AU-4LE2

BV-4LE2
MODEL
 General Information 0A-1

General Information
General Information
Table of Contents
General Information .............................................. 0A-2
Service Precautions ........................................... 0A-2
Reading the Model ............................................. 0A-7
General Information ........................................... 0A-8
Recommended Lubricant ................................. 0A-14
List of Trouble Symptom .................................. 0A-15
Repair Standard ............................................... 0A-24
0A-2 General Information

General Information
Service Precautions 5. Always use the correct specialized tool indicated in
the instructions. Using the incorrect tool may
In order to carry out work safely cause damage to the parts or injury to the person
1. Always use an engine stand when taking the using the tool.
engine down from the vehicle.
Do not place the engine directly onto the ground,
or place in a manner that interferes with the oil
pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical sys-
tem, always remove the minus side cable from the
battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.

WSHK0190

6. All regular tools, gauges and special tools should

be regularly inspected, and prepared before start-
ing work. Do not use bent spanners, hammers with
damaged edges, chipped chisels, or any other
faulty or damaged tools.

4. Do not perform painting work or leave the engine

running for long periods of time in an enclosed or
badly ventilated indoor workshop.
 General Information 0A-3
7. Always pay close attention to safety and handling 9. Pay close attention to the risk of ignition if you are
requirements when using grinders, cranes, weld- handling parts that carry a high voltage.
ers, and other such equipment. Furthermore, any oil or grease spilt onto rubber
Moreover, always wear the correct protective gar- parts must be wiped off immediately, as it will
ments and use the necessary safety tools for the cause deterioration of the rubber.
job in hand.

WSHK0192

WSHK0191

8. Always check that there are no fuel leaks when Replacement parts and part numbers
performing maintenance work on the fuel system. 1. Always replace packing, oil seals, O-rings, caulk-
(It may cause a fire.) ing lock nuts, folding lock plates, split pins and
other such parts with brand new parts.
2. The parts numbers contained in this manual may
not represent the supply condition of the parts, and
the part numbers may be changed due to revi-
sions. Therefore, parts should always be checked
against a parts catalogue before use.
0A-4 General Information
Liquid gasket 3. Please take care not to apply too much or too little
liquid gasket.
1. Each time you disassemble parts that use liquid
Also, you should always re-apply the liquid gasket
gasket, completely remove the old gasket residue
upon itself when you start and finish application.
from each of the parts and matching sections using
a scraper, then clean each of the parts to com- 4. Make sure that there are no gaps when reinstalling
pletely remove oil, water, and dirt etc. from the var- the liquid gasket parts to each other. If there are
ious surfaces by a cloth. Using the specified type gaps between the two parts, re-apply the liquid
of liquid gasket, apply new liquid gasket to each of gasket. Some parts, especially the oil pan, use the
the surfaces before reassembling the parts. same size studs as a guide to eliminate the need
for knock pin positioning etc.
2. In order to make it easier to clean liquid gasket sur-
faces, apply gasket remover liquid (Pando- 391D 5. Re-install these parts within 5 minutes of applying
made by ThreeBond Co., Ltd.) and leave the part the liquid gasket.
to stand for approximately 10 minutes, after which If more than 5 minutes passes, remove the previ-
the old liquid gasket residue will be easier to ous liquid gasket and re-apply it.
remove. 6. Please wait for at least 30 minutes since the last
However, this should not be used on resin compo- part is installed before starting the engine.
nents or painted components.

Liquid gasket

Applied area Use conditions

Liquid gasket
Parts Matching parts Seal object Application name
groove
Engine oil (10W
1 Rocker bracket Cylinder head Equipped TB 1207B
— 30)
2 Air inlet pipe Cylinder head cover Air Equipped TB 1207C
Engine oil (10W
3 Timing case Cylinder block Equipped TB 1207B
— 30)
Engine oil (10W
4 Housing cover; injection pump Cylinder block None TB 1207C
— 30)
Engine oil (10W
5 Solenoid; fuel cut Cylinder block Equipped TB 1207C
— 30)
Engine oil (10W
6 Retainer; oil seal Cylinder block Equipped TB 1207B
— 30)
7 Housing ASM; PCV Cylinder head cover Blow-by gas None TB 1207C
8 Indicator; air cleaner Air cleaner Air None (Seal tape)

• Always use the liquid gasket products listed above, or a liquid gasket identical to the ones listed above.
• Use the correct quantity of liquid gasket. Always follow the handling instructions for each product.
 General Information 0A-5
Application procedure Example: Procedure for measuring the clearance
1. Wipe the contact surfaces clean of all water, oil or between the connecting rod bearing and crank pin.
grease. The contact surfaces should be dry. • Clean the connecting rod and bearing, and install
2. Apply a regular bead width of liquid gasket to one the bearing to the rod.
of the contact surfaces. Make sure that the bead • Cut the plastigauge to the same width as the crank
does not break at this point. pin, and while avoiding the oil hole of the crank pin
lay the gauge parallel to the pin.
Note: • Line up the marks on the connecting rod and cap,
If there are special regulations concerning the applica- and install the crank pin. Apply molybdenum disul-
tion procedure in the repair document, please follow fide to the thread section and seating surface of
those regulations. the tightening bolt, and rotate both cap and bolt to
the correct torque.
Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and Important:
threads clean of water, grease, and oil. The con- Do not move the connecting rod while using the
tact surfaces should be dry. plastigauge.
2. Apply Loctite to the top 1/3 of the screw.
• Gently remove the cap and connecting rod, and
3. Tighten the bolt to the specified torque. measure the crushed width of the plastigauge
(clearance between rod and pin) using the scale
printed on the bag.

Important:
After tightening the bolt, do not apply excessive
torque or try to rotate the bolt until at least one
hour has passed, and the Loctite has hardened.

Procedure for using the plastigauge

Type Measurable range mm {in}

PG-1 (Green) 0.025 — 0.076 {0.001 — 0.003}
PR-1 (Red) 0.051 — 0.152 {0.002 — 0.006}
PB-1 (Blue) 0.102 — 0.229 {0.004 — 0.009}
0A-6 General Information
Example: Measuring the clearance between the crank
bearing and crank journal
• Clean the clamp face of the cylinder block and
crankcase bearing, and also the bearing, and
install the cylinder block to the crankcase.
• Gently rest the crankshaft on the cylinder block,
and rotate it approximately 30 degree to stabilize it.
• Cut the plastigauge to the same size as the journal
width, and while avoiding the oil hole of the journal
lay the gauge parallel to the journal.
• Gently rest the crankcase on the cylinder block,
apply molybdenum disulfide to the thread section
and seating surface of the tightening bolt, and
tighten in sequence to the correct torque.

Important:
Do not rotate the crankshaft while using the plasti-
gauge.

• Gently remove the crankcase, and measure the

crushed width of the plastigauge (clearance
between bearing and journal) using the scale
printed on the bag.
 General Information 0A-7
Reading the Model
Engine number stamping position

WSLE0352
0A-8 General Information
General Information Description of abbreviations
Terminology, description of abbreviations
Abbrevia- Description
Terminology definitions tion
Maintenance standard AC Alternating Current
The generic name for reference values required for
ACC Accessory
maintenance, such as nominal dimension, assembly
specification, and limit. ACG Alternating Current Generator
Nominal dimension API American Petrol Institute
Shows the standard value at the point of manufacture ASM Assembly
that does not include the common difference. (Assy)
Assembly specification ATDC After Top Dead Center
Shows the standard value after assembling, repairing,
or adjusting. BAT, BATT Battery
BRG, Brg Bearing
Service limit
When this value (dimensions) is reached, it shows that BKT, BRKT Bracket
the part has reached its full limit and must be replaced
BTDC Before Top Dead Center
or repaired.
CO Carbon Oxide
Wear
Shows the difference between the dimension of non- CONN Connector
worn part (nominal dimension unless there is such part) CPU Central Processing Unit
and that of the most worn part (the dimension of worn
part). C/U Control Unit
DC Direct Current
Uneven wear
Shows the difference between the maximum and the DI Direct Injection
minimum wear amount. ECU Engine Control Unit/Electronic Control Unit
Front/Rear, Right/Left, Top/Bottom ECM Engine Control Module
These show each orientations of parts installed to the
vehicle when looking from the vehicle's forward direc- EGR Exhaust Gas Recirculation
tion. Exh, EXH Exhaust
Unit Ft, FRT Front
Units written to SI conventions (mainly torque, pres-
FWD Forward
sure, force)
[Example] Length: mm, Torque: N⋅m {kgf⋅m} F/C Fuel Cut

Warning GND Ground

Items that carry the warning mark pose a danger to life IC Integrated Circuit
or threat of serious injury if not strictly observed.
ID Plate Identification Plate
Caution
Items that carry the caution mark may cause injury or IN Intake, Inlet
lead to accidents if not strictly observed. ISO International Organization for Standardiza-
tion
Important
Items that carry the important mark may cause the I/PUMP Injection Pump
vehicle to break down, or may prevent the guaranteed JIS Japanese Industrial Standard
normal operation of the system or related parts if not
strictly observed. L/H, LH Left Hand

Note M/V Magnetic Valve

Items that should receive special mention within a work NOx Nitrogen Oxide
procedure.
N-TDC Number - Top Dead Center
OPT Option
P Pole(S)
PCV Pump Control Valve/Positive Crankcase
Ventilation
 General Information 0A-9

Abbrevia- Description SI (International System of Units)

tion With regards the conversion to SI (International
PM Particulate Matter System of Units)
PS Pre-Stroke The introduction of the SI systems aims to internation-
ally unify the metric system and the various units used
PTO Power Take Off by different countries (traditional weights and mea-
QOS Quick On System sures, the foot pound method etc.), and to curb the
confusion that occurs between the different units (con-
Rr, RR Rear
version calculations etc.).
R/H, RH Right Hand The new calculating method which adopted SI units
R/L Relay was completely adopted in Japan in 1992, and is stan-
dardized by JIS-Z-8203.
STD Standard All of the units in this manual are written in line
SW Switch with the International System of Units SI units, and
conventional units are written in { } brackets.
TICS Timing & Injection rate Control System
VGS Turbo Variable Geometry turbocharger System SI
Abbreviation of French word “Le Systeme International
W/L Warning Lamp
d’Unites”

Connection between main SI units and conventional units

SI Conventional unit Item, unit conversion

Length m m Same as the conventional unit
Weight (Mass) kg kg Same as the conventional unit
Force N * kg, kgf 1 kgf = 9.80665 N
Torque N⋅m * kg⋅m, kgf⋅m 1 kgf⋅m = 9.80665 N⋅m
Pressure Pa * kg/cm2, mmHg 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa
Power output, W PS 1 PS = 0.74 kW
horsepower
Capacity, air vol- m3 Liter, L, cc 1 Liter = 1 dm3, 1 cc = 1 m Liter = 1 cm3
ume displacement
Fuel consumption g/(kW⋅h) g/(PS⋅h) 1 g/(PS⋅h) = 1.360 g/(kW⋅h)

*1 Published service data may conveniently use kg for Conversion formula

force and mass (weight) instead of kgf. Length
*2 Some conversion results may be rounded off to 1 or
• km × 0.6214 = mile
2 decimal places.
• m × 3.281 = ft
Converting expressions of quantity • mm × 0.03937 = in
When converting, prefixes such as k (kilo) or m (milli) Pressure
are used. • kPa × 0.0101972 = kg/cm2
• kPa × 0.145038 = psi
M Mega 106 1,000,000
• MPa × 10.197162 = kg/cm2
k Kilo 103 1,000
• MPa × 145.03774 = psi
h Hecto 102 100 Tightening torque
d Deci 10-1 0.1 • N⋅m × 0.101972 = kg⋅m
c Centi 10-2 0.01 • N⋅m × 0.737562 = lb⋅ft
Speed
m Milli 10-3 0.001
• km/h × 0.6214 = MPH
µ Micro 10-6 0.000001 Temperature
• °C × 1.8 + 32 = °F
• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa
• 40 mmHg = 5,332 Pa = 5.3 kPa
0A-10 General Information
Table of Isuzu standard tightening torque
The tightening torque values in the table below apply to all situations unless a special tightening torque is specified.

Isuzu standard bolts, nuts

N⋅m {kgf⋅m}
Strength classifica- 4.8
7T
tion 4T
Shape of bolt head Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
*M10 × 1.5 19.6 — 33.3 {2.0 — 3.4} 22.3 — 37.2 {2.3 — 3.8} 27.5 — 45.1 {2.8 — 4.6} 30.3 — 50.4 {3.1 — 5.1}
M12 × 1.25 49.0 — 73.5 {5.0 — 7.5} 54.9 — 82.3 {5.6 — 8.4} 60.8 — 91.2 {6.2 — 9.3} 68.1 — 102.1 {6.9 —
10.4}
*M12 × 1.75 45.1 — 68.6 {4.6 — 7.0} 51.0 — 76.5 {5.2 — 7.8} 56.9 — 84.3 {5.8 — 8.6} 62.7 — 94.0 {6.4 — 9.6}
M14 × 1.5 76.5 — 114.7 {7.8 — 83.0 — 124.5 {8.5 — 93.2 — 139.3 {9.5 — 100.8 — 151.1 {10.3 —
11.7} 12.7} 14.2} 15.4}
*M14 × 2 71.6 — 106.9 {7.3 — 77.2 — 115.8 {7.9 — 88.3 — 131.4 {9.0 — 94.9 — 142.3 {9.7 —
10.9} 11.8} 13.4} 14.5}
M16 × 1.5 104.0 — 157.0 {10.6 — 115.6 — 173.3 {11.8 — 135.3 — 204.0 {13.8 — 150.1 — 225.2 {15.3 —
16.0} 17.7} 20.8} 23.0}
*M16 × 2 100.0 — 149.1 {10.2 — 109.4 — 164.2 {11.2 — 129.4 — 194.2 {13.2 — 142.5 — 213.8 {14.5 —
15.2} 16.7} 19.8} 21.8}
M18 × 1.5 151.0 — 225.6 {15.4 — — 195.2 — 293.2 {19.9 — —
23.0} 29.9}
*M18 × 2.5 151.0 — 225.6 {15.4 — — 196.1 — 294.2 {20.0 — —
23.0} 30.0}
M20 × 1.5 206.0 — 310.0 {21.0 — — 269.7 — 405.0 {27.5 — —
31.6} 41.3}
*M20 × 2.5 190.2 — 286.4 {19.4 — — 249.1 — 374.6 {25.4 — —
29.2} 38.2}
M22 × 1.5 251.1 — 413.8 {25.6 — — 362.8 — 544.3 {37.0 — —
42.2} 55.5}
*M22 × 2.5 217.7 — 327.5 {22.2 — — 338.3 — 507.0 {34.5 — —
33.4} 51.7}
M24 × 2 358.9 — 539.4 {36.6 — — 430.5 — 711.0 {43.9 — —
55.0} 72.5}
*M24 × 3 338.3 — 507.0 {34.5 — — 406.0 — 608.0 {41.4 — —
51.7} 62.0}

The * mark indicates where soft materials have been used for internal thread sections, such as castings.
 General Information 0A-11

N⋅m {kgf⋅m}
Strength classifica- 9.8
8.8
tion 9T
Shape of bolt head Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
M6 × 1 5.6 — 11.2 {0.6 — 1.1} 6.6 — 12.2 {0.6 — 1.2} — —
M8 × 1.25 13.4 — 25.7 {1.4 — 2.6} 15.3 — 28.4 {1.6 — 2.9} 16.7 — 30.4 {1.7 — 3.1} 18.1 — 33.6 {1.9 — 3.4}
M10 × 1.25 31.3 — 52.5 {3.2 — 5.4} 35.4 — 58.9 {3.6 — 6.1} 37.3 — 62.8 {3.8 — 6.4} 42.3 — 70.5 {4.3 — 7.2}
*M10 × 1.5 31.3 — 51.4 {3.2 — 5.2} 34.5 — 57.5 {3.5 — 5.8} 36.3 — 59.8 {3.7 — 6.1} 40.1 — 66.9 {4.1 — 6.8}
M12 × 1.25 69.3 — 104.0 {7.1 — 77.7 — 116.5 {7.9 — 75.5 — 113.8 {7.7 — 85.0 — 127.5 {8.7 —
10.6} 11.9} 11.6} 13.0}
*M12 × 1.75 64.8 — 96.1 {6.6 — 9.8} 71.4 — 107.2 {7.3 — 71.6 — 106.9 {7.3 — 79.5 — 119.2 {8.1 —
10.9} 10.9} 12.2}
M14 × 1.5 106.2 — 158.8 {10.8 — 114.9 — 172.3 {11.7 — 113.8 — 170.6 {11.6 — 123.4 — 185.1 {12.6 —
16.2} 17.6} 17.4} 18.9}
*M14 × 2 100.6 — 149.8 {10.3 — 108.2 — 162.2 {11.1 — 106.9 — 160.0 {10.9 — 115.5 — 173.3 {11.8 —
15.3} 16.6} 16.3} 17.7}
M16 × 1.5 154.3 — 232.5 {15.7 — 171.1 — 256.7 {17.4 — 160.0 — 240.3 {16.3 — 176.9 — 265.3 {18.0 —
23.7} 26.2} 24.5} 27.1}
*M16 × 2 147.6 — 221.4 {15.0 — 162.5 — 243.8 {16.6 — 153.0 — 229.5 {15.6 — 168.5 — 252.7 {17.2 —
22.6} 24.9} 23.4} 25.8}
M18 × 1.5 222.5 — 334.3 {22.7 — — 229.5 — 345.2 {23.4 — —
34.1} 35.2}
*M18 × 2.5 223.6 — 335.4 {22.8 — — 230.5 — 346.2 {23.6 — —
34.2} 35.3}
M20 × 1.5 307.4 — 461.7 {31.4 — — 316.8 — 475.6 {32.3 — —
47.1} 48.5}
*M20 × 2.5 284.0 — 472.1 {29.0 — — 293.2 — 440.3 {29.2 — —
43.5} 44.9}
M22 × 1.5 413.6 — 620.5 {42.2 — — 424.6 — 636.5 {43.3 — —
63.3} 64.9}
*M22 × 2.5 385.7 — 578.0 {39.3 — — 394.2 — 592.3 {40.0 — —
58.9} 60.4}
M24 × 2 490.8 — 810.5 {50.0 — — 554.1 — 830.6 {56.5 — —
82.7} 84.7}
*M24 × 3 462.8 — 693.1 {47.2 — — 520.7 — 781.6 {53.1 — —
70.7} 79.7}

The * mark indicates where soft materials have been used for internal thread sections, such as castings.
0A-12 General Information
Designations for Isuzu standard bolt heads

Name
1. Hexagon Head Bolt (4.8, 4T) 9. Hexagon Head Bolt (Nonthermal Refined 8.8)
2. Hexagon Head Bolt (4.8, 4T) 10. Hexagon Head Bolt (Nonthermal Refined 8.8)
3. Flange Bolt (4.8, 4T) 11. Flange Bolt (8.8)
4. Flange Bolt (4.8, 4T) 12. Flange Bolt (8.8)
5. Hexagon Head Bolt (7T) 13. Hexagon Head Bolt (9.8, 9T)
6. Flange Bolt (7T) 14. Hexagon Head Bolt (9.8, 9T)
7. Hexagon Head Bolt (Thermal Refined 8.8) 15. Flange Bolt (9.8, 9T)
8. Hexagon Head Bolt (Thermal Refined 8.8) 16. Flange Bolt (9.8, 9T)

Flare nut

Pipe diameter Tightening torque Width across flats of flare nut

(for medium and large size (mm)
vehicles)
Old New
Flare nut tightening torque φ 4.76 mm 12.8 — 18.6 {1.3 — 1.9} 14 14
(service standard value) N⋅m {kgf⋅m}
φ 6.35 mm 23.5 — 49 {2.4 — 5.0} 17 17
φ 8.0 mm 23.5 — 49 {2.4 — 5.0} 19 17
φ 10.0 mm 44.1 — 93.2 {4.5 — 9.5} 22 19
φ 12.0 mm 58.8 — 137.3 {6.0 — 14.0} 27 24
φ 15.0 mm 78.5 — 156.9 {8.0 — 16.0} 30 30
 General Information 0A-13
Taper screw from connectors (brass)

N⋅m {kgf⋅m}
Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 PT (R) 1/12
— 2.0 — 14.7 4.9 — 15.7 9.8 — 16.7 9.8 — 17.7
{0.2 — 1.5} {0.5 — 1.6} {1.0 — 1.7} {1.0 — 1.8}

About angle method tightening

Though the general and current way to tighten bolts
and nuts is torque indication, using this way results in
large unevenness of shaft power to indicated torque.
Therefore, bolts may be damaged at upper limit when
you try to ensure minimal shaft power.
To ensure shaft power with small unevenness, it is nec- A
essary to tighten bolts measuring stretch amount of
C D
bolts, but this is actually impossible. So the angle
method focuses on screw pitch as equivalent to bolt
stretch, and controls using the screw rotation amount. B
E
The method can reduce the unevenness of shaft power
by tightening to plastic range.
F
How to tighten
1. Apply molybdenum disulfide or engine oil to the
threads and the seating surface of the bolt follow-
ing the instruction. WSLE0009

2. Tighten all bolts to the pre-indicated tightening

torque. Be sure to check the mark to see whether you
tighten the bolt to the specified angle or not.
3. Draw lines on the surface of the parts you tighten:
If you fail this, you may tighten the bolt by the
the lines which pass through the bolt’s center (A —
angle method again by accident and damage the
B: bolt side) (C — D: parts side) and the line at the
bolt. Take extreme care.
specified tightening angle from the bolt’s center (E
— F). Important:
• Follow the instructed order to tighten bolts.
• Do not retighten if you tighten by the angle
method.

Bolt angle gauge (5-8840-0266-0), the tool for tighten-

ing bolts by the angle method, is set.

A B C D Special tool classification

A; Essential tool

1
Servicing operation cannot be done with any other
E
tools than the essential tool.

F B; Recommend tool
Servicing work can be done with a general-purpose
tool commercially available. However, it is advisable to
use the recommended tool as much as possible for a
WSLE0008
reduced work time and an improved safety in work
Name operations.
1. Specified Tightening Torque
C; Available tool
4. Tighten the bolt with wrench until the line on the Although it takes a more working time, servicing opera-
bolt (A — B) aligns with the specified angle line (E tions can be made with a tool commercially available as
— F on the surface of the parts). substitute for the available tool.
0A-14 General Information
Recommended Lubricant
Engine oil
Use the engine oil below.

Engine oil grade

Engine classification Engine oil grade (API service category)

With turbocharger CD or CF-4
* (CE, CF, CH-4, CI-4 or CI-4 Plus)

* mark may vary depending on each machine. Refer to the machine manufacturer specification.

ISUZU genuine engine oil

Besco Super: CC
Besco S — 3: CD
Besco Multi Z: CD

Engine oil viscosity chart

ENGINE OIL VISCOSITY GRADE – AMBIENT TEMPERATURE

SAE 5W-20

[Single grade] SAE 20, 20W SAE 40

SAE 10W SAE 30

Ambient -25 C -20 C -15 C -0 C 15 C 25 C 30 C

temperature (-13 F) (-4 F) (5 F) (32 F) (59 F) (77 F) (86 F)

SAE 10W-30
[Multi grade]
SAE 15W-40, 20W-40

WSLE0034

The engine oil affects the startability, driving performance, oil consumption, wear of the sliding part, and seizure,
depending on the viscosity. You should select the engine oil depending to a temperature and the chart above.

Engine oil level

4LE2X model: Approx. 9.3 — 12.1 L {9.8 — 12.8 qts}
4LE2N model: Approx. 5.9 — 8.4 L {6.2 — 8.9 qts}

Note:
Engine oil level may vary depending on the machine specification.
 General Information 0A-15
List of Trouble Symptom
Engine does not start

Engine does not start

Starter does not run Starter runs but does Engine starts but
not start does not run
continuously.
Check battery

Engine Fuel system Fuel injected Air mixed in

(*2)
Battery in OK fuel pump
discharging Check
(Charge) compression
(*) No fuel Fuel injected
pressure
injected
Retighten, OK
Check wiring
replace
Check if fuel Check OK packing,
Low OK comes preheating bleed air
Loosened OK compression to fuel pump circuit
connector or pressure
broken wire
(Retighten or Check for air
replace with Defective mixing Poor Normal Disordered
new wiring) valve, spring, operation operation idling
gasket, etc. of glow of glow
(Overhaul) plug plug
Air mixed OK control control
Check starter switch resistance resistance
(Retighten it,
replace (Replace) OK
packing, bleed
air) OK
Defective OK Adjust
(Replace) Check idling
injection
Check fuel timing
filter (*2)

Check magnetic
switch Abnormal OK Check for the
(Adjust) stuck EGR valve
Clogged OK
(opened position)
(*) (Clean)
(*3)
Defective OK Check nozzle
(Replace)
Check engine stop Replace the EGR OK
solenoid return cut solenoid and
Defective OK
(Repair or valve case by
Check starter bush replace) the set
Check solenoid

(*3) Refer to "EGR Control"

OK Defective injection
Poor contact in the Exhaust System
Stuck solenoid or OK pump (Bring
(Repair or section.
poor operation it to a specialty
replace)
(Repair or replace) shop for repair)

Defective starter Note: "Bring it to a specialty shop" means that defective parts of the injection pump
(Bring it to a specialty and electricals must be brought to a specialty shop for repair. (This note is
shop for repair) applicable to all the following procedures.)

WSLE0192
0A-16 General Information
Engine speed lacks smoothness

Unstable engine rotation

Unstable engine Idling speed Unstable rotation at Unstable rotation at Engine does not
idling too high medium speed high speed change from high to
(Hunting) low rotation

Defective idling Defective control Governor spring Check fuel for air Check accelerator
adjustment lever adjustment deteriorated mixing pedal

Defective OK Defective OK Air mixed OK Pedal OK

valve return (Repair or (Bleed air) sticking or
(Adjust) replace) hitching
(Clean or
replace)

Check high pressure Defective injection Check fuel pipe for Check fuel filter for
pipe for cracking, pump (Bring it to a crash clogging
clogging or bending specialty shop for Defective injection
repair) pump (Bring it to a
specialty shop for
repair)
Crash OK Clogged OK
Cracked, OK (Replace) (Clean or
clogged or replace)
bent
(Replace)

Check uneven fuel

injection
Check nozzle

Uneven OK
Defective OK
(Adjust)
(Repair or
replace)

Check valve clearance

Check cylinder for adjustment
uneven compression
pressure

Poor OK
adjustment
Uneven OK (Adjust)
compression
pressure
(Adjust)
Defective injection
pump (Bring it to a
specialty shop for
Defective injection repair)
pump (Bring it to a
specialty shop for
repair)

WSLE0193
 General Information 0A-17
Output shortage

Insufficient output

Fuel system Mechanical There is insufficient

system torque and a lot of
black smoke at
low-speed
Check fuel for air
mixing Check engine
control Check for the
stuck EGR valve
(opened position)
Air mixed OK (*)
(Bleed air) Poor OK
adjustment
(Adjust) Replace the OK
Check fuel filter EGR cut
or fuel hose for solenoid
clogging and valve
Check inlet air case by
temperature the set

Clogged OK
(Clean or OK Check the fuel
Temperatu
Replace) system and
re too high
(Improve mechanical system
ventilation)
Check high (*) Refer to "EGR Control"
pressure pipe for in the Exhaust System
clogging or section.
bending Insufficient inlet
air

Clogged OK
Air cleaner OK
or bent
(Replace) stained
(Clean or
replace)

Check nozzle

Check valve
clearance and
Defective OK cam lift
(Repair or
replace)

Abnormal OK
(Adjust or
Check injection
replace)
timing

Abnormal OK Check compression

(Adjust) pressure

Low
Defective
injection pump
(Bring it to a
specialized shop
Low
for repair)
Excessive
blow-by Gas leak from
gas valve and gasket
(Overhaul) (Repair or replace)
WSLE0194
0A-18 General Information
Overheat

Overheat

Cooling system Handling

Check cooling Check fan belt Check if oil used

water level for slip is inferior quality,
or engine oil is
too much

Insufficient OK Slipping OK
(Adjust)
Care must OK
be taken
when
Replenish Check Check thermostat replenishing
for (Replace)
leakage
Malfunction OK
(Replace)
Engine Overloaded

Leak to Leak to rotation

external internal too high
Check cooling
system for stain,
and radiator for
Repair or clogging
Repair
replace Temperature
abnormally high
Stained or
clogged
(Clean) OK Improve
ventilation

WSLE0195
 General Information 0A-19
Exhaust fault

Abnormal exhaust gas

White smoke too much Black smoke too much Check for the stuck EGR
valve (opened position) (*)

Check if fuel used is of Check fuel for water Check nozzle Air cleaner clogged
inferior quality mixing

Defective (Repair OK Replace air OK Replace the EGR OK

or replace) cleaner cut solenoid and
Change fuel OK Water mixed OK
element valve case by
(Change fuel) the set

Check if engine oil is too Check injection timing Check air hose for crash
much (*) Refer to "EGR Control"
Check injection timing in the Exhaust System
Advanced too much OK section.
OK (Adjust)
Delayed
(Adjust)

Check injection pump

Check compression ratio

Defective injection pump OK

Low OK (Bring it to a specialty
shop for repair)

Gas leak from

Check up and 1. Disordered valve timing
Excessive valve and
down 2. Broken piston ring or
blow-by gas gasket (Repair
movement of oil misassembly
(Overhaul) or replace)
3. Worn camshaft
4. Worn valve or insert
Stuck (Overhaul) (Overhaul)

WSLE0196
0A-20 General Information
Battery over discharge

Over-discharge of battery

Battery Wiring Regulator and generator

Check electrolyte level Check terminals for warp, Check belt for slip or damage
deformation or corrosion

Low OK Slipping or OK
OK damaged (Repair
Poor contact
or replace)
(Repair or replace)
Battery Natural
case consumpt Over
cracked ion charge Test charging condition
(Replace) (Replenish) Check for broken wire
(Repair or replace)
Note: Improper maintenance Abnormal OK

Bring it to a battery shop

Check specific gravity

Low

Recharging
Recharge impossible

Bring it to a battery specialty shop

WSLE0197
 General Information 0A-21
Oil pressure is too low Fuel consumption deteriorates

Oil pressure too low Fuel consumption too much

Check oil level Check for fuel leakage

Low (Replenish) OK Leaking (Retighten, OK

replace packing seal)

Check cooling water temperature

Check nozzle

High OK
(See "Overheat") Defective OK
(Repair or replace)

Check oil in crankcase

Check injection timing
Improper OK
viscosity
Abnormal (Adjust) OK
Water or fuel mixed. Check fuel
system and cooling system Check compression ratio

Check relief valve Low OK

Defective OK Defective injection pump

(Repair or replace) (Bring it to a specialty
shop for repair)

1. Oil pump malfunction

2. Loosened or cracked pipe Excessive Gas leak from
3. Wear of sliding part blow-by gas valve and gasket
4. Oil pump clogged (Repair or
(Overhaul) replace)

WSLE0198 WSLE0199
0A-22 General Information
Oil consumption deteriorates

Oil consumption too much

Check for oil leakage

Leaking (Retighten, OK
replace packing seal)

Check oil quality

Poor quality OK
(Change to specified oil)

Check bleeder for clogging

Clogged (Clean) OK

Check up and down movement of oil

1. Oil pump malfunction

2. Loosened or cracked pipe
3. Wear of sliding part (*)
4. Oil pump clogged
5. Defective valve stem seal
(Overhaul)

(*) Worn bore,and worn or broken

ring (Measure compression
pressure, and check entrance of
dust)

WSLE0200
 General Information 0A-23
Engine knocking

Engine knocking

Mechanical system Fuel system

Check up movement of oil Check injection timing

Oil stained (Overhaul) OK Abnormal (Adjust) OK

Check compression pressure Check nozzle

Low OK Defective OK
(Repair or replace)
To fuel system
Note: Fuel used is of poor quality.

