged port. driver. When the assembly will not come off, hold down
• Remove the vacuum pump fixing bolts. Hold the rear cover and hit the end face of the shaft gently
the center plate and remove the vacuum pump with a plastic hammer to detach it.
horizontally in direction in line with the rotor 6. Rotor
shaft. • With the rotor gripped with a vise, remove the
2. Lead Wire pulley nut (1), and then take off the pulley (2),
3. Through Bolts fan (3), front cover (4) and the rotor (5).

N6A3528E N6A3530E

7. Rear Bearing
Legend
8. Terminal Bolt and Nut
1. Seal protector
9. Rear Cover
4. Rotor and Front Cover Assembly • Remove the nuts fixing the B terminal and di-
5. Stator and Rear Cover Assembly ode holder.
Separate the stator and rear cover.
• Insert a screwdriver into the clearance between
Note the position of insulation washers to en-
the front cover and the stator core, and remove
sure reassembly into original position.
the assembly.

N6A3531E
N6A3529E

10. Stator
11. Diode
LG4JB-WE-1111.book 25 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-25

• Separate the diodes from the stator by melting
away solder on stator coil and diode.
When melting solder, hold the lead wire with
long nose pliers to prevent heat from being
transferred to the diodes.
12. IC Regulator Assembly
• Separate the IC regulator from the diode by
melting away solder on IC regulator holder
plate and removing the nut.

N6A3533E

Legend
1. Wear limit

Inspection and Repair

Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Rotor
N6A3532E
1. Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500 — 600
Legend sandpaper.
1. Terminal bolt 2. Measure the slip ring diameter, and replace if it ex-
2. Terminal plate ceeds the limit.
3. Rivet
4. Diode mm (in)
Standard Limit
13. Brush Holder
34.6 (1.36) 33.6 (1.32)
• Remove the serrated bolts and melt away sol-
der on IC regulator.
• Do not remove the serrated bolts unless the re-
placement of brush or condenser.
To install, follow the removal steps in the re-
verse order.

N6A3534E

3. Check for continuity between slip rings, and re-

place if there is no continuity.
LG4JB-WE-1111.book 26 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-26 ENGINE ELECTRICAL

Bearing press-in measurement: L

mm (in)
Standard 41.8 — 42.0 (1.64 — 1.65)

N6A3535E

Legend
1. Slip ring
2. Tester
N6A3537E
4. Check for continuity between slip ring and rotor
core or slip ring and rotor shaft.
Legend
In case of continuity, replace the rotor assembly.
1. Stopper ring
2. Ball bearing
3. Spline

Stator Coil
1. Check for continuity between respective phases.
In case of no continuity, replace the stator.

N6A3536E

Legend
1. Slip ring
2. Tester

Rear Ball Bearing N6A3538E

Check to see if the ball bearing rotates smoothly with no
noises.
When it does not rotate smoothly or any noises are Legend
heard, replace it with a new one. 1. Tester
When installing the bearing, press it in with the stopper 2. Lead wire
ring turned to the spline side, while pushing the bearing
inner ring.
LG4JB-WE-1111.book 27 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-27

2. Check for continuity across one of the stator coils
and stator core. If a continuity exists, replace the Legend
coil. 1. Tester

- side diode check

Across terminals BAT (Positive side (+) diodes)
Tester
Positive side Negative side
pin
Positive
No continuity
side
U.V.W
Negative
Continuity
side

+ side diode check

Across terminals E (Negative side (−) diodes)
Tester
Positive side Negative side
pin
N6A3539E Positive
Continuity
side
U.V.W
Legend Negative
1. Tester No continuity
side
2. Lead wire

Diode
1. Check for continuity across the terminal (example:
across BAT and U). If a continuity exists, the diode
is in satisfactory condition. If no continuity exists
the diode is defective.
2. Make a test with the polarities reversed. If no con-
tinuity exists, the diode is in satisfactory condition.
If a continuity exists at any point, the diode is de-
fective and should be replaced.
Auxiliary diodes are not provided with the terminal
and continuity test should be made across the ter-
minals of the conventional diodes.

N6A3541E

Brush
Measure length of brushes.
Brush length (L)

mm (in)
Standard Limit
20 (0.79) 6 (0.24)

Brushes are provided with a line which indicates the limit

of usage.