Excessive Gas leak from

blow-by gas valve and gasket
(Overhaul) (Repair or
replace)

WSLE0201
0A-24 General Information
Repair Standard
1. This table specifies the repair standard for 4LE2 model “ISUZU diesel engine”.
2. This repair standard consists of items to be checked, nominal dimension, assembly specifications, service limit,
and repairing procedure.
• “Nominal dimension” is the standard value at the time of manufacture.
• “Assembly specification” is the target value after repairing (at assembling). It may differ in some degree from
“assembly dimension” of the new engine.
• “Service limit” is the limit value of wear, etc. which must not be exceeded. When it is reached, the part should
be repaired or replaced.
• “Repairing procedure” indicates general methods to repair.
• The unit for the numbers in the table are all “millimeter {inch}” if not otherwise specified.
3. If the whole engine is requested for repair, “check the locations which need to be repaired” first by “the bench
test” or something. Then perform the minimum overhaul. If a part of engine is requested for repair, perform
repairing based on this “repair standard”.
4. This repair standard may be changed in the value, specification, and others without notice due to “design
change” of the engine.

Time to overhaul the engine

Standard
Item to be checked Service limit Repairing procedure Remarks
value
Coolant temperature: 70
— 85°C {158 — 185°F}
Compression pressure of the cylinder Engine speed: approx.
3.04 {441} 2.5 {363}
(MPa {psi}) 250 rpm
Overhaul the engine. Vary depending on alti-
tude.
Fuel consumption rate (L/h) 100% 140%
Lubricant consumption rate (L/h) 100% 200%

Cylinder block

Item to be checked Standard Service limit Repairing procedure Remarks

value
Wear of the cylinder bore
Perform boring along the
Measurement position: 13 {0.512} φ85.2
φ85 {3.3465} oversize piston, then per-
lower from the top surface of the cyl- {3.354}
form honing.
inder block
Maximum amount of
repaired value; 0.3 {0.012}
0.075
Distortion of upper surface of the cyl- Repair with a surface The total amount of
{0.00295} or 0.15 {0.006}
inder block grinder. repaired values of the cyl-
less
inder head and of the cyl-
inder block.
Water pressure test (three minutes) Repair or replace the one
490 {71}
(kPa {psi}) with water leakage.
 General Information 0A-25
Cylinder head

Item to be checked Standard Service limit Repairing procedure Remarks

value
IN 0.7 {0.028} 1.2 {0.047} Replace the valve and
Valve seat depression Valve seat angle is 45°
EX 0.9 {0.035} 1.5 {0.059} insert.

Repair with the valve seat Wrap the contact surface

Contact width of the valve seat 2.0 {0.079} 2.5 {0.098}
cutter. sufficiently after repair.
Maximum amount of
repaired value; 0.3 {0.012}
Distortion (flatness) of the under sur- 0.075
Repair with a surface The total amount of
face (installation surface) of the cylin- {0.00295} or 0.15 {0.006}
grinder. repaired values of the cyl-
der head less
inder block and of the cyl-
inder head.
Distortion of exhaust manifold instal- 0.05 {0.002} or
0.2 {0.008} Repair.
lation surface less
Water pressure test (three minutes) Repair or replace the one
490 {71}
(kPa {psi}) with water leakage.
83.4 — 93.2 - Clean the seating sur-
{8.5 — 9.5/ face and thread of the
Tightening torque of M12 × 1.5 61.5 — 68.7} bolt.
the cylinder head bolt: ↓ - Apply engine oil to the
(N⋅m {kgf⋅m/lb⋅ft}) 60° — 90° seating surface and
(Angle method) 24.5 — 34.3 thread of the bolt.
M8 × 1.25 {2.5 — 3.5/ - Never retighten after
18.1 — 25.3} angle method tightening.

Piston
Connecting rod small end diameter (φ25 mm {0.9843 in})
Item to be checked Standard Service limit Repairing procedure Remarks
value
Clearance with the cylinder 0.040 — 0.085
Grade position from the top surface: {0.0016 —
54.85 {2.159} 0.0033}
0.004 — 0.017 If significant knocking
Clearance between piston pins and
{0.00016 — sound occurs, replace the
piston pin holes
0.0007} piston pin or the piston.
φ24.970
Wear of the pin φ25 {0.9843}
{0.9449}
0.20 — 0.35
Top ring {0.008 —
0.014}
1.5 {0.059}
0.35 — 0.50 Replace piston ring. When
Second
Piston ring end gap {0.014 — overhauling the engine,
ring
0.020} replace the piston ring.
0.20 — 0.40
Oil ring {0.008 — 1.0 {0.039}
0.016}
0A-26 General Information
Connecting rod small end diameter (φ27 mm {1.063 in})
Item to be checked Standard Service limit Repairing procedure Remarks
value
Clearance with the cylinder 0.040 — 0.085
Grade position from the top surface: {0.0016 —
54.85 {2.159} 0.0033}
0.004 — 0.017 If significant knocking
Clearance between piston pins and
{0.00016 — sound occurs, replace the
piston pin holes
0.0007} piston pin or the piston.
φ26.970
Wear of the pin φ27 {1.063}
{1.0618}
0.20 — 0.35
Top ring {0.008 —
0.014}
1.5 {0.059}
0.20 — 0.40 Replace piston ring. When
Second
Piston ring end gap {0.008 — overhauling the engine,
ring
0.016} replace the piston ring.
0.20 — 0.40
Oil ring {0.008 — 1.0 {0.039}
0.016}

Piston ring
Connecting rod small end diameter (φ25 mm {0.9843 in})
Item to be checked Standard Service limit Repairing procedure Remarks
value
0.085 — 0.120
Top ring {0.0033 — 0.2 {0.008} When assembling the ring to
0.0047} the piston, be sure to
assemble with the mark of
Clearance between 0.050 — 0.085
Second Replace the ring or the the ring facing upward.
the piston ring groove {0.0020 — 0.15 {0.006}
ring piston. Inverse assembly makes oil
and the ring 0.0033}
consumption deteriorate.
0.030 — 0.065 The oil ring is independent
Oil ring {0.00120 — 0.15 {0.006} of top or bottom.
0.00256}
The ring end direction 180° alternate

Connecting rod small end diameter (φ27 mm {1.063 in})

Item to be checked Standard Service limit Repairing procedure Remarks
value
It cannot be
measured due
Top ring — When assembling the ring to
to the taper
the piston, be sure to
type ring.
assemble with the mark of
Clearance between
0.070 — 0.110 Replace the ring or the the ring facing upward.
the piston ring groove Second
{0.0028 — 0.15 {0.006} piston. Inverse assembly makes oil
and the ring ring
0.0043} consumption deteriorate.
The oil ring is independent
0.030 — 0.070
of top or bottom.
Oil ring {0.00120 — 0.15 {0.006}
0.00276}
The ring end direction 180° alternate
 General Information 0A-27
Connecting rod
Connecting rod small end diameter (φ25 mm {0.9843 in})
Item to be checked Standard Service limit Repairing procedure Remarks
value
Play of the small end and the piston
boss between front and back direc- 1.0 {0.039} Reference value
tion (one side)
Extrusion Use the one with extrusion
Tension of the connecting rod bear- 0.02 — 0.06 and tension, and be care-
ing {0.00079 — ful about sticking of rear
0.00236} side.
0.035 — 0.073
Clearance between the connecting Be careful with the preci-
{0.0014 — 0.1 {0.0039} Replace the bearing.
rod bearing and crank pin sion of the crank pin.
0.0029}
Replace the one with
Contact surface of the connecting
defective contact or abra-
rod bearing and crank pin
sion.
0.008 — 0.020 Clearance should be wide
Clearance between the small end Replace the bushing or
{0.00031 — 0.05 {0.002} enough to turn smoothly
bushing and the piston pin the pin.
0.00079} with its big end held.
0.20 — 0.33
Axial play of the connecting rod and
{0.008 — 0.35 {0.014}
the crank pin
0.013}
Center distance between the big end
133.5 {5.256} Reference value
and small end
Torsion of holes on the big end and 0.05 {0.002} or
0.2 {0.008} Repair or replace.
small end (L = per 24 mm {0.945 in}) less
Parallelism of holes on the big end
0.075 {0.003}
and small end (L = per 100 mm 0.15 {0.006} Repair or replace.
or less
{3.937 in})
19.6 — 29.4
Apply engine oil to the
{2.0 — 3.0/
Tightening torque of the bearing cap thread of the bolt and the
14.5 — 21.7}
bolt (N⋅m {kgf⋅m/lb⋅ft}) seating surface of the nut,
→ 100° —
and tighten.
115°

Connecting rod small end diameter (φ27 mm {1.063 in})

Item to be checked Standard Service limit Repairing procedure Remarks
value
Play of the small end and the piston
boss between front and back direc- 1.0 {0.039} Reference value
tion (one side)
Extrusion Use the one with extrusion
Tension of the connecting rod bear- 0.055 — 0.085 and tension, and be care-
ing {0.00217 — ful about sticking of rear
0.00330} side.
0.026 — 0.067
Clearance between the connecting Be careful with the preci-
{0.0010 — 0.1 {0.0039} Replace the bearing.
rod bearing and crank pin sion of the crank pin.
0.0026}
Replace the one with
Contact surface of the connecting
defective contact or abra-
rod bearing and crank pin
sion.
0.008 — 0.020 Clearance should be wide
Clearance between the small end Replace the bushing or
{0.00031 — 0.05 {0.002} enough to turn smoothly
bushing and the piston pin the pin.
0.00079} with its big end held.
0A-28 General Information

Item to be checked Standard Service limit Repairing procedure Remarks

value
0.20 — 0.33
Axial play of the connecting rod and
{0.008 — 0.35 {0.014}
the crank pin
0.013}
Center distance between the big end
133.5 {5.256} Reference value
and small end
Torsion of holes on the big end and 0.05 {0.002} or
0.2 {0.008} Repair or replace.
small end (L = per 24 mm {0.945 in}) less
Parallelism of holes on the big end
0.075 {0.003}
and small end (L = per 100 mm 0.15 {0.006} Repair or replace.
or less
{3.937 in})
23 — 26 {2.3 Apply engine oil to the
Tightening torque of the bearing cap — 2.7/17.0 — thread of the bolt and the
bolt (N⋅m {kgf⋅m/lb⋅ft}) 19.2} → 100° seating surface of the nut,
— 115° and tighten.

Crankshaft

Item to be checked Standard value Service limit Repairing procedure Remarks

Uneven wear of the journal and the
0.05 {0.002} Replace the crankshaft.
pin
0.14
Wear of the journal φ60 {2.362} Replace the crankshaft.
{0.0055}
Wear of the pin φ46 {1.811} 0.13 {0.005} Replace the crankshaft.
Both ellipse and
Finishing precision of the journal and
taper:
the pin (taper and ellipse)
0.007 {0.00028}
Extrusion Use the one with extrusion
0.02 — 0.06 and tension, and be care-
Tension of the journal bearing
{0.0008 — ful about sticking of rear
0.00236} side.
0.029 — 0.072
Clearance between the journal and 0.11
{0.0011 — Replace the bearing.
the bearing {0.0043}
0.0028}
Measure at the front of
0.058 — 0.208
Replace the thrust bear- the thrust in No.2 jour-
Axial play of the crankshaft {0.0023 — 0.3 {0.012}
ing. nal portion of the crank-
0.0082}
shaft.
0.025 {0.00098}
Crankshaft runout 0.05 {0.002} Replace.
or less
Chamfer the warped ones
Ring gear and replace the remark-
ably damaged ones.
0.20
Balance of the crankshaft (N⋅cm Check the dynamic bal- (Reference value) At
{20/ 0.2778} or
{gf⋅cm/on⋅in}) ance. both ends of the journal
less
Apply engine oil to the Be sure that there is no
83.4 — 93.2 {8.5
Tightening torque of the crank bear- thread and the seating scratch or foreign object
— 9.5/61.5 —
ing cap bolt (N⋅m {kgf⋅m/lb⋅ft}) surface of the bolt, and pinched on the bearing
68.7}
tighten. cap match surface.
Be careful with the oil
Wear of the oil seal in the crankshaft Replace the oil seal when seal collapsed. (Apply
rear part there is oil leakage. oil sufficiently before
assembly.)
 General Information 0A-29
Camshaft

Item to be checked Standard Service limit Repairing procedure Remarks

value
Repair or replace the cam-
Uneven wear of the center journal 0.05 {0.002}
shaft.
φ51.92
Wear of the center journal φ52 {2.047} Replace the camshaft.
{2.044}
0.02 {0.0008}
Camshaft runout 0.1 {0.0039} Replace the camshaft.
or less
Inlet 6.13 {0.241} 5.83 {0.230} Repair light stepped wear
Height of the cam Replace the camshaft.
Exhaust 6.43 {0.253} 6.13 {0.241} of the cam.

Timing gear

Item to be checked Standard Service limit Repairing procedure Remarks

value
Crank gear/Idle
0.04 {0.0016} 0.2 {0.008}
Backlash of the gear
Replace the gear.
timing gear Idle gear/Cam-
0.03 {0.0012} 0.2 {0.008}
shaft gear
−0.004 —
Clearance between the crank gear +0.050
and the crankshaft {−0.00016 —
+0.0020}
Clearance between the camshaft 0 — 0.042
gear and camshaft {0 — 0.0017}
0.025 — 0.085
Clearance between the idle gear Replace the idle gear or
{0.00098 — 0.2 {0.008}
bushing and shaft the shaft.
0.00330}
Uneven wear of the idle gear shaft 0.1 {0.0039} Replace the gear shaft.
0.058 — 0.115
Play between front and back direc-
{0.0023 — 0.2 {0.008} Replace the thrust collar.
tion of the idle gear
0.0045}

Valve

Standard
Item to be checked Service limit Repairing procedure Remarks
value
φ6.85 If the valve should be
Wear of the inlet valve stem φ7 {0.276}
{0.270} replaced due to wear of
Replace the valve.
φ6.80 the valve seat, also
Wear of the exhaust valve stem φ7 {0.276} replace the valve guide.
{0.268}
0.023 — 0.056
Clearance between the inlet valve
{0.0009 — 0.2 {0.008}
stem and valve guide
0.0022} Replace the valve or valve
0.030 — 0.063 guide.
Clearance between the exhaust 0.25
{0.0012 —
valve stem and valve guide {0.0098}
0.0025}
Interference of the valve guide and Apply oil to the valve
0.023 {0.0009}
cylinder head guide and press-fit.

Thickness of IN 1 {0.039} 0.7 {0.028}

Replace the valve.
valve EX 0.8 {0.031} 0.5 {0.020}
0A-30 General Information

Standard
Item to be checked Service limit Repairing procedure Remarks
value
Height of the valve guide from the
9.5 {0.374} Reference value
cylinder head
Be careful not to damage
Lip of the valve stem oil seal φ6.5 {0.256} φ6.8 {0.268} Replace oil seal
the lip.
Tension (N {lb})
(When compressed
167 {38} 147 {33}
to installing length
29.9 mm {1.177 in})
Valve spring Replace the valve spring.
Free height 42.1 {1.657} 40.0 {1.575}
1.8 {0.071} or
Squareness 2.5 {0.098}
less
0.35 — 0.45
Valve clearance; inlet and exhaust
0.40 {0.016} {0.014 — Adjust.
(at cold condition):
0.018}
Repair light stepped wear
Contact surface of the valve stem Replace if there is exces-
and damage with the oil
end and the rocker arm sive wear or damage.
stone.
0.005 — 0.045
Clearance between the rocker arm Replace the rocker arm or
{0.0002 — 0.2 {0.008}
and the rocker arm shaft the shaft.
0.0018}
φ11.85
Wear of the rocker arm shaft φ12 {0.472} Replace.
{0.467}
0.3 {0.012}
Bend of the push rod Replace.
or less

Tappet

Standard
Item to be checked Service limit Repairing procedure Remarks
value
0.020 — 0.054
Clearance between the tappet and
{0.0008 — 0.1 {0.0039} Replace the tappet.
the cylinder block
0.0021}
φ20.97 —
φ20.92
Wear of the tappet 20.98 {0.8256 Replace the tappet.
{0.824}
— 0.8260}
Contact surface of the tappet and the Replace if there is exces- Repair light damage with
cam sive wear or deformation. the oil stone.

Air cleaner

Standard
Item to be checked Service limit Repairing procedure Remarks
value
Machine manufacturer
Condition of the air cleaner element
arrangement parts
 General Information 0A-31
Water pump

Item to be checked Standard Service Repairing procedure Remarks

value limit
0.008 — 0.010
Play of the water pump ball bearing (radius 0.2
{0.00031 — Replace.
direction) {0.008}
0.00040}
Pump speed: 2,800 rpm
Coolant temperature is nor-
mal. 70 4LE2N
Full pressure: 0.035 MPa
Discharge {3.5 m⋅Aq}
amount
(L/min) Pump speed: 1,900 rpm
Coolant temperature is nor-
mal. 61 4LE2X
Full pressure: 0.045 MPa
{4.5 m⋅Aq}
With two belts: Approx. 7.5 —
(approx. 98 N {22 lb}) 8.5 mm {0.295
— 0.335 in}
Approx. 5.5 —
Generator
Deflection of 6.0 mm {0.217
30A model
the fan belt — 0.236 in}
With one belt:
(approx. 98 N {22 lb}) Approx. 8.0 —
10.0 mm Generator
{0.315 — 50A model
0.394 in}
Replace the thermo-
Thermostat working start temperature (at
82°C {180°F} stat if its working is
barometric pressure)
incomplete.
The temperature when
Thermostat full-open temperature (at baromet- thermostat lift amount
95°C {203°F}
ric pressure) is 8.0 mm {0.315 in} or
more

Fuel feed pump

Standard Service
Item to be checked Repairing procedure Remarks
value limit
At 28.4 kPa {4.1 psi} 1.35 or more
Discharge
amount At 17.7 kPa {2.6 psi} 0.70 or more Repair or replace.
(L/min)
At 13.7 kPa {2.0 psi} 1.41 or more
Be sure that
Repair or replace
Airtight (98.1 kPa {14.2 psi}) there is no
when there is leakage.
leakage.
0A-32 General Information
Injection pump
Adjustment conditions

Pump part number 898030-5690

898096-5800
Counterclockwise (viewed from drive-
Revolution direction
end)
898095-5920 (NP-DLLA152PN381)
Nozzle
898069-0380 (NP-DLLA152PN375)
Nozzle holder ASM 897361-6960
Nozzle No.1 opening pressure (MPa
17.2 — 18.2 {2495 — 2640}
{psi})
Nozzle No.2 opening pressure (MPa
25.5 — 27.0 {3698 — 3916}
{psi})
Oil feed pressure (MPa {psi}) 0.05 {7.3}
Pipe
Outside diameter × inside diameter × φ6 {0.236} × φ2 {0.079} × 450 {17.717}
length (mm {in})
Inspecting oil JIS No.2 diesel fuel
Oil temperature °C {°F} 35 — 40 {95 — 104}

Injection amount adjustment

Rack position (adjustment

Pump speed Average injection amount
Pump part number point: A) Remarks
(rpm) (mm3/stroke)
(mm {in})
898030-5690 11.8 {0.465} ± 0.05 {0.002} 1,000 68.7 ± 0.5 Standard
898096-5800 11.1 {0.437} ± 0.05 {0.002} 900 37.2 ± 0.5 Standard

Generator
24V30A Mitsubishi Electric
Item to be checked Standard Service limit Repairing procedure Remarks
value
Shaft bend Replace the rotor.
Turn it by hand and check
Play of bearing Replace the bearing. that it rotates smoothly
and has no noise or play.
Outside diameter of the slip ring 22.7 {0.894} 22.1 {0.870} Replace the rotor.
Repair with a sand paper
Slip ring surface dirty or the like if there is dirt or
damage.
Brush Repair when the following
5.0 {0.197}
length 18.5 {0.728} occurs: the spring contact
(1.5
(amount of (10.0 {0.394}) surface of the brush is
{0.059})
extrusion) incomplete, the brush
Brush and brush spring pressure is not
spring even or not appropriate,
Tension N 4.8 — 6.0 2.2 the brush is excessively
{lb} {1.08 — 1.35} {0.49} worn or chipping, support-
ing degree of the brush
holder is not appropriate.
Output current (27 V 1,800 r/min) 18 A or more 18 A or less Replace.
 General Information 0A-33

Item to be checked Standard Service limit Repairing procedure Remarks

value
28 or less,
Regulated voltage by regulator (V) 28.5 or 29 or Replace the regulator.
more

24V50A Nikko Electric

Item to be checked Standard Service limit Repairing procedure Remarks
value
24.996 —
25.005 24.95
Wear of the shaft (front) Replace the rotor.
{0.9841 — {0.982}
0.9844}
16.996 —
17.012 16.95
Wear of the shaft (rear) Replace the rotor.
{0.6691 — {0.667}
0.6698}
Turn it by hand and check
Play of bearing Replace the bearing. that it rotates smoothly
and has no noise or play.
Output current (27 V 5000 rpm) 50 A or more 50 A or less
Regulated voltage by regulator (V) 27.5 — 29.5 Replace the regulator.

12V20A Hitachi, Ltd.

Item to be checked Standard Service limit Repairing procedure Remarks
value
Shaft bend Replace the rotor.
Turn it by hand and check
Play of bearing Replace the bearing. that it rotates smoothly
and has no noise or play.
Output current (12 V 5,000 r/min) 20 A or more 20 A or less Replace.
13.3 or less,
Regulated voltage by regulator (V) 13.3 — 14.3 or 14.3 or Replace the regulator.
more

Starter
24V3.2kW Mitsubishi Electric
Item to be checked Standard Service limit Repairing procedure Remarks
value
Wear of the outside diameter of com-
32 {1.26} 31.4 {1.236} Replace.
mutator
Uneven wear of the outside diameter 0.1 {0.0039}
— Replace.
of commutator or more
0.5 — 0.8
Depth of mica between commutator 0.2 {0.008}
{0.020 — Repair or replace.
segments or less
0.031}
Brush length 17.5 {0.689} 11 {0.433} Replace.
0.5 — 2.0 2.0 {0.079} Repair or replace if there
Pinion (gap) {0.020 — or more is excessive wear or chip-
0.079} ping.
0A-34 General Information

Item to be checked Standard Service limit Repairing procedure Remarks

value
Rotates smoothly when
the pinion is turned to the
Clutch action — — — drive direction, and locks
when turned to the inverse
direction.
No load test 3,750 r/min or 3,750 r/min
Repair or replace.
Revolution speed (23 V/80 A or less) more or less
12.94 N⋅m
12.94 N⋅m {1.3
Torque {1.3 kgf⋅m Repair or replace.
Load test kgf⋅m}
or less
18.6 V/250 A or less
Revolution 1,550 r/min or 1,550 r/min
Repair or replace.
speed more or less
Restraint test 47.07 N⋅m
47.07 N⋅m {4.8
Load Torque {4.8 kgf⋅m} Repair or replace.
kgf⋅m} or more
8 V/760 A or less or less

12V2.0kW DENSO
Item to be checked Standard Service limit Repairing procedure Remarks
value
Wear of the outside diameter of com-
35 {1.378} 34 {1.339} Replace.
mutator
Uneven wear of the outside diameter 0.1 {0.0039}
— Replace.
of commutator or more
0.55 — 0.85
Depth of mica between commutator 0.2 {0.008}
{0.021 — Repair or replace.
segments or less
0.033}
Brush length 15 {0.591} 12 {0.472} Replace.
Repair or replace if there
Pinion (gap) is excessive wear or chip-
ping.
Rotates smoothly when
the pinion is turned to the
Clutch action — — — drive direction, and locks
when turned to the inverse
direction.
No load test
4,000 r/min or 4,000 r/min
Revolution speed (11.5 V/100 A or Repair or replace.
more or less
less)
8.83 N⋅m
8.83 N⋅m {0.9
Torque {0.9 kgf⋅m} Repair or replace.
Load test kgf⋅m}
or less
7.6 V/400 A or less
Revolution 1,380 r/min or 1,380 r/min
Repair or replace.
speed more or less
Restraint test 16.67 N⋅m
16.67 N⋅m {1.7
Load Torque {1.7 kgf⋅m} Repair or replace.
kgf⋅m} or more
2.4 V/800 A or less or less
 General Information 0A-35
Preheating device

Item to be checked Standard Service limit Repairing procedure Remarks

value
Replace when there is an
Glow plug open circuit or a short cir-
cuit.

Oil pressure

Standard
Item to be checked Service limit Repairing procedure Remarks
value
At 1,000 rpm: 147 {21}
Lubrication oil pressure At 1,800 rpm: 294 {43}
(kPa {psi})
343 — 686 {50
At 2,200 rpm:
— 100}

Oil pump and relief valve

Item to be checked Standard Service limit Repairing procedure Remarks

value
0.28 — 0.41
Clearance between the pump body Replace the bushing,
{0.0110 — 0.4 {0.016}
and outer circle of the outer rotor rotor, or body.
0.0161}
Discharge amount (L/min)
(engine speed 2,700 rpm SAE#30
26.8
discharge pressure 392 kPa {57 psi}
oil temperature 50°C {122°F})
0.040 — 0.085
Replace the rotor or the
{0.0016 — 0.15 {0.006} 4LE2N
cover.
Axial clearance between the pump 0.0033}
cover and the rotor 0.040 — 0.087
Replace the rotor or the
{0.0016 — 0.15 {0.006} 4LE2X
cover.
0.0034}
Tip clearance between the inner rotor 0.15 {0.0059}
0.2 {0.008} Replace the rotor.
and the outer rotor or less
0.032 — 0.072
Clearance between the drive shaft
{0.0013 — 0.15 {0.006}
and the pump cover
0.0028}
φ21.9
Diameter of the drive shaft φ16 {0.629} Replace the shaft.
{0.862}
391 — 489
4LE2N
Relief valve starting {56.7 — 70.9}
Oil pump
pressure kPa {psi} 490 — 588
4LE2X
{71.1 — 85.3}
0A-36 General Information
Complete inspection

Standard
Item to be checked Service limit Repairing procedure Remarks
value
Perform for 30 minutes
“Grinding” drive of the engine
or more
Compression pressure of the cylinder
Coolant temperature: 70
(MPa {psi}) 3.04 {441} 2.5 {363} Repair.
— 85°C {158 — 185°F}
(approx. 250 rpm)
Difference between the compression ±5% or less to
Coolant temperature: 70
pressure of the cylinders the average Repair.
— 85°C {158 — 185°F}
(approx. 250 rpm) value
At 1,000 rpm: 147 {21}
Lubrication oil pressure At 1,800 rpm: 294 {43}
(kPa {psi})
343 — 686 {50
At 2,200 rpm:
— 100}
Output inspection 90% or more Assume that the actual
performance of the new
Fuel consumption inspection 110% or less engine is 100%.
 4LE2 Engine Mechanical 1A-1

Engine
4LE2 Engine Mechanical
Table of Contents
ISUZU Diesel Engine ............................................ 1A-2 Crankshaft Rear Oil Seal ....................................1A-78
Service Precautions ........................................... 1A-2 Components.....................................................1A-78
How to Read the Model...................................... 1A-3 Removal ...........................................................1A-78
Explanations on Functions and Operation ......... 1A-3 Installation ........................................................1A-79
Function Check .................................................. 1A-4 Torque Specifications.......................................1A-80
Specifications ................................................... 1A-12 Timing Gear Train ...............................................1A-81
Engine Accessories............................................. 1A-13 Components.....................................................1A-81
Components..................................................... 1A-13 Removal ...........................................................1A-81
Removal ........................................................... 1A-14 Inspection.........................................................1A-82
Installation ........................................................ 1A-15 Installation ........................................................1A-83
Torque Specifications....................................... 1A-17 Torque Specifications.......................................1A-85
Engine Exterior Equipment ................................. 1A-18 Camshaft............................................................. 1A-86
Components..................................................... 1A-18 Components.....................................................1A-86
Removal ........................................................... 1A-23 Removal ...........................................................1A-86
Installation ........................................................ 1A-29 Inspection.........................................................1A-87
Torque Specifications....................................... 1A-38 Installation ........................................................1A-89
Rocker Arm Shaft................................................ 1A-39 Torque Specifications.......................................1A-90
Components..................................................... 1A-39 Crankshaft ...........................................................1A-91
Removal ........................................................... 1A-40 Components.....................................................1A-91
Disassembly..................................................... 1A-40 Removal ...........................................................1A-91
Inspection......................................................... 1A-41 Disassembly.....................................................1A-92
Reassembly ..................................................... 1A-43 Inspection.........................................................1A-92
Installation ........................................................ 1A-44 Reassembly .....................................................1A-95
Torque Specifications....................................... 1A-45 Installation ........................................................1A-95
Cylinder Head ..................................................... 1A-46 Torque Specifications.......................................1A-97
Components..................................................... 1A-46 Cylinder Block .....................................................1A-98
Removal ........................................................... 1A-47 Components.....................................................1A-98
Disassembly..................................................... 1A-48 Removal ...........................................................1A-98
Inspection......................................................... 1A-48 Inspection.........................................................1A-99
Reassembly ..................................................... 1A-53 Installation ......................................................1A-100
Installation ........................................................ 1A-56 Special Tool ......................................................1A-101
Torque Specifications....................................... 1A-57 List of Special Tool.........................................1A-101
Piston, Connecting Rod ...................................... 1A-58
Components..................................................... 1A-58
Removal ........................................................... 1A-58
Disassembly..................................................... 1A-60
Inspection......................................................... 1A-60
Reassembly ..................................................... 1A-65
Installation ........................................................ 1A-66
Torque Specifications....................................... 1A-69
Flywheel .............................................................. 1A-70
Components..................................................... 1A-70
Removal ........................................................... 1A-70
Installation ........................................................ 1A-71
Torque Specifications....................................... 1A-72
Crankshaft Front Oil Seal.................................... 1A-73
Components..................................................... 1A-73
Removal ........................................................... 1A-73
Inspection......................................................... 1A-75
Installation ........................................................ 1A-75
Torque Specifications....................................... 1A-77
1A-2 4LE2 Engine Mechanical

ISUZU Diesel Engine

Service Precautions Service precautions specific to this engine
Service precautions about maintenance Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the nozzle
To prevent damage to the engine and ensure reliability
holder, are made with extreme precision. They are
of its performance, pay attention to the following in
therefore highly sensitive to foreign matter and the
maintaining the engine:
entry of foreign matter could cause serious damage.
• When taking down the engine on the ground, do Take extreme care not to allow foreign matter to enter.
not make the bearing surface of the oil pan touch When servicing the fuel system, every precaution must
directly the ground. Use a wood frame, for exam- be taken to prevent the entry of foreign material into the
ple, to support the engine with the engine foot and system.
the flywheel housing.
• Before beginning the service procedure, wash the
Because there is only a small clearance between
fuel line and the surrounding area.
the oil pan and the oil pump strainer, it can dam-
age the oil pan and the oil strainer. • Perform the service procedures with clean hands.
Do not wear work gloves.
• When the air duct or air cleaner is removed, cover
the air intake port to prevent foreign matter from • Immediately after removing the fuel hose and/or
getting into the cylinder. If foreign matter gets in, it fuel pipe, carefully tape vinyl bags over the
can considerably damage the cylinder and others exposed ends of the hose or pipe.
while the engine is operating. • If parts are to be replaced (fuel hose, fuel pipe,
• When maintaining the engine, never fail to remove etc.), do not open the new part packaging until
the battery ground cable. Otherwise, this may installation.
damage the wire harness or electrical parts. If you
need electricity on for the purpose of inspection, Work procedure
for instance, watch out for short circuits and others. • The fuel opening must be quickly sealed when
• Apply engine oil to the sliding contact surfaces of removing the fuel pipe, injection pipe, nozzle
the engine before reassembling it. This ensures holder, and injection pump.
adequate lubrication when the engine is first • The eyebolts and gasket must be stored in a clean
started. parts box with a lid to prevent adhesion of foreign
• When valve train parts, pistons, piston rings, con- matter.
necting rods, connecting rod bearings or crank- • Fuel leakage could cause fires. Therefore, after
shaft journal bearings are removed, put them in finishing the work, wipe off the fuel that has leaked
order and keep them. out and make sure there is no fuel leakage after
• When installing them, put them back to the same starting the engine.
location as they were removed.
• Gaskets, oil seals, O-rings, etc. must be replaced
with new ones when the engine is reassembled.
• As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust may be
clung to them. Then, apply the designated liquid
gasket to each place anew before assembly.
• Surfaces covered with liquid gasket must be
assembled within 5 minutes of gasket application.
If more than 5 minutes have elapsed, remove the
existing liquid gasket and apply new liquid gasket.
• When assembling or installing parts, fasten them
with the specified tightening torque so that they
may be installed properly.
 4LE2 Engine Mechanical 1A-3
How to Read the Model

WSLE0422

Name
1. Stamped Engine Number

Explanations on Functions and Operation EGR system

Cylinder block Based on coolant temperature and engine speed, it is
controlled by EGR cut controller to purify exhaust by
The cylinder block is cast-iron with the center distance
recycling part of it.
of each bore being equal and is of the highly rigid, sym-
Its main components include an EGR cut solenoid, an
metrical structure with the crankshaft center being the
EGR cooler and various sensors.
center.
Connecting rod cap bolt
Piston
Do not pull out the connecting rod cap bolt from the
The piston is aluminum-alloy and an autothermatic pis-
connecting rod except when you need to replace it.
ton with a strut cast, while the combustion chamber is a
round reentrant type.
Nozzle holder
Cylinder head Multi-hole type nozzle is used for the nozzle holder.
The cylinder head is cast-iron and there are two valves
per cylinder. The angular tightening method of the cyl-
Sedimenter
inder head bolt further increases reliability and durabil- Sedimenter gets rid of water by making use of the dif-
ity. ference in specific gravity between diesel oil and water.

Crankshaft Preheating system

The crankshaft which is stamped “N” on the front end The preheating system consists of the glow plug timer,
surface is made of tufftride. the glow plugs and the glow indicator lamp. The pre-
heating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.
1A-4 4LE2 Engine Mechanical
Lubrication system 2. Remove the cylinder head cover and check
whether the No.1 cylinder is in the compression
It is an oil filter with full-flow bypass, which uses a
top dead center position or in the exhaust top dead
water-cooled oil cooler and oil jet to cool the piston.
center position.
The cylinder is in the compression top dead center
Function Check position if both intake and exhaust valves are
closed. The cylinder is in the exhaust top dead
Inspection/adjustment of valve clearance center position if both intake and exhaust valves
To do this work, use the thickness gauge when the are open.
engine is cold.
1. Rotate the crankshaft over 360 degrees into a
proper direction (clockwise), and set the mark
groove of the crank pulley to the TDC mark (cast)
of the timing gear case cover.

1 2

2
1

WSLE0022

Name
1. Intake of No.1 Cylinder
2. Exhaust of No.1 Cylinder

WSLE0021 3. Measure the clearance of the valve with ❍ mark or

Name × mark in the table, depending on the status of the
1. TDC Mark No.1 cylinder. If the clearance is not the standard
2. Mark Groove value, adjust it to the standard value using the
adjusting screw.

CAUTION:
To measure the clearance, use the thickness gauge
when the engine is cold.

Valve clearance standard mm {in}

value
Inlet valve 0.40 ± 0.05 {0.016 ± 0.002}
Exhaust valve (at cold condition)
 4LE2 Engine Mechanical 1A-5

WSLE0020

Name
1. Adjusting Screw
2. Lock Nut

4. Rotate the crankshaft again into a proper direction,

and set the mark in the same way as 1. after 3. is
completed. Then measure and adjust the clear-
ances of the remaining valves.

CAUTION: WSLE0405

• Rocker arm is die-cast aluminum. So do not 2. Remove the cylinder head cover and check
over-tighten the rocker arm when tightening the whether the No.1 cylinder is in the compression
adjusting screw. top dead center position or in the exhaust top dead
center position. The cylinder is in the compression
• The load of the used valve spring is low. So do
top dead center position if both intake and exhaust
not push down the spring when measuring or
valves are closed. The cylinder is in the exhaust
adjusting the clearance.
top dead center position if both intake and exhaust
Adjustment table valves are open.
Make the No.1 cylinder to the compression top
Cylinder No. 1 2 3 4 dead center position.
Valve arrange- IN EX IN EX IN EX IN EX 3. Measure and adjust the valve clearance of the
ment No.1 cylinder.
No.1 cylinder 4. Rotate the crank 180 degrees clockwise from the
compression position in step 3, and align the mark groove (2)
❍ ❍ ❍ ❍
top dead center with the TDC mark of the timing gear case cover.
position Measure and adjust the valve clearance of the
No.1 cylinder No.3 cylinder.
exhaust top 5. Rotate the crank 180 degrees clockwise from the
× × × ×
dead center position in step 4, and align the mark groove (1)
position with the TDC mark of the timing gear case cover.
Measure and adjust the valve clearance of the
Type of the crank pulley that has two mark grooves No.4 cylinder.
on outer circumference 6. Rotate the crank 180 degrees clockwise from the
Adjustment procedure position in step 5, and align the mark groove (2)
1. Rotate the crankshaft to a proper direction (clock- with the TDC mark of the timing gear case cover.
wise) of the engine, and set the mark groove (1) of Measure and adjust the valve clearance of the
the crank pulley to the TDC mark of the timing gear No.2 cylinder.
case cover.
1A-6 4LE2 Engine Mechanical
3. Install the delivery valve holder and tighten it, leav-
Cylinder No. 1 2 3 4 ing the delivery valve and spring removed.
Valve arrange- IN EX IN EX IN EX IN EX Tightening torque:
ment 39.2 — 44.1 N⋅m {4.0 — 4.5 kgf⋅m/28.9 — 32.5
Step 3: lb⋅ft}
Crank pulley
4. Turn the starter switch to the drive position with the
alignment ❍ ❍
groove posi-
lever of the sedimenter in the open position. Then
tion (1) rotate the crankshaft slowly feeding fuel by the
electromagnetic pump, the gap with the fuel tank,
Step 4: the feed pump lever, etc. And when the fuel stops
Crank pulley flowing from the delivery holder and bulging at the
alignment ❍ ❍
dent on top, stop the crankshaft rotating.
groove posi-
tion (2)
Note:
Step 5: Take extreme care to rotate the crankshaft as slowly as
Crank pulley possible and not to miss the position where the fuel
alignment ❍ ❍ stops bulging.
groove posi-
tion (1) 5. Check the degree in the timing mark on the timing
Step 6: gear case where the mark groove of the crank pul-
Crank pulley ley is positioned in above 4. status.
alignment ❍ ❍ Adjust if the value is out of the standard value of
groove posi- the injection timing.
tion (2)
* Injection timing BTDC 2°
Inspection and adjustment of injection timing
Note:
1. Remove the No.1 cylinder injection pipe.
Injection timing varies depending on the machine spec-
2. Then remove the delivery valve holder of the No.1 ification.
cylinder injection pump, and pull out the delivery
valve and the delivery spring.

1 2

4
1

WSLE0021
WSLE0026 Name
Name 1. TDC Mark
1. Delivery Valve Holder 2. Mark Groove
2. Delivery Spring
3. Delivery Valve
4. Injection Pump
 4LE2 Engine Mechanical 1A-7
6. Adjust injection timing by the shim between the 7. Assemble removed delivery valve to the injection
injection pump and the cylinder block. pump after cleaning, and tighten the delivery
The following nine types of identifying symbols are holder to the specified torque.
stamped (or sealed) on the shim.
Tightening torque:
The identifying symbols and thickness mm {in} 39.2 — 44.1 N⋅m {4.0 — 4.5 kgf⋅m/28.9 — 32.5
of the shim lb⋅ft}
Symbol Thick- Symbol Thick- Symbol Thick- CAUTION:
ness ness ness Be careful with dirt getting inside when removing
2 0.2 5 0.5 8 0.8 and installing the delivery valve or spring.
{0.008} {0.020} {0.031}
8. Install the injection pipe to the injection pump and
3 0.3 6 0.6 10 1.0 the nozzle holder, and tighten it with the sleeve
{0.012} {0.024} {0.039}
nut.
4 0.4 7 0.7 12 1.2 a. Screw the thread portion of the sleeve nut two
{0.016} {0.028} {0.047} or three turns by your hand.
b. Hold the delivery valve holder of the injection
CAUTION: pump with a wrench and tighten the sleeve nut
Adjust the shims for each injection pump of four securely.
cylinders at the same time.
Tightening torque:
Note: 14.7 — 24.5 N⋅m {1.5 — 2.5 kgf⋅m/10.8 — 18.1
If the shim is thickened by 0.1 mm {0.0039 in}, the lb⋅ft}
injection timing is delayed for approx. 0.6 degree, and if
thinned by 0.1 mm {0.0039 in}, put forward for approx. Important:
0.6 degree. If over-tightening the delivery valve holder, the rack
cannot move smoothly as the plunger and the
housing are compressed. Therefore, when tighten-
ing the sleeve nuts of the injection pipe, hold the
delivery valve holder with a wrench to prevent
corotation.

1
2
3
5
1

4 2

WSLE0027

Name
1. Injection Pump
2. Cylinder Block
3. Shim
4. Knock Hole WSLE0159

5. Identifying Symbol Name

1. Injection Pipe
2. Nozzle Holder
3. Injection Pump
1A-8 4LE2 Engine Mechanical
Inspection of compression pressure
1. Warm-up the engine.
2. Disconnect the battery cable from the negative ter-
minal and remove all the glow plugs.
3. Disconnect the wire connector of the solenoid for
engine stopping.
4. Install the battery cable to the negative terminal.
5. Install an adapter and a gauge of a compression
gauge (special tool).
Special tool
Compression gauge (with adapter)
5-8840-2675-0
Adapter
5-8840-9029-0

1
Perform the measurement described above for all
cylinders. If the compression pressure is the ser-
vice limit or less, overhaul the engine.
2
CAUTION:
• Be sure to measure for all cylinders.
• Be sure to use the full-charged battery to main-
tain the engine speed of 250 rpm or more.

Injection nozzle
Use the nozzle tester to check the injecting condition.

WARNING:
WSLE0029
Do not put hands close to the nozzle hole area
when checking.
Name
Diesel oil may permeate to your body and cause
1. Compression Gauge
blood poisoning due to high pressure injection.
2. Adapter

6. Turn the starter until the indicator of compression

gauge becomes stable and measure the compres-
sion pressure.

Compression pressure (250 rpm) MPa {psi}

Standard value Service limit Difference between
cylinders
3.04 {441} 2.5 {363} ±5 % or less to the
average value

WSLE0033
 4LE2 Engine Mechanical 1A-9
Injecting condition
Judge the nozzle condition by injecting condition.

1 2 3

WSLE0028

Name
WSLE0032
1. Injection Pump
Name
1. Good
Electromagnetic pump inspection procedure
2. Defective (fine or clogged)
3. Defective (dropping) 1. Turn the key switch to ON, and check for pulsation
in the fuel hose.
• It is normal if pulsation exists.
Note:
2. Disconnect the electromagnetic pump connector,
• Do not overhaul the engine as a two-step valve
and connect 24 V power supply to the electromag-
pressure nozzle is adapted to this engine.
netic pump side to check if the pump operates.
• If a overhaul of the nozzle and inspection and
• If it operates properly, there may be open cir-
adjustment of the injection pressure are required,
cuit, short circuit or poor contact in the
contact a BOSCH service center.
machine-side harness. Repair the faulty part,
and check again from Step 1.
Bleeding air from fuel system
• If the electromagnetic pump does not operate,
In case of automatic air bleed system replace the pump.
Turn the starter switch to the drive position. The elec-
tromagnetic pump operates, the fuel is pressure-fed to
the fuel pipe and the leak-off pipe, and the air in the fuel
system is automatically bled out.

In case of other than automatic air bleed system

Bleed air from the fuel pipe eyebolt of the No.1 cylinder
injection pump, the leak-off pipe eyebolt of the injection 1

nozzle, and the air bleed plug of the fuel filter in the 2

order from the part installed to lower portion, feeding

the fuel by the electromagnetic pump, the gap with the
fuel tank, the feed pump lever, etc.

TSHK0106

Name
1. Electromagnetic Pump
2. + Terminal
3. - Terminal
1A-10 4LE2 Engine Mechanical
3. Blow air into the inlet of the electromagnetic pump Fan belt
with your mouth.
Tension inspection
• The internal seal may be stuck. Blow air to elim-
Push between the fan pulley and the generator pulley
inate sticking.
with your finger (about 98 N {22 lb}). If the deflection is
out of the standard value, adjust the belt tension.

Deflection mm {in}
2 Standard With two belts: approx. 7.5 — 8.5 {0.295 —
value 0.335}
With one belt (generator 30A):
Approx. 5.5 — 6.0 mm {0.217 — 0.236 in}
With one belt (generator 50A):
Approx. 8 — 10 {0.315 — 0.394}

TSHK0107

Name
2
1. Fuel Inlet Port
5
2. Fuel Outlet Port
3

4. Install the removed parts, and check again from

Step 1. 4

WSLE0025

Name
1. Fan Pulley
2. Deflection
3. Generator Pulley
4. Crank Pulley
5. Fan Belt

Adjustment procedure
1. Loosen the adjusting plate which fixes the genera-
tor, and the mounting bolt of the generator.
2. Adjust the adjusting bolt to the standard value and
fix the generator at this position.
Be sure to tighten the mounting bolts which you
have loosened.

Note:
Recheck the tension of the belt after fixing the genera-
tor since the tension varies in some degree when the
generator gets fixed.
Tightening torque:
M8 bolt or nut: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/
13.7 — 20.9 lb⋅ft}
M10 bolt or nut: 41.2 — 55.0 N⋅m {4.2 — 5.6 kgf⋅m/
30.4 — 40.6 lb⋅ft}
 4LE2 Engine Mechanical 1A-11

3 WSLE0204

Name
1. Nut
2. Adjusting Bolt
3. Mounting Bolt
1A-12 4LE2 Engine Mechanical
Specifications

Engine name
4LE2X 4LE2N
Item
Engine structure type 4-cycle, water cooled-type, inline four-cylinder, OHV type
Cylinder number − bore × stroke (mm {in}) 4 − 85{3.35} × 96{3.78}
Total displacement (L {cu⋅in}) 2.179 {133}
Compression ratio 18.3:1 18.8:1
Combustion chamber type Direct injection
Overall length × overall width × overall height * 756.3{29.78} × 557{21.93} × 675.4{26.6} × 455.7{17.9} ×
(mm {in}) 747.3{29.42} 620.7{24.4}
Dry weight (kg {lb}) * 210 {463} * 160 {352.8}
Firing order 1—3—4—2
Fuel injection timing (BTDC) (at stop) * 2° * 3°
Compression pressure (MPa {psi}) 3.04 {441} / 250 rpm
Intake 0.40 {0.016}
Valve clearance (at cold condition) air
(mm {in})
Exhaust 0.40 {0.016}
Open (before top 15°
Intake dead center)
valve Closed (after bot- 29°
Opening/clos- tom dead center)
ing period of
valve Open (before bot- 40°
Exhaust tom dead center)
valve Closed (after top 16°
dead center)
Injection pump type Bosch type, PFR1KX model, four
Governor type Centrifugal type, all speeds controlled
Nozzle type Hole type (KBDL model)
Injection pressure (MPa {psi}) * First step: 16.7 {2422}
Second step: 25.0 {3626}
Fuel type Diesel (JIS K2204)
Cooling method Forced circulation, water cooling pressurization type
Cooling fan * φ500 × 8 pieces
Coolant amount (L {qts}) Approx. 4.3 {4.5} (Engine only) Approx. 2.8 {3.0} (Engine only)
Lubrication oil amount: total (L {qts}) * Approx. 12.1 {12.8} at MAX, 9.3 * Approx. 8.4 {8.9} at MAX, 5.9 {6.2}
{9.8} at MIN at MIN
Lubricant type (API service category) CD or CF-4
* (CE, CF, CH-4, CI-4 or CI-4 Plus)
Generator output (V — A) * 24 — 30 (Mitsubishi) * 12 — 20 (Hitachi)
* 24 — 50 (Nikko)
Starter output (V — kW) * 24 — 3.2 (Mitsubishi) * 12 — 2.0 (DENSO)
Recommended battery (rating) 95D31R 64 (five hour rating), the machine manufacturer arrangement

Caution: This specification may be changed partially without notice.

* mark may vary depending on each machine. Refer to the machine manufacturer specification.
 4LE2 Engine Mechanical 1A-13

Engine Accessories
Components

1
5
4

3
2

1 10

WSLE0312

Name
1. Cooling Fan 6. Fan Belt
2. Fan Clutch 7. Starter
3. Fan Clutch Set Plate 8. Adjusting Plate
4. Spacer 9. Generator
5. Fan Pulley 10. Generator Bracket
1A-14 4LE2 Engine Mechanical
Removal • Remove the bolts, and remove the cooling fan
and the spacer. (Without the fan clutch)
1. Remove the cooling fan.
• Remove the nuts and remove the cooling fan
from the fan clutch set plate. (With the fan
clutch) 2
• Remove the nuts and remove the fan clutch
from the cooling fan. (With the fan clutch) 3

• Remove the bolts and remove the fan clutch set

plate and the spacer. (With the fan clutch)

4
3
5
2
1

WSLE0345

Name
1. Cooling Fan
2. Spacer
3. Fan Belt

1 2. Loosen the mounting bolts of the generator and of

the adjusting plate, loosen the belt tension, and
WSLE0208 remove the fan belt.
Name 3. Remove the mounting bolts of the fan pulley, and
1. Cooling Fan remove the fan pulley from the water pump.
2. Fan Clutch 4. Remove the generator together with the adjusting
3. Fan Clutch Set Plate plate.
4. Spacer
5. Fan Belt

2
3

WSLE0209

Name
1. Fan Pulley
2. Adjusting Plate
3. Generator

5. Remove the generator bracket.

6. Remove the starter.
 4LE2 Engine Mechanical 1A-15
Installation
1. Install the starter to the flywheel housing and
tighten to the specified torque.
Tightening torque:
93.2 — 113 N⋅m {9.5 — 11.5 kgf⋅m/68.7 — 83.3 1
lb⋅ft}
2

WSLE0166

Name
1. Water Pump
1 2. Adjusting Plate
3. Generator

4. Install the fan pulley to the water pump and tighten

WSLE0165
two positions.
Name Tightening torque:
1. Starter 7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7 lb⋅ft}
5. Install the fan belt to each pulley.
2. Install the generator bracket.
Tightening torque:
M8 bolt: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 —
20.9 lb⋅ft}
M10 bolt: 41.2 — 55.0 N⋅m {4.2 — 5.6 kgf⋅m/30.4
— 40.6 lb⋅ft} 1
3. Install the generator.
a. Temporarily install and tighten the adjusting
plate with the water pump.
b. Install the lower side of the generator to the
2
generator bracket and temporarily tighten the
bolts and nuts.
c. Install the mounting bolt to the upper part of the 3
generator through the adjusting plate. (Tempo-
rarily tighten)

WSLE0167

Name
1. Fan Pulley
2. Water Pump
3. Fan Belt
1A-16 4LE2 Engine Mechanical
6. Adjust the tension of the fan belt.
Move the generator installation position outside,
adjust the belt deflection to the specified value,
4
and tighten the generator and the adjusting plate.

mm {in} 3

Deflection With two belts: approx. 7.5 — 8.5 {0.295 — 2

(Push 0.335} 1
between the With one belt (generator 30A):
pulleys by 98 Approx. 5.5 — 6.0 mm {0.217 — 0.236 in}
N {22 lb}) With one belt (generator 50A):
Approx. 8 — 10 {0.315 — 0.394}

Tightening torque:
M8 bolt or nut: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/
13.7 — 20.9 lb⋅ft}
M10 bolt or nut: 41.2 — 55.0 N⋅m {4.2 — 5.6 kgf⋅m/
30.4 — 40.6 lb⋅ft}
WSLE0169

Name
1. Cooling Fan
2. Fan Clutch
3. Fan Clutch Set Plate
4. Spacer

• Assemble the spacer and install the cooling fan.

(Without the fan clutch)
Tighten this part to the torque according to the
tightening torque specification table in this
workshop manual. (Find the torque value
{medium value — upper limit} depending on a
screw size against the symbols on the bolt
head.)

WSLE0168
1
7. Install the cooling fan. 2

• Install the fan clutch set plate and the spacer.

(With the fan clutch)
Tightening torque:
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
lb⋅ft}
• Install the fan clutch to the cooling fan.
Tightening torque:
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
lb⋅ft}
• Install the cooling fan to the fan clutch set plate.
(With the fan clutch) WSLE0346

Tightening torque: Name

18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9 1. Cooling Fan
lb⋅ft} 2. Spacer
 4LE2 Engine Mechanical 1A-17
Torque Specifications

N m (kg m / lb ft)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

93.2 - 113 (9.5 - 11.5 / 68.7 - 83.3)

M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7) 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)

M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)

M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)
M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)

WSLE0426
1A-18 4LE2 Engine Mechanical

Engine Exterior Equipment

Components
4LE2X

3 4 5 6 7

11

10

WSLE0035

Name
1. Water Pump 7. EGR Cooler Inlet Pipe
2. Water Pump Outlet Pipe (Thermostat) 8. Turbocharger
3. Exhaust Manifold 9. Oil Level Gauge
4. Cylinder Head Cover 10. Turbocharger Oil Return Pipe
5. Air Inlet Pipe 11. Turbocharger Oil Feed Pipe
6. Intake Chamber
 4LE2 Engine Mechanical 1A-19

1 2 3 4

9 5

WSLE0036

Name
1. Injection Pipe 6. Injection Pump Housing Cover
2. Leak-off Pipe 7. Oil Cooler
3. Fuel Pipe 8. Solenoid ASM
4. Fuel Hose 9. EGR Cooler Bracket
5. Injection Pump
1A-20 4LE2 Engine Mechanical

4 3 2 1

WSLE0359

Name
1. PCV Valve 4. EGR Cooler Outlet Pipe
2. Orifice Plate 5. EGR Cut Solenoid
3. Valve Case 6. EGR Cooler
 4LE2 Engine Mechanical 1A-21
4LE2N

3 4
2
5

WSLE0427

Name
1. Water Pump 5. Air Inlet Pipe
2. Water Pump Outlet Pipe (Thermostat) 6. Starter
3. Exhaust Manifold 7. Water Drain Plug
4. Cylinder Head Cover 8. Generator
1A-22 4LE2 Engine Mechanical

4
3 5

10

9 7
8

WSLE0428

Name
1. Injection Pump 6. Oil Filler Cap
2. Injection Pipe 7. Fuel Filter
3. Nozzle Holder 8. Oil Drain Plug
4. Fuel Hose 9. Oil Filter
5. Thermostat Housing
 4LE2 Engine Mechanical 1A-23

3 2

WSLE0429

Name
1. Oil Filler Cap 3. Injection Pump
2. Cooling Fan

Removal
1. Disconnect the drain plug of the oil pan and drain
the engine oil.
2. Loosen the water drain cock on the cylinder block
to drain the coolant remaining in the engine.

2
1 WSLE0207

Name
1. Drain Plug (Oil)
2. Drain Cock (Coolant)
1A-24 4LE2 Engine Mechanical
3. Remove the EGR cooler outlet pipe. 8. Remove the rear hanger from the EGR cooler
bracket.
Note:
After removing the pipe, seal so that foreign matter
3
does not enter.
2

4. Remove the connector of the EGR cut solenoid,

and remove the orifice plate, the valve case and
the EGR cut solenoid.

2 3 1

1
5 4
WSLE0334

4
Name
1. EGR Cooler Water Inlet Hose
2. EGR Cooler
3. EGR Cooler Water Outlet Hose
4. Rear Hanger
5. EGR Cooler Bracket
WSLE0333

Name 9. Remove the EGR cooler inlet pipe.

1. EGR Cut Solenoid
2. Valve Case Note:
3. Orifice Plate After removing the pipe, seal so that foreign matter
4. EGR Cooler Outlet Pipe does not enter.

5. Remove the EGR cooler water inlet hose and the

outlet hose.
6. Remove the EGR cooler.

Note:
After removing the EGR cooler, seal so that foreign
matter does not enter.

7. Remove the EGR cooler bracket from the cylinder

head.

WSLE0335

Name
1. EGR Cooler Inlet Pipe

10. Remove the turbocharger oil feed pipe and the

return pipe.
11. Remove the exhaust adapter from the turbo-
charger.
 4LE2 Engine Mechanical 1A-25
12. Remove the turbocharger ASM from the exhaust 17. Remove the mounting bolts and nuts of the
manifold. exhaust manifold, and remove the manifold and
the gaskets.