N6A3540E
LG4JB-WE-1111.book 28 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-28 ENGINE ELECTRICAL

N6A3533E N6A3542E

• Measurement the voltage across the E — F while

Legend varying resistance gradually from zero using vari-
1. Wear limit able resistor.
Then check that voltage increases from 2V to 10 —
IC Regulator
13.
Measuring instruments is necessary.
If increase in voltage is interrupted at any point, re-
Take the following measurements with the instruments
place the regulator.
connected as shown in the illustration.
• V4 Measure the voltage across the intermediate
V1 Voltage at Battery1 V tap on variable resistor and ‘E’ terminal without ac-
tuating the variable resistor.
Standard 10 — 13
V
V2 Voltage across F — E V Standard voltage at 20°C (68°F) 14.0 — 14.9
Standard Limit
If measured value deviates from the standard, re-
2 or less 2 or more place the regulator.

Take measurement with ‘S’ terminal disconnected.

V3 Measure the voltage at Battery1 — Battery2.

V
Standard 20 — 26

N6A3543E

Check the following with the instrument connected as il-

lustrated.
Measure the voltage across the terminals B and E by
gradually increasing voltage with variable resistor RV.
LG4JB-WE-1111.book 29 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-29

Check to see if voltage increases from lower than 2V to
range from 10 to 13 volts.
If the voltage does not vary, the regulator is defective
and should be replaced.
Check the voltage across the intermediate tap of the
variable resistor and terminal E without actuating the
variable resistor.

V
Standard voltage at 20°C (68°F) 14.5 — 16.9

If measured voltage deviates from the standard value,

replace the regulator.
Vacuum Pump
Visual Check
• Inspect the following parts for wear, damage or
other abnormal conditions.
Disassembly of Vacuum Pump N6A3545E

• For the center plate, rotor and vane in the men-

Vane
tioned.
Measure the length of vanes

mm (in)
Standard 12.5 — 13.5 (0.492 — 0.531)

Check Valve
1. Apply a light pressure onto the “B” side of valve
with a screwdriver and check that valve operates
smoothly.
2. Apply compressed air 100 — 500 kPa (1 — 5 kg/
cm2/14.5 — 72.5 psi) onto “A” side of valve and
check if there is air leak.

N6A3544E

Legend
1. Center plate
2. Vane
3. Rotor
4. Housing

Housing
• Measure the inside diameter of housing and place
if it exceed the standard.
N6A3546E
mm (in)
Standard 57.0 — 57.1 (2.244 — 2.248)
Legend
1. Compressed air
2. Push
LG4JB-WE-1111.book 30 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-30 ENGINE ELECTRICAL

Reassembly of Vacuum Pump • Put the IC regulator on the brush holder and
1. Position the rotor, with the serrated boss turned up, press the bolt.
on the center plate and housing. Bushing and connecting plate (1) must be in-
Align the holes in center plate and rotor. stalled when pressing the bolt.
2. Install vanes into slits in rotor.
The vanes should be installed with chamfered side
turned outward.
3. Install the O-ring and center plate

N6A3549E

3. Diode
• Connect the terminals by fixing the rivet at (1)
and soldering the terminal at (2).
N6A3547E

Legend
1. Chamfered side

Reassembly
1. Brush Holder
2. IC Regulator Assembly
• Hold the brush in the holder as shown in the il-
lustration and solder the lead wire.

N6A3550E

4. Stator
• When connecting stator coil leads and diode
leads using solder, use long-nose pliers and
finish the work as quickly as possible to prevent
the heat from being transferred to the diodes.

N6A3548E
LG4JB-WE-1111.book 31 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-31

N6A3551E N6A3553E

5. Rear Cover 12. Lead wire

6. Terminal Bolt and Nut 13. Vacuum Pump
7. Rear Bearing • Install and mount the housing to the generator
8. Rotor using 3 bolts.
• Cover vice with copper plates, clamp the rotor • Pour engine oil (5 cc or so) in through the filler
with the vice, and tighten nut to the specified port, then check that generator pulley can be
torque. turned smoothly with hand.
Tighten: • Tighten the pump fixing bolts (A) to the speci-
Pulley Nut to 90 N⋅m (9.2 kg⋅m/67 lb⋅ft) fied torque.
Tighten:
Through Bolts to 3.5 N⋅m (0.36 kg⋅m/31 lb⋅in)