3
2
1

4
3
4

6
7
WSLE0336

Name WSLE0210

1. Turbocharger Oil Return Pipe Name

2. Turbocharger Oil Feed Pipe 1. PCV Valve
3. Turbocharger 2. Intake Chamber
4. Exhaust Adapter 3. Cylinder Head Cover
4. Air Inlet Pipe
13. Remove the PCV valve from the intake chamber. 5. Gasket
14. Remove the air inlet pipe from the intake chamber. 6. Exhaust Manifold
15. Remove the intake chamber from the cylinder 7. Gasket
head.
18. Disconnect the water outlet pipe and pull out the
16. Remove the mounting bolts (M6×1.0, 15 bolts) of thermostat.
the head cover, and remove the head cover
together with the gasket from the cylinder head.
• Remove the baffle plate from the cylinder head
cover.
1A-26 4LE2 Engine Mechanical
19. Remove the water pump from the cylinder head 21. Disconnect the leak-off pipe and remove the pack-
and the cylinder block. (M8: 5 bolts, 2 nuts) ing.

Note: CAUTION:
The water pump is installed to both the cylinder head Always put a cap to prevent dust from getting in
and the cylinder block. the delivery valve holder and the nozzle holder.

22. Remove the eyebolt and disconnect the fuel pipe.

CAUTION:
Always put a cap to prevent dust from getting in
the delivery valve holder and the nozzle holder.
2

1
3

1 2

6 4

WSLE0211
5
Name
1. Thermostat
2. Water Outlet Pipe
3. Packing
4. Water Pump
WSLE0037

20. Loosen the sleeve nuts on the nozzle holder side Name
and on the injection pump side and remove the 1. Leak-off Pipe
injection pipe. 2. Fuel Pipe
3. Eyebolt
Important: 4. Nozzle Holder
If over-tightening the delivery valve holder, the rack 5. Injection Pump
cannot move smoothly as the plunger and the 6. Injection Pipe
housing are compressed. Therefore, when loosen-
ing the sleeve nuts of the injection pipe, hold the 23. Remove the solenoid ASM inserted in the back of
delivery valve holder with a wrench to prevent the injection pump installation part of the cylinder
corotation. block.

CAUTION: Note:
Always put a cap to prevent dust from getting in Take care when removing it since liquid gasket is used.
the delivery valve holder and the nozzle holder.
 4LE2 Engine Mechanical 1A-27
24. Remove the housing cover of the injection pump 25. Remove the injection pump.
installation part. a. Align the hole of the fuel cut lever with the hole of
Since the liquid gasket is applied to the mating sur- the governor cover, and then insert a pin (φ6 mm
face of the cylinder body, insert a bolt to the hole {0.236 in}) to the hole to hold the fuel cut lever.
for M8 × 1.25 thread on the cover to remove the
housing cover.
Do not extract the two stud bolts since the sealant
is attached to them.
1
Note: 2
Take care when removing it since liquid gasket is used.

3
3

WSLE0041

Name
2 1. Fuel Cut Lever
2. Pin (φ6 mm {0.236 in})
1 3. Governor Cover

b. Make sure that the pin groove of the control link

is aligned with the center of the injection pump.
WSLE0039

Name CAUTION:
1. Solenoid ASM If the pin groove of the control link is not aligned
2. Housing Cover with the center of the injection pump, you may not
3. Stud Bolt remove the injection pump because the rack pin of
the injection pump is stuck to the cylinder block.

1 2

2 3

WSLE0040

Name WSLE0042
1. Housing Cover
Name
2. M8 × 1.25 for Replacer
1. Control Link
2. Center Position of Injection Pump
3. Rack Pin of Injection Pump
1A-28 4LE2 Engine Mechanical
c. Remove the injection pump, and remove the 26. Remove the control link.
shim inserted in the pump installation part. Pull out the snap pin on the connecting part to the
link plate of the governor assembled in the timing
CAUTION: gear case.
• Put the removed shim and the injection pump
together, attach a tag with cylinder number, and Note:
check the thickness. Take care not to lose the snap pin.
The removed shim cannot be reused.
• Do not extract the eight studs since the sealant
is attached to them.
1

1 2

2 3

4
3

WSLE0212

Name
1. Control Link
2. Link Plate (Governor)
WSLE0043
3. Snap Pin
Name
1. Injection Pump ASM
27. Disconnect the oil cooler water outlet hose and the
2. Shim
inlet hose.
3. Cylinder Block
4. Stud 28. Disconnect the water hose (between water pipe
and water pump).

WSLE0337

Name
1. Water Hose
2. Oil Cooler Water Outlet Hose
3. Oil Cooler Water Inlet Hose
 4LE2 Engine Mechanical 1A-29
29. Remove the water pipe from the rocker arm Installation
bracket.
1. Insert the oil level gauge.
2. Install the oil cooler ASM to the cylinder block.
• Install the packing to the oil cooler ASM and the
center bolt.
Tightening torque:
Center bolt: 24.5 — 34.3 N⋅m {2.5 — 3.5 kgf⋅m/
18.1 — 25.3 lb⋅ft}
3. Install the oil cooler cover to the oil cooler.
• Install the O-ring to the oil cooler cover.
Tightening torque:
24.5 — 34.3 N⋅m {2.5 — 3.5 kgf⋅m/18.1 — 25.3
lb⋅ft}

WSLE0338

Name
1. Water Pipe

30. Remove the plug, and remove the oil cooler cover
from the oil cooler. 5
31. Remove the center bolt, and remove the oil cooler
ASM from the cylinder block.

1
2
3
4

WSLE0213

Name
1. Oil Cooler ASM
5
2. Center Bolt
3. Oil Cooler Cover
4. Plug
5. Packing

1
2 4. Install the water pipe to the rocker arm bracket.
3
4 Tightening torque:
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
lb⋅ft}
WSLE0213

Name
1. Oil Cooler ASM
2. Center Bolt
3. Oil Cooler Cover
4. Plug
5. Packing

32. Pull out the oil level gauge.

1A-30 4LE2 Engine Mechanical

WSLE0338 WSLE0212

Name Name
1. Water Pipe 1. Control Link
2. Link Plate (Governor)
5. Install the water hose (between water pipe and 3. Snap Pin
water pump).
6. Install the oil cooler water outlet hose and the inlet 8. Install the injection pump.
hose with a white paint applied area in the oil a. Align the hole of the fuel cut lever with the hole
cooler side. of the governor cover, insert a pin (φ6 mm
{0.236 in}) to the hole and get the lever upright.
(Control link is positioned on the center.)

CAUTION:
1 If the control link is not positioned on the center,
you may fold the link when installing the injection
pump.
4

2
2 4
3
3
1

WSLE0339

Name
1. Water Hose
2. Oil Cooler Water Outlet Hose
3. White Paint Applied Area
4. Oil Cooler Water Inlet Hose

7. Install the control link.

WSLE0151
a. Insert the control link from the back to the con-
Name
necting hole of the injection pump of the cylin-
1. Control Link
der block, align it with the guide pin in the
2. Center Position of Injection Pump
connecting hole and assemble.
3. Pin (φ6 mm {0.236 in})
b. Assemble the pin part of the control link to the 4. Fuel Cut Lever
link plate hole of the governor assembled in the
timing gear case, and fix it with the snap pin.
 4LE2 Engine Mechanical 1A-31
b. Align the shim with each stud and the knock
pin, check the thickness of the shim and install
it. (Shim thickness; Refer to 1A-4, “Function
Check, ISUZU Diesel Engine”)

CAUTION:
Install a new shim whose thickness is the same as 2
one being removed when disassembling.
1
3

WSLE0153

Name
1. Control Link
3 2. Center Position of Injection Pump
3. Rack Pin

f. Remove the pin (φ6 mm {0.236 in}) inserted into

the fuel cut lever, and make sure that the fuel
cut lever moves smoothly.
WSLE0152
9. Install the injection pump housing cover.
Name
Apply the liquid gasket (TB1207C) to the housing
1. Injection Pump ASM
cover and install it to the cylinder block on the
2. Shim
injection pump side.
3. Cylinder Block
Tightening torque:
c. Align the rack pin of the injection pump with the 7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7 lb⋅ft}
center position of the pump.
d. Insert the injection pump along with the two Note:
studs, align the knock hole with the knock pin of • Remove the sealant attached to the housing cover
the cylinder block, and assemble them. installation part of the cylinder block with a packing
e. Make sure that the rack pin and the groove of scraper completely and degrease sufficiently.
the control link are aligned from the housing • Apply approx. 4 mm {0.157 in} width of liquid gasket
cover installation part of the cylinder block side, to the cover edge and approx. 2 mm {0.079 in} width
and tighten the injection pump. of liquid gasket to the circumference of the bolt in
the housing cover.
Tightening torque:
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
lb⋅ft}
1A-32 4LE2 Engine Mechanical
b. Insert the solenoid ASM from the back of the
cylinder block (back of the No.4 injection pump
rack) and tighten to the specified torque.
Tightening torque:
14.7 — 24.5 N⋅m {1.5 — 2.5 kgf⋅m/10.8 — 18.1
lb⋅ft}

1 1

WSLE0154

Name
1. Housing Cover

WSLE0156

1 2 Name
1. Solenoid ASM

3
1
4 2

WSLE0155
3
Name
1. Housing Cover
2. Liquid Gasket Applied Area
3. Approx. 4 mm {0.157 in} width of the cover edge
4. Approx. 2 mm {0.079 in} of the circumference of
the bolt
WSLE0157

10. Install the solenoid ASM. Name

a. Apply liquid gasket (TB1207C) to the installa- 1. Solenoid ASM
tion surface (bit groove) of the solenoid for the 2. Installation Surface (Liquid Gasket Applied Area)
engine stopping. 3. Thread Portion (Do not apply the liquid gasket.)

Note: 11. Install the fuel pipe to the injection pump and
tighten to the specified torque.
• Remove the sealant attached to the installation part
of the solenoid and of the cylinder block with a pack- Tightening torque:
ing scraper completely and degrease. 19.6 — 24.5 N⋅m {2.0 — 2.5 kgf⋅m/14.5 — 18.1
• Do not apply the liquid packing to the thread portion. lb⋅ft}
 4LE2 Engine Mechanical 1A-33
12. Install the leak-off pipe to the nozzle holder and
tighten to the specified torque.

CAUTION:
Hold the pipe by your hand to prevent it from rotat-
ing when tightening. 1

Tightening torque: 2
9.8 — 13.7 N⋅m {1.0 — 1.4 kgf⋅m/7.2 — 10.1 lb⋅ft}
13. Connect the fuel pipe and the leak-off pipe with the
fuel hose and fix it with a clip. 3

2
1

5
WSLE0159

Name
1. Injection Pipe
3 2. Nozzle Holder
3. Injection Pump
4
15. Install the water pump ASM.
• Install the water pump ASM and the gasket to
the cylinder block and the cylinder head, and
tighten it to the specified torque.
WSLE0158 Tightening torque:
Name 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
1. Leak-off Pipe lb⋅ft}
2. Fuel Pipe
3. Nozzle Holder
4. Injection Pump
5. Fuel Hose

14. Install the injection pipe to the injection pump and

the nozzle holder, and tighten it with the sleeve
nut.
a. Screw the thread portion of the sleeve nut two
or three turns by your hand. 3
b. Hold the delivery valve holder of the injection
pump with a wrench and tighten the sleeve nut
securely.
1
Tightening torque:
14.7 — 24.5 N⋅m {1.5 — 2.5 kgf⋅m/10.8 — 18.1
2
lb⋅ft}

Important: WSLE0160
If over-tightening the delivery valve holder, the rack
Name
cannot move smoothly as the plunger and the
1. Tighten adjusting plate together.
housing are compressed. Therefore, when tighten-
2. Bolt: L = 40
ing the sleeve nuts of the injection pipe, hold the
3. Bolt: L = 60
delivery valve holder with a wrench to prevent
corotation.
1A-34 4LE2 Engine Mechanical
16. Connect the water outlet pipe. 18. Install the cylinder head cover.
a. Assemble the thermostat, install the packing a. Apply the liquid gasket (TB1207B) to the posi-
and the water outlet pipe, and tighten it to the tion in the cylinder head cover shown in the fig-
specified torque. ure, and install the baffle plate to the cylinder
head cover.
Tightening torque:
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
lb⋅ft}

4
2

WSLE0331

Name
1. Liquid Gasket Applied Area
WSLE0161

Name b. Install the gasket to the cylinder head cover.

1. Water Outlet Pipe
2. Packing Note:
3. Water Pump Take care not to slide or distort the gasket when install-
4. Thermostat ing.

17. Install the exhaust manifold to the cylinder head. c. Install the cylinder head cover to the rocker arm
bracket and tighten it to the specified torque.
• Insert the gasket and tighten to the specified
torque. Tightening torque:
7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7
Tightening torque:
lb⋅ft}
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
lb⋅ft} 19. Install the intake chamber to the cylinder head
cover.
• Insert the gasket and tighten to the specified
torque.
Tightening torque:
7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7
lb⋅ft}
20. Apply the liquid gasket (TB1207C) to the air inlet
pipe and install it.
Tightening torque:
7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7 lb⋅ft}
 4LE2 Engine Mechanical 1A-35
21. Install the PCV valve.

3
2
1

4
3
4

6
7
WSLE0336
WSLE0210 Name
Name 1. Turbocharger Oil Return Pipe
1. PCV Valve 2. Turbocharger Oil Feed Pipe
2. Inlet Chamber 3. Turbocharger
3. Cylinder Head Cover 4. Exhaust Adapter
4. Air Inlet Pipe
5. Gasket 26. Install the EGR cooler inlet pipe to the exhaust
6. Exhaust Manifold manifold.
7. Gasket • Insert the gasket and temporarily tighten the
bolts and nuts.
22. Install the turbocharger ASM to the exhaust mani-
fold.
• Insert the gasket and tighten to the specified
torque.
Tightening torque:
21.6 — 31.4 N⋅m {2.2 — 3.2 kgf⋅m/15.9 — 23.2
lb⋅ft}
23. Install the exhaust adapter to the turbocharger.
• Insert the gasket and tighten to the specified
torque.
Tightening torque:
21.6 — 31.4 N⋅m {2.2 — 3.2 kgf⋅m/15.9 — 23.2
lb⋅ft}
1
24. Install the turbocharger oil feed pipe.
Tightening torque:
Turbocharger side: 9.8 — 14.7 N⋅m {1.0 — 1.5 WSLE0335
kgf⋅m/7.2 — 10.8 lb⋅ft} Name
Cylinder block side: 22.0 — 27.0 N⋅m {2.2 — 2.8 1. EGR Cooler Inlet Pipe
kgf⋅m/16.2 — 19.9 lb⋅ft}
25. Install the turbocharger oil return pipe. 27. Install the EGR cooler bracket to the cylinder head
• Insert the gasket and tighten to the specified and temporarily tighten the bolts.
torque. 28. Install the EGR cooler.
Tightening torque: • Insert the gasket and temporarily tighten the
7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7 bolts.
lb⋅ft}
1A-36 4LE2 Engine Mechanical

2
WSLE0340 WSLE0403

Name Name
1. EGR Cooler 1. Stud Bolt
2. EGR Cooler Bracket 2. Tap End

29. Install the orifice plate, the valve case and the 30. Install the EGR cooler outlet pipe.
EGR cut solenoid to the intake chamber. • Insert the gasket and temporarily tighten the
• Install the orifice plate and the gasket with pro- bolts and nuts.
truding section in the position shown in the fig-
ure.
• Install the connector of the EGR cut solenoid.

Note:
Always apply Loctite (#262) to the stud bolt tap end
when removing (loosening) the stud bolt indicated with
an arrow in the illustration or replacing the stud bolts.

2
1 1

WSLE0342

Name
1. EGR Cooler Outlet Pipe

WSLE0402

Name
1. EGR Cut Solenoid
2. Valve Case
3. Protruding Section
4. Orifice Plate
 4LE2 Engine Mechanical 1A-37
31. Temporarily tighten the bolts and nuts to the speci- 32. Install the rear hanger.
fied torque according to the order given on the fig-
Tightening torque:
ure.
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
lb⋅ft}

5 3

WSLE0354

Name
1. Rear Hanger

33. Install the EGR cooler water inlet hose with a white
paint applied area in the cylinder block side.
34. Install the EGR cooler water outlet hose with a
6
white paint applied area in the water return pipe
WSLE0344
side.
Name
1-6. Show the order to tighten bolts and nuts.
2
Tightening torque:
1,2,3,4,5: 21.6 — 31.4 N⋅m {2.2 — 3.2 kgf⋅m/15.9
— 23.2 lb⋅ft}
6: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
lb⋅ft}

3
WSLE0343

Name
1. EGR Cooler Water Inlet Hose
2. EGR Cooler Water Outlet Hose
3. White Paint Applied Area

35. Add coolant.

36. Add engine oil.
1A-38 4LE2 Engine Mechanical
Torque Specifications

N m (kg m / lb ft)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

9.8 - 13.7 (1.0 - 1.4 / 7.2 - 13.8)
21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

14.7 - 24.5 (1.5 - 2.5 / 10.8 - 18.1)

21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

14.7 - 24.5 (1.5 - 2.5 / 10.8 - 18.1)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

24.5 - 34.3 (2.5 - 3.5 / 18.1 - 25.3)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)
18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)
21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

9.8 - 14.7 (1.0 - 1.5 / 7.2 - 10.8)

22.0 - 27.0 (2.2 - 2.8 / 16.2 - 19.9)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7) 21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

WSLE0430
 4LE2 Engine Mechanical 1A-39

Rocker Arm Shaft

Components

2 3

WSLE0214

Name
1. Rocker Arm Shaft 5. Rocker Arm Shaft Plug
2. Lock Nut 6. Rocker Arm Bracket
3. Rocker Arm 7. Rocker Arm Shaft Pin
4. Adjusting Screw 8. Rocker Arm Spring
1A-40 4LE2 Engine Mechanical
Removal Disassembly
1. Remove the EGR cooler. 1. Remove plug of the rocker arm shaft.
Refer to 1A-23, “Removal, Engine Exterior Equip- 2. Pull out the rocker arm shaft backward.
ment”.
2. Remove the cylinder head cover. CAUTION:
Refer to 1A-23, “Removal, Engine Exterior Equip- When reinstalling the rocker arm, prepare tags writ-
ment”. ten down the cylinder numbers and symbols to dis-
3. Remove the water pipe. tinguish “intake” and “exhaust”, to avoid installing
Refer to 1A-23, “Removal, Engine Exterior Equip- the improper position.
ment”.
4. Remove the rocker arm bracket ASM.
(M6 × 1.0: 5 bolts, 6 nuts)

Note:
Since liquid gasket is used on the mating surface to the
cylinder head, be careful not to damage the rocker arm
bracket when removing it.
* With screws for replacer (M8 × 1.25)

*
1
*

WSLE0047

Name
1. Rocker Arm Bracket
2. Nut
3. Bolt

5. Pull out the eight push rods.

 4LE2 Engine Mechanical 1A-41
Inspection Inspection for wear of the rocker arm shaft
Inspection of rocker arm and rocker arm shaft Measure the outside diameter of the shaft at sliding
portions (eight points) in the rocker arm.
Check for wear, damage, clogging of oil port and other
abnormality. mm {in}
Nominal dimension Service limit Repairing procedure
φ12 {0.472} φ11.85 {0.467} Replace.

WSLE0232

Inspection for a bend of the rocker arm shaft

Hold the shaft on both ends with V block, and measure
the runout of the center by the dial gauge. (The bend
value should be a half of the runout.)

mm {in}
Standard value Service limit Repairing procedure
0.2 {0.008} or 0.3 {0.012} Replace.
less
1A-42 4LE2 Engine Mechanical
Inspection of clearance between the rocker Inspection of rocker arm
arm and the rocker arm shaft Check the contact surface of the valve stem of the
Measure the bushing bore and calculate the clearance rocker arm for stepped wear or damage.
between the arm and the outside diameter of the shaft. If the stepped wear (1) and damage (2) of the contact
surface are slight, repair with the oil stone.
Clearance between the arm and the mm {in} If the stepped wear and damage are extreme, replace
shaft the rocker arm.
Standard value Service limit Repairing procedure
0.005 — 0.045 Replace the rocker
0.2 {0.008}
{0.0002 — 0.0018} arm or the shaft.
2

3
1
4

WSLE0236

Name
1. Stepped Wear of the Contact Surface
2. Damage of the Contact Surface
3. Rocker Arm
WSLE0235
4. Oil Stone

Visual check of push rod

Replace with new one if there is excessive wear or
damage.

WSLE0088
 4LE2 Engine Mechanical 1A-43
Inspection for a bend of the push rod Reassembly
Rotating the push rod on a surface plate, measure the 1. Clean the rocker arm shaft and the oil port of the
bend with the thickness gauge. rocker arm by air.
If the measured value exceeds the limit, replace with 2. Apply the engine oil to the rocker arm shaft and the
new one. rocker arm sliding portion.
Push rod bend mm {in} 3. Install the rocker arm shaft and the rocker arm.
When positioning the rocker arm shaft, align the
Service limit 0.3 {0.012} or less rocker shaft pin inserted to the rocker arm bracket
with the cutout of the rocker arm shaft.

Note:
When reinstalling the rocker arm, be sure to check the
tag and install to the original position.

1 2

WSLE0080

Name
1. Push Rod
2. Thickness Gauge

WSLE0251

Name
1. Pin
2. Rocker Arm Shaft

4. Install the plug of the rocker arm.

1A-44 4LE2 Engine Mechanical
Installation 3. Contact the rocker arm to the rocker spring, rotate
the crank, and set the No.1 cylinder to the exhaust
1. Put the push rod through the cylinder block and
top dead center.
insert it to the tappet.
4. Install the rocker arm bracket ASM along with the
2. Align it with a groove on the bottom of the rocker
stud bolt of the cylinder head, and tighten it to the
arm bracket and apply liquid gasket (TB1207B).
specified torque.
Note: Tightening torque:
Do not apply the liquid gasket to a groove around the 7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7 lb⋅ft}
oil gallery.
Note:
• Remove paint and sealant attached to the top of the
cylinder head and the bottom of the rocker arm
bracket with a PKG scraper etc., and degrease suffi-
ciently.
• Assemble it to the cylinder head within 5 minutes
1 after applying the sealant.
• When assembling, align the saucer part of the push
rod and the rocker arm adjusting screw.
2

WSLE0254 3
Name
1. Liquid Gasket Applied Area
2. Do not apply the liquid gasket to the groove.
(important)
1
3. Oil Gallery

Applied width of sealant

WSLE0145

Name
1. Rocker Arm Bracket
2. Nut
3. Bolt

1 5. Adjustment of valve clearance

Refer to 1A-4, “Function Check, ISUZU Diesel
Engine”.
2
6. Install the water pipe.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
7. Install the cylinder head cover.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
WSLE0255
8. Install the EGR cooler.
Refer to 1A-29, “Installation, Engine Exterior
Name
Equipment”.
1. Approx. 4 mm {0.157 in}
2. Approx. 2 mm {0.079 in}
 4LE2 Engine Mechanical 1A-45
Torque Specifications

N m (kg m / lb ft)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

WSLE0302
1A-46 4LE2 Engine Mechanical

Cylinder Head
Components

2
3
1
4

6
5
7

12

10

11
WSLE0050

Name
1. Connector 7. Spring Seat
2. Glow Plug 8. Valve Spring
3. Do not extract the five stud bolts since the seal- 9. Valve
ant is attached to them. 10. Hot Plug
4. Valve Seal 11. Valve Seat Insert
5. Valve Guide 12. Nozzle Holder
6. Split Collar
 4LE2 Engine Mechanical 1A-47
Removal 13. Gradually loosen the cylinder head bolts at an
equal balanced rate from outside toward the center
1. Remove the cooling fan.
as the order indicated in the diagram. (M12: 10
Refer to 1A-14, “Removal, Engine Accessories”.
bolts, M8: 5 bolts)
2. Remove the fan belt.
Refer to 1A-14, “Removal, Engine Accessories”.
3. Remove the fan pulley.
Refer to 1A-14, “Removal, Engine Accessories”.
4. Remove the generator.
Refer to 1A-14, “Removal, Engine Accessories”. 5 4 3 2 1
5. Remove the EGR cooler and the bracket.
Refer to 1A-14, “Removal, Engine Accessories”. 8 7
6. Remove the cylinder head cover. 12 15 11
Refer to 1A-23, “Removal, Engine Exterior Equip-
ment”. 9 13 14 10 6

7. Remove the turbocharger.

Refer to 1A-23, “Removal, Engine Exterior Equip-
ment”.
8. Remove the water pump.
Refer to 1A-23, “Removal, Engine Exterior Equip-
ment”.
WSLE0049
9. Remove the injection pipe.
14. Remove the cylinder head ASM and the head gas-
Refer to 1A-23, “Removal, Engine Exterior Equip-
ket.
ment”.
15. Pull out the tappet from the cylinder block.
10. Remove the leak-off pipe.
Refer to 1A-23, “Removal, Engine Exterior Equip-
ment”.
11. Remove the rocker arm bracket.
Refer to 1A-40, “Removal, Rocker Arm Shaft”.
12. Remove the front hanger.

WSLE0048

Name
1. Cylinder Head ASM
2. Head Bolt (M12)
3. Head Gasket
4. Front Hanger
5. Head Bolt (M8)
1A-48 4LE2 Engine Mechanical
Disassembly 5. Remove the valve guide.
1. Remove the exhaust manifold. • Use a valve guide installer to pull out the valve
Refer to 1A-23, “Removal, Engine Exterior Equip- guides from the bottom of the cylinder head.
ment”. Special tool
Valve guide installer
2. Remove the connector, glow plug and nozzle
5-8840-9035-0
holder ASM before disassembling the valve sys-
tem.
3. Compress the valve spring to remove the split col-
lar, spring seat, valve spring and valve.
Special tool
Valve spring remover
5-8840-9030-0

CAUTION:
• Disassemble the cylinder head ASM on the flat
wood to prevent part damage.
• When removing the nozzle holder ASM, take
great care not to damage the nozzle tip.

4. Remove the valve seal.

• Use pliers to remove the valve seal.

WSLE0330

Inspection
Inspection of cylinder head
Remove any carbon attached to the bottom of the
head, taking care not to damage the valve seat surface.
Check each part for damage and perform the color
check as required.
Water leakage: Water pressure test 490 kPa {71 psi}
(for three minutes)

WSLE0356

WSLE0063
 4LE2 Engine Mechanical 1A-49
Inspection of bottom distortion
(Reference) Cylinder head height mm {in}
Place a straightedge on the four side-directions and the
two diagonal directions, and measure the distortion Engine model Standard value
with the thickness gauge. (Refer to the diagram.) 4LE2X 63.90 — 64.10 {2.516 — 2.524}

mm {in}
Standard Abnormal Repairing procedure
value value (need
repair)
Repair it with a surface
grinder. The total amount of
repaired values of the cylinder
0.075 block and of the cylinder head
{0.00295} 0.15 {0.006} should not exceed 0.3
or less {0.012}. If the measured value
exceeds the maximum
repaired value, replace the H
cylinder head.

WSLE0066

Distortion of exhaust manifold installation

surface
Place a straightedge on the four side-directions and the
two diagonal directions, and measure the distortion
with the thickness gauge.

mm {in}
Standard value Service limit Repairing procedure
0.05 {0.002} or less 0.2 {0.008} Repair.

WSLE0064

WSLE0332

WSLE0230
1A-50 4LE2 Engine Mechanical
Inspection of valve seat Repair of valve seat
Contact width: A 1. Remove any carbon attached to the valve seat sur-
Check the contact surface of the valve seat. If any face. Use a seat cutter (15°, 45°, 75°) to cut off
scratches and hollows exist or measured contact width scratches and hollows at minimum until they disap-
exceeds the limit, repair it. pear, and adjust the contact width to the standard
value.
Depression level: B 2. Grind them after repair.
Install the valve to the cylinder head. Measure the
depression level of the seat with a depth gauge or with
a straightedge and a scale.
If the measured value exceeds the limit, replace the
valve seat insert.

mm {in}
Standard Service Repairing
value limit procedure
Contact width (A) 2.0 {0.079} 2.5 {0.098} Repair or
replace.
Depression IN 0.7 {0.028} 1.2 {0.047}
level (B) EX 0.9 {0.035} 1.5 {0.059}

1
Replacement of valve seat insert
If the depression level of the seat exceeds the limit,
3
replace the valve seat insert.
1. Arc-weld the entire inside diameter of the valve
A

2 seat insert.
2. Cool the valve seat insert for two to three minutes.
B It contracts as it cools down, making it easier to
remove the valve seat insert.
4 45 3. Remove the valve seat insert, using a screwdriver.
Be sure not to hurt the cylinder head.

WSLE0067

Name
1. Cylinder Head
2. Valve Seat Insert
3. Valve
4. Cylinder Head Lower Surface
 4LE2 Engine Mechanical 1A-51
Inspection for wear of the valve stem
Measure the outside diameter at position as shown in
the figure.
Repair light stepped wear with the oil stone.
If the measured value is below the service limit, replace
the valve guide and the valve as a set.

mm {in}
Nominal Service limit Repairing
dimension procedure
Inlet φ7 {0.276} φ6.85 {0.270}
Replace.
Exhaust φ7 {0.276} φ6.80 {0.268}

Name
1. Arc-weld
2. Valve Seat Insert
3. Screwdriver

4. Clean off carbon and metallic oxides on the insert

bore of the cylinder head.
5. Use a smooth pad and press-fit with a press. (9.8
— 14.7 kN {2,203 — 3,305 lb})
6. Apply compound to the valve seat surface, grind
them while rotating the valve, and make sure that it
contacts evenly over the circumference.

CAUTION:
After grinding, remove compound completely.
Inspection of valve guide
Note:
If there is a scratch or abnormal abrasion on the valve
stem and the inside diameter part of the valve guide,
replace the valve and valve guide together.

1. Measure the valve guide clearance.

• Measure the clearance between the valve
guide and valve stem within 10 mm {0.39 in}
from the valve guide, using a dial gauge.
• If the measured value exceeds the limit, replace
the valve guide and valve altogether.

Clearance between the valve guide and mm {in}

valve stem
Standard Limit
Inlet valve 0.023 — 0.056 0.2 {0.008}
{0.0009 — 0.0022}
Name Exhaust valve 0.030 — 0.063 0.25 {0.0098}
1. Pad {0.0012 — 0.0025}
2. Valve Seat Insert
3. Press
1A-52 4LE2 Engine Mechanical
Inspection of force (tension) of the valve
spring
Use a spring tester and read the scale when the spring
is compressed to the specified dimension.

N {lb}
Standard Service Repairing
value limit procedure
When compressed to
167 {38} 147 {33} Replace.
29.9 mm {1.177 in}

Inspection of thickness of the valve

If the measured value is below the service limit, replace
the valve guide and the valve as a set.

mm {in}
Nominal Service limit Repairing pro-
dimension cedure
IN 1 {0.039} 0.7 {0.028} Replace.
EX 0.8 {0.031} 0.5 {0.020}

Inspection of free height and squareness of

the valve spring
Free height (free length) ; A
Measure free length of the valve spring and if it is
shorter than the limit, replace the valve spring.

mm {in}
Standard value Service limit Repairing procedure
42.1 {1.657} 40 {1.575} Replace.

Squareness; B
Use a surface plate and a square to measure the valve
spring squareness.
If the measurement exceeds the limit, replace the valve
spring.

mm {in}
Standard value Service limit Repairing procedure
1.8 {0.071} or 2.5 {0.098} Replace.
less
 4LE2 Engine Mechanical 1A-53

WSLE0075

2. Install the valve seal.

Reassembly a. When press-fitting, apply engine oil sufficiently
over the outer circle of the valve guide.
1. Install the valve guide.
b. Beat until the oil seal protruding section is
a. Hammer in the valve guide from the upper sur- securely held to the valve guide groove.
face of the cylinder head, using the valve guide Also, check that the spring does not come off.
installer. Special tool
Special tool Valve seal setting tool
Valve guide installer 5-8840-9033-0
5-8840-9035-0
CAUTION:
Take care to avoid damaging the lip of the seal.

WSLE0357

Height from the upper surface of the cylinder

head to the edge surface of the valve guide: 9.5 WSLE0108
mm {0.374 in}

Note:
When replacing the valve guide, it must be replaced
together with the valve.
1A-54 4LE2 Engine Mechanical
4. Install the valve spring and the spring seat.
Install the valve spring with its narrow pitched side
(white paint side) facing downward.

WSLE0247
1
Name
1. Valve Guide
2. Groove WSLE0110

3. Protruding Section Name

1. White Paint
3. Install the valve.
Apply the mixture of the oil and Bellmoly Paste 5. Install the split collar.
(molybdenum disulfide) to the valve stem part. Use the tool (remover) to compress the spring and
Engine oil : molybdenum = 1:1 insert the split collar securely.
Special tool
CAUTION: Valve spring remover
Be sure to prevent the valve from coming off and 5-8840-9030-0
causing dents after installing the valve.

1 2

WSLE0111

Name
WSLE0248
1. Split Collar
Name 2. Remover
1. Valve Stem
 4LE2 Engine Mechanical 1A-55
6. Install the nozzle holder ASM.
a. Check the injection condition and injection
pressure of the injection nozzle, and perform
service before assembly. (Refer to 1A-4, “Func-
tion Check, ISUZU Diesel Engine”.) 2
b. Install the gasket to the cylinder head.
c. Install the nozzle holder ASM and tighten the
nozzle bracket to the specified torque.
Tightening torque:
31.4 — 41.2 N⋅m {3.2 — 4.2 kgf⋅m/23.2 — 30.4
lb⋅ft}

CAUTION:
• Be sure to prevent the nozzle holder tip from 1
adhering of dirt and from damaging.
• Use new gasket.
WSLE0249

Name
1. Exhaust Manifold
2. Gasket

8. Assemble the glow plug to the cylinder head and

1
tighten to the specified torque.
2
Tightening torque:
20.0 — 25.0 N⋅m {2.0 — 2.5 kgf⋅m/14.8 — 18.4
3 lb⋅ft}
9. Install the connector to the glow plug and tighten to
4
the specified torque.

5
Tightening torque:
0.9 — 1.1 N⋅m {0.09 — 0.11 kgf⋅m/0.7 — 0.8 lb⋅ft}

1
WSLE0112

Name
1. Bolt
2. Eyebolt 2
3. Bracket
4. Nozzle ASM
5. Gasket

7. Install the exhaust manifold.

Assemble the stamp mark (or seal) side of the gas-
ket facing the manifold.
Tightening torque:
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
lb⋅ft}

WSLE0113

Name
1. Glow Plug
2. Connector
1A-56 4LE2 Engine Mechanical
Installation 5. Install the rocker arm bracket.
Refer to 1A-44, “Installation, Rocker Arm Shaft”.
1. Assemble the tappet to the cylinder block. (Check
the assemble position marked at the disassem- 6. Install the front hanger and tighten to the specified
bling.) torque.
2. Install the head gasket. Tightening torque:
Install the head gasket with the stamped mark fac- 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
ing upward. lb⋅ft}

1
1

WSLE0143
WSLE0147
Name Name
1. Stamped Mark 1. Front Hanger
3. Install the cylinder head ASM gently on the gasket. 7. Install the leak-off pipe.
4. Apply engine oil to the threads and the seating sur- Refer to 1A-29, “Installation, Engine Exterior
faces of the head bolts, and tighten them from the Equipment”.
center part to the outside bolts symmetrically in the 8. Install the injection pipe.
numerical order shown in the illustration. Refer to 1A-29, “Installation, Engine Exterior
Tightening torque: Equipment”.
M12: 83.4 — 93.2 N⋅m {8.5 — 9.5 kgf⋅m/61.5 — 9. Install the water pump.
68.7 lb⋅ft} → 60° — 90° Refer to 1A-29, “Installation, Engine Exterior
M8: 24.5 — 34.3 N⋅m {2.5 — 3.5 kgf⋅m/18.1 — Equipment”.
25.3 lb⋅ft} 10. Install the turbocharger.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
11. Install the cylinder head cover.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
12. Install the EGR cooler and the bracket.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
13. Install the generator.
Refer to 1A-15, “Installation, Engine Accessories”.
14. Install the fan pulley.
Refer to 1A-15, “Installation, Engine Accessories”.
15. Install the fan belt.
Refer to 1A-15, “Installation, Engine Accessories”.
16. Install the cooling fan.
Refer to 1A-15, “Installation, Engine Accessories”.
WSLE0144
 4LE2 Engine Mechanical 1A-57
Torque Specifications

N m (kg m / lb ft)

20.0 - 25.0 (2.0 - 2.5 / 14.8 - 18.4)

31.4 - 41.2 (3.2 - 4.2 / 23.2 - 30.4)

83.4 - 93.2 (8.5 - 9.5 / 61.5 - 68.7)

60 - 90

24.5 - 34.3 (2.5 - 3.5 / 18.1 - 25.3)

WSLE0303
1A-58 4LE2 Engine Mechanical

Piston, Connecting Rod

Components

4
2

1 5

10

WSLE0053

Name
1. Piston Pin 6. Bearing
2. Piston 7. Cap Nut
3. Piston Ring 8. Cap
4. Snap Ring 9. Connecting Rod
5. Bushing 10. Connecting Rod Bolt

Removal
1. Remove the cylinder head cover.
Refer to 1A-23, “Removal, Engine Exterior Equip-
ment”.
2. Remove the rocker arm bracket.
Refer to 1A-40, “Removal, Rocker Arm Shaft”.
3. Remove the cylinder head ASM.
Refer to 1A-47, “Removal, Cylinder Head”.
 4LE2 Engine Mechanical 1A-59
4. Remove the mounting bolts and nuts of the oil pan, b. Loosen the cap nut of the connecting rod and
and then remove the oil pan from the cylinder remove the cap.
block. (M6: 18 bolts, 4 nuts) c. Further rotate the crank and bring the piston to
the top dead center.
d. Put a handle of a hammer or something on the
bottom of the connecting rod, and push the pis-
1 ton ASM upward from the inside of the cylinder
block.

CAUTION:
• Remove any carbon attached to the inner wall of
the cylinder using a scraper before removing
the piston.
• Be careful not to damage the inner wall of the
cylinder when pushing out the piston ASM.
• Attach tags with each cylinder number to the
removed cap and the bearing and arrange them.
2

WSLE0215

Name
1. Oil Pan
2. Drain Plug
1

5. Remove the oil strainer mounting bolts from the

bearing cap, and remove the oil strainer from the
oil pump.
6. Loosen the sleeve nut and remove the oil pipe
(between the oil pump and the cylinder block).
2

1
2
3
WSLE0054

Name
1. Piston
2. Connecting Rod Cap

WSLE0216

Name
1. Oil Pump
2. Cylinder Block
3. Oil Pipe
4. Oil Strainer

7. Remove the piston and the connecting rod.

a. Rotate the crank and bring the removed piston
to the bottom dead center.
1A-60 4LE2 Engine Mechanical
Disassembly
1. Use the piston ring setting tool (tool commercially
available is also acceptable) to remove the piston
ring. 2
Special tool
Piston ring setting tool
1
1-8522-1029-0

CAUTION:
Piston ring deforms if it is expanded beyond the
limit.

WSLE0056

Name
1. Piston Pin
2. Brass Stick

Inspection
Axial play of the connecting rod and the crank
pin
Measure an axial play before removing the connecting
rod.
WSLE0055
1. Pull the connecting rod all the way to the front.
2. Remove the piston pin.
2. Insert a thickness gauge to the clearance between
a. Use a commercial tool to remove the snap ring. the connecting rod cap and the crankshaft, and
b. Put a brass stick on the piston pin and gently then measure a play.
tap by a hammer to knock it out.
mm {in}
CAUTION:
Standard value Service limit
Put the piston, piston ring, piston pin, connecting
rod, and so on in order according to the cylinder 0.20 — 0.33 {0.008 — 0.013} 0.35 {0.014}
number.
 4LE2 Engine Mechanical 1A-61
Inspection of clearance with the cylinder bore Inspection for wear of the piston pin (outside
1. Measure the outside diameter of the piston at the diameter)
specified distance from top surface in the right- Use a micrometer to measure the outside diameter of
angle direction to the piston pin. the piston pin.
Measurement position of outside diameter: 54.85 If the measured value exceeds the limit, replace the
mm {2.159 in} from the top surface. piston pin.

mm {in}
Nominal Service Repair-
dimension limit ing proce-
dure
Connecting rod φ27 {1.063} φ26.970
small end diame- {1.0618}
ter (φ27 mm {1.063
in})
Replace.
Connecting rod φ25 φ24.970
small end diame- {0.9843} {0.9449}
ter (φ25 mm
{0.9843 in})

WSLE0089

2. Calculate the clearance by the dimension of the cylinder

bore and the outside diameter dimension of the piston.

mm {in}
Clearance with 0.040 — 0.085
major axis {0.0016 — 0.0033}

Outside diameter of the piston for service

mm {in}
Piston outside diameter Grade
φ84.945 — 84.960 {3.3443 — 3.3449} NON
φ85.195 — 85.210 {3.3541 — 3.3547} 025 WSLE0239

Inspection of clearance between the piston

pins and piston pin holes
Measure the inner diameter of the piston pin hole and calcu-
late the clearance with the outside diameter of the piston pin.

mm {in}
Standard value
0.004 — 0.017 {0.00016 — 0.00070}

WSLE0090
1A-62 4LE2 Engine Mechanical
Inspection of piston ring end gap Inspection of clearance between the piston
Insert the ring to the cylinder bore and push it with the ring groove and the ring
piston head so that the ring makes a right angle with 1. Remove any carbon sludge from the piston ring groove.
the cylinder, then measure. Using the old piston ring helps you to remove the
carbon easily.
Connecting rod small end diameter (φ27 mm mm {in}
{1.063 in})
2. Measure the clearance between the piston ring
and the ring groove using a thickness gauge at
Standard value Service limit Repairing several points.
procedure If the measured value exceeds the limit, replace
Top ring 0.20 — 0.35 the piston ring or the piston.
{0.008 — 0.014}
1.5 {0.059} CAUTION:
Second 0.20 — 0.40 When replacing the piston, replace the piston ring
Replace.
ring {0.008 — 0.016}
also at the same time.
Oil ring 0.20 — 0.40
1.0 {0.039}
{0.008 — 0.016} Connecting rod small end diameter (φ27 mm mm {in}
{1.063 in})
Standard value Service Repairing
Connecting rod small end diameter (φ25 mm mm {in}
limit procedure
{0.9843 in})
Top ring It cannot be mea- Replace
Standard value Service limit Repairing
sured due to the — the ring or
procedure
taper type ring. the piston.
Top ring 0.20 — 0.35
Second 0.070 — 0.110
{0.008 — 0.014}
1.5 {0.059} ring {0.0028 — 0.0043} 0.15
Second 0.35 — 0.50 {0.006}
Replace. Oil ring 0.030 — 0.070
ring {0.014 — 0.020}
{0.00120 — 0.00276}
Oil ring 0.20 — 0.40
1.0 {0.039}
{0.008 — 0.016}
Connecting rod small end diameter (φ25 mm mm {in}
{0.9843 in})
Standard value Service Repairing
limit procedure
Top ring 0.085 — 0.120 0.2 Replace
{0.0033 — 0.0047} {0.008} the ring or
the piston.
Second 0.050 — 0.085
ring {0.0020 — 0.0033} 0.15
Oil ring 0.030 — 0.065 {0.006}
{0.00120 — 0.00256}

WSLE0093
 4LE2 Engine Mechanical 1A-63
Inspection of distortion and parallelism of the
connecting rod
Use a connecting rod aligner to measure it.

mm {in}
Standard Service limit Repairing
value procedure
Distortion (L = Repair or
0.05 {0.002}
per 24 mm 0.2 {0.008} replace.
or less
{0.945 in})
Distortion (L = 0.075
per 100 mm {0.003} or 0.15 {0.006}
{3.937 in}) less

Replacement of bushing
Use the bench press to press-fit the bushing to the con-
necting rod.

Finished size of the bore after the bushing is mm {in}

press-fitted
Standard value
Connecting rod φ27.00 {1.063}
small end diam- (+0.008 — 0.015 {+0.00031 — 0.00060})
eter (φ27 mm
{1.063 in})
Connecting rod φ25.00 {0.9843}
small end diam- (+0.008 — 0.015 {+0.00031 — 0.00060})
eter (φ25 mm
{0.9843 in})
Inspection of clearance between the
connecting rod small end pin holes and the
piston pins
Measure the bushing bore and the piston pin outside
diameter and calculate the clearance.

mm {in}
Standard value Service limit Repairing proce-
dure 1

Replace the bush-

0.008 — 0.020
0.05 {0.002} ing or the piston
{0.00031 — 0.00079}
pin.

WSLE0240

Name
1. Press
1A-64 4LE2 Engine Mechanical
Inspection of tension of the connecting rod Clearance between the bearing and the crank
bearing pin
Check whether the tension of the bearing is sufficient. 1. Tighten the bearing cap to the specified torque.
Then measure the inside diameter.
mm {in}
Tightening torque:
Standard value Repairing proce- Connecting rod small end diameter (φ27 mm
dure {1.063 in}): 23 — 26 N⋅m {2.3 — 2.7 kgf⋅m/17.0 —
Connecting W = 49.5 {1.949} or Use the one with 19.2 lb⋅ft} → 100° — 115°
rod small more extrusion and ten- Connecting rod small end diameter (φ25 mm
end diame- D = φ49 {1.929} sion, and be care- {0.9843 in}): 19.6 — 29.4 N⋅m {2.0 — 3.0 kgf⋅m/
ter (φ27 mm L = 0.055 — 0.085 ful about sticking of 14.5 — 21.7 lb⋅ft} → 100° — 115°
{1.063 in}) {0.00217 — 0.00330} rear side.
2. Measure the outside diameter of the after-men-
Connecting W = 49.9 {1.965} or tioned crankshaft pin, and calculate the clearance.
rod small more
end diame- D = φ49 {1.929} mm {in}
ter (φ25 mm L = 0.02 — 0.06
{0.9843 in}) {0.00079 — 0.00236} Standard value Service limit Repairing
procedure

Standard for the bearing tension (reference) Connecting 0.026 — 0.067 Replace the
rod small {0.0010 — bearing.
1 end diame- 0.0026}
ter (φ27 mm
{1.063 in})
0.1 {0.0039}
Connecting 0.035 — 0.073
rod small {0.0014 —
end diame- 0.0029}
ter (φ25 mm
3kN {674lbf} {0.9843 in})
2

WSLE0241

Name
1. Tension (Free Condition)
2. Extrusion

WSLE0097
 4LE2 Engine Mechanical 1A-65
Inspection of outside diameter of the Reassembly
crankshaft pin 1. Assemble pistons and connecting rods.
Measure the outside diameter of the crankshaft pin, a. It is advisable to warm the piston at a tempera-
and calculate the wear and the uneven wear. ture of approx. 100°C {212°F} with a piston
If it exceeds the limit, replace the crankshaft. heater. However, the piston is able to be
1. Nominal dimension assembled when it is cold.

mm {in}
Pin φ46 {1.811}

2. Uneven wear (the difference between the mea-

surements in X − X, Y − Y directions)

mm {in}
Service limit Repairing procedure
Pin 0.05 {0.002} Replace the crankshaft.

3. Amount of wear

mm {in}
Service limit Repairing procedure
Pin 0.13 {0.005} Replace the crankshaft.
WSLE0115

b. Apply engine oil sufficiently to the piston pin.

c. Assemble the connecting rod with the cylinder
number stamped side facing the piston com-
bustion chamber direction, and push in the pis-
ton pin.
At this time, check that the front mark on the
piston head and the casting mark (ISUZU) on
Y the connecting rod are in the same direction.
X X

Y 1
2

WSLE0098

Cylinder and piston combination 4

The pistons are selected by the grade when assembled
at the factory. However, the grades are not set to the 5
standard pistons for service.

Piston grade
Cylinder bore grade At the ISUZU
WSLE0116
When servicing Name
factory
1. Combustion Receiver Side
A A NON-Grade 2. Front Mark
B B 3. Engine Forward Direction
4. ISUZU Mark
C C
5. Cylinder Number Stamped Side
1A-66 4LE2 Engine Mechanical
2. Install the snap ring.
Insert the snap ring and fix it with the piston pin.
Check to see the piston and connecting rod move
smoothly.

WSLE0118

Name
1. Top Ring
2. Second Ring
WSLE0117 3. Oil Ring
3. Install the piston ring.
Use the piston ring setting tool to install the piston
ring.
Special tool
Piston ring setting tool
1-8522-1029-0
a. Install the oil ring so that the end of the ring is in
the opposite direction of 180° to that of the coil
expander. 1

Note:
For the coil expander, make sure that there is no gap in 2
the joint.

b. Install the compression rings with T, 1T or 2T

mark facing upward in the order of the second
and top compression rings.

CAUTION:
The shapes of the top and second compression WSLE0252

rings are different. Name

1. T, 1T or 2T
2. Joint

Installation
1. Before inserting the piston ASM to the cylinder, set
the piston ring end as shown in the illustration,
avoiding the side-pressure direction (the right-
angle direction to the piston pin).
 4LE2 Engine Mechanical 1A-67
5. Install the connecting rod cap.
a. Rotate the crank slowly to the bottom dead cen-
ter position.
1
At this time, push in the piston ASM as it follows
the crank.
b. Apply engine oil to the bearing and crank pin,
and install aligning the marking numbers of the
2 connecting rod and the bearing cap.
c. Apply engine oil to the threads and the seating
surface of the connecting rod.
Tightening torque:
Connecting rod small end diameter (φ27 mm
3
{1.063 in}): 23 — 26 N⋅m {2.3 — 2.7 kgf⋅m/17.0
— 19.2 lb⋅ft} → 100° — 115°
Connecting rod small end diameter (φ25 mm
{0.9843 in}): 19.6 — 29.4 N⋅m {2.0 — 3.0 kgf⋅m/
14.5 — 21.7 lb⋅ft} → 100° — 115°
WSLE0125

Name Note:
1. Top Ring Check that the crankshaft turns smoothly after assem-
2. Second Ring bly of the connecting rod.
3. Oil Ring

2. Bring the crankshaft to the top dead center posi-

tion.
3. Install the bearing to the connecting rod and the
bearing cap.
4. Apply engine oil to the inside of the bearing, the
piston ring, the ring groove and the side surface of
the piston, and the inside of the cylinder. Then
push the piston in the cylinder bore with the front
mark on it facing forward.
Also, check that the connecting rod alignment 1
number (cylinder number) is facing to the injection
pump side.
Special tool
Piston ring compressor
5-8840-9018-0

WSLE0127

Name
1. Cylinder Number

6. Install the oil pipe (between the oil pump and the
cylinder block) and tighten the sleeve nut.
Tightening torque:
24.5 — 34.3 N⋅m {2.5 — 3.5 kgf⋅m/18.1 — 25.3
lb⋅ft}

WSLE0253
1A-68 4LE2 Engine Mechanical
7. Install the oil strainer to the oil pump and tighten
the strainer bracket to No.2 bearing cap.
Tightening torque:
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9 1
lb⋅ft}

2
2

WSLE0215

Name
1 1. Oil Pan
2. Drain Plug

9. Install the cylinder head ASM.

WSLE0141 Refer to 1A-56, “Installation, Cylinder Head”.
Name 10. Install the rocker arm bracket.
1. Oil Pipe Refer to 1A-44, “Installation, Rocker Arm Shaft”.
2. Oil Strainer
11. Install the cylinder head cover.
3. To No.2 Bearing Cap
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
8. Install the oil pan.
a. Install the oil pan and the packing to the cylin-
der block and tighten the bolts evenly.
Tightening torque:
7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7
lb⋅ft}
b. Install the drain plug.
Tightening torque:
68.6 — 88.2 N⋅m {7.0 — 9.0 kgf⋅m/50.6 — 65.1
lb⋅ft}
 4LE2 Engine Mechanical 1A-69
Torque Specifications

N m (kg m / lb ft)

Connecting rod small end ( 27mm {1.063in})

: 23 - 26 (2.3 - 2.7 / 17.0 - 19.2) 100 - 115
Connecting rod small end ( 25mm {0.984in})
: 19.4 - 29.4 (2.0 - 3.0 / 14.5 - 21.7) 100 - 115

WSLE0431
1A-70 4LE2 Engine Mechanical

Flywheel
Components

WSLE0313

Name
1. Flywheel

Removal
1. Remove the flywheel.
a. Block the crankshaft from rotating, and loosen
the mounting bolts in the order indicated in the
diagram to remove the flywheel.
b. Put alignment marks before removing the fly-
wheel from the crankshaft. (Doing so makes
installing easy because the positions of the 3 1
mounting bolts are fixed even if pitch of them is 5 6
not equal.) 2 4

c. Gently tap the flywheel by a plastic hammer or

similar tool to remove it.

CAUTION:
Be careful not to damage the ring gear.

WSLE0218
 4LE2 Engine Mechanical 1A-71
2. Take out the ring gear. 2. Install the flywheel.
Put a brass stick on the ring gear and strike with a Apply engine oil to the threads and the seating sur-
hammer to remove it. face of the mounting bolts, and then install the fly-
wheel to the crankshaft.
Tighten the mounting bolts in a balanced way in
the numerical order shown in the illustration.
Tightening torque:
88.3 — 108 N⋅m {9.0 — 11.0 kgf⋅m/65.1 — 79.7
lb⋅ft}

Note:
Install the flywheel checking the installation position
since the bolt hole pitch is not equal.

WSLE0103

3 1
5 6
Installation 2 4

1. Install the ring gear.

Heat the ring gear evenly using a gas burner and
strike with a hammer to install it. 1
After shrinkage fit, make sure that the ring gear is
stuck to the flywheel.

CAUTION:
Do not heat the ring gear at a temperatures above WSLE0139
200°C {392°F}. Name
1. Engine Oil Application
1A-72 4LE2 Engine Mechanical
Torque Specifications

N m (kg m / lb ft)

88.3 - 108 (9.0 - 11.0 / 65.1 - 79.7)

WSLE0314
 4LE2 Engine Mechanical 1A-73

Crankshaft Front Oil Seal

Components

WSLE0315

Name
1. Crankshaft Pulley 3. Timing Gear Case
2. Front Oil Seal 4. Governor Cover

Removal 8. Remove the injection pump housing cover.

Refer to 1A-23, “Removal, Engine Exterior Equip-
1. Remove the cooling fan and the fan belt.
ment”.
Refer to 1A-14, “Removal, Engine Accessories”.
9. Remove the injection pump.
2. Remove the fan pulley.
Refer to 1A-23, “Removal, Engine Exterior Equip-
Refer to 1A-14, “Removal, Engine Accessories”.
ment”.
3. Remove the generator.
10. Remove the control link.
Refer to 1A-14, “Removal, Engine Accessories”.
Refer to 1A-23, “Removal, Engine Exterior Equip-
4. Remove the generator bracket. ment”.
Refer to 1A-14, “Removal, Engine Accessories”.
11. Remove the oil pan.
5. Remove the injection pipe. Refer to 1A-58, “Removal, Piston, Connecting
Refer to 1A-23, “Removal, Engine Exterior Equip- Rod”.
ment”.
12. Remove the crank pulley.
6. Remove the fuel pipe.
a. Block the crankshaft from rotating, and loosen
Refer to 1A-23, “Removal, Engine Exterior Equip-
the mounting bolts of the pulley to remove it.
ment”.
b. Remove the washer and the pulley.
7. Remove the solenoid ASM.
Refer to 1A-23, “Removal, Engine Exterior Equip- CAUTION:
ment”. Do not reuse the bolt and washer.
1A-74 4LE2 Engine Mechanical
b. The timing gear case should be removed with
the governor and the front oil seal.

Note:
4 Since liquid gasket is applied to the mating surface to
the cylinder block, take great care not to remove them
forcedly to damage or deform them.
3

WSLE0217

Name
1. Mounting Bolt
2. Washer
3. Crank Pulley
4. Crankshaft

13. Remove the timing gear case.

WSLE0221
a. Before removing the timing gear case, make
14. Remove the front oil seal from the timing gear
sure that control link supported by the cylinder
case.
block and the link plate of the governor are sep-
arated. • Remove the oil seal with a screwdriver avoiding
If they are connected, remove the snap pin and damage to the oil seal contact surface on the
separate them. timing gear case.

WSLE0212

Name
1. Control Link
2. Link Plate (Governor)
3. Snap Pin
 4LE2 Engine Mechanical 1A-75
Inspection
Inspection of oil seal
If fault is found in the lip section of the oil seal, replace it
with the new one.
1
2

L
1

WSLE0136

Name
1. Front Oil Seal
2. Timing Gear Case

WSLE0102 2. Install the timing gear case (with governor) to the

Name cylinder block.
1. Timing Gear Case a. Let the link plate of the governor which is
2. Front Oil Seal assembled in the gear case through the con-
nection hole of the injection pump.
b. Apply engine oil to the both ends of the bushing
Installation section of the governor main spring lever.
1. Install the front oil seal. c. Apply the liquid gasket (TB1207B) to the gear
a. Apply enough engine oil to the felt section of case and install to the cylinder block.
the oil seal. Tightening torque:
b. Install the front oil seal to the timing gear case 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9
with a front oil seal installer. lb⋅ft}
Install it at the position due to the L dimension d. Assemble the packing and the governor cover
shown in the illustration. to the top of the gear case and tighten them to
Special tool the specified torque.
Front oil seal installer
5-8840-9031-0 Tightening torque:
7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7
mm {in} lb⋅ft}
L dimension 60.5±0.1 {2.382±0.0039}
Note:
Apply enough engine oil to the main and dust lip sec-
tion of the front oil seal before installing.
1A-76 4LE2 Engine Mechanical
4. Install the oil pan.
Refer to 1A-66, “Installation, Piston, Connecting
1 Rod”.
5. Install the control link.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
2
6. Install the injection pump.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
7. Install the injection pump housing cover.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
3 8. Install the solenoid ASM.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
9. Install the fuel pipe.
Refer to 1A-29, “Installation, Engine Exterior
WSLE0137
Equipment”.
Name
10. Install the injection pipe.
1. Governor Cover
Refer to 1A-29, “Installation, Engine Exterior
2. Timing Gear Case
Equipment”.
3. Front Oil Seal
11. Install the generator bracket.
3. Install the crank pulley. Refer to 1A-15, “Installation, Engine Accessories”.
a. Install the crank pulley to the crankshaft. 12. Install the generator.
b. Block the crankshaft from rotating, assemble Refer to 1A-15, “Installation, Engine Accessories”.
the washer, and tighten it with the mounting 13. Install the fan pulley.
bolts. Refer to 1A-15, “Installation, Engine Accessories”.
14. Install the cooling fan and the fan belt.
CAUTION: Refer to 1A-15, “Installation, Engine Accessories”.
Replace the bolt and washer with new ones.
Tightening torque:
167 — 186 N⋅m {17.0 — 19.0 kgf⋅m/123.2 —
137.2 lb⋅ft}

3
1

WSLE0140

Name
1. Washer
2. Crank Pulley
3. Front Oil Seal
4. Crankshaft
 4LE2 Engine Mechanical 1A-77
Torque Specifications

N m (kg m / lb ft)
7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

167 - 186 (17.0 - 19.0 / 123.2 - 137.2)

WSLE0305
1A-78 4LE2 Engine Mechanical

Crankshaft Rear Oil Seal

Components

3
1 2

WSLE0316

Name
1. Flywheel Housing 3. Retainer
2. Rear Oil Seal

Removal
1. Remove the starter.
Refer to 1A-14, “Removal, Engine Accessories”.
2. Remove the flywheel.
Refer to 1A-70, “Removal, Flywheel”.
3. Remove the flywheel housing.
a. Remove the mounting bolt to the cylinder block.
b. Gently tap the housing by a plastic hammer or
similar tool to remove it from the cylinder block.