N6A3552E

9. Stator and Rear Cover Assembly N6A3554E

10. Rotor and Front Cover Assembly
11. Through Bolts • Pour engine oil (5 cc or so) through the filler
port, and then check the pulley for smooth rota-
• Place guide bar through the holes in front cover
tion.
and rear cover flange for alignment, then install
the through bolts.
• Tighten the through bolts to the specified
torque
Tighten:
Through Bolts to 3.5 N⋅m (0.36 kg⋅m/31 lb⋅in)
LG4JB-WE-1111.book 32 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-32 ENGINE ELECTRICAL

QOSII PREHEATING SYSTEM

General Description
QOS II preheating system features a quick-on glow plug with thermometer control of the glowing time and the after-
glow time function.
The system consists of a controller, indicator lamp, thermo switch, relay, and glow plug (4 pcs).
With the employment of the thermo switch, the glow time changes according to the engine coolant temperature, thus
allowing optimum starting conditions to be obtained.
System Diagram

N6A3572E

QOS II Timing Chart

N6A3573E
LG4JB-WE-1111.book 33 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-33

Inspection on QOSII System Operation
Thermo Switch
The thermo switch is located on the water outlet pipe.

N6A3576E

N6A3387E

Use a circuit tester to check the thermo switch for conti-

nuity.

OFF → ON : 7 — 13°C (44.6 — 55.4°F)

ON → OFF : Below 3°C (37.4°F)

N6A3575E

Glow Plug
Use a circuit tester to test the glow plugs for continuity.

Glow Plug Resistance (Reference)

Ohms
Conventional model Approximately 1.5
Quick on start model Approximately 0.9
LG4JB-WE-1111.book 34 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6D-34 ENGINE ELECTRICAL

QOSII System Troubleshooting

N6A3577E

1. Problems when the water temperature of the engine is 0°C below.

Condition Cause Circuit

Glow plug relay will Bad connection of Fusible link wire between battery and starter. 3
not be lit.
Bad connection or disconnection of starter SW circuit
Bad connection or disconnection of Fuse No. SBF3
2
Malfunction of other circuits occurred simultaneously.
Bad starter switch.
Bad connection of glow plug relay terminal. 1
Disconnection of glow plug relay excitation coil.
Disconnection of circuit between glow plug relay and timer. 6
Bad glow relay. (The main contact does not pass electricity.)
Bad connection of timer.
Bad timer.
Bad earth circuit of timer. 7
Bad thermo switch. (It remains ON even in water temperature below 0°C.)
Earth short-circuiting of thermo switch. 7
Through glow plug Bad connection of Fusible link wire between battery and glow relay. 1
relay turns ON, pre- Bad connection or disconnection in preheating circuit of glow relay main
heating is not done. contact terminal connector.
Bad connection between plug connector and preheating circuit. 9
Glow plug relay Bad timer.
turns ON, but does Bad timer. Short circuiting in circuit or earth between 5 terminal and glow
not go OFF. 6
relay.
Bad glow relay.
Indication lamp is Bad timer.
not lit. Burning-out of light bulb. 8 8

Notice:
Circuit number is shown in the previous pre-heating chart.
LG4JB-WE-1111.book 35 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE ELECTRICAL 6D-35

2. Problems when the time water temperature of the engine is 0°C or above.

Condition Cause Circuit

Indicator lamp is not Bad timer
lit
Burning-out of bulb. 8 8
Turn glow relay ON. Bad thermo switch or disconnection of thermo SW circuit.
4
(Indicator will light up for 3.5 seconds.)
Bad timer.
Bad timer. Short-circuiting in circuit or earth between terminals 5 and glow
relay.

Notice:
Circuit number is shown in the previous pre-heating chart.
3. Burning-out of glow plug
When only one line is burned out, it has no effect on the start up of the engine. Even if one line is burned out,
judging from the characteristics of the glow plug, the impressed voltage will change only slightly.
Therefore, no judgment can be made by normal testing while the glow plug is installed. In order to check for
disconnections and burn-outs, the glow plugs will have to be removed from the connectors and checked one by
one for continuity.
LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

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LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

EXHAUST GAS RECIRCULATION (EGR) SYSTEM (WITH EGR SYSTEM ONLY) 6E-1

ENGINE
SECTION 6E
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
(WITH EGR SYSTEM ONLY)
Contents
GENERAL DESCRIPTION ................................... 6E-2
EGR SYSTEM WIRING DIAGRAM ...................... 6E-3
EGR SYSTEM OPERATION ................................ 6E-4
INSPECTION ........................................................ 6E-5
EGR COOLER ...................................................... 6E-6
Component ........................................................ 6E-6
Removal ............................................................ 6E-6
Installation ......................................................... 6E-7
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6E-2 EXHAUST GAS RECIRCULATION (EGR) SYSTEM (WITH EGR SYSTEM ONLY)