WSLE0138
 4LE2 Engine Mechanical 1A-79
4. Remove the retainer.
Remove the retainer with the rear oil seal from the
back of the cylinder block.

CAUTION: 1
Since liquid gasket is applied, be careful not to
remove it forcedly to damage or deform it.
4
3

1 2

WSLE0329

Name
1. Retainer
2. Rear Oil Seal
3. 1.75 mm {0.069 in}
4. 1.25 mm {0.049 in}

2. Install the retainer.

WSLE0226
Apply a thin coat of engine oil to the lip section of
Name the oil seal and install the retainer. (Apply the liquid
1. Retainer gasket TB1207B)
2. Rear Oil Seal
CAUTION:
5. Remove the rear oil seal from the retainer. Be sure to prevent the big end of the crankshaft
• Remove the oil seal with a screwdriver avoiding from adhering of dust or foreign materials.
damage to the oil seal contact surface on the
retainer. The tightening order of the retainer is as shown in
the illustration and you should tighten it to the fol-
lowing torque.
Installation Tightening torque:
1. Install the rear oil seal to the retainer with a rear oil 7.8 — 11.8 N⋅m {0.8 — 1.2 kgf⋅m/5.8 — 8.7 lb⋅ft}
seal installer.
Special tool
Rear oil seal installer
5-8840-9032-0

6 4

8 7

1 2

3 5

WSLE0128
1A-80 4LE2 Engine Mechanical
3. Install the flywheel housing to the cylinder block.
Tightening torque:
41.2 — 54.9 N⋅m {4.2 — 5.6 kgf⋅m/30.4 — 40.5
lb⋅ft}

WSLE0138

4. Install the flywheel.

Refer to 1A-71, “Installation, Flywheel”.
5. Install the starter.
Refer to 1A-15, “Installation, Engine Accessories”.

Torque Specifications

N m (kg m / lb ft)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

41.2 - 54.9 (4.2 - 5.6 / 30.4 - 40.5)

WSLE0306
 4LE2 Engine Mechanical 1A-81

Timing Gear Train

Components

WSLE0317

Name
1. Thrust Collar 3. Idle Gear Shaft
2. Idle Gear 4. Crankshaft Gear

Removal 8. Remove the injection pump housing cover.

Refer to 1A-23, “Removal, Engine Exterior Equip-
1. Remove the cooling fan and the fan belt.
ment”.
Refer to 1A-14, “Removal, Engine Accessories”.
9. Remove the injection pump.
2. Remove the fan pulley.
Refer to 1A-23, “Removal, Engine Exterior Equip-
Refer to 1A-14, “Removal, Engine Accessories”.
ment”.
3. Remove the generator.
10. Remove the control link.
Refer to 1A-14, “Removal, Engine Accessories”.
Refer to 1A-23, “Removal, Engine Exterior Equip-
4. Remove the generator bracket. ment”.
Refer to 1A-14, “Removal, Engine Accessories”.
11. Remove the oil pan.
5. Remove the injection pipe. Refer to 1A-58, “Removal, Piston, Connecting
Refer to 1A-23, “Removal, Engine Exterior Equip- Rod”.
ment”.
12. Remove the crank pulley.
6. Remove the fuel pipe. Refer to 1A-73, “Removal, Crankshaft Front Oil
Refer to 1A-23, “Removal, Engine Exterior Equip- Seal”.
ment”.
13. Remove the timing gear case.
7. Remove the solenoid ASM. Refer to 1A-73, “Removal, Crankshaft Front Oil
Refer to 1A-23, “Removal, Engine Exterior Equip- Seal”.
ment”.
14. Remove the idle gear and the idle gear shaft.
1A-82 4LE2 Engine Mechanical
Inspection
Inspection of backlash of the timing gear
Before removing the timing gear, measure backlash of
it.
1. Put a dial gauge on the tooth of the measured
gear.
2. Move the gear right and left lightly, and read the
deflection of the dial gauge.
If it exceeds the limit, replace the timing gear.

Backlash of the timing gear mm {in}

Location Standard Service limit
value 1
Crank gear/Idle gear 0.04 {0.0016} 0.2 {0.008}
Idle gear/Camshaft gear 0.03 {0.0012} 0.2 {0.008}
WSLE0225

Name
1. Thickness Gauge

Inspection of idle gear and gear shaft

1. If there is excessive wear or damage on the sliding
surface of the idle gear and the gear shaft, and on
the inside of the idle gear bushing, replace either
the shaft or the gear.
2. If there is stepped wear or something on the idle
gear and the thrust collar, replace either the idle
gear or the thrust collar.

WSLE0224

Inspection of axial play of the idle gear

Measure an axial play of the gear before removing the
idle gear.
1. Insert a thickness gauge between the idle gear and
the thrust collar to measure a clearance. 1
2. If the measurement exceeds the limit, replace
either the thrust collar or the idle gear.

Axial play of idle gear mm {in}

Standard value Service limit
WSLE0246
0.058 — 0.115 {0.0023 — 0.2 {0.008} Name
0.0045}
1. Idle Gear Shaft

Inspection of uneven wear of the idle gear

shaft
Measure the outside diameter of the idle gear shaft
using a micrometer, and calculate the amount of
uneven wear.
 4LE2 Engine Mechanical 1A-83
Installation
mm {in}
1. Install the idle gear.
Nominal dimension Service limit Repairing procedure
a. Install the idle gear shaft to the cylinder block.
φ45 {1.772} 0.1 {0.0039} Replace. (The position where the oil hole is located
obliquely upward)
b. Apply engine oil to the bushing surface and the
tooth surface of the idle gear, and the idle gear
shaft. Then assemble the idle gear with its tim-
ing points (black dots) facing the forward direc-
tion and aligning the timing points (black dots)
of the camshaft gear and the crank gear at the
same time.

1
2

WSLE0105

Inspection of clearance between the idle gear

bushing and the shaft 4 3
Measure the idle gear bushing bore and calculate the
clearance between the bushing and the outside diame-
ter of the idle gear shaft.
WSLE0132

mm {in} Name
Standard value Service limit Repairing procedure
1. Camshaft Gear
2. Timing Point
0.025 — 0.085 Replace the idle gear 3. Crank Gear
0.2 {0.008}
{0.00098 — 0.00330} or the shaft. 4. Idle Gear

c. Apply engine oil to the thrust collar sliding sur-

face and the threads and the seating surfaces
of the bolts. Then install to the idle gear with the
chamfered side of the collar facing the outside,
and tighten it with the bolts.
Tightening torque:
20.6 — 30.4 N⋅m {2.1 — 3.1 kgf⋅m/15.2 — 22.4
lb⋅ft}

CAUTION:
Assemble the idle gear shaft aligning the position-
ing pin with the knock hole.
1A-84 4LE2 Engine Mechanical
13. Install the fan pulley.
Refer to 1A-15, “Installation, Engine Accessories”.
14. Install the cooling fan and the fan belt.
Refer to 1A-15, “Installation, Engine Accessories”.

3
2

WSLE0131

Name
1. Thrust Collar
2. Timing Point
3. Idle Gear
4. Idle Gear Shaft
5. Timing Point

2. Install the timing gear case.

Refer to 1A-75, “Installation, Crankshaft Front Oil
Seal”.
3. Install the crank pulley.
Refer to 1A-75, “Installation, Crankshaft Front Oil
Seal”.
4. Install the oil pan.
Refer to 1A-66, “Installation, Piston, Connecting
Rod”.
5. Install the control link.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
6. Install the injection pump.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
7. Install the injection pump housing cover.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
8. Install the solenoid ASM.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
9. Install the fuel pipe.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
10. Install the injection pipe.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
11. Install the generator bracket.
Refer to 1A-15, “Installation, Engine Accessories”.
12. Install the generator.
Refer to 1A-15, “Installation, Engine Accessories”.
 4LE2 Engine Mechanical 1A-85
Torque Specifications

N m (kg m / lb ft)

20.6 - 30.4 (2.1 - 3.1 / 15.2 - 22.4)

WSLE0307
1A-86 4LE2 Engine Mechanical

Camshaft
Components

10

6
5
4

WSLE0318

Name
1. Sleeve 6. Bearing
2. Lock Nut 7. Pin
3. Flyweight ASM 8. Camshaft
4. Camshaft Gear 9. Wear Ring
5. Snap Ring 10. Bearing

Removal 7. Remove the camshaft gear.

1. Remove the EGR cooler and the bracket. a. Pull out the sleeve from the end of the cam-
Refer to 1A-23, “Removal, Engine Exterior Equip- shaft.
ment”. b. Remove the lock nut from the camshaft gear,
2. Remove the cylinder head cover. and remove the flyweight ASM and the cam-
Refer to 1A-23, “Removal, Engine Exterior Equip- shaft gear.
ment”. 8. Remove the camshaft.
3. Remove the rocker arm bracket. a. Remove the snap ring which holds the front
Refer to 1A-40, “Removal, Rocker Arm Shaft”. bearing of the camshaft from the ring groove of
4. Remove the cylinder head. the cylinder block.
Refer to 1A-47, “Removal, Cylinder Head”. b. Pull out the camshaft with the bearing from the
5. Remove the tappet. cylinder block.
Refer to 1A-47, “Removal, Cylinder Head”.
6. Remove the timing gear case.
Refer to 1A-73, “Removal, Crankshaft Front Oil
Seal”.
 4LE2 Engine Mechanical 1A-87
Inspection of journal and cam
1. Height of the cam (A − B)

mm {in}
Standard Service limit Repairing
value procedure
1
Inlet 6.13 {0.241} 5.83 {0.230}
Replace.
Exhaust 6.43 {0.253} 6.13 {0.241}
2
2. Center journal diameter (the dimensions in X − X
and Y − Y directions)

mm {in}
Nominal dimension Service limit Repairing procedure
φ52 {2.047} φ51.92 {2.044} Replace.

WSLE0052
3. Uneven wear of the journal (the difference
Name
between the measurements in X − X and Y − Y
1. Camshaft
directions)
2. Snap Ring
mm {in}
Nominal dimension Service limit Repairing procedure
Inspection
φ52 {2.047} 0.05 {0.002} Replace.
Inspection of camshaft
Check the journal portion and the cam portion for wear,
damage, and other abnormality.

CAUTION:
The ball bearings are fitted to the front and rear
parts of the camshaft. Also, the roller bearing is
press-fitted to the cylinder block at the center part.
Check that each bearing has no rattle and rotates
smoothly with this condition.

WSLE0082

WSLE0081

Name
1. Camshaft
1A-88 4LE2 Engine Mechanical

3 2 1

I II
I II
Y
A X X

B Y

WSLE0083 WSLE0237

Name
Inspection of camshaft runout 1. Normal
1. Put the camshaft on the V block. 2. Cracks
3. Pitching
2. Place the dial gauge to the center journal part.
4. Abnormal Contact
3. Rotate the camshaft once and read the deflection
of the indicator.
If the measured value exceeds the limit, replace Inspection for wear of the tappet outside
the camshaft. diameter
mm {in} Use a micrometer to measure the outside diameter of
the tappet.
Standard value Service limit Repairing procedure If the measured value exceeds the limit, replace the
0.02 {0.0008} or 0.1 {0.0039} Replace. tappet.
less
Outside diameter of the tappet mm {in}
Standard value Service limit
φ20.97 — 20.98 {0.8256 — 20.92 {0.8240}
0.8260}

WSLE0084

Inspection of tappet
Check the contact surface with the camshaft.
If there is pitching, defective contact, vermiculation, or WSLE0091
crack, replace the tappet.
 4LE2 Engine Mechanical 1A-89
Inspection of clearance between the tappet Installation
and the cylinder block 1. Install the camshaft ASM.
Use the bore gauge to measure the bore diameter of a. Apply engine oil to the camshaft journal, bear-
the tappet insertion hole on the cylinder block and cal- ing, cam surface, and the inside of the cylinder
culate the clearance. block bearing. Then assemble the camshaft
ASM.
Clearance between the tappet and the cylinder mm {in}
block hole CAUTION:
Standard value Service limit Be careful not to damage the bearing when assem-
bling.
0.020 — 0.054 {0.0008 — 0.1 {0.0039}
0.0021}
b. Install the snap ring to the outside of the front
bearing, and check that the camshaft rotates
smoothly.

WSLE0238

WSLE0129

2. Install the camshaft gear and the sleeve.

a. Install the camshaft gear to the camshaft with
its timing point (black dot) facing the forward
direction.
b. Assemble the flyweight, apply engine oil to the
thread and the seating surface of the lock nut,
and tighten.
Tightening torque:
165 — 185 N⋅m {16.8 — 18.8 kgf⋅m/121.7 —
136.4 lb⋅ft}
c. Apply engine oil to the sleeve shaft and the slid-
ing surface of the flyweight.
d. Insert the sleeve collar section to the concave
portion of the flyweight. Then insert the sleeve
shaft to the end of the camshaft.

Note:
Check that the sleeve moves smoothly.
1A-90 4LE2 Engine Mechanical
3. Install the timing gear case.
Refer to 1A-75, “Installation, Crankshaft Front Oil
Seal”.
4. Install the tappet.
5
4 Refer to 1A-56, “Installation, Cylinder Head”.
3
5. Install the cylinder head.
Refer to 1A-56, “Installation, Cylinder Head”.
2
6. Install the rocker arm bracket.
1 Refer to 1A-44, “Installation, Rocker Arm Shaft”.
7. Install the cylinder head cover.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.

WSLE0130

Name
1. Sleeve
2. Lock Nut
3. Flyweight
4. Timing Point
5. Camshaft Gear

Torque Specifications

N m (kg m / lb ft)

165 - 185 (16.8 - 18.8 / 121.7 - 136.4)

WSLE0308
 4LE2 Engine Mechanical 1A-91

Crankshaft
Components

WSLE0319

Name
1. Crankshaft Gear 3. Crankshaft
2. Bearing Cap

Removal 8. Remove the crankshaft rear oil seal.

Refer to 1A-78, “Removal, Crankshaft Rear Oil
1. Remove the engine accessories.
Seal”.
Refer to 1A-14, “Removal, Engine Accessories”.
9. Remove the idle gear.
2. Remove the engine exterior equipment.
Refer to 1A-81, “Removal, Timing Gear Train”.
Refer to 1A-23, “Removal, Engine Exterior Equip-
ment”. 10. Remove the camshaft.
Refer to 1A-86, “Removal, Camshaft”.
3. Remove the rocker arm bracket.
Refer to 1A-40, “Removal, Rocker Arm Shaft”.
4. Remove the cylinder head.
Refer to 1A-47, “Removal, Cylinder Head”.
5. Remove the piston and the connecting rod.
Refer to 1A-58, “Removal, Piston, Connecting
Rod”.
6. Remove the flywheel.
Refer to 1A-70, “Removal, Flywheel”.
7. Remove the crankshaft front oil seal.
Refer to 1A-73, “Removal, Crankshaft Front Oil
Seal”.
1A-92 4LE2 Engine Mechanical
11. Remove the oil pump ASM from the cylinder block. Disassembly
1. Remove the gear from the crankshaft.

Inspection
1 Inspection of axial play of the crankshaft
Measure an axial play before removing the crankshaft.
1. Pull the crankshaft all the way to the front.
2. Insert the thickness gauge to the front side of No.2
journal portion of the crankshaft (thrust bearing
installation part) and measure the play.
If the measured value exceeds the limit, replace
the thrust bearing.

Axial play of crankshaft mm {in}

Standard value Service limit
0.058 — 0.208 {0.0023 — 0.3 {0.012}
WSLE0223
0.0082}
Name
1. Cylinder Block

12. Remove the crankshaft.

a. Gradually loosen the bolts of each bearing cap
evenly in the order shown in the illustration.
Tap the cap lightly with a copper hammer to
1
remove it with the bearing.
b. Remove the crankshaft ASM.
c. Remove the thrust bearing from No.2 journal of
the cylinder block. 2

CAUTION:
Attach tags with each cylinder number to the
removed cylinder parts to identify installation posi-
tions, and put them in order.

WSLE0228

Name
1. Measurement of Play
1 2. Front

1 5 4 Inspection of crankshaft
9 8
Check for wear, damage, clogging of oil port and other
2
abnormality.
6 10 7
2 3

WSLE0229

Name
1. Arrow Mark
2. Front
 4LE2 Engine Mechanical 1A-93
Inspection of outside diameter of the 2. Uneven wear (the difference between the mea-
crankshaft journal surements in X − X, Y − Y directions)
Measure the outside diameter of the crankshaft journal, mm {in}
and calculate the amount of wear and uneven wear.
If it exceeds the limit, replace the crankshaft. Service limit Repairing procedure

1. Nominal dimension Pin 0.05 {0.002} Replace the crankshaft.

mm {in} 3. Amount of wear

Journal φ60 {2.362}
mm {in}

2. Uneven wear (the difference between the mea- Service limit Repairing procedure
surements in X − X, Y − Y directions) Pin 0.13 {0.005} Replace the crankshaft.
mm {in}
Service limit Repairing procedure
Journal 0.05 {0.002} Replace the crankshaft.

3. Amount of wear

mm {in}
Y
Service limit Repairing procedure
Journal 0.14 Replace the crankshaft. X X
{0.0055}
Y

WSLE0098

Y
Inspection of clearance between the journal
X X and the bearing
Y
Tighten the bearing cap to the specified torque and
measure the inside diameter of the bearing to calculate
the clearance.
Tightening torque:
83.4 — 93.2 N⋅m {8.5 — 9.5 kgf⋅m/61.5 — 68.7 lb⋅ft}

Clearance between the journal and mm {in}

WSLE0098 the bearing
Standard value Service limit Repairing proce-
Inspection of outside diameter of the dure
crankshaft pin
0.029 — 0.072 0.11 {0.0043} Replace the bear-
Measure the outside diameter of the crankshaft pin, {0.0011 — 0.0028} ing.
and calculate the wear and the uneven wear.
If it exceeds the limit, replace the crankshaft.
1. Nominal dimension

mm {in}
Pin φ46 {1.811}
1A-94 4LE2 Engine Mechanical
Inspection of crankshaft runout
Hold the journal portions on both ends of the crankshaft
with V block, and measure the runout of the center jour-
nal using the dial gauge.

mm {in}
Standard value Service limit Repairing proce-
dure
0.025 {0.00098} or 0.05 {0.002} Replace.
less

WSLE0099

Inspection of tension of the journal main

bearing
Check whether the tension of the bearing is sufficient.

mm {in}
Standard value Service limit
W = 64.5 — 65.5 {2.539 — 2.579}
D = φ64 {2.520} W = 64.1 {2.524}
L = 0.02 — 0.06 {0.0008 — 0.00236}
WSLE0100
Repairing procedure: use the one with extrusion and
tension, and be careful about sticking of the rear side. Inspection of crankshaft gear
Standard for the bearing tension (reference) Check visually for damage and other abnormality.
Replace if there is damage or serious pitching.
1

4.9kN {1101.6lbf}
2

WSLE0242

Name WSLE0101
1. Tension (Free Condition)
2. Extrusion
 4LE2 Engine Mechanical 1A-95
Reassembly b. Wipe the rear side of the crankshaft bearing
and the inside of the crank bearing housing of
1. Install the crankshaft gear.
the cylinder block, and check that there is no
Put a brass stick on the gear and strike with a
foreign matter.
hammer to install.
c. Assemble the pawl of the bearing to the cutout
portion of the cylinder block securely, and apply
engine oil sufficiently to the inside of the bear-
ing (sliding surface).
2. Install the crankshaft.
Put the crankshaft on the cylinder block carefully.
3. Install the crankshaft lower bearing.
Assemble the thrust bearing with the oil groove
facing outward. (No.2 journal portion)

CAUTION:
• Be sure to prevent the installation position and
sliding surface of the bearing from adhering of
dirt.
• Be sure to prevent the backside of the bearing
(installation position) from adhering of oil.

WSLE0245

Installation 1
1. Install the crankshaft upper bearing.
a. While there are the oil holes and oil grooves on 2
the upper bearing (block side), there is none on
the lower bearing (bearing cap side). Take care
when assembling.

CAUTION:
If assembling the lower bearing and upper bearing 4
inversely, seizure occurs in the crankshaft bearing.
Be careful with it.
3

WSLE0123
1
Name
1. Thrust Bearing
2. Crankshaft
3. Upper Bearing Pawl
4. Lower Bearing Pawl
2

WSLE0122

Name
1. Upper Bearing
2. Lower Bearing
1A-96 4LE2 Engine Mechanical
4. Install the crankshaft bearing cap.
a. Install the bearings to each bearing cap and
apply engine oil sufficiently. Then assemble
them from the front so that the arrow marks on
the caps facing toward the front of the engine in
the order of the marking numbers. 1

b. Apply engine oil to the threads and the seating

surface of the bearing cap bolt. Then tighten
evenly in several batches in the order shown in
the illustration, and at the end, tighten to the
specified torque.
Tightening torque:
83.4 — 93.2 N⋅m {8.5 — 9.5 kgf⋅m/61.5 — 68.7
lb⋅ft}
c. After assembling, check that the crankshaft
rotates.
WSLE0133

Name
1. Cylinder Block

1
6. Install the camshaft.
10 7
Refer to 1A-89, “Installation, Camshaft”.
6
2 3 7. Install the idle gear.
5 4 3 2 1
Refer to 1A-83, “Installation, Timing Gear Train”.
5 4
9 1 8 8. Install the crankshaft rear oil seal.
Refer to 1A-79, “Installation, Crankshaft Rear Oil
Seal”.
9. Install the crankshaft front oil seal.
2
Refer to 1A-75, “Installation, Crankshaft Front Oil
Seal”.
10. Install the flywheel.
Refer to 1A-71, “Installation, Flywheel”.
WSLE0124 11. Install the pistons and connecting rods.
Name Refer to 1A-66, “Installation, Piston, Connecting
1. Arrow Mark Rod”.
2. Engine Oil Application 12. Install the cylinder head.
Refer to 1A-56, “Installation, Cylinder Head”.
5. Install the oil pump ASM. 13. Install the rocker arm bracket.
a. Pour engine oil to the oil pipe and installation Refer to 1A-44, “Installation, Rocker Arm Shaft”.
port of the oil strainer. 14. Install the engine exterior equipment.
b. Install the oil pump ASM to the cylinder block. Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
Tightening torque:
18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 — 20.9 15. Install the engine accessories.
lb⋅ft} Refer to 1A-15, “Installation, Engine Accessories”.
 4LE2 Engine Mechanical 1A-97
Torque Specifications

N m (kg m / lb ft)

83.4 - 93.2 (8.5 - 9.5 / 61.5 - 68.7)

WSLE0309
1A-98 4LE2 Engine Mechanical

Cylinder Block
Components

WSLE0310

Name
1. Cylinder Block

Removal 9. Remove the idle gear.

Refer to 1A-81, “Removal, Timing Gear Train”.
1. Remove the engine accessories.
Refer to 1A-14, “Removal, Engine Accessories”. 10. Remove the camshaft.
Refer to 1A-86, “Removal, Camshaft”.
2. Remove the engine exterior equipment.
Refer to 1A-23, “Removal, Engine Exterior Equip- 11. Remove the crankshaft.
ment”. Refer to 1A-91, “Removal, Crankshaft”.
3. Remove the rocker arm bracket.
Refer to 1A-40, “Removal, Rocker Arm Shaft”.
4. Remove the cylinder head.
Refer to 1A-47, “Removal, Cylinder Head”.
5. Remove the piston and the connecting rod.
Refer to 1A-58, “Removal, Piston, Connecting
Rod”.
6. Remove the flywheel.
Refer to 1A-70, “Removal, Flywheel”.
7. Remove the crankshaft front oil seal.
Refer to 1A-73, “Removal, Crankshaft Front Oil
Seal”.
8. Remove the crankshaft rear oil seal.
Refer to 1A-78, “Removal, Crankshaft Rear Oil
Seal”.
 4LE2 Engine Mechanical 1A-99
Inspection
Inspection of cylinder block
Check the cylinder block for wear, damage, water leak-
age and other abnormality.
1. Use a wooden plug or something to block the
Y
water passage and check for leakage.
Water leakage: Water pressure test 490 kPa {71 X X
psi} (for three minutes) Y
2. Check for damage by the color check.
3. Check the jet hole of the piston cooling and water
hole between bores for clogging or something
abnormal.

WSLE0058

Cylinder bore diameter and grade mark

Grade mark is stamped to each installation surface of
the injection pump of the cylinder block.

mm {in}
Bore diameter Grade
φ85.000 — 85.010 {3.3465 — 3.3468} A
φ85.011 — 85.020 {3.3469 — 3.3472} B
φ85.021 — 85.030 {3.3473 — 3.3476} C

WSLE0057

Inspection of cylinder bore

Measure the cylinder bore at specified positions with a
cylinder gauge.
Measurement position: 13 mm {0.512 in} lower from the
top surface. 1
(Measure in the X − X and Y − Y directions.)
(Near top ring)

mm {in}
Nominal Service limit Repairing procedure
dimension
φ85 φ85.2 Perform boring along the pis-
{3.3465} {3.354} ton and perform honing.

CAUTION:
• Oversized piston and piston ring are set to 0.25 WSLE0059

mm {0.0098 in}. Name

• Be sure to perform honing after boring. 1. Bore Grade Mark (Marking Position)
Honing should be at 0 to 0.03 mm {0 to 0.0012
in} against oversize diameter. Difference of
each cylinder bore should be 0.02 mm {0.0008
in} or less.
1A-100 4LE2 Engine Mechanical
Inspection of top distortion
Place a straightedge on the four side-directions and the
two diagonal directions, and measure the distortion
with the thickness gauge.

mm {in}
Standard Abnormal Repairing procedure
value value (need
repair) H

Repair it with a surface

grinder. The total amount of
repaired values of the cylinder
head and of the cylinder block
0.075
should not exceed 0.3
{0.00295} 0.15 {0.006}
{0.012}.
or less
If the measured value
exceeds the maximum
repaired value, replace the
WSLE0062
cylinder block.

Installation
1. Install the crankshaft.
Refer to 1A-95, “Installation, Crankshaft”.
2. Install the camshaft.
Refer to 1A-89, “Installation, Camshaft”.
3. Install the idle gear.
Refer to 1A-83, “Installation, Timing Gear Train”.
4. Install the crankshaft rear oil seal.
Refer to 1A-79, “Installation, Crankshaft Rear Oil
Seal”.
5. Install the crankshaft front oil seal.
Refer to 1A-75, “Installation, Crankshaft Front Oil
Seal”.
6. Install the flywheel.
Refer to 1A-71, “Installation, Flywheel”.
7. Install the pistons and connecting rods.
WSLE0060 Refer to 1A-66, “Installation, Piston, Connecting
Rod”.
(Reference) Cylinder block height mm {in}
8. Install the cylinder head.
Standard value Refer to 1A-56, “Installation, Cylinder Head”.
307.94 — 308.06 {12.124 — 12.128} 9. Install the rocker arm bracket.
Refer to 1A-44, “Installation, Rocker Arm Shaft”.
10. Install the engine exterior equipment.
Refer to 1A-29, “Installation, Engine Exterior
Equipment”.
11. Install the engine accessories.
Refer to 1A-15, “Installation, Engine Accessories”.
 4LE2 Engine Mechanical 1A-101

Special Tool
List of Special Tool Illustration Tool No./Tool Name/Rank

Illustration Tool No./Tool Name/Rank

1-8522-1029-0
Piston ring setting tool
5-8840-2675-0 Rank B
J-26999-12
Compression gauge
Rank B

5-8840-9018-0
J-8037
Piston ring compressor
5-8840-9029-0 Rank B
Compression gauge adapter
Rank A

5884090290

5-8840-9031-0
Front oil seal installer
5-8840-9016-0 Rank A
J-28829
Nozzle tester
5884090310
Rank B

5884090160

5-8840-9032-0
Rear oil seal installer
5-8840-9030-0 Rank A
J-29760
Valve spring remover
5884090320
Rank B

5884090300

5-8840-9035-0
Valve guide installer
Rank B

5884090350

5-8840-9033-0
JKM-1009
Valve seal setting tool
Rank B

5884090330
 4LE2 Cooling System 1B-1

Engine
4LE2 Cooling System
Table of Contents
Cooling System ..................................................... 1B-2
Service Precautions ........................................... 1B-2
Explanations on Functions and Operation ......... 1B-2
Function Check .................................................. 1B-4
Water Pump .......................................................... 1B-7
Components....................................................... 1B-7
Inspection........................................................... 1B-7
Thermostat ............................................................ 1B-8
Inspection........................................................... 1B-8
Fan Clutch, Cooling Fan ....................................... 1B-9
Inspection........................................................... 1B-9
1B-2 4LE2 Cooling System

Cooling System
Service Precautions Explanations on Functions and Operation
WARNING: Cooling water system
Do not remove the radiator cap when the cooling
The cooling water system, which is the forced circula-
water is at high temperature. Steam or boiling
tion system, consists of a water pump, thermostat, and
water will gush out and you may be burnt. To open
radiator as its main components.
the radiator cap, cover the cap with a thick cloth
when the cooling water is cool, release the pres-
sure by slowly turning the cap, and then remove
the cap.

3
2

1 4

7
6 5
WSLE0172

Name
1. Thermostat (Bottom Bypass type) 5. Cylinder Block
2. Oil Cooler 6. Water Pump
3. EGR Cooler 7. Radiator
4. Cylinder Head 8. Bypass Circuit
 4LE2 Cooling System 1B-3
Water pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.

1
2

WSLE0350

Name
1. Fan Center 3. Seal Unit
2. Impeller 4. Bearing Unit
1B-4 4LE2 Cooling System
Thermostat
The thermostat, which is a wax pellet type, has an valve initial opening temperature of 82±1.5°C {180±34.7°F}.

3
1

WSLE0349

Name
1. Valve 3. Jiggle Valve
2. Piston

Function Check Coolant

Cooling water level check 1. About the engine coolant concentration
• Check the cooling water level within the reserve • Take the concentration corresponding to the
tank and the level is appropriate when the cooling minimum temperature because the freezing
water level is within the MAX (upper limit) and MIN temperature varies according to the concentra-
(lower limit) range. In case the volume of the cool- tion of the engine coolant.
ing water is deficient, remove the reserve tank cap • Use only Isuzu genuine engine coolant.
and replenish the tank with a mixture of tap water • Use engine coolant with a mix ratio in the range
(soft water), distilled water or demineralized water of 30 to 60% because over heating is likely to
and antifreeze in the ratio of 1:1 until the level occur if the ratio is greater than 60% and corro-
comes close to the MAX line. sion prevention is inadequate if the ratio is less
than 30%.
Standard value
Cooling water level (engine 4.3 L {4.5 qts} (4LE2X)
only) 2.8 L {3.0 qts} (4LE2N)

ANTIFREEZE CONCENTRATION (㧑)

Cooling water leak check
• Use the radiator cap tester and apply a pressure of
FREEZING TEMPERATURE (͠)

200 kPa {29.0 psi} and check for leaks in the loca-
tions given below. Check that the radiator hose
and heater hose are not damaged or degraded
and the hose clamp is not loose.

Inspection location
• Radiator ASM, water pump ASM, radiator hose,
heater hose

WSUZ0149
 4LE2 Cooling System 1B-5
• Fix the temperature of the cooling water being
Freezing Maximum mix ratio Concentra- measured in the range of 0 to 50°C {32 to 122°F}.
temperature L {qts} tion
guideline of engine
• Measure the temperature and specific gravity and
Engine Tap water determine the concentration from the table given
coolant
coolant (soft water), below.
distilled water
or demineral-
ized water
−18°C {−0.4°F} 4.2 {4.4} 7.8 {8.2} 35%
−25°C {−13°F} 5.0 {5.3} 7.0 {7.4} 42%
−35°C {−31°F} 6.0 {6.3} 6.0 {6.3} 50%
−40°C {−40°F} 6.4 {6.8} 5.6 {5.9} 53%

2. Engine coolant concentration measurement

SPECIFIC GRAVITY
Methods for measuring specific gravity
• Measure the specific gravity and the temperature
of the cooling water using an antifreeze hydrome-
ter and thermometer.
Take precautionary measures as the boiled cool-
ing water may gush out at high temperatures if the
cap is removed.
• Use a deep container to suit the height of the spe-
cific gravity meter.

TEMPERATURE (͠)

WSUZ0148

Name
1. Antifreeze Hydrometer
2. Radiator
1B-6 4LE2 Cooling System
Coolant scope method
• Measure the concentration using the coolant
scope.

EGR cooler air bleeding procedure

When replacing the coolant, bleed air from the EGR
cooler with the following procedure.

Note:
Be sure to replace the coolant when it is cooled.

1. Loosen the air bleed plug (1) on the EGR cooler.

WSLE0355

2. Pour coolant into the radiator via its opening.

3. Tighten the plug when the coolant spills over from
the air bleed plug.

CAUTION:
If loosening the air bleed plug, be sure to replace
the copper packing with new one.

Note:
• Take care to prevent the spilt coolant from getting
the exhaust system parts wet.
• Be sure to wipe off the spilt coolant.
Tightening torque:
24.5 — 30.5 N⋅m {2.5 — 3.1 kgf⋅m/18.1 — 22.5
lb⋅ft}
4. Pour coolant into the radiator via its opening again
until it is filled.
5. After filling the radiator, idle the engine for approx.
5 minutes. Air in the cooler comes off and the cool-
ant level is lowered, then stop the engine. After
engine is cooled, check the radiator and the
reserve tank coolant levels. If they are low, replen-
ish the coolant.
 4LE2 Cooling System 1B-7

Water Pump
Components

WSLE0173

Name
1. Water Pump

Inspection Inspection of the bearing rattle

Appearance check
Rattle of the water pump ball bearing mm {in}
• Check for cracks or damage in the pump body.
Standard value Service limit Repairing proce-
• Check for cracks and corrosion in the impeller. dure
• Check for water leakage from the seal unit.
0.008 — 0.010 0.2 {0.008} Replace.
• If you find abnormalities, replace the water pump {0.00031 — 0.00040}
ASM.

Inspection of bearing
• Rotate the fan center while pushing it along the
radial direction. Confirm that there is no abnormal
noise and no excessive play.
• If you find abnormalities, replace the water pump
ASM.
1B-8 4LE2 Cooling System

Thermostat
Inspection
Replace it if there is wear, damage, or other abnormal-
ity.

Open start tem- °C {°F} 82±1.5 {180±34.7}

perature
Valve lifting mm {in} 8.0 {0.315} or more
height (95°C {203°F})

WSJJ0148

Name
1. Thermometer
2. Stirrer
3. A Piece of Wood
 4LE2 Cooling System 1B-9

Fan Clutch, Cooling Fan

Inspection 2. Inspection (single unit)
If wear, damage or any fault is found during the inspec- a. Warm up the bimetal area of the fan clutch
tion, replace or repair as required. using a heat gun until the temperature reading
on the thermistor reaches approx. 85°C
Visually check for damage, silicon grease leakage or {185°F}. Then check if considerable force
other faults. (clutch torque) is required to rotate the fan
clutch.
1. Inspection (on-vehicle)
At this time, if the fan clutch rotates easily, this
a. Before starting the engine, rotate the fan clutch indicates that the silicon grease is leaked
when it is cold by hand to check if it rotates eas- inside. Replace the fan clutch with new one.
ily.
b. Start the engine and warm it up until the tem-
perature of the fan clutch reaches approx. 85°C
{185°F}. Then stop the engine, and rotate the
fan clutch by hand to check if considerable Heat gun
force (clutch torque) is required to rotate. How-
ever, if the fan clutch rotates easily, this indi-
cates that the silicon grease is leaked inside.
Replace the fan clutch with new one.

Thermistor WSJJ0279

WSJJ0278
1B-10 4LE2 Cooling System
 4LE2 Fuel System 1C-1

Engine
4LE2 Fuel System
Table of Contents
Fuel System ..........................................................1C-2
Service Precautions ...........................................1C-2
Explanations on Functions and Operation .........1C-3
Governor ...............................................................1C-6
Service Precautions ...........................................1C-6
Components.......................................................1C-7
Disassembly.......................................................1C-9
Reassembly .....................................................1C-10
1C-2 4LE2 Fuel System

Fuel System
Service Precautions
Parts of the fuel system such as the internal part of the
nozzle holder, holes and clearances that form pas-
sages for fuel are finished to a very high degree of
accuracy. They are therefore highly sensitive to foreign
matter and the entry of foreign matter could cause
damage to the fuel passage. Take extreme care not to
allow foreign matter to enter.
If water removal agent is used in the fuel then it will
absorb moisture in the light oil and may cause rust.
Therefore, do not use water removal agent in the fuel
tank.
When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.), do not open the new part packaging until
installation.
Discard gaskets and O-rings and replace them with
new ones.

Work procedure
• The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, nozzle
holder, and injection pump.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, after
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage after
starting the engine.
 4LE2 Fuel System 1C-3
Explanations on Functions and Operation
Fuel system diagram

4
6

2
3

WSLE0180

Name
1. Fuel Tank 4. Injection Pump
2. Sedimenter 5. Nozzle Holder
3. Fuel Filter 6. Nozzle

Note:
• Be careful foreign material does not enter into the fuel system, because the precise fuel system is used.
1C-4 4LE2 Fuel System
Injection pump Nozzle holder
Note:
• Do not disassemble the injection nozzle installed
on this engine since it has the 2-stage open valve
pressure nozzle.
• If a overhaul of the nozzle and inspection and
adjustment of the injection pressure are required,
contact a BOSCH service center.

WSLE0328

WSLE0348
Name
Name 1. Nozzle
1. Rack Pin
 4LE2 Fuel System 1C-5
Fuel filter Sedimenter

2 5

1 6
4
7

WSLE0404

Name
1. Lever (Opening Position)
2. Lever (Closing Position)
3. Drain Plug
4. Ring Nut
1 5. Air Bleed Plug
6. Lever
7. Element
8. Cup
WSLE0327

Name
1. Cartridge CAUTION:
As the cartridge holds the fuel, take care not to
dirty around the system when removing it. Also,
take care of fire.

1. Rotate the water sedimenter lever until it stops with

its handle right above the supporting point (close)
to shut out the fuel flow.
2. Loosen the ring nut to remove the cup and take out
the element inside of the sedimenter.
3. Clean the cup and the element and install the new
packing in the ring nut.
4. Securely tighten the cup holding the element to the
body with the ring nut.
5. After installing, rotate the water sedimenter lever
until it stops with its handle right below the support-
ing point (open) to make the fuel flow.
Engine cannot be started or operated as the fuel is
shut out while the water sedimenter lever handle is
turned to the right above the supporting point.
1C-6 4LE2 Fuel System

Governor
Service Precautions
1. Engine performance test is required for adjustment
of the governor-related parts.
2. Measure the dimensions of A and B in the struc-
ture diagram (1) before disassembling, and set
them to the same dimensions when reassembling.
3. When you cannot carry out a performance test
after reassembling, do not disassemble it.
4. Apply engine oil to each sliding portion (the lever
end surface, the shaft hole and the outer circum-
ference of the shaft) when reassembling it.
5. Install the set spring securely to a groove of the pin
connecting the floating lever, taking care of the
assembly direction.
6. Before installing the start spring, make sure that
each lever moves by its weight.
7. After installing the start spring, make sure that
each lever moves smoothly.
Also, make sure that each spring operates nor-
mally.
 4LE2 Fuel System 1C-7
Components
Structure diagram (1)

3 5

A 6

2 7

1 8

22 9

21
10
20
11
19

B 12

18

13

17

14

16

15

WSLE0181

Name
1. Control Link 12. Tension Lever
2. Link Plate 13. Angleich
3. Start Spring 14. Full Load Stopper
4. Idle Speed Screw 15. Shifter
5. Idle Spring (Sub) 16. Flyweight
6. Fuel Cut Lever 17. Sleeve
7. Governor Shaft 18. Camshaft
8. Set Spring 19. Floating Lever
9. Governor Cover 20. Main Spring
10. Guide Lever 21. Lever (Main Spring)
11. Timing Gear Case 22. Injection Pump
1C-8 4LE2 Fuel System
Structure diagram (2)

18 20
17 19

16

15

A 21
14
22 23

13
24
12 26
B
8

25
9
A
11 27

7 29
10

5 6 28
30
4 A
35
34
33

3 2
B
31

32
36
1

WSLE0182

Name
1. Timing Gear Case 19. Snap Pin
2. Lever Bushing 20. Control Link
3. Control Lever 21. Link Plate
4. O-ring 22. Guide Piece
5. Speed Control Screw 23. Shifter
6. Speed Control Screw 24. Shaft (Floating Lever)
7. Start Spring Bracket 25. Shifter Shaft
8. Fuel Cut Shaft 26. Main Spring
9. Return Spring 27. Tension Lever
10. Idle Spring 28. Angleich
11. O-ring 29. Lever (Main Spring)
12. Fuel Cut Lever 30. Return Spring
13. Set Screw 31. Cam Gear
14. Cap Nut 32. Flyweight
15. Floating Lever 33. Sleeve
16. Guide Lever 34. Lever Bushing
17. Set Spring 35. Shaft
18. Start Spring 36. Full Load Set Screw
 4LE2 Fuel System 1C-9
Disassembly
Disassembly of the governor lever-related
components
1. Remove the levers and spring from the timing gear
case.

Disassembly of the full load stopper

1. Remove the full load stopper from the timing gear
case.

Disassembly of the governor cover

1. Remove the fuel cut lever and the idle spring-
related components from the governor lever.

Disassembly of the shifter

1. Remove the snap ring and the shaft to remove the
shifter from the guide lever.

Disassembly of the control lever-related

components
1. Remove the nut to remove the control lever.
2. Take off the hook on the return spring from the pro-
jection of the lever (main spring) and pin.
3. Remove the bushing.
4. Remove the return spring.
5. Remove the lever (main spring).
1C-10 4LE2 Fuel System
Reassembly
Reassembly of the control lever-related components
1. Put the lever (main spring) through lever holes of the timing gear case.

CAUTION:
Put both axes of the lever through lever holes alternately before assembling the bushings.

2. Put the return spring of the control lever through a axis of the lever (main spring).
3. Assemble the bushing.
Assemble the bushing of the lever (main spring), and then assemble the bushing of the control lever.

CAUTION:
Apply Loctite (No.601) to the outer circle of the bushing when assembling the bushing.

6 7

3
2
4

5
WSLE0183

Name
1. Lever (Main Spring) 5. Timing Gear Case
2. Bushing 6. Bushing
3. Return Spring 7. Protrusion
4. Pin

4. Assemble the hooks on both ends of the return spring (control lever) to the protrusion of the lever (main spring)
and pin securely.
5. Assemble the control lever.
After installing the O-ring to a groove of the bushing (control lever), assemble the washer and the control lever,
and tighten the nut.
Tightening torque:
11.8 — 17.7 N⋅m {1.2 — 1.8 kgf⋅m/8.7 — 13.1 lb⋅ft}
 4LE2 Fuel System 1C-11

1 4 6
7

WSLE0184

Name
1. Bushing 5. Control Lever
2. Groove 6. Spring Washer
3. O-ring 7. Nut
4. Washer

CAUTION:
• When tightening the control lever, fix the control lever.
(Fix the lever of the main spring. Do not over-tighten it.)
• After assembling, make sure that the control lever moves smoothly.

Reassembly of the shifter

1. Assemble the shifter to the guide lever, put the
shaft through it, and assemble the snap ring.
2. Make sure that the shaft rotates smoothly.
1
3. Make sure that the shifter moves smoothly.

4 WSLE0185

Name
1. Guide Lever
2. Shifter
3. Snap Ring
4. Shaft
1C-12 4LE2 Fuel System
Reassembly of the governor cover
Assemble the fuel cut lever and the idle spring-related components to the governor cover.

5 6
2 22 22

7
1 3
4 Z

9
12 10 8
14 11
13

Z
WSLE0186

Name
1. Folding Part 8. Idle Spring
2. Governor Cover 9. Nut
3. Return Spring 10. Spring Washer
4. Thrust Washer 11. Fuel Cut Lever
5. Stop 12. O-ring
6. Driving 13. Cutout Groove
7. Governor Cover 14. Shaft

1. Apply engine oil to the sliding surface of the gover-

nor cover when assembling the shaft.
2. Assemble the both ends of the return spring to the
cutout groove on the bottom of the cover and the
folding part of the lever securely.
3. After assembling, make sure that it moves
smoothly.
4. When assembling the governor cover to the timing
gear case, temporarily tighten it with dimension A
in the diagram 2 — 3 mm {0.079 — 0.118 in}.
Assemble B part after the performance set.

mm {in}
Dimension A (When temporarily assembling) 2 — 3
{0.079 — 0.118}
 4LE2 Fuel System 1C-13
Arrow view of WSLE0186 Reassembly of the full load stopper
Install the full load stopper to the timing gear case, and
temporarily tighten the nut.

1
2

4
1
B

5
A

6
2

7
3
8
12

9
11 10

WSLE0187

Name
1. Cap
2. Cap Nut WSLE0188

3. Packing Name
4. Lock Nut 1. Timing Gear Case
5. Packing 2. Full Load Stopper
6. Idle Screw 3. Set Screw Nut
7. Governor Cover
8. Tension Lever
9. Idle Spring
10. Snap Ring
11. Washer
12. Washer
1C-14 4LE2 Fuel System
Reassembly of the governor lever-related components
Assemble each lever and the spring to the timing gear case.

8
6
9
7
10

4
11

12

3
1
2 13

14

WSLE0189

Name
1. Plug 8. Main Spring Lever
2. Shaft (Floating Lever) 9. Tension Lever
3. Snap Piece 10. Main Spring
4. Guide Piece 11. Set Screw
5. Start Spring Eye 12. Start Spring
6. Lever Shaft 13. Guide Lever
7. Link Plate 14. Floating Lever
 4LE2 Electrical System 1D-1

Engine
4LE2 Electrical System
Table of Contents
Charging System...................................................1D-2 Components.....................................................1D-30
General Description ...........................................1D-2 Inspection.........................................................1D-31
Maintenance.......................................................1D-3
Generator (24V-30A).............................................1D-4
Structure.............................................................1D-4
Removal .............................................................1D-5
Installation ..........................................................1D-5
Torque Specifications.........................................1D-5
Specifications .....................................................1D-6
Connector Terminal............................................1D-6
Internal Connections ..........................................1D-6
Components.......................................................1D-7
Bench Test .........................................................1D-7
Trouble Diagnosis ..............................................1D-9
Maintenance Standard .......................................1D-9
Generator (24V-50A)...........................................1D-10
Structure...........................................................1D-10
Removal ...........................................................1D-11
Installation ........................................................1D-11
Torque Specifications.......................................1D-12
Specifications ...................................................1D-13
Connector Terminal..........................................1D-13
Internal Connections ........................................1D-13
Components.....................................................1D-14
Inspection (reference) ......................................1D-14
Bench Test .......................................................1D-17
Handling ...........................................................1D-18
Trouble and Action ...........................................1D-19
Generator (12V-20A)...........................................1D-20
Structure...........................................................1D-20
Removal ...........................................................1D-21
Installation ........................................................1D-21
Torque Specifications.......................................1D-21
Specifications ...................................................1D-22
Connector Terminal..........................................1D-22
Internal Connections ........................................1D-22
Components.....................................................1D-23
Maintenance Standard .....................................1D-23
Starting System...................................................1D-24
General Description .........................................1D-24
Service Precautions .........................................1D-25
List of Trouble Symptom ..................................1D-25
Starter (24V-3.2kW) ............................................1D-26
Specifications ...................................................1D-26
Components.....................................................1D-27
Removal ...........................................................1D-28
Installation ........................................................1D-28
No Load Test....................................................1D-28
Maintenance Standard .....................................1D-28
Starter (12V-2.0kW) ............................................1D-29
Specifications ...................................................1D-29
Output Characteristic (reference).....................1D-29
1D-2 4LE2 Electrical System

Charging System
General Description
The main charging system components are the batteries, the generator and the battery charge indicator light circuit.
The generator is a self-rectifying type with a built-in regulator.

1 2 3 4

WSLE0373

Name
1. Nut 5. Tension Adjusting Bolt
2. Sliding Piece 6. Generator
3. Generator Adjusting Plate 7. Lower Mounting Bolt
4. Adjusting Nut
 4LE2 Electrical System 1D-3
Maintenance Electrical tests
The most common indication of charging system trou- Before performing the following generator electrical
bles is an undercharged or overcharged battery. tests on the vehicle, be certain that the system wiring is
Since the battery itself may be defective, check the bat- not defective and generator belts are not slipping. Also,
tery first. Check if the battery is discharged because of the battery must be fully charged for a valid test of the
short circuit, or electrical components left turned on for charging system.
extended periods.
Keep the generator and all other electrical system ter- Note:
minals clean and tight. A loose or badly corroded termi- To avoid damage to the vehicle electrical system,
nal connection will create excessive resistance in the always observe the following precautions:
circuit and result in hard starting, dim lights, etc. • Do not polarize the generator.
Inspect the generator system at regular intervals and • Do not short across or ground any of the terminals
correct any potential causes of trouble before machine in the charging circuit.
performance is affected.
• Never operate the generator with the output termi-
nal open-circuited.
Diagnosis of charging system
• Be sure the generator and battery have the same
Trouble in the charging system will be evidenced as ground polarity.
one or more of the following three conditions:
• When connecting a charger or other battery to the
1. The battery charge warning lamp will stay on. machine's battery, connect negative to negative
2. An undercharged battery as evidenced by slow and positive to positive.
cranking.
3. An overcharge, or overvoltage, condition. 1. With the engine control switch “ON” and engine not
running, connect a voltmeter from terminal “E” to
Undercharged battery ground. The voltmeter should show 0 volts.
Inspection 2. With the engine control switch “ON” and engine not
running, connect a voltmeter from terminal “B” to
1. Accessories were not left turned on for extended
ground. The voltmeter should show 24 volts (24V
periods.
model) / 12 volts (12V model) or more.
2. Drive belt for proper tension.
3. With the engine control switch “ON” and the engine
3. The ECM main relay has been stuck ON with the not running, connect a voltmeter from white wire
key switch in OFF position. (Battery voltage is con- side of the connector to ground. The voltmeter
sumed.) should show 24 volts (24V model) / 12 volts (12V
4. Wiring and connections for corrosion or looseness. model) or more.
4. With the engine control switch “ON” and the engine
Overcharge (or Overvoltage) condition not running, the “charge” light should be on. This
A charging rate in excess of 29.5 volts (24V model) / 15 shows that the current is running into the initiating
volts (12V model) for a prolonged period may cause excitation circuit to the generator.
early electrical system failure. 5. With the engine running and the headlight high
Blown fuses, light bulbs burned out, and even battery beams (if equipped) turned on, read the voltage at
failure may result. If this condition exists, test the gen- the “B” post on the generator. The voltmeter
erator as described under “Generator Output Test” later should show 24 volts (24V model) / 12 volts (12V
in this section. model) or more.
Noisy generator 6. If steps 1 through 4 are not OK, check connectors
in the harness for looseness or corrosion and
Inspection retest.
1. Drive pulley for looseness. 7. If step 5 voltage is low, substitute a known good
2. Mounting bolts for looseness. regulator and test again. If the voltage is still low,
3. Bearings for dirt, damage, or wear. bench test the generator.
Generator noise may also be caused by the loose
belt, core touch, or worn or damaged diodes and/
or starter.
1D-4 4LE2 Electrical System

Generator (24V-30A)
Structure

WSLE0387

7 70
65
6 60
55
5 50
45
DRIVING TORQUE (N.m)

OUTPUT CURRENT(A)

4 40 COLD

35 DRIVING TORQUE
(HOT REF.)
3 30
25 HOT
2 20
15
1 10
IC REGULATOR
5
0 0
0 1 2 3 4 5 6
GENERATOR SPEED (X1000r/min)
WSLE0388 WSLE0397
 4LE2 Electrical System 1D-5
Removal Tightening torque:
M8 bolt: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7
• Battery ground cable
— 20.9 lb⋅ft}
1. Electrical wiring at the generator. M10 bolt: 41.2 — 55.0 N⋅m {4.2 — 5.6 kgf⋅m/
2. Loosen the adjusting nut. 30.4 — 40.6 lb⋅ft}
3. Loosen the ACG adjusting bolt. 2. ACG adjusting bolt.
4. Loosen the lower mounting bolt. 3. Adjusting nut.
• Loosen the lower mounting bolt while holding
Tightening torque:
the nut located on the back using a tool.
M8 nut: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 —
5. Drive belt. 20.9 lb⋅ft}
6. Generator. M10 nut: 41.2 — 55.0 N⋅m {4.2 — 5.6 kgf⋅m/30.4
— 40.6 lb⋅ft}

Installation 4. Electrical wiring at the generator.

• Battery ground cable
1. Generator.
• Install wiring (AV5.0 mm2, black) from the neg-
• Tighten the lower mounting bolt while holding
ative terminal of the generator to the engine
the nut located on the back using a tool.
ground and connect it to ground securely.

Torque Specifications

N m (kg m / lb ft)

M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6) M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)
M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)

M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)
WSLE0440
1D-6 4LE2 Electrical System
Specifications

Isuzu Part No. 8971822892

Nominal output (V-A) 24-30
Rated speed (r/min) 5,000
1 2
Regulator-type IC type
Regulated voltage (V) 28.5±0.5
Mass (kg) 5.1

Connector Terminal

Terminal symbol Lead wire color Wire specifica-

tions
R R AEX 0.75f
WSLE0398
L L AEX 0.75f
Name
1. R Terminal
2. L Terminal

Internal Connections

IC REGULATOR

WSLE0389
 4LE2 Electrical System 1D-7
Components

3 2

4
6 5

1
11

10

13

12

7
WSLE0390

Name
1. Pulley 8. Cover
2. Rear Bearing 9. Brush
3. Rotor 10. Regulator and Brush Holder
4. Retainer 11. Packing
5. Front Bearing 12. Rectifier
6. Front Bracket 13. Rear Bracket
7. Stator

Bench Test
Bench test is performed as follows.
1D-8 4LE2 Electrical System
Regulated voltage check Output current test
1. Wire as shown in the illustration. Output current test is performed to check if the genera-
Use an ammeter with 100 A rating and a voltmeter tor generates rated output.
with 30 V rating. 1. After checking regulated voltage, decrease the
generator speed until it stops.
2. Close the switch 1. The lamp should come on.
3. Set the value of no load resistance to maximum
(minimum current) and close the switch 2.
2 4 4. Increase the generator speed to 5,000 r/min and
keep it. Adjust the load resistance so that output
A current becomes maximum.
3 6 Keep this condition for 15 minutes and increase in
B temperature of the generator.
L
R 15 minutes later, set the generator speed to the
1 V 8 5 7 specified speed (1,800 r/min) and then adjust the
load resistance so that output current becomes
maximum in this condition.
In this time, if indication of ammeter is within speci-
fied value, the generator is normal.
If it is the specified value or less, check the genera-
tor again according to “Inspection”.
WSHK0100
Name
1. Voltmeter
2. Ammeter
3. Lamp (24 V, 3 W or less)
4. Switch 1
5. Battery (24 V)
6. Switch 2
7. Load Resistance
8. Generator

2. Close the switch 1. Leave the switch 2 open.

In this time, the lamp comes on.
If it does not, check the voltage on L terminal.
If the voltage is almost the same as battery volt-
age, check the generator.
If the voltage is low, lamp or the circuit is open.
3. Increase the generator speed gradually.
Make sure that the lamp goes off before the speed
reaches approx. 1,300 r/min.
Notice the voltage. If the voltage is not controlled
and exceeds 30 V, the IC regulator may be faulty.
If the voltage does not exceed battery voltage, the
generator does not generate electric power.
Check the generator again.
If the lamp does not go off, check the generator
again.
4. Set the generator speed to approx. 5,000 r/min
and read an ammeter. If the value is 5 A or less,
read indication on a voltmeter. This is regulated
voltage.
If an ammeter shows 5 A or more, keep charging
for a while until it shows below 5 A or replace the
battery with full-charged one.
If regulated voltage is out of specified value,
replace the regulator.
 4LE2 Electrical System 1D-9
Trouble Diagnosis

Symptom Trouble cause

No generation of elec- a. Defective IC regulator
tric power b. Open circuit in field coil
Output shortage a. Defective diode
b. Defective stator coil
c. Defective rectifier
d. Internal short circuit in field coil
Too high regulated a. Defective IC regulator
voltage
Noise a. Defective bearing
b. Defective rectifier
c. Foreign material in generator

Maintenance Standard

Item Standard value and limit

Isuzu Part No. 8-97182-289-2
Manufacturer code No. A002TA8383
Rated output V-A 24-30
Output characteristic Voltage V 27
(hot)
Current A 18 or more
Revolution r/min 1,800
speed
Field coil resistance Ω: at 20°C 6.4 — 7.6
Regulated voltage by regulator V 28-29
Revolution direction (viewed from pulley side) Clockwise
1D-10 4LE2 Electrical System

Generator (24V-50A)
Structure

WSLE0367
 4LE2 Electrical System 1D-11
Removal
• Battery ground cable
1. Electrical wiring at the generator.
2. Loosen the adjusting nut.
3. Loosen the ACG adjusting bolt.
4. Loosen the lower mounting bolt.
• Loosen the lower mounting bolt while holding
the nut located on the back using a tool.
5. Drive belt.
6. Generator.

Installation
1. Generator.
• Tighten the lower mounting bolt while holding
the nut located on the back using a tool.
Tightening torque:
M8 bolt: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7
— 20.9 lb⋅ft}
M10 bolt: 41.2 — 55.0 N⋅m {4.2 — 5.6 kgf⋅m/
30.4 — 40.6 lb⋅ft}
2. ACG adjusting bolt.
3. Adjusting nut.
Tightening torque:
M8 nut: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 —
20.9 lb⋅ft}
M10 nut: 41.2 — 55.0 N⋅m {4.2 — 5.6 kgf⋅m/30.4
— 40.6 lb⋅ft}
4. Electrical wiring at the generator.
• Battery ground cable
• Install wiring (AV5.0 mm2, black) from the neg-
ative terminal of the generator to the engine
ground and connect it to ground securely.
1D-12 4LE2 Electrical System
Torque Specifications

N m (kg m / lb ft)

M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6) M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)
M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)

M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)
WSLE0440
 4LE2 Electrical System 1D-13
Specifications

Isuzu Part No. 8980890630

Nominal output (V-A) 24-50
Rated speed (rpm) 5,000
1 2
Regulator-type IC type
Regulated voltage (V) 28.5±1
Mass (kg) 9.2

Connector Terminal

Terminal symbol Lead wire color Wire specifica-

tions
R R AEX 0.75f
WSHK0101
L L AEX 0.75f
Name
1. R Terminal
2. L Terminal

Internal Connections

SG L

IC
REGULATOR

WSHK0102
1D-14 4LE2 Electrical System
Components

5
6
7
8 3 12

11
10
9 13
18

15
14

19

23
21
20
2
1

17

16
22
WSLE0369

Name
1. Screw 13. Collar
2. Cover 14. Ball Bearing
3. Through Bolt 15. Rotor Assembly
4. Rotor, Front Bracket Assembly 16. Screw
5. Nut, Washer 17. Field Coil Assembly
6. Pulley 18. Stator Assembly
7. Fan 19. Holder
8. Collar 20. Regulator Assembly
9. Screw 21. Bolt (B Terminal)
10. Retainer 22. Condenser
11. Ball Bearing 23. Rectifier Assembly
12. Front Bracket

Inspection (reference)
CAUTION:
This section describes the inspection method after
disassembly as reference.
Note that the disassembly and maintenance per-
formed by the market is not included in the product
warranty.
 4LE2 Electrical System 1D-15
Diode Diode for initiating excitation, resistor
Check for continuity of forward and inverse directions Check for continuity between connector terminals R
with a tester. Normal diodes show low resistance in for- and L with a tester (at Ω × 100 range). Normal diodes
ward direction and high resistance in inverse one. and resistors show low resistance in forward direction
Judge that they are faulty other than those above. and high resistance in inverse one.
Judge that they are faulty other than those above.