GENERAL DESCRIPTION

N6A3578E

Legend
1. EGR valve 5. Vacuum pump
2. Potentiometer 6. V.S.V
3. Thermo switch 7. EGR controller
4. Injection pump 8. RPM sensor

This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber
through the intake manifold.
The EGR valve are controlled by VSV, also VSV are controlled by EGR controller according to signals from RPM sen-
sor and Potentiometer.
The amount of EGR depends on the number of engine rotations and the opening of the accelerator.
LG4JB-WE-1111.book 3 ページ ２０１１年７月２７日　水曜日　午後６時１４分

EXHAUST GAS RECIRCULATION (EGR) SYSTEM (WITH EGR SYSTEM ONLY) 6E-3

EGR SYSTEM WIRING DIAGRAM

N6A3580E

1. Connector Pin Assignment

No. Connector Name

1 —
2 Battery (−) c/u GND
3 Thermo Switch
4 Battery (+)
5 —
6 —
7 rpm Signal (+)
8 rpm Signal (−)
9 Potentiometer (+)
10 Potentiometer
11 Potentiometer (−) N6A3581E

12 —
13 VSV
LG4JB-WE-1111.book 4 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6E-4 EXHAUST GAS RECIRCULATION (EGR) SYSTEM (WITH EGR SYSTEM ONLY)

EGR SYSTEM OPERATION

1. On the input side of engine speed, there is provided a hysteresis of 50 rpm on the speed rising side.
2. It does not work until 70 seconds, pass after engine start.
3. It does not work while the water temperature switch is on (30°C or lower).
4. While engine speed drops from 3,800 rpm or higher, it does not work for 25 seconds.
Exhaust Gas Recirculation (EGR) System Check

Step Action Value YES NO

Check the EGR valve for looseness.
1 —
Is the EGR valve loose? Go to Step 2 Go to Step 3
Tighten the EGR valve.
2 —
Is the action complete? Verify repair —
1. Engine “OFF”.
2. Ignition “ON”.
3. Using test light to ground, check the EGR
3 harness between the EGR valve and igni- —
tion feed.
Does the test light illuminate? Go to Step 5 Go to Step 4
Repair the EGR harness ignition feed.
4 —
Was the problem corrected? Verify repair Go to Step 5
1. Remove the EGR valve.
2. Visually and physically inspect the EGR
valve pintle, valve passages and adapter
5 for excessive deposits, obstructions or —
any restrictions.
Does the EGR valve have excessive deposits,
obstructions or any restrictions? Go to Step 6 Go to Step 7
Clean or replace EGR system components as
6 necessary. —
Was the problem corrected? Verify repair Go to Step 7
1. Remove the EGR inlet and outlet pipes
from the intake and exhaust manifolds.
2. Visually and physically inspect manifold
EGR ports and EGR inlet and outlet pipes
7 for blockage or restriction caused by ex- —
cessive deposits or other damage.
Do the manifold EGR ports or inlet and outlet EGR system work-
pipes have excessive deposits, obstructions, ing properly. No
or any restrictions? Go to Step 8 problem found.
Clean or replace EGR system components as
8 necessary. —
Is the action complete? Verify repair —
LG4JB-WE-1111.book 5 ページ ２０１１年７月２７日　水曜日　午後６時１４分

EXHAUST GAS RECIRCULATION (EGR) SYSTEM (WITH EGR SYSTEM ONLY) 6E-5

INSPECTION
Vacuum Switch Valve (VSV)
Check the resistance between the VSV connector termi- Tool Number /
Illustration
nals using a circuit tester. Description / Remarks
Cold Resistance: 37 — 44 (Ω) (for 12 volt)
Connect battery voltage between VSV connector termi-
nals and make sure of the continuity between the ports.
5-8840-0366-0 / High
Impedance Multimeter
(Digital Voltmeter-DVM)

5884003660

5-8840-0279-0 / Vac-
uum Pump with Gauge

5884002790

N6A3583E

Legend
1. 2 pin
2. Port

EGR Valve
With negative pressure applied to the diaphragm cham-
ber, make sure that the valve is smoothly actuated to
make the area between (1) and (2) ventilated.
Startup: About — 18.66±2.67 kPa (−140±20 mmHg)
Check to see if EGR valve is normally actuated under
the following conditions:
QWS off (After warming up)
Engine coolant temp: 80°C or higher

N6A3584E
LG4JB-WE-1111.book 6 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6E-6 EXHAUST GAS RECIRCULATION (EGR) SYSTEM (WITH EGR SYSTEM ONLY)

EGR COOLER
Component

N6A3585E

Legend
1. EGR cooler bracket 3. EGR pipe
2. EGR cooler 4. EGR valve

Removal
Legend
Preparation 1. EGR cooler
• Disconnect the battery ground cable. 2. EGR cooler bracket
• Drain the coolant.
3. EGR Pipe
• Remove the water hose.
1. EGR Cooler Bracket 4. EGR Valve
Remove the bracket from the flywheel housing.
2. EGR Cooler
Remove the EGR fixing nuts. Remove the cooler
together with the gasket.

N6A3587E

Legend
1. EGR valve
N6A3586E 2. EGR pipe
LG4JB-WE-1111.book 7 ページ ２０１１年７月２７日　水曜日　午後６時１４分

EXHAUST GAS RECIRCULATION (EGR) SYSTEM (WITH EGR SYSTEM ONLY) 6E-7
Installation
1. EGR Valve
• Install the gasket to the intake manifold.
• Install the EGR valve and tighten the nuts to the
specified torque.
Tighten:
• Nut to 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

N6A3589E

4. EGR Cooler Bracket

• Install the bracket to the EGR cooler.
• Install the washer to the flywheel housing side.
• Tighten the bolts until they seat (do not final tight-
en).

N6A3588E

2. EGR Pipe
• Install the gasket to the EGR valve.
• Install the EGR pipe and tighten the bolts to the
specified torque.
Tighten:
• Bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
3. EGR Cooler
• Install the gaskets to the EGR pipe and the exhaust
manifold.
• Install the EGR cooler.
• Tighten the nuts until they seat (do not final tight-
en).

N6A3590E

Tighten the nuts and bolts to the specified torque in the

order shown in the illustration.
Tighten:
• Nuts to 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
• Bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
LG4JB-WE-1111.book 8 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6E-8 EXHAUST GAS RECIRCULATION (EGR) SYSTEM (WITH EGR SYSTEM ONLY)

N6A3591E
LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE EXHAUST 6F-1

ENGINE
SECTION 6F
ENGINE EXHAUST
Caution:
Exhaust system components must have enough clearance from the underbody to prevent overheating of the floor
pan and possible damage to the passenger compartment, insulation and trim materials.

Contents
GENERAL DESCRIPTION ................................... 6F-2
THREE WAY CATALYTIC CONVERTER (WITH
THREE WAY CATALYTIC CONVERTER MODEL
ONLY) ................................................................... 6F-3
On-Vehicle Service............................................ 6F-3
FRONT EXHAUST PIPE....................................... 6F-4
Component ........................................................ 6F-4
Removal ............................................................ 6F-4
Installation ......................................................... 6F-4
EXHAUST BRAKE UNIT (WITH EXHAUST BRAKE
SYSTEM ONLY) ................................................... 6F-6
Inspection .......................................................... 6F-6
LG4JB-WE-1111.book 2 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6F-2 ENGINE EXHAUST

GENERAL DESCRIPTION
Equipped Exhaust Catalytic Converter Model

N6A3592E

Without Exhaust Catalytic Converter Model

N6A3593E

When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on
the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation
and trim materials.
Check complete exhaust system and nearby body areas and rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes
to seep into the rear compartment or passenger compartment. Dust or water in the rear compartment may be an in-
dication of a problem in one of these areas. Any faulty areas should be corrected immediately.
LG4JB-WE-1111.book 3 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE EXHAUST 6F-3

THREE WAY CATALYTIC CONVERTER

(WITH THREE WAY CATALYTIC CONVERTER MODEL ONLY)
The three way catalytic converter is an emission control
device added to the exhaust system to reduce pollutants
from the exhaust gas stream.

N6A3594E

Caution:
The catalytic converter requires the use of unleaded fuel
only.
Periodic maintenance of the exhaust system is not re-
quired. If the vehicle is raised for other service, it is ad-
visable to check the condition of the complete exhaust
system.
A dual bed monolith catalytic converter is used in com-
bination with three way catalytic converter.
Catalytic Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction) con-
verter contains platinum and rhodium which lowers the
levels of oxide of nitrogen (NOx) as well as hydrocar-
bons (CH) and carbon monoxide (Co).