WSHK0104
WSHK0106
Condenser
Charge the condenser with a tester (at Ω × 1000
range), and connect a tester lead inversely. Judge it as
normal if the needle on a meter deflects a little and
returns to the original position.
Judge that they are faulty other than those above.

WSHK0105
1D-16 4LE2 Electrical System
Field coil Stator coil
• To judge the insulating condition of field coil, mea- • To judge the insulating condition of stator coil,
sure between the protrusion portions and core of measure between the stator coil and core with a
the coil with a tester (at Ω × 1000 range). Judge as tester (at Ω × 1000 range). Judge as faulty if it has
faulty if it has continuity. continuity.

WSHK0107 WSHK0109
• Measure between the protrusion portions of field • Judge as normal if there is continuity between N
coil with a tester, and judge as normal if the resis- lead of stator coil and three leads.
tance is about 6.7Ω (20°C {68°F}).

WSHK0110
WSHK0108
 4LE2 Electrical System 1D-17
Bearing Bench Test
• Check if the bearing rotates smoothly or has no noise. In the performance test of generator, connect as fol-
If the result of the inspection is unsatisfactory, lows and measure the regulated voltage and output
replace the bearing. current.

WSHK0111

Actual wiring diagram for performance test of IC regulator built-in generator

2 3 SW 1 SW 2

V 1

6 7

WSLE0368

Name
1. Voltmeter 5. Clamp Tester Ammeter
2. R Terminal 6. Battery 24 V
3. L Terminal 7. Variable Resistor
4. Charging Lamp 24 V-3 W
1D-18 4LE2 Electrical System
Regulated voltage measurement of regulator Handling
Close SW1 switch, and warm-up five to ten minutes at Be careful with the following when handling a genera-
approx. 1500 rpm in generator until an ammeter shows tor.
6 A or less. • Connecting the polarities of battery inversely
After confirming that an ammeter shows between 2 and causes generator diode to be broken.
6 A, set the generator between approx. 3000 to 4000
• While the engine runs, Never disconnect the wiring
rpm. If a voltmeter shows between 27.5 and 29.5 V, the
of battery terminal and charging circuit.
regulated voltage of regulator is normal.
If the ammeter shows 6 A or more, charge the battery • Wiring connection to terminal must be performed
for a while or replace it with full-charged battery. properly according to terminal symbol.
Replace the regulator if the voltmeter shows out of • Do not perform megger test on semiconductor
range between 27.5 and 29.5 V. device.
• Be sure to disconnect the battery terminal (−)
Specified value of regulated voltage
before inspection on equipment.
27.5 — 29.5 V (+25°C {77°F}) • Do not open/close the battery relay switch while
the engine runs.
Measurement of the output current • Disconnect the battery terminal when charging
Close SW1 and SW2 switches, and raise the generator from external source such as quick charge.
speed to 5000 rpm. While keeping the voltmeter show- • Do not pour steam cleaner or water directly on it.
ing 27 V, measure the maximum value of output current • After connecting to B terminal and E terminal,
with a variable resistor. tighten them to the following torque.
In this time, judge as normal if the output current is 50 B terminal: 4.9 — 6.9 N⋅m {50.0 — 70.4 kgf⋅cm/
A or more. 43.4 — 61.1 lb⋅in}
E terminal: 4.9 — 6.9 N⋅m {50.0 — 70.4 kgf⋅cm/
Note:
43.4 — 61.1 lb⋅in}
• Do not cut off battery circuit during generator rotat-
• Refer to 1A-4, “Function Check, ISUZU Diesel
ing.
Engine” for tension adjustment of the v-belt.
• Do not connect to L terminal if the charging lamp
(24 V-3 W) is not used.
Never connect L terminal and B circuit directly.
Diode for excitation may be broken.
• The electrical load from the L terminal should be
1.0 A or less continuously.
 4LE2 Electrical System 1D-19
Trouble and Action

Trouble symptom Trouble location Trouble cause Action to be

taken
Charging is impossi- Wiring and ammeter Open or short circuit, disconnection Repair.
ble.
Generator Open circuit, short to ground, short circuit in each coil Replace.
Broken diode Replace.
Regulator Defective regulator Replace.
Poor contact in terminal of regulator Repair.
Insufficient charging Wiring Open or short circuit, looseness in connection Repair.
Generator Looseness of generator drive belt Repair.
Layer or short circuit in field coil Replace.
Layer or short circuit in stator coil Replace.
Defective diode Replace.
Poor contact in each terminal Repair.
Regulator Defective regulator Replace.
Poor contact in terminal of regulator Repair.
Overcharging Regulator Defective regulator Replace.
Unstable charging Wiring Intermittent contact or nearly disconnected connection in wiring Repair.
current
Generator Looseness of generator drive belt Repair.
Short circuit or nearly disconnected connection in field coil Repair.
Short circuit or nearly disconnected connection in stator coil Repair.
Poor contact in each terminal Repair.
Regulator Defective regulator Replace.
Poor contact in terminal of regulator Repair.
Noisy generator Generator Improper installation of generator Repair.
Defective bearing Replace.
Contact of rotor core and stator core Repair.
Defective diode Replace.
Short circuit in stator coil Replace.
1D-20 4LE2 Electrical System

Generator (12V-20A)
Structure

WSLE0432

25
MAX
B I DC
20
OUTPUT CURRENT (A)

MIN

I 15

R
HIC
10
L

3
0 1 2 3 4 5 6 7 10
GENERATOR SPEED N (r/min)

WSLE0433 WSLE0434
 4LE2 Electrical System 1D-21
Removal Tightening torque:
M8 bolt: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7
• Battery ground cable
— 20.9 lb⋅ft}
1. Electrical wiring at the generator. M10 bolt: 41.2 — 55.0 N⋅m {4.2 — 5.6 kgf⋅m/
2. Loosen the adjusting nut. 30.4 — 40.6 lb⋅ft}
3. Loosen the ACG adjusting bolt. 2. ACG adjusting bolt.
4. Loosen the lower mounting bolt. 3. Adjusting nut.
• Loosen the lower mounting bolt while holding
Tightening torque:
the nut located on the back using a tool.
M8 nut: 18.6 — 28.4 N⋅m {1.9 — 2.9 kgf⋅m/13.7 —
5. Drive belt. 20.9 lb⋅ft}
6. Generator. M10 nut: 41.2 — 55.0 N⋅m {4.2 — 5.6 kgf⋅m/30.4
— 40.6 lb⋅ft}

Installation 4. Electrical wiring at the generator.

• Battery ground cable
1. Generator.
• Install wiring (AV5.0 mm2, black) from the neg-
• Tighten the lower mounting bolt while holding
ative terminal of the generator to the engine
the nut located on the back using a tool.
ground and connect it to ground securely.

Torque Specifications

N m (kg m / lb ft)

M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6) M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)
M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)

M8 : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

M10 : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)
WSLE0440
1D-22 4LE2 Electrical System
Specifications

Isuzu Part No. 8972268408

Nominal output (V-A) 12-20
Rated speed (r/min) 5,000
Regulator-type IC type
Regulated voltage (V) 13.8±0.5
Mass (kg) 2.5

Connector Terminal
1 2 3
Terminal symbol Lead wire color Diameter
I L 0.75f
R W/G 0.75f
WSLE0435
L W/R 0.75f Name
1. I Terminal
2. R Terminal
3. L Terminal

Internal Connections

HIC R

WSLE0436
 4LE2 Electrical System 1D-23
Components

6 1

4
5

10
11
WSLE0437

Name
1. Shaft 7. Stator
2. Pulley 8. Coil Plate
3. Flywheel 9. Bearing
4. Collar 10. Terminal Cover
5. Bearing 11. Regulator ASM
6. Collar

Maintenance Standard

Item Standard value and limit

Isuzu Part No. 8-97226-840-8
Manufacturer code No. 1A04121K
Rated output V-A 12-20
Output characteristic Voltage V 12
(hot)
Current A 20 or more
Revolution r/min 5,000
speed
Regulated voltage by regulator V 13.3-14.3
Revolution direction (viewed from pulley side) Clockwise
1D-24 4LE2 Electrical System

Starting System
General Description
The starter is a 3.2 kilowatt (24V model) or 2.0 kilowatt (12V model).

1
WSLE0385

Name
1. Starter
 4LE2 Electrical System 1D-25
Service Precautions 2. Precautions on starting
Handling of starter • Be careful with charging status of battery. Insuf-
ficiently-charged battery causes starting trou-
1. Precautions on handling ble.
• Improper gap between pinion and ring gear • After checking engine starting, turn off the
causes faulty mesh. (Gap 2 — 3.5 mm {0.079 starter switch immediately.
— 0.138 in})
• One continuous use should be less than 10
Also, the front bracket is installed on the engine
seconds. If re-starting is needed, wait until the
side securely.
pinion stops completely.
• Be sure to turn off the battery switch before
• If the starter does not stop rotating when the
removal/installation of starter.
starter switch is turned off, turn off the battery
• Tightening/inserting wiring must be performed switch immediately. In this case, check the wir-
properly. Looseness causes starting trouble ing, switch, etc.
due to high contact resistance.

List of Trouble Symptom

Condition Possible cause Correction

Starter does not operate when starter switch is Full discharge of battery Replace the battery.
turned on. Open circuit, poor contact Repair.
Poor contact in starter switch or Repair or replace it.
defective tightening of terminal
Poor contact in starter relay or Repair or replace it.
plug terminal
Short or open circuit in magnetic Replace.
switch coil
Pinion moves forward but it does not engage with Insufficient capacity of battery Charge the battery.
ring gear. Wear of pinion or ring gear tooth Replace the pinion or the ring
edge gear.
Dust on pinion shaft Repair.
Pinion engages and rotates motor but it does not Slippage of clutch Replace the clutch or the starter.
run engine. Breakage of reduction gear Replace the gear or the starter.
Pinion engages but it does not run engine. Insufficient capacity of battery Charge the battery.
Defective tightening of wiring cir- Repair.
cuit terminal
Short circuit of armature or field Replace the starter.
coil
Contamination of commutator Repair, or replace the starter.
Fatigue or wear of brush spring Replace the brush spring or the
brush.
Locking of bearing Replace the bearing or the starter.
Poor contact in magnetic switch Replace the magnetic switch.
When turning starter switch off after engine starts, Returning failure of starter switch Replace the starter switch.
starter does not stop. contact
Returning failure of starter relay Replace the starter relay.
contact
Short circuit in magnetic switch Replace the magnetic switch.
coil
1D-26 4LE2 Electrical System

Starter (24V-3.2kW)
Specifications

Manufacturer Mitsubishi Electric Co.

Isuzu Part No. 898072-3151
Manufacturer code No. M008T81571
Power output V-kW 24-3.2
Rating Sec 30
Outside diameter of yoke mm/in 81.6/3.213
Revolution direction Clockwise
Reduction mechanism Planetary gear
Weight kg 5.8
Pinion Module 3.0
Pressure angle 14.5
The number of teeth 11
Gear ratio {ring gear/pinion gear} 9 {99/11}
No load Voltage V 23
Current A 80 or less
Revolution speed r/min 3,750 or more
Restraint Voltage V 8
Current A 760 or less
Torque N⋅m {kgf⋅m} 47.07 {4.8} or more
Pinion engagement voltage V 16.0 or less
 4LE2 Electrical System 1D-27
Components

17
18
21
20
31
32
9
27

28
6 29

13

15
16
14 5
19
26 8

4 22 10
3 25
2 24 12
1 35
23
30
34
11

33
WSLE0441

Name
1. Snap Ring 19. Planetary Gear
2. Stop Ring 20. Lever
3. Pinion 21. Lever Spring
4. Pinion Spring 22. E-shaped Retaining Ring
5. Lead Wire with Terminal 23. Overrunning Clutch
6. Screw 24. Internal Gear
7. Magnetic Switch 25. Washer
8. Screw 26. Gear Shaft
9. Through Bolt 27. Front Bracket
10. Rear Bracket 28. Bearing
11. Yoke Assembly 29. Washer
12. Brush Holder 30. Brush
13. Armature 31. Ground Cable Bolt
14. Ball 32. Ground Cable
15. Plate 33. M Terminal
16. Packing 34. S Terminal (C Terminal)
17. Packing 35. B Terminal
18. Plate
1D-28 4LE2 Electrical System
Removal No Load Test
1. Battery ground cable from the battery. 1. Connect the starter as shown in the illustration
2. Cables and electrical leads from the starter. below.
3. Two mounting bolts. CAUTION:
4. Starter. Use a thick electric wire and tighten the connected
portion securely.
Installation 2. Close the switch and read the speed, current and
1. Starter voltage.
If the measured values are out of specified value,
2. Two mounting bolts.
disassemble and inspect again.
Tightening torque:
Mounting bolt: 93.2 — 113 N⋅m {9.5 — 11.5 kgf⋅m/
68.7 — 83.3 lb⋅ft}
Ground cable bolt: 93.2 — 113 N⋅m {9.5 — 11.5
kgf⋅m/68.7 — 83.3 lb⋅ft}
3. Cables and electrical leads to the starter.
4. Battery ground cable to the battery.
2 A SW B
S
Tightening torque: M
M terminal: 9.8 — 11.8 N⋅m {1.0 — 1.2 kgf⋅m/7.2 1 V 3
— 8.7 lb⋅ft}

WSHK0090
Name
1. Battery 24V
2. Ammeter
3. Voltmeter

Maintenance Standard

Item Standard value or limit

No load characteristic Voltage V 23
Current A 80 or less
Speed r/min 3,750 or more
Commutator Outside diameter mm/in 32/1.260
Limit mm/in 31.4/1.236
Commutator Undercut mm/in 0.5/0.020
Limit mm/in 0.2/0.008
Brush Length mm/in 17.5/0.689
Limit mm/in 11/0.433
Brush spring Pressure N 26.7 — 36.1
Limit N 14.7
Protruded position of pinion mm/in 0.5 — 2.0/0.020 — 0.079
 4LE2 Electrical System 1D-29

Starter (12V-2.0kW)
Specifications

Manufacturer DENSO CORPORATION

Isuzu Part No. 897112-8652
Manufacturer code No. 228000-3850
Power output V-kW 12-2.0
Rating Sec 30
Outside diameter of yoke mm/in 78/3.071
Revolution direction Clockwise
Protection Dust-proof, splash-proof
Reduction mechanism Internal gear
Weight kg 4.7
Pinion Module 2.75
Pressure angle 20
The number of teeth 9
Gear ratio {ring gear/pinion gear} 12 {108/9}
No load Voltage V 7.6
Current A 400 or less
Revolution speed rpm 1,380 or more
Restraint Voltage V 2.4
Current A 800 or less
Torque N⋅m {kgf⋅m} 16.67 {1.7} or more
Pinion engagement voltage V 8.0 or less

Output Characteristic (reference)

REVOLUTION (rpm)

TORQUE (kgf.m)

TORQUE (N.m)

OUTPUT (kW)

VOLTAGE (V)

JIS D1607 12-D 12V, 2.0kw

6000 3 30 2.4 12 V
kW
5000 2.5 25 2.0 10
TORQUE
4000 2 20 1.6 8

3000 1.5 15 1.2 6

2000 1 10 0.8 4 R
rpm
1000 0.5 5 0.4 2
0 0 0 0 0
0 200 400 600 800
CURRENT (A) WSLE0439
1D-30 4LE2 Electrical System
Components

5
4 9

2
8
7
1

3
16
22

18

17

12
11
10

21
15

14
13
20

19
WSLE0475

Name
1. Front Bearing 12. Idle Gear
2. Armature 13. Steel Ball
3. Rear Bearing 14. Coil Spring
4. O-ring 15. Magnetic Switch
5. Yoke 16. Plunger
6. Brush Holder 17. Rubber Cover
7. Brush 18. Cover
8. O-ring 19. Drive Housing
9. Through Bolt 20. Clutch
10. Retainer 21. Clutch Shaft
11. Roller 22. C Terminal
 4LE2 Electrical System 1D-31
Inspection Return test
CAUTION: 1. When connecting as follows, make sure that the
Complete each test within three to five seconds. pinion gear protrudes. When disconnecting the
lead to the 50 terminal with the connection, make
Pull-in test sure that the pinion gear returns to its original posi-
tion immediately.
1. Disconnect the lead wire of the C terminal.
2. When connecting as follows, make sure that the
pinion gear protrudes.

CAUTION:
When performing the inspection, be sure to discon- 50 terminal
nect the lead wire of the C terminal. C terminal

Disconnect

C terminal

WSHK0368
50 terminal

Note:
If you need repairing, bring it to the nearest DENSO
service station for needing the special tools in disas-
semble and assemble.

WSHK0366

Hold-in test
1. Make sure that the pinion gear remains out even
after disconnecting the test lead wire of the C ter-
minal with pull-in test condition.
2. Disconnect the ground wire and make sure that the
pinion gear returns to its original position.

C terminal

Disconnect
50 terminal

WSHK0367
 4LE2 Exhaust System 1G-1

Engine
4LE2 Exhaust System
Table of Contents
EGR Control..........................................................1G-2
Appearance of EGR Controller ..........................1G-2
EGR Controller Wiring Diagram .........................1G-2
Connector Pin Layout.........................................1G-3
Engine Coolant Temperature Sensor Circuit Diagram
1G-3
Tachosensor Circuit Diagram.............................1G-3
Boost Pressure Sensor Circuit Diagram ............1G-4
Engine Coolant Temperature Control ................1G-4
Control When the Sensor Has an Open Circuit .1G-4
Engine Speed and Boost Pressure Control .......1G-4
Inspection...........................................................1G-5
1G-2 4LE2 Exhaust System

EGR Control
Appearance of EGR Controller EGR Controller Wiring Diagram
The harnesses between the EGR controller and EGR
cut solenoid are machine parts. Contact the machine
manufacturer if it is found to be faulty.
1

4 9
(9)
(8) 6 10 (1)
11

(7) 13

3 (2)
1 (10)
(6) (3)
2

5 7

WSLE0360
PC (5) (4)
Name 12 8
1. Connector
WSLE0361

Name
1. Boost Pressure Sensor
2. Glow Plug Timer
3. Engine Coolant Temperature Sensor
4. Tachometer
5. Tachosensor
6. Starter Switch
7. EGR Relay
8. Stop Relay
9. Ignition Switch
10. EGR Cut Controller
 4LE2 Exhaust System 1G-3
Connector Pin Layout Engine Coolant Temperature Sensor
Pins are numbered by the arrangement when viewing Circuit Diagram
the EGR cut controller from the wiring side.
(1)
5V

(2)
7 8 9 10 11 12 13
1 2 3 4 5 6

(3)

WSLE0364
WSLE0370 Name
Name 1. EGR Cut Controller
1. Starter Switch 2. Engine Coolant Temperature Sensor
2. EGR Cut Controller GND 3. Glow Plug Timer
3. Engine Coolant Temperature Sensor
4. Ignition Switch (+)
5. (TXD)
6. Stop Relay Tachosensor Circuit Diagram
7. Tachosensor(+)
8. Tachosensor(−) (1)
9. Boost Pressure Sensor Power Supply
10. Boost Pressure Sensor Signal
5V
11. Boost Pressure Sensor GND
12. (EXD)
13. EGR Relay 7 8

(2)

(3)

WSLE0362

Name
1. EGR Cut Controller
2. Tachosensor
3. Tachometer
1G-4 4LE2 Exhaust System
Boost Pressure Sensor Circuit Diagram Engine Speed and Boost Pressure Control

(1)
kPa
{psi}
Vcc 1 2

15
9 10 {2.2}

Boost pressure
OFF
OFF OFF

ON ON
ON
4
{0.6}
(2)

0 1250 1400 1820 1850 rpm

Engine speed

WSLE0363 WSLE0371

Name Name
1. EGR Cut Controller 1. EGR Valve Closed
2. Boost Pressure Sensor 2. EGR Valve Open

When the engine speed and boost pressure

Engine Coolant Temperature Control increase
The EGR valve is opened when the engine coolant
temperature becomes 60°C {140°F} or more, and is
closed when 55°C {131°F} or less.
kPa
{psi}

Control When the Sensor Has an Open

Circuit
Boost pressure

The following sensors perform backup control when

they have an open circuit. In this case, EGR valve 1 3 2
operates according to other normal sensors.

Sensor Backup control when open cir-

cuit occurs
15
Engine coolant tempera- Control as the engine coolant {2.2}
ture sensor temperature is 60°C {140°F} or
more.
0 1400 1850 rpm
Tachosensor Control as the engine speed is Engine speed
between 1,400 and 1,850 rpm.
WSLE0365
Boost pressure sensor Control as the boost pressure Name
is 15 kPa {2.2 psi} or more. 1. EGR Valve Closed
2. EGR Valve Open
3. Engine Speed and Boost Pressure Increase
 4LE2 Exhaust System 1G-5
When the engine speed and boost pressure
decrease

kPa
{psi}
Boost pressure

1 3 2

4
{0.6}
0 1250 1820 rpm
Engine speed

WSLE0366

Name
1. EGR Valve Closed
2. EGR Valve Open
3. Engine Speed and Boost Pressure Decrease

Inspection
EGR valve check
1. Shine a light from the direction shown in the illus-
tration.
2. Replace the EGR cut solenoid and valve case
together if the light can be seen from the opposite
side. The EGR valve has been stuck at opened
position.

WSLE0372
1G-6 4LE2 Exhaust System
 4LE2 Lubrication System 1H-1

Engine
4LE2 Lubrication System
Table of Contents
Lubrication System................................................1H-2
Service Precautions ...........................................1H-2
Explanations on Functions and Operation .........1H-2
Function Check ..................................................1H-3
Oil Filter.................................................................1H-4
Removal .............................................................1H-4
Installation ..........................................................1H-4
Oil Pump ...............................................................1H-5
Components.......................................................1H-5
Inspection...........................................................1H-5
1H-2 4LE2 Lubrication System

Lubrication System
Service Precautions Explanations on Functions and Operation
• During each disassembly, remove the old gasket The lubrication system uses the filter element com-
adhering to each part and mating part completely bined with a full flow bypass, water-cooled oil cooler,
using a scraper at the location, where the fluid gas- and oil jet for piston cooling.
ket is to be used, clean the traces of oil, moisture
and dirt completely using a cloth, and apply the
specified new fluid gasket at each location.
• Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
coating due to clogging of the oil gallery and oil jet,
and oil and water leakage may occur if the coating
is insufficient.
• Always, the start and end of the application should
be overlapped.

Lubricating system diagram

Valve opening pressure 98 kPa (14.2psi)

Oil filter Oil gallery

Oil cooler Turbocharger Main bearing Idle gear bush Cylinder head

Valve
opening
pressure Rocker arm
Crankshaft Timing gear
539kPa (78.2psi) bracket

Connecting rod Governor Rocker shaft

Rocker arm

Oil pump Injection pump

Valve stem
Strainer Piston Tappet
end

Piston
pin boss

Oil pan

Pressure feeding Non pressure feeding

WSLE0170
 4LE2 Lubrication System 1H-3
Function Check
Engine oil
• Ensure the engine is at a level ground. Before
starting the engine or when 5 minutes or more
have elapsed after stopping the engine, check the
engine oil volume using the level gauge. The vol-
ume is appropriate if the engine oil is between the
upper and lower limits of the level gauge. Replen-
ish the engine oil, if level is below the lower limit.
Also, check for contamination of the engine oil.

Note:
Oil level gauge installation position and shape are dif-
ferent depeding on the model.

Name
1. Max.
2. Min.

Engine oil leakage

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

WSLE0400
1H-4 4LE2 Lubrication System

Oil Filter
Removal
Remove the oil filter using the oil filter wrench.
Remote filter type

WSLE0375

Cartridge type

WSLE0401

Installation
1. Apply engine oil to the O-ring of the oil filter.
2. Install the oil filter using the oil filter wrench.
Tightening torque:
14.7 — 20.6 N⋅m {1.5 — 2.1 kgf⋅m/10.8 — 15.2
lb⋅ft}
 4LE2 Lubrication System 1H-5

Oil Pump
Components

5
4

3
1 2 8
9
10

WSLE0171

Name
1. Pump Gear 6. Pin
2. Pump Cover 7. Oil Pump Body
3. O-ring 8. Relief Valve
4. Inner Rotor 9. Spring
5. Outer Rotor 10. Plug

Inspection Inspection of clearance between the outer

Replace or repair if there is wear, damage, or any other circle of the outer rotor and the pump body
defect on the rotor, etc. Use a thickness gauge to measure the clearance
between the outer rotor and the oil pump body, and
Inspection of clearance between the outer or replace the outer rotor if they exceed the limit.
inner rotor and the pump cover
mm {in}
Use a thickness gauge and square to measure the
clearance between the outer or inner rotor and the Standard value Service limit Repairing proce-
dure
pump cover, and replace the outer or inner rotor if they
exceed the limit. 0.28 — 0.41 0.4 {0.016} Replace.
{0.0110 — 0.0161}
mm {in}
Standard value Service limit Repairing Inspection of tip clearance between the inner
procedure rotor and the outer rotor
4LE2N 0.040 — 0.085 0.15 {0.006} Replace. Use a thickness gauge to measure the tip clearance
{0.0016 — 0.0033} between the inner rotor and the outer rotor, and replace
4LE2X 0.040 — 0.087 the inner or outer rotor if it exceeds the limit.
{0.0016 — 0.0034}
mm {in}
Standard value Service limit Repairing proce-
dure
0.15 {0.0059} or 0.2 {0.008} Replace.
less
 4LE2 Intake System 1J-1

Engine
4LE2 Intake System
Table of Contents
Turbocharger..........................................................1J-2
Components........................................................1J-2
Inspection............................................................1J-3
List of Measurement Tool....................................1J-3
1J-2 4LE2 Intake System

Turbocharger
Components

4 2
3

6
5
13
14
17
16
16

15

8
18

7
11
12
10
9

WSHK0128

Name
1. Compressor Housing 10. Seal Ring
2. Nut 11. Gasket
3. Compressor Impeller 12. Heat Protector
4. Seal Plate 13. Thrust Bearing
5. Oil Thrower 14. Thrust Collar
6. Seal Ring 15. Snap Ring
7. G Coupling 16. Floating Metal
8. Turbine Housing 17. Thrust Bearing
9. Turbine Shaft 18. Bearing Housing

CAUTION:
If you perform inspection with the turbocharger removed from the engine, plug the oil port opening before
work.
 4LE2 Intake System 1J-3
Inspection
• Measurement of axial play of turbine shaft

Axial play mm {in}

Assembly specification 0.06 — 0.09 {0.0024 — 0.0035}
Service limit 0.11 {0.0043}

If it exceeds the service limit, check the thrust

metal, the thrust bushing, and the oil thrower.

WSHK0129

List of Measurement Tool

Shape Name Part number Usage

Dial gauge — Measurement of axial play of turbine shaft

WSHK0158
 4LE2 Preheating System 1K-1

Engine
4LE2 Preheating System
Table of Contents
Preheating System................................................ 1K-2
Explanations on Functions and Operation ......... 1K-2
Glow Plug Check................................................ 1K-2
List of Trouble Symptom .................................... 1K-2
1K-2 4LE2 Preheating System

Preheating System
Explanations on Functions and Operation
The preheating system consists of the glow plug timer,
the glow plugs and the glow indicator lamp. The pre-
heating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.

Glow Plug Check

• Use the circuit tester and measure the resistance
of the glow plug.
• If the measured value deviates from the specified
value, then replace the glow plug.
Resistance value of glow plug is 3Ω.

Note:
Use a set of glow plug from the same manufacturer.

List of Trouble Symptom

Condition Possible cause Correction

The glow indicator lamp does not light up. Slow-blow fuse has blown. Replace the slow-blow fuse.
Fuse is unavailable. Replace the fuse.
Indicator bulb is burnt out. Replace the indicator bulb.
Preheating does not work. Slow-blow fuse has blown. Replace the slow-blow fuse.
Defective or faulty glow plug relay Re-mount or replace the glow
connector contact. plug relay.
Preheating time is too long or too short. Thermo-sensor fault and break in Replace the thermo-sensor.
circuit or short circuit. Repair the circuit.
Fault in glow plug. Replace or tighten the glow plug.
All rights reserved. This manual may not be
reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.

Issued by

ISUZU MOTORS LIMITED

Service Group
Powertrain Business Dept.

Tokyo, Japan
(Ver. 4LE2IT4-WE-0991)

March, 2009
IDE-2450