On-Vehicle Service
Rattles and noise vibrations in the exhaust system are
usually caused by misalignment of parts. When aligning
the system, leave all bolts or nuts loose until all parts are
properly aligned; then tighten, working from front to rear.
1. Check connections for looseness or damage, es-
pecially for exhaust gas leakage.
2. Check clamps and rubbers for weakness, cracks or
damage.
3. If any part of the converter heat shield is damaged
or dented to the extent that it contacts the catalyst,
repair or replace.
4. Check for dents or damage and for any holes or
cracks caused by corrosion.
LG4JB-WE-1111.book 4 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6F-4 ENGINE EXHAUST

FRONT EXHAUST PIPE

Component

N6A3595E

Legend
1. Exhaust manifold fixing washer and nut. 3. Front exhaust pipe fixing nut.
2. Front exhaust pipe mounting bracket fixing bolt 4. Front exhaust pipe.
and nut.

Removal • Remove two bolts fixed from front pipe and center
pipe.
Preparation
4. Front exhaust pipe.
• Battery ground cable
1. Exhaust manifold fixing nuts. • Take out the exhaust pipe to another side.

• Remove two fixing nuts from exhaust manifold and Installation

front pipe.
1. Front exhaust pipe.
2. Front exhaust pipe mounting bracket fixing bolt and
2. Front exhaust pipe fixing bolts and nuts.
nut.
• Tighten the fixing nuts to the specified torque
Tighten:
• 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
3. Front exhaust pipe mounting bracket fixing bolt and
nut.
• Tighten the fixing bolt to the specified torque
Tighten:
• 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
4. Exhaust manifold fixing nuts
• Tighten the fixing nuts to the specified torque
Tighten:
• 69 N⋅m (7 kg⋅m / 51 lb⋅ft)

N6A3596E

3. Front exhaust pipe fixing bolts and nuts.

LG4JB-WE-1111.book 5 ページ ２０１１年７月２７日　水曜日　午後６時１４分

ENGINE EXHAUST 6F-5

N6A3597E

• Connect battery ground cable.

• After assembling each part, start the engine to
check for any leakage of gas at each connection.
LG4JB-WE-1111.book 6 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6F-6 ENGINE EXHAUST

EXHAUST BRAKE UNIT (WITH EXHAUST BRAKE SYSTEM ONLY)

Inspection
Operational Inspection
• With the engine idling, operate the exhaust brake
to check for the sound of the valve hitting against
the stopper.
Unit Inspection
• Check to see if the exhaust valve opens and closes
smoothly when the power chamber is applied with
a negative pressure (400 mmHg — 700 mmHg) by
the vacuum pump.

N6A3598E

• Check to see if the clearance between the valve

and the body is in the range of 0.1 mm — 0.2 mm
(the minimum of 0.1 mm) on an average of the
points “A” and “B” when the power chamber is ap-
plied with a negative pressure (650 mmHg — 700
mmHg) by the vacuum pump.
When the clearance is outside this range, adjust
the clearance with the adjust bolt.

N6A3599E
LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

TURBOCHARGER 6G-1

ENGINE
SECTION 6G
TURBOCHARGER
Contents
TURBOCHARGER................................................6G-2
Main Data and Specifications ............................6G-2
GENERAL DESCRIPTION ...................................6G-3
Identification of Unit ...........................................6G-4
Turbocharger Servicing .....................................6G-4
Precautions........................................................6G-4
INSPECTION AND REPAIR .................................6G-5
LG4JB-WE-1111.book 2 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6G-2 TURBOCHARGER

TURBOCHARGER
Main Data and Specifications

Model IHI RHF 4H

Maximum permissible speed rpm 190,000 180,000
Wastegate control pressure by 2mm rod stroke kPa (mmHg) 108.7±4.4(815±33) 82±3.3(615±25)
Weight kg (lb) 41(4.1/9.3)

IHI Corporation.
LG4JB-WE-1111.book 3 ページ ２０１１年７月２７日　水曜日　午後６時１４分

TURBOCHARGER 6G-3

GENERAL DESCRIPTION

N6A3600E

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 consumption,
and minimal engine noise.
The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and
machined to extremely high precision.
Turbocharger servicing requires great care and expertise.
If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or
wear, trouble with the turbocharger may possibly be indicated.
LG4JB-WE-1111.book 4 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6G-4 TURBOCHARGER
Identification of Unit • Visual checks
The turbocharger nameplate gives the date of manufac- • Clearance measurements
ture and other important information required to identify • End play measurements
the unit when service inquiries are made. Refer to INSPECTION AND REPAIR

Precautions
Turbocharger servicing requires great care and exper-
tise.
Faulty turbocharger servicing procedures can result in
serious damage to pistons, valves, cylinder liners, and
other important engine parts.
ISUZU does not recommended the performance of any
servicing procedure not specified described in this Man-
ual.

N6A3601E

The turbocharger nameplate has the following informa-

tion stamped on it.
1. Turbocharger Specification Number, Production
Year and Month
2. Production Date, Serial Number
3. ISUZU Parts Number

N6A3602E

Turbocharger Servicing
1. Refer to TROUBLESHOOTING in this Manual to
determine whether or not turbocharger repair or re-
placement is required.
2. The following procedures should also be per-
formed (either with the turbocharger on the vehicle
or removed from the vehicle but not disassembled)
to determine whether or not turbocharger repair or
replacement is required.
LG4JB-WE-1111.book 5 ページ ２０１１年７月２７日　水曜日　午後６時１４分

TURBOCHARGER 6G-5

INSPECTION AND REPAIR

Turbocharger Pressure Check
1. Remove the waste gate control chamber connect-
ing hose.
2. Connect the pressure gauge.
3. Start the engine and gradually increase the engine
speed (the vehicle must be stationary with no load
applied to the engine).
4. Check to see that turbocharger pressure rises to
approximately 500 mmHg.
Pressure Gauge: 5-8840-0075-0

N6A3607E

Legend
1. Rod
2. Pressure

4. Check to see the pressure required to move the

control rod 2 mm is within the limits shown below.

Control Rod Operating kPa (mmHg)

Pressure
N6A3606E
4JB1-TC (IHI RHF4) 109 ± 4.4 (815 ± 33)
Waste Gate Operation Check
1. Remove the hose between the waste gate control
chamber and the intake pipe.
2. Connect the pressure gauge.
3. Check to see that the rod begins to move when a
pressure of approximately 665 mmHg is applied to
the waste gate, control chamber.
Notice:
Do not apply a pressure greater than 1467 mmHg (196
kPa) to the waste gate during this check.

N6A3608E
LG4JB-WE-1111.book 6 ページ ２０１１年７月２７日　水曜日　午後６時１４分

6G-6 TURBOCHARGER
Waste Gate Control Chamber Connecting Hose And
Clips Check
1. Check the hose and clips.
2. In case that the hose has damage or deterioration,
replace the hose and clips.

N6A3610E

Wheel Shaft and Bearing Clearance

Use a dial indicator to measure the wheel shaft and
bearing clearance.

LNWB1GSH001301 Wheel Shaft and Bearing mm (in)

Clearance
Important: Standard Limit
Wheel shaft end play and bearing clearance standards 0.08 — 0.10 0.16 (0.0063)
and limits are included below for your reference. (0.00315 — 0.00395)
Wheel Shaft End Play
Use a dial indicator to measure the wheel shaft end play.
Apply a force of 1.2 kg (2.6 lb / 11.8 N) alternately to the
compressor wheel end and the turbine wheel end.

Wheel Shaft End Play mm (in)

Standard Limit
0.03 — 0.08 0.09 (0.0035)
(0.00118 — 0.00315)

N6A3611E

Legend
1. Oil return port
2. Oil feed port

N6A3609E
LG4JB-WE-1111.book 7 ページ ２０１１年７月２７日　水曜日　午後６時１４分

TURBOCHARGER 6G-7

N6A3612E
LG4JB-WE-1111.book 1 ページ ２０１１年７月２７日　水曜日　午後６時１４分

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LG4JB-WE-1111_奥付_68651 2011.7.25 11:38 AM ページ 1

Published: Jul., 2011 All rights reserved.

First Edition

WORKSHOP MANUAL
ENGINE
(4JB1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
LG4JB-WE-1111_奥付_68651 2011.7.25 11:38 AM ページ 2
 2011MY
2011MY

WORKSHOP MANUAL ENGINE (4JB1 model)

WORKSHOP MANUAL

ENGINE
(4JB1 model)

No.LG4JB-WE-1111